Mechanical design

The Line5 universal joining module is robustly designed thus making it well suited for heavy duty cycles. The units use an inline design, i.e., the shaft is driven by a motor spindle in line with the shaft. The excellent rotational characteristics of this system provide excellent dynamic response. The mechanical system consists of the following components:

• Servo Motor with absolute encoder
• Precision gearbox (except 1, 3 and 10 kN)
• Integrated force transducer
• Robust housing
• Non-rotating press ram

Advantages of the mechanics:

• Absolute encoder eliminates the need for reference run
• Compact design, with angled motor (optional except for UFM Line5s)
• New concept for greasing and lubrication of the presses
• Robust mechanics for Long periods of use
• Tried-and-tested servo drive Technology, no proprietary hollow shaft motor solution

Modular and networkabel

The mechanics are triggered via a power amplifier with integrated NC-module. The risk processor fitted in the NC-module takes over the control and monitoring of the assembly unit. It can be programmed comfortably and easily with PROMESS software using a commercially available PC and thus guarantees the user the highest operating comfort as well as maximum reliability.

The force-distance course can be monitored by envelope or windows functions. Quality control data and press programs can be stored via the data base plug-in and can be used again at any time. The system features a digital pre amplifier that transmits the force signal trouble-free with a resolution of 24 Bit. The calibration by measuring map allows for a very high accuracy of the force measuring and replaces the switchover of measuring ranges.

ADVANTAGES OF THE CONTROL

• Compact control inside the power amplifier
• Fieldbuses can optionally be upgraded as plug-in module
• PLe for STO integrated by default
• No external analysis system required
• Real-time force distance analysis directly in the servo amplifier

Software Highlights

• Press to signal, press to force, press to an external signal (e.g., analog or TTL signals)
• Force and speed can be programmed indivially during the joining process
• Variables can be used to transmit setpoints, perform calculations using PLC and generate counters
• 100% quality control using window and/or envelope methods
• 100% process documentation using modern database structure
• 100% process anaylsis using standardized interface to QS-STAT (optional), alternative to process management software IPM (optional) - can be expanded using .net interface
• Trigger function for demanding applications
• High controller accuracy (minimization of overshoot in control processes)
• Display of two graphs in one diagramm
• Quick printout of a graph report (screenshot)

Process monitoring & force-displacement monitoring

For optimum monitoring of the joining process, PROMESS offers its universal joining modules with integrated process monitoring. The mechanics of the electromechanical NC joining systems are controlled via a power amplifier with integrated NC module. The control system in turn combines the force-displacement monitoring of the joining process and the motion control of the press mechanics. The joining process can be visualised on the screen and monitored by means of envelope curves, monitoring windows, measurement variables and thresholds. All process data is stored in a database and can then be analysed and evaluated. Alternatively, process, component and worker information can be transferred via field bus.

The basic idea of envelope technology is the monitoring of a signal curve, such as force-displacement, force-time or similar, by means of a freely editable upper and / or lower limit curve. Normal process fluctuations are tolerated, sudden disturbances are detected. The envelopes monitor the force-displacement curve over the entire press-in range. If the upper or lower envelope curve is violated, a NOK is issued for the joining process. The envelope curve technology integrates all elements of the window technology and structurally simplifies the monitoring of joining processes.

It is a prerequisite and basis for a technically sophisticated data analysis that uses all basic data - i.e. the measurement curves and limit values. The envelope curve technique offers a far more flexible adaptation of the limits than the window technique. The envelope curves can be set in the teach-in procedure (teaching) and subsequently adjusted.

When monitoring the joining process using the window technique, a defined area of the recorded curve is monitored. For this purpose, a rectangular window is defined and then it is determined where the curve should enter and exit the window. If the curve deviates from these definitions, the part to be added is marked with NOK. Envelope curve technology and measuring windows can be used in combination in process monitoring.

With the help of the PROMESS UFM V5.xx operating software, all process data is stored in a database and can be analysed, evaluated and exported to MS Excel via the database software plug-in DB Viewer. Optionally, standardised interfaces to QS-STAT and IPM are available for further analysis of the joining process.