Technology from Kistler opens up new possibilities for networking in industrial production.
In automated joining and press-fit processes, electromechanical NC joining systems from Kistler offer significant advantages over conventional systems: they play a key part in cutting energy costs, boosting plant capacity utilisation and making production more cost-effective across the board.
At this year’s AHTE during August 24-26 in Shanghai, Kistler will showcase its latest product innovations – impressively demonstrating the diverse range of possibilities already available for networking in automated production. At the same time, Kistler will show visitors to the event how the company is setting the standards that make such networking possible.
Especially in sectors where technology is a powerful driving force – such as the automotive industry – the vision of Industry 4.0 is already becoming a successful reality thanks to increased digitisation and the constant growth of machine and system networking. Even so, not all market players are equally aware of the diverse possibilities that are now available for networking in automated production; nor do they fully appreciate the economic benefits that more transparent production processes can also deliver. As a leading provider of process monitoring systems, Kistler has set itself a specific goal at this year’s AHTE: to focus attention on this highly relevant issue by showcasing prominent examples of the technologies involved. For joining, forming and testing processes alike, Kistler offers complete systems – from the sensor to the evaluation unit – that can map processes accurately, enabling comparisons and evaluations on a standardized basis across the globe thanks to a consistent operating philosophy.
NC joining systems
Kistler is showcasing its NCFR Joining Module – as well as the classical linear joining process, this new system can perform a controlled rotary movement of the ram, either sequentially or even simultaneously. Like the entire family of NC joining systems, this module delivers a host of benefits for its users: it offers great flexibility and excellent dynamics combined with simple operation – so even highly complex joining processes can be implemented rapidly and efficiently. Thanks to the servo amplifiers used in the module, all traverse movements performed in assembly and product testing can be controlled with high precision. Another example: all NC joining systems allow the user to change measuring ranges, with easy switching between measuring programs – so very different components can be manufactured on one and the same machine. Furthermore, end-to-end standardisation of the systems means that users of the new module can easily obtain spare parts – anywhere in the world. But at the end of the day, future users will probably be convinced by one argument above all others: thanks to their excellent flexibility and low energy consumption, all NC joining modules can help the automobile industry and the automotive supply sector to achieve lasting reductions in their series production costs.
4503B torque sensor
Kistler’s stand at the AHTE will also present the latest state-of-the-art in high-precision torque sensor technology: the Type 4503B torque sensor, which offers a wide range of additional functions. In this new sensor, for instance, optical speed and angle sensing has now been replaced by magnetic technology. This gives the sensor added resilience for reliable operation in heavily contaminated industrial environments (e.g. where oil mist is present), thereby saving valuable time on maintenance. The torque sensor’s electronics have also been optimised, and the 4503B now has a cut-off frequency of 10 kHz for highly dynamic measurements. Users can adjust this value individually with the help of an integrated digital low-pass filter, and the second measuring range is freely scalable up to a spread of 1:10. Other outstanding features of the Type 4503B include wide measuring ranges (from 0.2 to 5.000 Nm), integrated speed/angle sensing (up to 8,192 pulses/revolution) and a high-speed version with up to 50,000 revolutions per minute (1 min/rpm).
maXYmos TL 1.2 and maXYmos BL 2.3
Yet another highlight is in store for visitors to Kistler’s stand: the latest generation of maXYmos monitoring systems. Their purpose is to deliver consistent process-integrated quality assurance. The patterns of measurement curves can be used to monitor and control the quality of a single production step, a sub-assembly or an entire product. Now, maXYmos users can also measure multi-stage production processes (i.e. those with consecutive staggered steps): this new capability has been made possible by equipping the maXYmos TL 1.2 and BL 2.3 with a sequencer mode, in the same way as the successful maXYmos NC. The benefits for users are clear to see: thanks to integrated process control, test processes can now be mapped with no need for costly external PLC programming. Programs can be set up quickly and easily with the help of the intuitive user-interface on the touch display. Even for multi-stage processes, optimal cycle times can be achieved with maximum repeat accuracy. Because this control is integrated in the process, the system provides the basis for enhanced transparency in assembly and testing lines, paving the way for increased cost-efficiency throughout the production facility.
With their uniform operating philosophy, products in the maXYmos family are user-friendly and intuitive to operate. Thanks to these features, commissioning of electromechanical NC joining systems is simple and fast.
The variety of interfaces on the measurement and evaluation module can meet virtually any requirement. All commonly used interfaces are always on board: this ensures flexibility to cope with changing requirements for sensor or fieldbus types, and delivers enormous benefits as regards the spare parts inventory.
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