Servo Press P5124 for press fit

Servo press P51 24 BA

Perfection in press fit operation

2

Introduction

Auloma servo presses are suitable for al l kinds of

applications 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. P51 24-BA is a must to control

industrial processes and to produce gods with an high

level of quality without defects. the servo press P51 24-

BA can working in compression and if derated also in

tension. Thanks to its design developed to supply the

maximum repeatabil ity and precision, the P51 24-BA is a

device for precise analysis in run of your process. The

modules are tai lored for working in a load range of 1 3kN

to 60kN and the performance can be sized according

the customer needs. The frame is steel composed, the

sl ide surfaces of anti twist ram are hardened for

guarantee stiffness and avoid a backlash by wear. The

motor is jointed to the ball screw by a timing belt without

backlash. The brushless motor own a BiSS absolute

encoder to know ever the ram position also after an

emergency stop. All P51 24-BA servo presses series,

thanks to many threaded holes, could be mounted on

flange and is possible in horizontal or vertical position.

Standard layout as gape frame, 2 columns frame, 4

columns frame or integrated on all kinds of machines

layout are also possible.

Operation System

P51 24-BA Series consist in a range of precise robust

presses where is possible analyse in run the press

process through the sensors mounted in the device. A

strain gauge force sensor integrated in the body press

and an absolute encoder transmit its output signal

syncronised to the Servo drive with Built-In PLC to be

analysed by the APM-BA (Auloma Process Monitoring)

here instal led. The APM-BA software further executing

the process analysis, manage the press cycle included

the recipes with al l working paraters that can be

customised according the exigences of the workpiece.

To program the working recipes it is necessary use the

APM-PC toll kit, a software tool compatible with the MS

Vista operative system or later version and through the

Ethernet interface is possible program the press by

three differents press fit operations: press to force,

press to absolute position, press to relative position.

Process Monitoring

The APM-BA process monitoring software allow to set

up 6 zone of force off-set in part or on the entire press

stroke. This force off-set wrapping the analysis

waveform between a minimum and maximum force

value that represent the admisible force limits of your

process. The analysis is based on the capabil ity of the

process to be repeatable inside the force tolerance

limits . In each case where the process won't be

repeatable the Force VS Distance measured wil l be out

the tolerance limits and a warning signal wil l be sent to

the user's PLC.



3

Our Design

BUSHING INCOPPER

ALLUMINIUMALLOY WITHGRAPHITEINSERTION

HIGH LOADBALL SCREW

TO HAVE ASPINDLE

EXTENDEDLIFE

ANTI TWISTRAM IN

PHOSPHOUROSBRONZE

OVERSIZEDTHRUSTROLLER

BEARING FOREXTENDED

LIFE

TIMMINGBELT WITH

ZEROBACKLASH

RAMHARDENEDWITH ANTI

GRIPTHREATMENT

WIPERSAND SEAL

FORCOMPLETESEALING

BODY PRESSHARDENEDWITH ANTI

GRIPTHREATMEN

BRUSHLESSMOTOR

WITHABSOLUTEENCODER

SATELLITEGEARBOXWITH <3

ARCMIN OFBACKLASH



4

Our Reliability

The Auloma P51 24-BA servo presses mount ball screws with twin nut 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 screw 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 of for 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 themaximum precision standards ISO P1. On request the P5124BA can be executed less precise according the ISOstandards P3

Force Sensor

In P51 24 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

PROGRAM VARIABLES

COMMUNICATION

Profinet and

digital I /O

System Diagram

Features

• Grund ball screw execute according stantard ISO P1

• Twin nut pleloaded without axial backlash

• Twin nut with dynamic load at l ist 3 fold the press

thrust value

• Twin nut with static load at l ist 6 fold the press

thrust value

• Ram repeatabil ity <0.005 mm (A)

• Amplified force sensor integrated in the body press

• Force measure accuracy 0.5% the Full Scale

• Oversized Axial Thrust Roller Bearings

• High stiffness spindle to reduce the compressive

deformations

• Process monitoring integrated in the servo drive

• PC- Software tool for friendly press set-up

• Data analysis available in CSV format for SPC

(A) At the same working load and at the same thermal

steady state

Benefits

• Very precise mesuring system

• Real time process monitoring

• Products defect and process abnormalities detected in

run

• Scrap cost reduction

• Communication with al l kind of PLC through discrete

I /O

• Communication with al l kind of PC through discrete

Ethernet TCP/IP

• Servo press and process monitoring set-up don't

need any experince in PLC programming

• Maintenance cost lesser than an hydraul ic unit

• Energy cost per year lesser than an hydraul ic unit


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 industry in a continue improvement.

Industries as Automotive have 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 an register each variation. This

capabil ity further at seeking the defected parts can

provide the variation of efficiency in the productive

l ine and also in the servo press.

For Industries get informations in short time about

productive processes is a fundamental resources in

cost saving. As SIX-Sigma tools teach 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.

6


Process Monitoring APMBA

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.

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 have 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

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 high quality. 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


Programs Preconfigured Availabe

Press to abslolute position

Press to relative position

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.

7

Press to force



8

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).

Software Features



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

Electromecanic

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

Scope of Delivery

Servo Press ModuleStrain gauge force sensor amplified output 0-1 0 V

Brushless motor with or without holding brake

Absolute encoder multiturn 1 7 bits BiSS integrated in

the brushless motor

Servo DriveABB Servo drive power unit

Servo drive control unit with built in PLC

Software APM-BA instal led in the PLC memory

Memory card

APM PC ToolAPM PC tool kit MS Windows compatible from Vista

and later versions

Tool for the press program

Force vs Displacement Graph viewer

Shilded Cable SetForce sensor cable 3 mt

Motor power cable ready made 5mt

Motor encoder cable ready made 5mt



11

Nominal Thrust kN 1 3 Nominal Input Voltage 3Ø Vac 230

Nominal Pul l Force kN 3.5

Stroke mm 200

Nominal Ram Speed mm/s 111

Ram Acceleration m/s^2 0.37

Dwell Time at Nominal Thrust s 4

Stiffness N/µm 1 220

Smallest mesuring step µm 0.022

Ram Repeatabil ity < mm 0.005

Weight Kg 70

Admissible Tool Weight Kg 1 5

Operating Temperature range C° 0 - 40

Protection Class IP 62

Minimum Input Voltage 3Ø Vac 1 05

Maximum Input Voltage 3Ø Vac 250

Nominal Output Current A 6

Peak Output Current A 1 2

Nominal DC Bus Voltage VDC 321

Output Frequency Hz 0 - 2000

Dimensions VxH mm 82x1 80

Dimension Depth mm 1 57

Weight Kg 1 .5


NO.1 Ethernet Interface

NO.1 Ethercat Interface

NO.1 0 Digital Input

NO.6 Digital Input

NO.2 Analogl Input ±1 0V @ 1 2 bit

NO.1 Analogl Output ±1 0V @ 1 2 bit

Servo DriveServo Press Module

Force Mesuring

VDC 1 - 9

Linearity Error < %FS 0.5

Output Signal ±

Supply Voltage Range VDC 1 9 - 30

-01 30-200-



1 2

Nominal Thrust kN 30 Nominal Input Voltage 3Ø Vac 230

Nominal Pul l Force kN 9

Stroke mm 200

Nominal Ram Speed mm/s 1 20



Stiffness N/µm 8072.6



Weight Kg 11 0












Weight Kg 1 .55





NO.6 Digital Input




Force Mesuring

VDC 1 - 9


Output Signal ±


-0300-200-



1 3

-0300-325-


Nominal Pul l Force kN 9

Stroke mm 325




Stiffness N/µm 7024



Weight Kg 1 23












Weight Kg 1 .55





NO.6 Digital Input




Force Mesuring

VDC 1 - 9


Output Signal ±




1 4

-0400-200-


Nominal Pul l Force kN 1 2

Stroke mm 200




Stiffness N/µm 1 4288,6



Weight Kg 1 72.5

Admissible Tool Weight Kg 32





Nominal Output Current A 1 2

Peak Output Current A 36



Dimensions VxH mm 76x362

Dimension Depth mm 260

Weight Kg 4.8





NO.6 Digital Input




Force Mesuring

VDC 1 - 9


Output Signal ±




1 5

-0400-325-



Stroke mm 325




Stiffness N/µm 11 91 7,2



Weight Kg 1 90












Weight Kg 4.8





NO.6 Digital Input




Force Mesuring

VDC 1 - 9


Output Signal ±




1 6

-0600-200-



Stroke mm 200




Stiffness N/µm 24945

Smallest mesuring step µm 0.001 8


Weight Kg 224












Weight Kg 4.8





NO.6 Digital Input




Force Mesuring

VDC 1 - 9


Output Signal ±




1 7

-0600-250-



Stroke mm 325




Stiffness N/µm 21 022

Smallest mesuring step µm 0.001 8


Weight Kg 248.5












Weight Kg 4.8





NO.6 Digital Input




Force Mesuring

VDC 1 - 9


Output Signal ±




1 8

How to Order

P5124 XXX 0XXXX X X BA

Thrust

1 3 kN = 01 30

30 kN = 0300

40 kN = 0400

60 kN = 0600

Standard Stroke

200 mm = 200

325 mm = 325

Available Stroke

1 00 mm = 1 00

1 25 mm = 1 25

1 50 mm = 1 50

1 75 mm = 1 75

225 mm = 225

250 mm = 250

275 mm = 275

300 mm = 300

350 mm = 350

PLC Communication

Standard = 0

I/O Expansion = 1

Brake

Without = 0

With = 1

Auloma Holding S.r.l.

Address:

Via Mussolina 1 074 - 4001 8 San Pietro in Casale ( BO)

ITALY

T. +39 051 81 82 85

[email protected]

www.auloma.com

21 04-11 -11 - Rev. 00 - MMXIV

© Auloma Holding S.r. l . , al l rights are reserved. I t is prohibited to use text or immages from this

documentation, in whole or in part, without written permission. All products are subject to

technical change without notice. Liabil ity for printing errors in the technical data is excluded.

Servo Press P5124 for press fit

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Transcript of Servo Press P5124 for press fit