Kistler at MOTEK 2011 in Stuttgart: Various In-process Quality Monitoring and Product Testing Innovations for 100 % Quality in Joining and Assembly
QUALITY JOINING is the seal of 100 % quality in joining and assembly, QUALITY TESTING that of 100 % quality in product testing. Both stand for zero-defect production in automobile, electrical, precision and medical engineering achieved through comprehensive inprocess quality monitoring and quality testing with the aid of force or torque curves.
The product presentations at MOTEK focus on the enhanced functionality of the XY monitor maXYmos BL, and on a new cleanroom-compatible NC joining module NCFT with inte-gral force monitoring for small joining and test forces, with cable-free signal transmission for use in manufacturing, assembly and product testing.
As an XY monitor for process monitoring and product testing, the maXYmos BL Type 5867A… from Kistler has quickly established a wide base of actual and potential customers in industrial joining and assembly, and in product testing. The maXYmos BL records the interrelation of all of the measurands that can be measured with piezoelectric or strain gage sensors on the Y-channel, and potentiometric sensors on the X-channel. It can monitor and evaluate the quality of a product or production step on the basis of the curve and dif-ferent evaluation objects.
The ENVELOPE CURVE evaluation object now provides the standard version of the very versatile and compact monitor, which already offers unbeatable value for money, with many practical features. During setup the band of the envelope curve automatically wraps around the outside contour of a previously measured bundle of curves evaluated as GOOD. Automatic trend tracking, which can be activated for the band of the envelope curve, tracks the setpoint limits, for example with progressive tool wear, and adjusts the evaluation function to suit the actual process situation. One or two separate envelope curves in addition to the other evaluation objects UNI-BOX, LINE or NO-PASS are available for each measurement curve.
The new PC software maXYmos PC allows direct transfer of the test record from the maXYmos BL to the PC and offers many functions for visualizing, measuring and analyzing measurement curves and process values, and for evaluating process capability.
New: Cleanroom Compatible NC Joining Module NCFT for Small Joining and Test Forces with Cable Free Signal Transmission Telemetric transmission of the force signal without having to rely on a cable, and suitability as standard for use in production in cleanrooms to ISO 8, are the outstanding attributes of the new electromechanical NC joining module NCFT with integral force monitoring in the ram, which is marked by Kistler as Type 2157B... . These new features make it particularly advantageous in processes with small test and joining forces, such as sensitive press-fit op-erations and test routines in the medical sector.
The new NC joining module provides reliably accurate measurements by transmitting the force signal telemetrically, i.e. without any cable. With their compact mechanism and inte-gral piezoelectric force sensors, the modules comprehensively cover measuring ranges from 50 … 1 500 N. Advantages include ease of selection of the ideal measuring range and a high overload factor. The NC joining system's particularly dynamic response makes it absolutely ideal for short cycle times. Complex drive profiles with a maximum speed of up to 400 mm/s and a displacement repeatability of 0,002 mm can be achieved.
The new NC joining module offers the possibility of ultra high precision measurement of extremely small forces directly on the tool holder under actual process conditions, without having to mount an additional sensor on the ram. This eliminates any possibility of the measurement signal being impaired by dynamic characteristics of masses or moving cables.
Many medical consumables are required to be manufactured under cleanroom conditions. The NC joining module meets stringent production environment requirements laid down by the Fraunhofer Institute for Manufacturing Engineering and Automation IPA in Stuttgart (IPA) in Stuttgart: Manufacturing can be performed in ISO 8 cleanrooms as standard, or even under ISO 7 conditions with the adoption of a minor additional measure.
Kistler is expanding its selection of electromechanical NC joining modules NCFB Type 2160A…, which offer particularly good value for money. The present size with the predefined measuring ranges of 25 kN and 50 kN is being supplemented with a second, smaller model with ranges of 5 kN and 15 kN.
Despite its 200 mm stroke and cost-optimized design, the new module is only about 750 mm long. This compactness means it can be incorporated into assembly systems with great flexibility. Its high speed of 250 mm/s ensures short cycle times. The integral piezo-electric force sensor for measuring in the direction of the pressure offers a high overload factor, and with two measuring ranges covers a very wide range of forces. The NC joining module is available with holding brake as an option.
The NC Compact firmware (Type 2159A…) loaded on the servo controller is ideal for simple force-displacement evaluation and documentation of standard joining processes with the NC joining module NCFB. With very low capital and installation costs it facilitates integration into existing user control environments. As an alternative to the NC Compact Firmware, the force-displacement monitoring units DMF-P A310 Universal Type 4740A… or DMF-P A300 NCF Type 4734A… can also be used. With the aid of a wide variety of tolerance windows they evaluate complex force-displacement curves of virtually any application. They can also comprehensively document the curve and associated setpoints and actual values.
Electromagnetic NC joining modules from Kistler make it easier to automate force-displacement monitored joining and press-fit processes. The new NCFT and NCFB round off the range of products from Kistler. Five series in different sizes now provide seamless coverage of measuring ranges from 0,05 … 300 kN. They are available not only as a system subassembly but also in complete manual workstations for development, prototyping or smallbatch production.
Comments