The extreme flexibility of the electro-press KB TECH allows for a multitude of different applications in all fields of activity. Data are not only stored but also analyzed for the whole cycle in order to monitor the assembly quality.
The advantage of total flexibility
The mechanical transmission elements have been selected with care in order to ensure minimal play between drive and tool.
The press is equipped with a force sensor as standard, located as close as possible to the tool, permitting real-time force measurement and also the detection of abnormal collisions or frictions during compression and traction
The process may be optimized comfortably on the touch-screen by setting of speed, position and force. This mode is protected by a password in order to restrict access to maintenance staff.
Quality in the core of the process
Acquisition chains are dimensioned for a high reliability of the description of the press process, with one force value for every 10 µm. Data are stored within the equipment and represented on the display showing force (N) as function of position (mm).
Data are not only stored but also analyzed for the whole cycle in order to monitor the assembly quality. For this purpose, press criteria have been configured in order to limit the force curve (N) and the according mathematical derivative (N/mm). In order to compensate the height tolerance properties of the assembled parts it is possible to configure the conditions of the end of the press process and of the analysis conditions by setting a trigger point. This trigger point corresponds to the beginning of an increase of force.
The design of the electro-press KB TECH is based on an extensible modular PLC – well adapted for upgrades. There are 2 free Ethernet ports and one USB port on the front side as standard, thus it is possible to integrate a serial interface, a profibus line or additional inputs/ outputs. By this, the press is perfectly adapted for integration in any type of traceability system.
USB-port : the USB port is situated on the front of the press and permits the recovery of all press data by means of a USB stick. Data are exported in the form of CSV files.
Ethernet ports (2x) : they permit the connection of a console for programming and interfacing with the site network. Also, the remote maintenance of the system is possible.
Bar code reader : for the reliable identification of a product or of a batch of components it is possible to connect a mobile or fixed bar code reader with the press.
Visual control : if a control of the press product is required, a sensor or an AOI system can be installed directly in the press cage.
Optimal user-friendliness for optimized productivity
The unique design of the electro-press KB TECH places man veraciously into the center of the process. The easy access, the user-friendliness and safety have been designed with special care and make this equipment efficient and attractive for use.
The loading of the parts is done on a drawer outside of the press process zone, for improved loading conditions and for optimized safety for the user. The drawer is moved by means of a pneumatic actuator, powered with low pressure for ensuring a quick transfer and for avoiding any risk of pinching.
Cycle start is triggered by the short passage of the hand in front of a touch button on the front façade of the press near the loading zone. There is no need for a distinct pressure, a simple streaking is sufficient.
During the press process operator’s hands are free and he can ensure parallel tasks.
The touch-screen is located on the front side of the equipment, and it supplies to the operator essential information about the correct process of press cycles: equipment state, production number, cycle OK or NOK, preview of the force/ position curve etc.. Screens for configuration and for diagnostics are permitting to the maintenance staff the configuration of the pressing profile and the use of the help for resolution of errors and trouble-shooting. The display is based on Microsoft Windows CE, permitting for example the connection of external USB equipment (keyboard, USB-stick) or the use of the explorer of the operation system.
Simple and efficient
The drawer and the upper tool are equipped with mechanical interfaces allowing for comfortable tool change without wrench. If required by the application, there may be electric and pneumatic distributors on board of the drawer, permitting to equipment the tool with actuators and/ or detectors. As an example, it is possible to check the presence of parts before starting a cycle, or to maintain parts by means of cylinders.
A mechanical poka-yoke prohibits a wrong positioning of the tool, and a check by software is performed in order to control the correspondence of the upper and lower tools. This identification permits also to select automatically the appropriate press program, without need of any intervention on the control board.
Stop in position
The tool descends until a programmed position. This may be an absolute or a relative position in order to compensate height tolerances. If high forces are used, a compensation of deformations of the press and of the assembly may be taken into account in order to improve the precision of the positioning.
Stop with force
The press descends until a programmed force is reached. This force can be held for a given time if required. This movement profile permits also a precise and rapid stop by a limit stop in order to ensure that the components to assemble are perfectly pressed one against the other.
Stop at inclination
The press descends until the proportion force/ effort corresponds to an inclination of the assembly. Such a stop condition may be required in order to ensure tightness of certain pneumatic or hydraulic plug types.