Process solution competence through project planning and delivery of complete, ready-to-install Process stations, consisting of the components TOX®-connection technology, TOX®-robot tongs and TOX®-ElectricDrive drives

Today, the construction of special purpose machines and assembly plants is characterized on the one hand the know-how-based integration of detailed processes into system solutions and on the other hand by the extensive use of products available on the market available plant engineering components. If then still the competence for one or the other detailed process, the customer receives customer from one responsible hand a functional production system. Since the complexity of the plant due to this integration of detailed processes is constantly increasing, it is in the sense Risk minimization is obvious, in one case or another the to insure the support of a technology supplier. At Special machine manufacturer M.A.i GmbH & Co. KG, D-96317 Kronach-Neuses, large interlinked assembly lines for customers from the automotive industry, among others. This production lines represent, due to the numerous components to be installed, a plastic and electronic components and the necessary production capacities and cycle times, complex tasks. One of the last converted plant consists of a circulating Workpiece carrier transport system integrated in a 30 meter long production line with three modules and a 48 meter long Production line with five modules. The plant includes a total of 15 manual workstations, furthermore automated handling and assembly stations as well as three assembly rotary indexing tables with six stations, which in turn are operated by industrial robots, integrated. Among other things, some of the assembly stations and a the three assembly rotary indexing tables for joining and connecting equipped with different busbars and fuses.

To meet the demands of the end customer such as high electrical conductivity, process-safe joining of metallic components to form the conductor rail assembly, complete monitoring and documentation of the connections, durable components and reliable replacement supply the developers and designers of the new system have set themselves the goal of being able to M.A.i with the application engineers of TOX® PRESSOTECHNIK GmbH & Co. KG, D-88250 Weingarten, Germany.

Everything from one source in assembly machine construction

As a technology company, TOX® PRESSOTECHNIK not only about clinch technologies for joining sheets and the same, but also about the pressing technology equipment, corresponding press force drives and finally Press force/process monitoring systems. Since the electrical Conductivity of the clinching procedure TOX®-round-point scientifically and in industrial applications long proven this one was also used to connect the sheet metal parts of the assembly Conductor rail for carrying. Besides the conventional design as The process variant TOX®-TWINpoint is inserted. This is a colon connection with Anti-twist, ideal for small flange widths. In total of the production line a total of 10 stations for joining the sheet metal parts where TOX® PRESSOTECHNIK with the complete delivery of all TOX®-Pressing. The individual joining process stations all consist of one and the same standard components of the TOX®-modular system for process solutions. The basic units are TOX®-robot tongs type TZ in use. These in turn are equipped with electromechanical TOX®-servo drives type EPMR for generating the pressing forces for clinching. Furthermore, guide carriages (ram guide), wipers with TOX®-ToolCheck (in-process monitoring of the condition of the of the clinching die), spraying device (minimum quantity lubrication by means oil enriched air to reduce the wiping forces on the clinching tools), cable set and control interface and finally TOX®-Round point tool sets for equipment. All Despite different requirements, components have the same performance characteristics. Therefore they are interchangeable, which of course also positive on the spare parts stock and the costs has an effect.

Technology-based process solutions as a complete system

The machine tongs for the individual stations have a throat of 150 mm and an opening between the tools (punch and die) of 95 mm. The electromechanical Servo drives generate up to 55 kN pressing force. This means that everyone is equipped with the TOX®-round-point-connections to sheet metal components to be joined combinations of different thicknesses; also what is needed for the product changes and future product versions. In all Joining / clinching stations are the machine tongs with the TOX®-Software which, during the clinching process, takes all relevant process parameters monitored and registered. With the production and delivery of the respective ready-to-install TOX®-pliers for joining the sheet metal components for the conductor rail assembly, the plant constructor M.A.i and the End customer/user from a single source Complete process technology solutions that only mechanically adapted and integrated in the control system had to be.

Image Descriptions

Figure 1 shows a section of the production plant, here an assembly rotary indexing table with six stations, three of them TOX®-Clinching stations, consisting among others of TOX®-machine tongs with electromechanical TOX®-servo drives

Figure 2 shows one of 10 TOX®-machine pliers incl. drive, clinching tool and control/interface ready for docking

Figure 3 shows a TOX®-TWINpoint connection

Figures 4a and 4b show single-point and TWINpoint connections on conductor rails