aiPRESS

automatic intelligent pressing

aiPRESS servo presses

serve in the production

of safe and

reproducible joints!

Applications of the servo press aiPRESS

pressing in

joining

grouting

deep drawing

fasten

calibrating

bending

clinching

imprinting

embossing

straightening

riveting

Advantages that only the IEF servo presses can offer you

Repeat accuracy
2 micrometres (µm)

Award winning
overall concept

Flexible and ergonomic
user surface
with top design

Highest precision
during construction,
production and assembly

Easily understandable
good/bad display
via four-colour LED

Intuitive user concept
for very short
training periods

The reasons why the IEF servo presses are able to
produce safe and reproducible joints

Precision

Machines that are able to work this precisely belong worldwide to the high-end products. Already during the production of subcomponents of the servo presses, precision is the top priority.
Hereby all components have to be manufactured of high quality and the depositories have to be coordinated precisely. The used materials are also decisive, because they have to withstand permanently the high load which occurs during the joining process. IEF-Werner counts on a c-shaped basic frame consisting of massive and torsion-resistant tool steel.

Construction

Smart ideas and their constructive realisation are just as important. For example, at IEF-Werner the pressing sleeve is guided exactly by a precision guidance, in contrary to the usual servo presses. This is how transverse forces, that have a negative impact on the measuring procedures, can be eliminated completely. Positioning errors, which occur through the deviation of a conventional sleeve, are therefore excluded.

Only exact measurements
lead to an exact positioning

High-tech measuring technics

The solid mechanics as well as the innovative construction solutions are the basis to employ effectively high-tech measuring technics with the highest resolution. Therefore a special distance measuring system is used, which offers the incredible resolution to one nanometre. The high-tech scale is assembled directly on the pressing sleeve.

Side plate

The measuring head is located on a floating supported side plate, which is mechanically decoupled from the c-shaped basic frame. Every deformation, bending up or setting mode, which affects the force-transmitting parts during the pressing process, is automatically eliminated or compensated through the servo control through this ordering.

Measuring the offset

The directly operating measuring system makes a new start of an already pressed composite with a defined force possible, in order to exactly measure the offset of the component. Through that, the spring back rate of the rammed component can easily be defined, the corresponding correction values may be determined and the desired pressing result can be achieved.

All customer demands can be realised with an on-board control

Servo presses of IEF-Werner can be retrofitted with many additional measuring instruments, sensors as well as different actuators. For example digital in and outputs, or rather analogue signals as well as usual signals conforming to the industry standards can be processed. For this purpose, the equipment can comfortably be installed in the upper and lower tool of the client.

No matter what you need in order to depict your process, much can be processed by an intelligent control without great efforts. The intelligent modular system enables that and also makes it possible to optionally enlarge the numerous on-board automatic programmes by IEF-Werner. This functional principal gave the IEF servo press its name at the end, because aiPRESS stands for “automatically intelligent pressing”.

Simple operation for the best results

A machine is as good
as the handling is easy

Thanks to the process visualization aiLIGHT the user does not need a user surface during normal operation. The so-called aiLIGHT with energy efficient, glare-free four-colour LED technology uses hereby the reflection features of the implanted materials in order to interact with the operator. He becomes every information signalized that is necessary to operate the machine. In order to support the set up operation or the implanting of a component, the LED glow white.

When pressing the components, the colour changes to blue. If the result complies with the demands, the light turns green; if not, it turns red. In addition, the integrated traffic light function at the upper edge of the press signalizes the quality of the press result and is visible for third parties from every direction. Thus, no information of the user surface is needed in order to evaluate the pressing result; an averting of the glaze on the pressing curve is redundant. This makes a comfortable and concentrated work without distraction possible and increases the efficiency.

Operation surface

A glance on the control console is of course necessary for a detailed observation of the press result or during commissioning or retrofitting, despite aiLIGHT.

The graphical user surface of the aiPRESS was equipped with its own operation system for press processes in order  to make the commissioning and operating concept as ergonomic and user friendly as possible. The core of the operation system is the “aiQ-CONTROL”.

 

aiQ-CONTROL is a force-distance monitor, which illustrates the pressing process graphically and monitors its course. Measurands, which are in certain positions to each other, can be via different functions, as for example:

 

Window

Curve has to pass through the box. Leading and trailing edge can be chosen freely.

Force-Barrier

Curve has to cross the line. It is monitored if a certain force is reached or exceeded.

Distance-Barrier

Curve has to cross the line. It is monitored if a certain distance is observed or exceeded.

Envelope-curve

The measuring curve cannot leave the envelope or touch it.

All testing results can be transmitted via TCP/IP to a QM-system or simply dropped on the intern hard drive, on a server or another data carrier as for example a USB stick.

Functions

  • aiLIGHT-process space visualisation
  • aiSTART-start button with fild effect sensor
  • aiQ-CONTROL clearly structured operator guidance
  • Curve movements over envelope curves, windows or force-distance-barriers
  • Probing function during press process
  • Chain of different processes of a product
  • QM-process documentation, recording of the force-distance-barriers in .CSV format
  • Warning and alarm messages
  • User management
  • 16 digital in- and outputs (24 V) standard, free extendable
  • Communication via Ethernet TCP/IP
  • Optional 16" multi-touch screen
An example, how easily the servo press can be set up

Application example

Type-overview

aiPRESS 02

aiPRESS 05

aiPRESS 1

aiPRESS 3

aiPRESS 02 | 05 | 1 | 3

aiPRESS 6

aiPRESS 12

aiPRESS 6 | 12

aiPRESS 6

aiPRESS 12

aiPRESS 30

aiPRESS 6 | 12 | 30

aiPRESS 02 – Stroke 50 mm

Force range: 200 N
Repeat accuracy:+/- 0,002 mm
Measurement accuracy: to +/- 2 N

Download data sheet

aiPRESS 05 – Stroke 50 mm

Force range: 500 N

Repeat accuracy: +/- 0,002 mm

Measurement accuracy:  to +/- 5 N

Download Data sheet

aiPRESS 1 – Stroke 50 mm

Force range: 1000 N

Repeat accuracy: +/- 0,002 mm

Measurement accuracy: to +/- 10 N

Download data sheet

aiPRESS 3 – Stroke 50 mm

Force range: 3000 N

Repeat accuracy: +/- 0.002 mm

Measuring accuracy: to +/- 30 N

Download data sheet

aiPRESS 02 | 05 | 1 | 3 – Stroke 50 mm

Ready for mounting in the automation

Special rim widths possible for an additional charge

Pressing width: 60 mm

Download data sheet

aiPRESS 6 – Stroke 100 mm

Force range: 6000 N

Repeat accuracy: +/- 0.002 mm

Measuring accuracy: to +/- 60 N

Download data sheet

aiPRESS 12 – Stroke 100 mm

Force range: 1200 N

Repeat accuracy: +/- 0.002 mm

Measuring accuracy: to +/- 120 N

Download data sheet

aiPRESS 6 | 12 – Stroke 100 mm

Ready for mounting in the automation

Special rim widths possible for an additional charge

Pressing width: 100 mm

Download data sheet

aiPRESS 6 – Stroke 150 mm

Force range: 6000 N

Repeat accuracy: +/- 0.002 mm

Measuring accuracy: to +/- 60 N

Download data sheet

aiPRESS 12 – Stroke 150 mm

Force range: 12000 N

Repeat accuracy: +/- 0.002 mm

Measuring accuracy: to +/- 120 N

Download data sheet

aiPRESS 30 – Stroke 150 mm

Force range: 3000 N

Repeat accuracy: +/- 0.002 mm

Measuring accuracy: to +/- 300 N

Download data sheet

aiPRESS 6 | 12 | 30 – Stroke 150 mm

Ready for mounting in the automation

Special rim widths possible for an additional charge

Pressing width: 120 mm

Download data sheet

Accessories

Compressed air / vacuum supply

Rotary plate

Force measurement chain

Distance measuring system

Protective housing

Electric height adjustable worktable

Work table (max 400 kg)

Rotary plate

aiLIGHT

aiSTART

Thrust System

Compressed air / vacuum supply

Directly at pressing quill

Automatic deactivation at closed vacuum

Carried along across the entire stroke range

view product details

The integrated compressed air or vacuum supply respectively can be used for different tasks directly at the tool. This is a huge advantage as no external supply lines are needed.

The vacuum is produced by an economical and quiet ejector. The vacuum generator has the following features:

High vacuum, high suction rate

Compact construction

Monitoring and visualisation of the negative pressure by vacuum sensor with LCD display

Rotary plate

Tool intake below

180° swivel range

View product details

Rotary plates are necessary when efficient processes and high cycle times are at stake. Loading and pressing or joining may be conducted simultaneously. Rotary plates are produced exclusively according to customer specifications.

Thereby you profit from the long-term experience of our engineers. Important keywords are:

Industrial safety

Weight decoupling of the tool carriers

Opening and closing of the tool devices

NC turning drives or cycle automatic

Tool changing systems

Integration into assembly lines and automations

Working method

The user inserts components into lower and upper stamp.

The user triggers the joining process by confirming the two-hand control. The turning unit swivels 180° to the pressing unit.

The pressing sleeve proceeds down and joins the components to a finished part. While the pressing unit joins the single parts, the tool can be loaded again.

The user triggers the joining process by confirming the two-hand control. The turning unit swivels back in the opposite direction. The finished parts can be extracted and components inserted.

Force measurement chain

Extension of the measurable accuracy to <1% of the force range.

View product details.

The force measurement, when joining components, is conducted by the motor current by default. This cost-effective approach permits a measurable accuracy of ca. 10 % of the force range.

The force measurement chain is used during highly precise joining tasks. The measuring chain extends the measurable accuracy to <1% of the force range.

The force measurement chain has the following characteristics:

Force transducers with compact construction in combination with industrial charge amplifier

Variants 1kN and 50 kN

Galvanic isolation

Reverse polarity protection

Distance measuring system

Extension of the positioning accuracy to < 0.002 mm

View product details

The distance measuring system enlarges the positioning accuracy of the servo press and makes an absolute position feedback over the entire route possible.

Thereby the distance measuring system is mounted decoupled from the remaining servo press. This permits to gather the smallest deformations of the workpiece (e.g. through spring back).

An accuracy of <0.002 mm can be reached with constant ambient conditions.

Protective housing

Made of polycarbonate

Safety switch

Pneumatic stroke cylinder

View product details

The active protective housing made of polycarbonate prevents the access to the danger zone and is equipped with a pneumatic opening and closing mechanism. The pressing process can only be started when the protective housing is completely closed.

A safety switch monitors the position of the protective housing. The safety switch meets the following requirements:

EN 60204-1 and IEC 60204-1

EN 60947-5-3

EN 62061: SIL CL 3

EN ISO 13849-1: PLe and Kat. 4

Electric height adjustable worktable

Adjustable feet

Control cabinet

Main switch and network socket

Download data sheet

Work table (max 400 kg)

Height electronically adjustable

Four height profiles can be saved

Control cabinet with main switch

Network socket

Download data sheet

Rotary plate

Lower tool mount

Upper tool mount

Pneumatic opening automatic

180° swivel range

View product details

Integration in Fertigungslinien und Automatisierung

Rotary plates are necessary when efficient processes and high cycle times are at stake. Loading and pressing or joining may be conducted simultaneously. Rotary plates are produced exclusively according to customer specifications.

Thereby you profit from the long-term experience of our engineers. Important keywords are:

Industrial safety

Weight decoupling of the tool carriers

Opening and closing of the tool devices

NC turning drives or cycle automatic

Tool changing systems

Integration into assembly lines and automations

Working method

The user puts components into lower and upper stamp.

The user triggers the joining process by confirming the two-hand control. The turning unit swivels 180° to the pressing unit.

The pressing sleeve proceeds down and joins the components to a finished part. While the pressing unit joins the single parts, the tool can be loaded again.

The user triggers the joining process by confirming the two-hand control. The turning unit swivels back in the opposite direction. The production parts can be extracted and components inserted.

aiLIGHT

Thanks to the LED process visualization, the user does not need any information of the user surface.

View product details

 

A further (h)aiLIGHT is the process visualization via energy efficient four-colour LED technology. Thanks to the process visualization, the user does not need any information of the user surface. The pressing process can be triggered via a remote release (e.g a foot switch).

A bright white light is available for the insertion of components. The joining process is depicted by the colours blue (pressing), green (component OK) and red (component defective).

aiSTART

The start button makes it possible to start the joining process in direct proximity of the workspace.

View product details

aiSTART makes it possible to start the joining process in direct proximity of the workspace. This means: short distances and short loading times. The field effect sensors, which trigger the joining process, are positioned on the right and left side of the servo press. A quick touch is enough to start the joining process. The pressing process can be terminated at any time through an emergency stop button positioned at the front.

Furthermore, the pressing process may also be triggered via a remote release, e.g. a foot switch. Therefore, special interfaces are available.

Thrust System

The thrust system is the solution when it comes to ergonomic loading of the press.

View product details

Depending on complexity and scope of the loading, it might be useful to conduct the loading externally of the press, in order to maintain a more comfortable working position. The thrust system – deliverable for aiPRESS servo presses of frame sizes aiPRESS6…30 – is the solution when ergonomic loading is at stake. The stable unit offers a great free space when loading the device and room to place small objects. The thrust system is locked pneumatically in extended and retracted position. After loading is completed, the component is pushed manually under the sleeve and pressed automatically.

Download our product booklet

Maximum technical data

aiPRESS020513
Pressing force0.2 kN0.5 kN1 kN3 kN
Rim width A*129 mm129 mm129 mm129 mm
229 mm229 mm229 mm229 mm
Stroke50 mm50 mm50 mm50 mm
Total height B with 129553 mm553 mm553 mm553 mm
Total height B with 229653 mm653 mm653 mm653 mm
Spindle pitch5 mm2mm2mm1mm
Maximum
traverse speed
375 mm/s150 mm/s150 mm/s75 mm/s
Reverence switchnononono
Motor encoder systemabsoluteabsoluteabsoluteabsolute
Opening path bulkhead C100 mm100 mm100 mm100 mm
Dimensions (L x W x H)107 mm x 231 mm
x 553 mm
107 mm x 231 mm
x 553 mm
107 mm x 231 mm
x 553 mm
107 mm x 231 mm
x 553 mm
Weight36 kg36 kg36 kg36 kg
Power feed230 V AC / 1 P /
50 Hz
230 V AC / 1 P /
50 Hz
230 V AC / 1 P /
50 Hz
230 V AC / 1 P /
50 Hz
Supply line3 x 2.5 mm²3 x 2.5 mm²3 x 2.5 mm²3 x 2.5 mm²
Protection10 A10 A10 A16 A
Control voltage24 V24 V24 V24 V
Pneumatic pressure< 5.5 bar< 5.5 bar< 5.5 bar< 5.5 bar
*Special rim width:229 mm - on request!
aiPRESS 612
Pressing force6 kN12 kN
Rim width A*229 mm229 mm
Stroke100 mm 100 mm
Total height B836 mm 836 mm
Spindle pitch21
Maximum traverse speed 150 mm/s75 mm/s
Reference switchnono
Motor encoder systemabsoluteabsolute
Opening path bulkhead C240 mm240 mm
Dimensions154 mm x 405 mm x 836 mm154 mm x 405 mm x 836 mm
Weight150 kg 150 kg
Power feed400V AC/3Ph/50Hz400V AC/3Ph/50Hz
Supply line5 x 2.5 mm²5 x 2.5 mm²
Protection16 A16 A
Control voltage24 V24 V
Pneumatic pressure<5.5 bar<5.5 bar
*Customer adaption possible
aiPRESS61230
Pressing force6 kN12 kN30 kN
Rim width A*277 mm277 mm277 mm
Stroke150 mm 150 mm 150 mm
Total height B 992 mm 992 mm 992 mm
Spindle pitch211
Maximum
traverse speed
150 mm/s75 mm/s75 mm/s
Reference switchnonono
Motor encoder systemabsoluteabsoluteabsolute
Opening path bulkhead C270 mm270 mm270 mm
Dimensions (L x B x H) 175 mm x 457 mm x 994 mm175 mm x 457 mm x 994 mm175 mm x 457 mm x 994 mm
Weight260 kg260 kg 260 kg
Power feed400V AC / 3Ph / 50 Hz400V AC / 3Ph / 50 Hz400V AC / 3Ph / 50 Hz
Supply line5 x 2.5 mm²5 x 2.5 mm²5 x 2.5 mm²
Protection16 A16 A16 A
Control Voltage24 V24 V24 V
Pneumatic pressure< 5.5 bar< 5.5 bar< 5.5 bar
*Customer adaption possible
aiPRESS servo presses is a pressing concept
that is proven

More than 600 IEF-servo presses

work reliably all over the world

– in the hard, industrial Service!

Your are looking for a servo press?

We would be pleased to advise you.

Feel free to send us a message via the contact form.


Your direct contact

We are looking forward to a personal contact

IEF-Werner GmbH
Wendelhofstraße 6
78120 Furtwangen
Germany

+49 7723 / 925 – 0

info@ief-werner.de