A repeatable and energy-efficient servo press

The flexible design of the aiPRESS Series allows it to be integrated into manual work stations as well as automatic assembly lines. A solid torsion-resistant, steel C-frame forms the basis of the drive chain that consists of a ball screw and servo drive. A precision guide absorbs all the transverse forces to ensure the drive chain remains rigid throughout the cycle, eliminating positioning errors.

A configuration system continuously adjusts the drive chain in accordance with the applied forces so the servo drive always operates optimally. The aiPRESS can also be equipped with a sensor that captures the absolute distance of travel to an accuracy of <1µm.

When pressing components, the force is determined by measuring motor current. For standard applications this process provides a measurement accuracy of about 10 percent of the force range. If higher precision is required, an enhanced force measurement system is used which boosts accuracy to less than 1 percent.

To control and provide a graphic representation of the pressing process, the aiPRESS Series is equipped with the intelligent force-path-monitor, aiQ-CONTROL.  This includes a variety of functions such as envelope curves, windows and force-path-barriers.  It allows related values to be monitored and, dependent on the application, the results can be output via TCP/IP to a QM system or stored in the data system as a CSV file.

Another feature of this series is the intelligent process area lighting aiLIGHT consisting of an energy efficient four colour LED technology. To support the setup mode or the insertion of a component the LEDs shine white. While pressing, the colour changes to blue. If the result meets the requirements the light becomes green; a red LED alerts the operator to a failure.

The energy efficiency credentials of aiPRESS are particularly impressive.  In single-shift operation, the system only uses as much energy as a conventional 60W light bulb.  It is also compact in design.  A vacuum or compressed air connection is integrated into the cabinet so no separate supply lines have to be fed to the tool from outside.  

The aiPRESS servo press series is currently available in four versions.  aiPRESS1 applies forces from 200N to 1kN and is best suited to high precision applications.  Respectively aiPRESS6, aiPRESS12 and aiPRESS30 have press forces of 6kN, 12kN and 30kN for heavier duty tasks.