SERVO PRESS FOR INDUSTRIAL AUTOMATION

SERVO PRESS P2113BA

Servo press P211 3 BA

Perfection in press fit operation

2

Introduction

Auloma servo presses are suitable for al l kinds ofapplications where is required a production quality with

zero defects, an high level of flexibi l ity and look also to

energy cost saving. Our servo presses are used in

several of industrial automated processes as: press fit,

joining and forming.

P2113BA is a must to control industrial processesthanks to the precise force sensor embedded in the tool

holder capable to detect any force variation during the

press fit operation.The brushless motor own a 1 7 bits

BiSS absolute encoder to provide an high resolution of

the ram position. Through this two measure system the

software APM ( Auloma Process Monitoring), instal led inthe servo drive, can control l your press fit operation in

run.

The press design is developed to provide a ram re-peatabil ity less of



3

Our Design

BUSHING INCOPPER

ALLUMINIUMALLOY WITHGRAPHITEINSERTIONS

HIGH LOADBALL SCREWTO HAVE ASPINDLE

EXTENDEDLIFE

ANTI TWISTRAM IN

PHOSPHOUROSBRONZE

OVERSIZEDTHRUSTROLLER

BEARING FOREXTENDED

LIFE

JOINTCOUPLINGWITH ZEROBACKLASH

RAMHARDENEDWITH ANTI

GRIPTHREATMENT

WIPERSAND SEAL

FORCOMPLETESEALING

BODY PRESSHARDENEDWITH ANTI

GRIPTHREATMEN

BRUSHLESSMOTORWITH

ABSOLUTEENCODER17 BITS

SATELLITEGEARBOX

WITH



4

Our Reliability

The Auloma P211 3-BA servo presses mount ball screws with nut preloaded that own a dynamic capacity superior

than the competitors. In the market are available many servo presses with a l ife of the ball screw around the 1 0

mil l ions of cycles. Auloma servo press, according the definite drive profi le, can perform for >1 0 mil l ions of cycles.

Our servo presses mount ball screws with a static load of 6 fold the working load and a dynamic load 3 fold the

working load. Thanks to the ball screw endurance the management costs of Auloma servo press wil l be the half

than our competitors cost.

Auloma is special ised in tai lor made servo presses. Our product range can provide servo press with ball screw life

extended unti l 20'000 hours or more of working l ife.

Ball Screw Life Diagram

Auloma Servo Press

20 mil l ions of

cycles

Competitors

1 0 mil l ions of

cycles

All ball screw are ground and the execution standard is made according the standards ISO P3 in pitch deviation.On request the P2113BA can be executed with pitch deviation more precise according the ISO standards P1

Force Sensor

In P211 3-BA is mounted a strain gauge force sensor capable to measure the minimum variation of the force

applied on the ram. The high stiffness of our spindle avoid force dispersion caused by elastic parts deformations. In

this way we can transmit the minimum thrust reaction on the force sensor.



5

DISPLACEMENT (X)

FORCE (Y)

PROCESS ANALYSIS

START AND STOP AND OK

OR NOK PARTS

COMMUNICATION I/O

MAIN PLC ( MACHINE EQIPMENT )

MASTER

CURVE VIEW

PRESS SETUP

PROCESS

MONITORING

SETUP

COMMUNICATION

ETHERNET

TCP/IP

ETHERNET

SWITCH

APM PC TOOL

SERVO

PRESS

NOTEBOOK

INDUSTRIAL PC

PROCESS

ANALYSIS AND

PROGRAM

SERVO DRIVE

WITH BUILT-IN

PROCESS

MONITORING

PRSS PROGRAMS

COMMUNICATION

digital I /O

System Diagram

COMMUNICATION

digital I /O

COMMUNICATION

ETHERNET

TCP/IP

System diagram valid for the fol low presses:

P211 3-0200-250-BA

P211 3-0250-250-BA

P211 3-0500-200-BA

P211 3-0500-250-BA

P211 3-0600-325-BA

P211 3-1 000-325-BA



6

DISPLACEMENT (X)

FORCE (Y)

PROCESS ANALYSIS

START AND STOP AND OK

OR NOK PARTS

COMMUNICATION I/O

MAIN PLC ( MACHINE EQIPMENT )

MASTER

CURVE VIEW

PRESS SETUP

PROCESS

MONITORING

SETUP

COMMUNICATION

ETHERNET

TCP/IP

ETHERNET

SWITCH

APM PC TOOL

SERVO

PRESS

NOTEBOOK

INDUSTRIAL PC

PROCESS

ANALYSIS AND

PROGRAM

SERVO DRIVE

WITH BUILT-IN

PROCESS

MONITORING

PRESS PROGRAMS

System Diagram

COMMUNICATION

digital I /O

System diagram valid for the fol low presses:

P211 3-0050-1 50-BA

P211 3-0050-200-BA

P211 3-01 00-200-BA

P211 3-01 00-250-BA

P211 3-0200-200-BA



7

Process Monitoring APMBA

How do you determine the quality of your parts? In

contrast to conventional practices of inspecting the

finished part for defects, our system can combine the

encoder feedback with the analogue force signals. The

system receives the necessary data to monitor the

process and provides the capabil ity to create a warning

system. Our systems has the capabil ity of measuring

the process variation during production, thus detecting

problems at the source before they become quality

issues, thanks to the capabil ity of combined control of

the two parameters Force vs Displacement.

Comparisons can now be made with the waveforms

generated by a masterpiece saved in the systems

memory. This information is very important because this

waveform rappresent a mathematical model of your

quality standards. In other words if an acceptable

process is known, our system can be calibrated to

repeat the known process and produce parts that

conform and the process is verifiably consistent and

repeatable. A constant control of Force vs Displacement

indicates that the resulting part has been produced

according to the previously verified acceptable part. By

continuously monitoring the measurement parameters

of the servo press, it is possible to detect variances that

can mean the process is no longer quality capable.

Catching defects at the source gives manufacturers the

confidence that only good parts are shipped to their

customers.

The Software

The APM software is developed to monitoring industrial

applications as pressing or joining. This application is

very common in several industries. Press fit monitors,

measure two magnitudes, Force versus distance to

cheek if the processed parts has made according the

quality standard. APM is a basical ly process monitoring

developed for al l users that want reduce the scrap cost,

seek the defects and individuate the process

abnormalities. Auloma APM process monitoring is

particularly useful for which users that want operate

according standards ISO/TS 1 6949. The software is

very flexible and can be set without efforts in both

environments, press motion set-up and process

monitoring force off-set management. The process

monitoring analyse in real time the cycle execute by the

press ram. The press ram can be moved by a specific

program, developed according the user exigences . In

each cycle, the waveform obtained by the process

analysis could be checked by an force off-set envelope.

The APM - Tool kit al low a complete management of

the data analysis. The tol l kit can be instal led on a

notebook or on an industrial PC.

Press to abslolute position

Press to relative position

Press to force

Programs Preconfigured Available



8

Software Features

Press Programs

APM-BA has as default three press programs:

press to force

press to absolute position

press to relative position

By the APM-PC toll kit it is possible, through the

Ethernet connection, set up each program with the

appropriate parameters and save all in the servo

drive. The servo drive programmed can perform the

press fit operations as your requirement

Curves View

In APM-BA it is possible assign six off-set force value

in each part stroke of the recipe. The six off-set force

limits could be set continuosly to create an envelop,

separated to have six different boxes or a mixing of

boxes and envelope.

This capabil ity al lows to draw some maximum and

minimum force limits to monitor the force behaviour

during the press fit operations.

Data Analysis

The APM-BA analyse each cycle and through a

discrete output provide to the user's PLC the analysis

result OK or NOK,

All data of each analysis in CSV format can be saved

through the Ethernet connection by an hosted PC.

Here the data analysis could be managed by ERP or

others tools as SPC (Static Process Control).



9

Correct

Assembly

Parts Missing

Part

Excessive

Distance

Insufficent

Distance

Incorrect

Insertion

Incorrect

Part

Incorrect

Orientation

Monitor every machine production

cycle for process variance, and

detect changes in the process

before they become quality issues

Advanced signature analysis

algorithms combined with the force

versus position ensures the highest

level of discrimination between

good and defective products

Graphical ly display the process

signature profi le

Network Interface

Simple instal lation

Scrap cost reduction

Automotive powertrain

Automotive components

Appliances

Electronics

Electromechanic

OEM

Whire

Whatches

Defence

Areonautics

Medical

Weapons

Hydraulic

Heart Mover

Energy

Cracked

Parts

Example of rusted part detection. The rust increase thecontact friction and the insertion force increase andgoes out the right values.

Three different press fit program

programmable

Infinite recipes stored in your PC

thanks to the APM-PC tool

Data analysis can be downloaded

by Ethernet network to an hosted

PC in CSV format

Graph points (force and position

values) visible by APM-PC tool on

hosted PC

Six off-set force value for control

the Forve VS Displacement

waveform

Defects Detected

Industries Process Monitoring Benefit Process Monitoring Features



1 0

Applications

Assembly / Press fit Inserting / Fasteners Rivetting / Flaring Punching / Piercing Coining / Marking

Clamping / Tensioning Pressing / Compressing

Bending

Spring Testing Crimping Straightening

Nowadays in many industries it is very important

improve the quality. Standard quality as ISO 9000

influence all process level in the productive plant and

forcing the industries in a continue improvement.

Industries as Automotive has developed a certification

such as ISO/TS 1 6949 with standards more restrictive

than the ISO 9000 and this to obtain a supply chain,

Tier 1 and Tier 2, capable of provide goods with a low

percentage of defects. The goal is one in which

99.99966% of the products manufactured are

statistical ly expected to be free of defects (3.4 defects

per mil l ion). The benchmark to obtain these

performances needs of a system capable to provide all

data necessary to produce an assessment of the

process. Auloma Process Monitoring APM for servo

press is an instrument of measure and control

developed to monitoring the production in run and

seeking defects and abnormalities of produced parts.

The mathematical model (Force vs Displacement)

obtained thanks to APM can monitoring continuously

the production and can register each variation. This

capabil ity further to seeking the defected parts can

provide the variation of efficiency in the productive

l ine and also in the servo press.

For Industries gather informations in short time about

productive processes is a fundamental resources in

cost saving. As SIX-Sigma tools teach that the best

way to enhance the quality process is a reduction of

defects and of waste. The use of our device APM is a

valid instrument to obtain the SIX-Sigma target in al l

applications that need of a continuos feedback values

of Force and Position.



11

Servo Press Features and Benefits

Features

Grund ball screw execute according stantard ISO P3

Ball screw nut pleloaded without axial backlash

Ball screw nut with dynamic load at l ist 3 fold the

press thrust value

Ball screw nut with static load at l ist 6 fold the press

thrust value

Ram repeatabil ity



1 2

Calibration set

Before and After Purchase

Our portfol io of services is at your disposal from the day

you make the first contact. Long before you even think

about buying a servo press we provide essential

support in the form of advice, engineering and test

measurements. A wealth of services, from simple hotl ine

inquiries to comprehensive maintenance agreements, is

also opened up after purchase if you decide to choose

one of our proposal for cal ibration and maintenance

In Our Place or Yours

We provide our services at the point of need. On your

premises or your customer's site, in one of our Training

Centers, or in one of our production facil ities whatever

makes sense as the most efficient option for you.

Test Equipment

Auloma provides a calibration set to verify the efficency

of the servo press. The kit is composed by:

Reference sensor

Analysis unit for reference sensor with display and

other functions for reference sensor maintenance

Interface cable

Factory calibration report or Qrics ISO 1 7025 certifi-

cations (extra charge)

Calibration Good Practices

Established quality guidel ines necessitate regular

cal ibration of your sensors and measuring instru-

ments. Calibration determines the relation between

the measured value and a reference value. The

measuring equipment used for calibration is traceable

to national measurement standards and subject to

international ly harmonized quality assurance.

Cheek in calibration certificates document the values

measured during calibration and the conditions under

which it is carried out. Use this value to verify the effi-

cency of your servo press.

The calibration is a fundamental maintenance ope-

ration to due in intervals basical ly at the responsibi l ity

of the user and depends on how often the produced

workpieces are used and the extent to which they

affect safety.

Calibration Service in customer's plant provided by

Auloma ensures force calibration can be performed

on the spot with minimum downtime whether this is

in production, development or the test facil ity.

Test Equipment



1 3

Scope of Delivery

Servo Press ModuleStrain gauge force sensor embedded in the tool holder

Brushless motor without holding brake

Absolute encoder multiturn 1 7 bits BiSS integrated in

the brushless motor

Servo DriveABB Servo drive with built in PLC

Software APM-BA instal led in the PLC memory

Memory card

Force Sensor AmplifierOutput 1 0V

Zero adjustment

Shunt cal ibration

Gain and Span Adjustment

Shilded Cable SetForce sensor cable 3 mt

Motor power cable ready made 5mt

Motor encoder cable ready made 5mt

APM PC ToolAPM PC tool kit for MS Windows compatible from

Vista and later versions

Tool for the press program

Tool for process monitoring program

Force vs Displacement Graph viewer

Scope of Delivery available for the fol low servo pres-

ses:

P211 3-0050-1 50-BA

P211 3-0050-200-BA

P211 3-01 00-200-BA

P211 3-01 00-250-BA

P211 3-0200-200-BA

Note: the force sensor amplifier rappresented in thepicture could be different than the device supplied



1 4

Scope of Delivery

Servo Press ModuleStrain gauge force sensor embedded in the tool holder

Brushless motor without holding brake

Absolute encoder multiturn 1 7 bits BiSS integrated in

the brushless motor

Servo DriveABB Servo drive with built in PLC

Software APM-BA instal led in the PLC memory

Memory card

I/O Module ExpansionDigital input ports

Digital outpoy ports

Ethernet TCP/IP interface

Force Sensor AmplifierOutput 1 0V

Zero adjustment

Shunt cal ibration

Gain and Span Adjustment

Shilded Cable SetForce sensor cable 3 mt

Motor power cable ready made 5mt

Motor encoder cable ready made 5mt

APM PC ToolAPM PC tool kit for MS Windows compatible from

Vista and later versions

Tool for the press program

Tool for process monitoring program

Force vs Displacement Graph viewer

Scope of Delivery available for the fol low servo pres-

ses:

P211 3-0200-250-BA

P211 3-0250-250-BA

P211 3-0500-200-BA

P211 3-0500-250-BA

P211 3-0600-325-BA

P211 3-1 000-325-BA

Note: the force sensor amplifier and the I/O moduleexpansion rappresented in the picture could be different than the devices supplied



1 5

Nominal Thrust kN 5

Nominal Input Voltage 3

Vac 230

Nominal Pul l Force kN 3.5

Stroke

mm

1 50

Nominal Ram Speed mm/s 1 00

Ram Acceleration

m/s^2 0.666

Dwell Time at Nominal Thrust

s

4

Resolution

m

0.02

Ram Repeatabil ity

SERVO PRESS FOR INDUSTRIAL AUTOMATION

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