TOX -Powerpackage. Pneumatic Forces from kn

Transcription

1 TOX Powerpackage Pneumatic Forces from kn

2 TOX Powerpackage The Ideal Pressure for your TOX Powerpackage the energy saving Pneumatic intensifier with integrated oil system and automatic activated powerstroke. Our technology combines Pneumatics and Hydraulics providing you with the following advantages: Lower energy consumption Compact, clean design High stroke frequency Softtouch: easy on your tooling Reduced noise level The TOX Powerpackage operates only on shop air, without hydraulic power units. The controls are very simple, the same as for any double acting pneumatic cylinder. The operating stroke is divided into three stages: airoperated approach stroke pneumohydraulic powerstroke airoperated return stroke The simple design, with few moving parts, assures you of troublefree operation for many years. The low approach forces protect your tooling and reduce the noise level. High stroke frequencies are easily achieved with minimal air consumption. In addition, small air connections allow the use of small, compact, more economical valves. Application Any manufacturing operation requiring pressing forces from kn with powerstroke up to 80 mm and total stroke up to 400 mm. The Logical Alternative Our compact, integrated system puts the pressure on all mechanical, toggle, hydraulic, and airguzzling pneumatic systems. Simple installation and controls make it the ideal alternative. The advantages in detail The thoroughly thought out design of our TOX Powerpackage is proved by the patented details. So, for example, the oil refill system is equipped with an antioverfill safety for troublefree maintenance. Overfilling is avoided. Our patented intensifier with absolute air/oil separation is unique in its simplicity. Due to the intensifier piston being equipped with spring reset, savings of 85% of the energy needed for the powerstroke of a doubleacting cylinder are realized. Stroke Frequency Diagram at 70% Force Capacity Powerstroke (mm) Strokes/min. TOX Powerpackage Note: Precise stroke frequency and air consumption figures are available on request. 2

3 Forming Operations from kn with shop air Reliable Power, Day In and Day Out The double supported working rod has a bearing length to diameter ratio of 10:1. The hermetically sealed, constant pressure intensifier was designed for troublefree operation regardless of the mounting orientation. Absolute air/oil separation. Any mounting position possible TOX sheet metal joining system Punching Stamping Notching Hoopsteel cutting Marking Coining Squeezing Straightening Riveting Spotwelding Projectionwelding Edging Bending Shearing Clamping Holding Peening 3

4 TOX Powerpackage Simple to handle like a Pneumatic The Power in Detail The TOX Powerpackage is a completely integrated power drive. The different configurations and the specially developed accessories make it universally adaptable. In special applications, such as spotwelding, the TOX Powerpackage is optimized according to your requirement. Developed to the smallest detail: Nearly successful worldwide applications have proven it. 1. The pilot mounting gives precise location, and the standard bolt pattern allows for quick and easy mounting. 1.2 Flow Control Forward Stroke Flow Control X NEW: Electronic Pressure Switch ZDO Power Valve ZDO Flow Control Retract Stroke 2. The working rod is cushioned in both end positions with longlife cushions; this is the key to smooth operation, even at high frequencies. 3. The seals have been optimized thru extensive endurance testing. 4. Teflon wipers allow nonlubricant operation. Functioning of the TOX Powerpackage Oil Level In pneumatic fast approach start of powerstroke Retracted position Air operated fast approach Resistance activates powerstroke independent of travel position Fast approach the main control valve a) is switched. The working piston 1 extends at high speed until resistance is encountered at any point of the stroke. This resistance effects the changeover of the assembled power stroke valve. Powerstroke the intensifier piston 2 closes the high pressure chamber and compresses the oil in working area 5 up to 400 bar. This oil pressure applies pressure to the back of working piston 1 and brings about the powerstroke. Return stroke After the changeover of main control valve a) the powerstroke valve d) automatically vents chamber e). The working piston 1 and the intensifier piston 2 return to their initial position. 5. The TOX Powerpackage delivers high forces in a compact design. The double supported working rod has enormous significance for tolerating the most rugged working environments. 6. The absolute air/oil separation is the reason for low maintenance, high stroke frequencies and troublefree operation. An annular groove, between the seals separating the air and oil sections and vented to the atmosphere, prevents the air from mixing with the oil. powerstroke return stroke Pneumatic hydraulic powerstroke 4

5 Cylinder. Powerful like a Hydraulic Cylinder the TOX Powerpackage in any orientation, which makes it also ideal for robotic applications. 11. The antioverfill safety makes refilling easy. dicator or electric Flow Control Power Stroke 7. A standard high pressure measuring connection can be used to monitor and control the quality of the manufacturing process. In conjunction with a pressure switch, a pressure transducer or a pressure gauge, the following functions can be performed: constant pressforces independent of supply air pressure by activating the return stroke as soon as a preset oil pressure is reached. varying the pressforce for certain applications by controlling and adjusting the supply air pressure in a closed loop system. Back Pressure Line Air Supply Intensifier green: included in delivery activation of subsequent operations, e.g., trigger the weld current for spot welding as soon as the right force is applied by the electrodes. 8. Oil level indicator. Available with pneumatic or electric microswitch. 9. Oil refill connection. Connection possibility for pneumatic impulse Powerstroke 10. Integrated closed system constant pressure oil reservoir does not require external plumbing and, therefore, requires low maintenance. The springloaded oil reservoir is under constant pressure and allows use of 12. The intensifier spring has a double function: the return of the intensifier piston, and it also provides constant pressure on the oil reservoir. The piston s spring return minimizes air consumption. 13. The ratio of the intensifier piston area to the plunger area gives the intensification of the air pressure to generate up to 5,800 psi in the hydraulic highpressures section. Different powerstroke requirements can be easily achieved by changing the dimensions of the plunger of intensifier piston. 14. The changeover from approach stroke to powerstroke takes place automatically as soon as the working rod meets resistance. The changeover time can be adjusted with the flow control valve X. These controls are either mounted to the TOX Powerpackage or have been integrated into the flange for an even more compact design. 15. The TOX Powerpackage is supplied completely plumbed. It is operated like any double acting pneumatic cylinder. You must only supply a standard pneumatic 4/2 or 5/2way valve. If your application requires different controls, e.g. travel dependent activation of powerstroke, variation of pressforce during powerstroke, etc., please contact us or our local representative. 5

6 TOX Powerpackage: Comparison with other Systems 1. Costs Investment Amortization The TOX Powerpackage Relatively low to medium costs; inexpensive pneumatic controls: simple mounting. for 24 kn for 80 kn for 300 kn for 1000 kn Based on cycle rates: for 24 kn 100 strokes/min for 80 kn 80 strokes/min for 300 kn 50 strokes/min for 1000 kn 30 strokes/min 1. Alternative Toggle with pneumatic cylinder Low to medium costs. Limited force range not available not available not available 60 strokes/min Energy Consumption per Stroke in liters (CF) normal air: for 24 kn 4.75 l (.17 CF) for 80 kn l (.57 CF) for 300 kn l (2.08 CF) for 1000 kn l (7.00 CF) Approach force Press force Retract force in liters (CF) normal air: 17.0 l (60 CF) Force output Approach stroke Powerstroke Forward stroke Retract stroke Forward stroke Retract stroke Maintenance Easy to exchange; compact design; minimal wear; seals last many millions of cycles. Simple maintenance consists of oil refilling and bleeding when low oil level indicator pops out. Large ports and connections requirements. Prone to linkage wear and excessive play affecting end product quality. 2. Quality 3. System Flexiblity 4. Environment 5. Disadvantages Easy on tooling due to soft touch during approach stroke. Independent speed controls for approach, retract and powerstrokes. Force can be precisely controlled with a pressure switch and monitored with a gauge. Workpiece tolerance stackups are compensated automatically by the resistance activated powerstroke. Stroke adjustment is not required when changing tooling. Precise rod guidance is provided by supporting it on both ends. Units available in many stroke lengths. In special cases, the units can be stroked repeatedly to press assemblies together that require longer powerstrokes than available. Ideal for sterile room applications. Low noise due to soft touch. Low air consumption also provides low noise levels of exhausts. Units are long for very long powerstroke requirements (split execution can be used in such cases). The force curve rises parabolically and is not adjustable. Therefore, ram position must be adjusted for proper force output. Powerstroke adjustment is not possible. The force is position dependent. Part tolerances are critical. External ram guidance is required. Stroke is constant. No choices are available Same as The TOX Powerpackage Design results in large, bulky pressframes The following parameters were considered for comparison of the different systems: 6 bar (87.5 psi) air pressure, 60 mm (2.36 in) total stroke, 3 mm (.12 in) included powerstroke, pressforce 24kN/80kN/300kN/1000kN (5,400 lbf/18,000 lbf/67,500 lbf/224,000 lbf) 6

7 2. Alternative Pneumatic cylinder Low costs. Limited force range not available not available 60 strokes/min 30 strokes/min 3. Alternative Hydraulic system Medium to high costs. Complicated controls and installation up to strokes/min 60 strokes/min 30 strokes/min 20 strokes/min in liters (CF) normal air: 35.0 l (1.24 CF) l (4.13 CF) Force output Depending on controls. For simple controls and small loads, up to 80 kn/80 strokes/min. Very complicated controls required for large units. Force output Forward stroke Retract stroke Forward stroke Retract stroke Large ports and connections requirements. Large in size. Low wear. Change of oil and filters required periodically. Oil leakage, contamination requires continuous maintenance. Complicated installation and plumbing. High impact forces. Forward and retract strokes are adjustable in speed and force. No possibility for powerstroke adjustments. Power throughout stroke. No compensation for variations in part tolerances. Lowforce approach stroke is possible only with special systems. Approach and retract speeds are adjustable; powerstroke can be controlled with pressure switch. Force available throughout stroke, compensates for variations in part tolerances. Force available throughout stroke. Force available throughout stroke. High air consumption. High noise level due to exhaust of large ports. High noise levels. Contamination, oil leakage. Heat generated by pump. Large bores result in large mounting envelopes and high air consumption. High energy consumption. Leakage. 7

8 TOX Powerpackage the Complete Power Source Program Type S (Standard) Application: general Fast Approach/Return Strokes High Stroke Frequencies Force Range: kn Total Strokes: up to 400 mm Powerstrokes: up to 80 mm Operating Pressure: up to 10 bar (Version.30 up to 6 bar) Type S Type K (Compact) Application: general Fast Approach/Return Strokes High Stroke Frequencies Short Design Side by Side Force Range: kn Total Strokes: up to 400 mm Powerstrokes: up to 50 mm Operating Pressure: up to 10 bar (Version.30 up to 6 bar) Type KT Force Range: kn Total Strokes: up to 400 mm Powerstroke: up to 400 mm Operating Pressure: up to 10 bar Type K Type RP (Marking Cylinder) Application: Marking Force Range: up to 150 kn Total Stroke: 32 mm Powerstroke: 3 mm Type O (Short Strokes/No Fast Approach) Application: Operation without approach stroke. Force Range: up to 150 kn Stroke: 6 and 12 mm Type P/K/VHZ (Spot Welding Cylinders) Application: Welding engineering for portable and robotic guns as well as for stationary fixtures. Type RP 8

9 Type S Long Powerstrokes Type S. 50 Powerstroke Limiter Type K 51 Total Stroke Limiter Type KT Separate Booster Type O Type VHZ (Ask for our separate TOX Welding Cylinder Catalog) 9

10 TOX Powerpackage in Industrial Applications TOX Powerpackage Presses The functional Buildingblock Principle of our TOX presses simplifies the match to the individual application and results in an efficient, economical solution to your specifications. The power is supplied by the TOX Powerpackage, the ideal solution for efficiency and troublefree operation. The PATENTED TOX System, riveting without rivets, is the latest development from TOX PRESSOTECHNIK. TOX joins all types of sheet metal, replacing riveting and spot welding, forming a strong, burrfree connection. TOX also joins galvanized and prepainted materials. Dissimilar materials of different thicknesses, even sandwiched layers are easily joined with TOX. The TOX Powerpackage is the ideal drive for TOX, whether used in portable guns, robot guns or in single and multipoint fixtures. The picture depicted below shows a 20point TOX machine to join electric cable channels. Over applications worldwide have proven the TOX Powerpackage as a reliable power source in special machines, assembly and packaging equipment. The TOX Powerpackage can be easily mounted on linear tracks, thereby providing a simple, flexible customized machine. Simplicity is further provided by the lack of hydraulics and the use of simple controls. 10

11 The TOX Powerpackage is used for Spotwelding in robotic and portableguns. The TOX Powerpackage s compact, lightweight design can be easily incorporated into your individual welding specifications. An extensive program of cylinder strokes, mounting styles and weld forces is available to cover the whole spectrum of welding parameters. See separate Weld Cylinder Catalog for more information. The TOX Powerpackage has been standardized for many years by leading car manufactures for use in spot welding guns. The followup characteristics obtained with the TOX Powerpackage in projection welding can not easily be matched with other conventional spot welding equipment. Additional benefits of the TOX Powerpackage are its low air consumption, the fast approach and return strokes, the softtouch, and the simple controls and maintenance. The compactness and speed of the TOX Powerpackage make it the ideal power source for portable, roboticor fixtureguns used for piercing, stamping, riveting, and so on. The simple controls and air connections are further reasons for making the TOX Powerpackage a favorite with maintenance personnel everywhere. The qualification and personal commitment of our employees are one of our most important strengths. Our unconventional, flexible internal structure and distribution of tasks enables us to use their abilities to their fullest. Our sales, development, testing and management departments are not separated. Instead, they are tightly connected. This creates a healthy climate in which not only the employees but also new ideas thrive. Use of 2 TOX Powerpackages in a standard press for upsetting screw heads. High stroke frequency, compactness and reliability were the customer s main requirements. Extract from our customer list: AGFA, AUDI, BASF, Bauknecht, BMW, BoschSiemens, Buderus, DaimlerChrysler, FAG, Ferrari, Fiat, Ford, GEZE, GM, Kienzle, Mann & Hummel, Metabo, Michelin, MTU, Olympia, Opel, Peugeot, Philips, Phoenix, Porsche, Siemens, Thyssen, VARTA, VDO, VW, etc. In the following countries we are represented by subsidiaries, joint ventures, or specialized agencies: Argentinia, Australia, Austria, Belgium, Brazil, China, Columbia, Czechia, Egypt, England, Finland, France, Hungary, India, Italy, Japan, Korea, the Netherlands, Portugal, Poland, Singapore, Slowenia, Spain, South Africa, Sweden, Switzerland, Turkey and the USA. 11

12 Worldwide Sales and Service Network TOX GMBH & PRESSOTECHNIK CO. KG Riedstraße 4 D88250 Weingarten Tel /7 51 / Fax 00 49/7 51 / info@toxde.com Edition: Subject to technical alterations.