aiPRESS 02 – Stroke 50 mm
Force range: 200 N
Repeat accuracy:+/- 0,002 mm
Measurement accuracy: to +/- 2 N
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aiPRESS servo presses
serve in the production
of safe and
reproducible joints!
pressing
joining
sizing
deep drawing
fasten
calibrating
bending
clinching
imprinting
stamping
straightening
riveting
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
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.
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.
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.
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.
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”.
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.
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:
Curve has to pass through the box. Leading and trailing edge can be chosen freely.
Curve has to cross the line. It is monitored if a certain force is reached or exceeded.
Curve has to cross the line. It is monitored if a certain distance is observed or exceeded.
The measuring curve cannot leave the envelope or touch it.
aiPRESS 02 – Stroke 50 mm
Force range: 200 N
Repeat accuracy:+/- 0,002 mm
Measurement accuracy: to +/- 2 N
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aiPRESS 05 – Stroke 50 mm
Force range: 500 N
Repeat accuracy: +/- 0,002 mm
Measurement accuracy: to +/- 5 N
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aiPRESS 1 – Stroke 50 mm
Force range: 1000 N
Repeat accuracy: +/- 0,002 mm
Measurement accuracy: to +/- 10 N
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aiPRESS 3 – Stroke 50 mm
Force range: 3000 N
Repeat accuracy: +/- 0.002 mm
Measuring accuracy: to +/- 30 N
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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
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aiPRESS 6 – Stroke 100 mm
Force range: 6000 N
Repeat accuracy: +/- 0.002 mm
Measuring accuracy: to +/- 60 N
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aiPRESS 12 – Stroke 100 mm
Force range: 1200 N
Repeat accuracy: +/- 0.002 mm
Measuring accuracy: to +/- 120 N
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aiPRESS 6 | 12 – Stroke 100 mm
Ready for mounting in the automation
Special rim widths possible for an additional charge
Pressing width: 100 mm
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aiPRESS 6 – Stroke 150 mm
Force range: 6000 N
Repeat accuracy: +/- 0.002 mm
Measuring accuracy: to +/- 60 N
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aiPRESS 12 – Stroke 150 mm
Force range: 12000 N
Repeat accuracy: +/- 0.002 mm
Measuring accuracy: to +/- 120 N
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aiPRESS 30 – Stroke 150 mm
Force range: 3000 N
Repeat accuracy: +/- 0.002 mm
Measuring accuracy: to +/- 300 N
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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
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Compressed air / vacuum supply
Directly at pressing quill
Automatic deactivation at closed vacuum
Carried along across the entire stroke range
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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
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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
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.
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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
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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
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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
Height electronically adjustable
Four height profiles can be saved
Control cabinet with main switch
Network socket
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Work table
Adjustable feet
Control cabinet
Main switch and network socket
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Rotary plate
Lower tool mount
Upper tool mount
Pneumatic opening automatic
180° swivel range
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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
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.
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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.
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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.
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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.
| aiPRESS | 3 | 15 | 36 | 100 |
|---|---|---|---|---|
| Pressing force | 0-3 kN | 0-15 kN | 0-36 kN | 0-100 kN |
| Workspace | 180 mm | 230 mm | 280 mm | 350 mm |
| Stroke | 75 mm | 125 mm | 175 mm | 200 mm |
| Spindle pitch | 2 mm | 2 mm | 3 mm | 4,5 mm |
| max. operating speed | 150 mm/s | 150 mm/s | 150 mm/s | 85 mm/s |
| Motor encoder system | absolute | absolute | absolute | absolute |
| Dimensions L x W x H | 346 mm x 115,5 mm x 754 mm | 422 mm x 145,5 mm x 1031 mm | 554 mm x 175,5 mm x 1267 mm | 592 mm x 269 mm x 1583 mm |
| Weight press (without cable) | 78 kg | 179 kg | 371 kg | 622 kg |
| Weight control cabinet | approx. 45 kg | approx. 45 kg | approx. 45 kg | approx. 45 kg |
| Power feed | 230V AC /1 PH / 50 Hz | 400 V AC / 3 PH / 50 Hz | 400 V AC / 3 PH / 50 Hz | 400 V AC / 3 PH / 50 Hz |
IEF-Werner GmbH
Wendelhofstraße 6
78120 Furtwangen
Germany
+49 7723 / 925 – 0
info@ief-werner.de