electricdrive electro-mechanical servo systems · 3 qx l i n e - the electro-mechanical servo...

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TOX®-ElectricDrive

Electro-mechanical Servo-Systems0,5 – 400 kN Press forceline-Qline-X

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TOX®-ElectricDrive

Scope of delivery:

TOX®-Electric Power Moduleor TOX®-Electric Power Curver

Cable set consisting ofmotor cable, resolver cableand force sensor cable

Axis-Controller(line-X shown)

Ballastresistor

The set:

TOX®SoftWare on CD-Rom

• no licence fee• can be updated• Independent of operating system• free unlimited use without additional

cost

MechanicalHousing with planetary roller spindle(EPMS 10 with ball screw), workingrod, bearing, resolver, motor withreducer, DMS force transducers

ControllerComplete control unit, incl. ballastresistor and Ethernet cable.

Cable setApplicable for use with cable tracks(pay attention to the minimum ben-ding radius).1x Motor cable, 1x resolver cable, 1xforce sensor cable, (standard length5 m, additional lengths up to 25 m insteps of 5 m are available). Cablesfor robotic applications available alsoon request.

www.tox-de.com 40.0804.02

Applications for TOX®-Servo-System:

Clinching MarkingRivetingEdgingBending

FormingAssemblingFastener insertion

PressingSqueezing

DrawingFlaring

TestingPeening

Advantages TOX®-ElectricDrive:• High life expectancy and robust-

ness due to the compact planetary roller screw spindle

• Future-oriented project planning and very good retooling capability due to its universal applicability

• Maximum energy efficiency, i.e.significantly reduced operating costs compared to conventional drives

• Special executions can be easily realized due to the modular design

• High-dynamic performance by force and distance regulation and the possibility of transition speed

When work processes require highflexibility and precision, then con-ventional drives are often no longersufficient. This calls for the use ofelectromechanical servo drives.

Tailored drives from 0,5 – 400 kN.

From the standard drive up tothe complex special machine.

• High precision due to adaptable, regulated deflection compensation

• Simple and comprehensive para-meter setting, control, service, via TOX®

softWare• Can be run on most commonly

used operating systems• Utmost safety up to and including

category 4 as per EN 954-1, Performance level e as per EN ISO 3849-1 and SIL3 as per EN/IEC 62061 is possible

• Stand-alone operation without PC/PLC is possible

• The system is pre-configured and calibrated, thus, ready for service

plug and play

TOX®SoftWare

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The electro-mechanical servosystems are designed such that onlyminimal maintenance work is requi-red.• Maintenance-free servo motors• Maintenance-free gears• Maintenance-free belt drive

(for EPMK-/EPMR-Series)• Long lubrication intervals for the

spindle

Network for modern productionProcess monitoring, operating, programming and diagnostics directly over your network.

Quality data

Productionmonitoring

Productiondata

Statistics Logfile

Ethernet

Ethernet

Zone controller

TOX®sofWare

Fieldbus e.g. Profibus DP

PLC controller

TOX®-Service:The decisive advantage

Maintenance:

• Dependable service worldwide (see brochure backside)

• Remote service possible over modem generally installed in each complete machine delivered or via company network (VPN)

• Wide experience in various applica-tions (general industry, automobile, medical technology, …)

• TOX® is your active partner during the entire project duration, from the planning to the operation stages

• Installation and process optimizationassistance

• Training at the customer or in-houseat TOX®

• Calibration and repair service• Hotline service

+49 (0) 160 / 96372299

www.tox-de.com40.0804.02

PC/Laptop orIPC for servi-cing, parametersetting andvisualization

From single components to complete machinesSystem solutions from one source. See page 22 - 23 for application examples.

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Advantages:• Compact design• High life expectancy• High static capacity due to large

bearing area• Highest transmission speed• Highest efficiency• Highest rigidity• High revolutions

Planetary roller screws are designedfor high loads over millions of cyclesmaking them the best choice.

We will be glad to provide a calculati-on of the expected life expectancy ifyou provide us with your cycle loadrequirements.

Planetary Roller Screw

Construction of a Planetary Roller Spindle

Mounting instructions:The working rod should be guidedexternally in order to avoid anypotential side loads. You will find cor-responding examples in the TOX®-Presses catalog. The connection tothe external guidance or ram guideplate must be done using a flexiblecoupling. For more information onour couplings, please see data sheet10.00 for TOX®-Powerpackage acces-sories.

Spindle

Planetary roller Spindle nut

Design (example: EPMK 55)

Anti-rotationfor spindle

2 greasing points(plugged)

Housing with plane-tary roller spindle

Housing with belt drive

Eyebolt provision(both sides)

Mounting pilot Bolt circle formounting screws

Force sensors Resolver(for distancemeasurement)

Electricalinterfaces

Servo-motor

Gearbox (notwith EPMK 10)

Working rod

The electromechanical servo spindle

Referencing:Generally, referencing is done usingthe internal positive stop of the servodrive. Alternatively, referencing canbe done using an external limitswitch. For CAD files, please

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www.tox-de.com

The data required or the calculationcan be found in your offer or atwww.tox-de.com.

The calculated life expectancy is atheoretical value with a 90% probabi-lity.

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The compact driveTOX®-Electric Power Module EPMK10*, 25, 55, 100, 200, 400 kN

• Compact design• Optional brake (see option)

Applications:• Joining machines• Assembly machines• Special machines• Press drive for presses with the

highest safety requirements(see page 2)

The slim standard driveTOX®-Electric Power Module EPMS10*, 25, 55, 100, 200 kN

• Standard design• Minimum space requirement

Electromechanical servo drive withplanetary roller screw:• High speed• Highly dynamic• Precise• Long lifetime• Modular design• Precise force measuring• Integrated anti-rotation

Applications:• Joining machines• Assembly machines• Special machines

The robotic tongs driveTOX®-Electric Power Module EPMR55, 100 kN

• Super compact• Super light• With special flanging system

Application:• Minimum space requirement• TOX® robot mounted clinch units

type TZ

*EPMS/EPMK 10 with ball screw and without gear reducer.

Model Overview• Press force from 0,5 – 400 kN• can be mounted in all TOX® press frames (see TOX®-Presses catalog)• can be mounted in any orientation

Option:Holding brake/redundant safetybrakeThe EPMK drive can be additionallyequipped with brakes: either with aholding brake to avoid a drifting ofthe working piston in case of heavytool loads or with a redundant safetybrake to fulfill highest safety require-ments (see page 2).

The maximum holding force of thebrake is at least 5% of the corre-sponding nominal force. Technicaldata and dimensions incl. modelswith stronger brakes on request.


How to order:EPMS 025.030.250.

Stroke [mm]Variant numberRated force kNDesign: S = standard/K = compact/R = robotic tongs driveElectric Power Module

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Data sheetTOX®-Electric Power Module EPMS 10, 25, 55, 100, 200 kN

Dimensions

*Recommended operating range 5-100%**Specials on request.(colour, stroke, speed, ..)***Zero position of drive is the reference (marked) position + 3 mm****in thermal transient condition

Order no.

Type Stroke

Nomi-nalforce[kN] A A1 A2 B C D Ff7 G H I J K L M N R T U Vg6 W

Weightapprox.

kg

EPMS 010.030. 250 10 70 90 76 939 8xM8x16 60 50 10 30 15° 75° 20 M12x1,5 32 24 300 390 720 – – 21

EPMS 025.030. 250 25 70 90 76 1047 8xM8x16 60 50 10 30 15° 75° 28,5 M22x2 48,5 24 300 390 568 18 7 25

EPMS 055.030. 300 55 95 105 105,5 1218 8xM10x20 83 70 10 40 15° 75° 35 M30x2 60 34 316 456 678 26 7 43

EPMS 100.030. 300 100 115 130 122 1373 8xM12x25 98 75 15 50 15° 75° 36 M30x2 61 41 343 483 1316 26 7 72

EPMS 200.030. 300 200 145 – 146 1618 8xM16x25 125 100 18 70 15° 75° 46 M39x2 81 60 385 525 – – – 140

Specifications EPMS 010.030.250 EPMS 025.030.250 EPMS 055.030.300 EPMS 100.030.300 EPMS 200.030.300Mechanical

Rated force* push 10 kN 25 kN 55 kN 100 kN 200 kN

Rated force pull 3 kN 7,5 kN 16,5 kN 30 kN 60 kNStroke** 250 mm 250 mm 300 mm 300 mm 300 mm

Max. speed** 300 mm/s 220 mm/s 200 mm/s 200 mm/s 85 mm/sMax. short-termoverload

10% of rated force

Positional repeatabilityunder load****

< ± 0,01 mm

SensorsLoad cell 0,5 – 10 kN 1,25 – 25 kN 2,75 – 55 kN 5 – 100 kN 10 – 200 kNRated force 10 kN 25 kN 55 kN 100 kN 200 kNAccuracy < +/- 0,5 % of rated force,pressing

Resolver x x x x xResolution 0,0012 mm 0,0004 mm 0,0004 mm 0,0005 mm 0,0003 mmElectrical

Protection class Motor/drive IP54 (as component)

Mains supply see axis controller

Climatic conditions + 10 to + 40°C, from 40° C performance loss, max. 55° C; air moisture < 75%**, without condensation

For CAD files, please

visit us at

www.tox-de.com

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Dimensions

Data sheetTOX®-Electric Power Module EPMK 10, 25, 55, 100, 200, 400 kN

Optional with brake

for category 4 safety

requirements

*Recommended operating range 5-100%**Specials on request. (colour, stroke, speed, ..)***Zero position of drive is the reference (marked) position + 3 mm****in thermal transient condition*****EPMK 400 only with Axis Controller line-X available

Specifications EPMK 010.030.250 EPMK 025.030.250 EPMK 055.030.300 EPMK 100.030.300 EPMK 200.030.300 EPMK 400.030.300*****MechanicalRated force* push 10 kN 25 kN 55 kN 100 kN 200 kN 400 kNRated force pull 3 kN 7,5 kN 16,5 kN 30 kN 60 kN 400 kNStroke** 250 mm 250 mm 300 mm 300 mm 300 mm 300 mm

Max. speed** 300 mm/s 250 mm/s 200 mm/s 200 mm/s 85 mm/s 40 mm/s

Max. short-termoverload

10% of rated force

Positional repeatabilityunder load****

< ± 0,01 mm

SensorsLoad cell 0,5 – 10 kN 1,25 – 25 kN 2,75 – 55 kN 5 – 100 kN 10 – 200 kN 20 – 400 kN or

-20 – -400 kNRated force 10 kN 25 kN 55 kN 100 kN 200 kN 400 kNAccuracy < +/- 0,5 % of rated force,pressing

Resolver x x x x x xResolution 0,0012 mm 0,0004 mm 0,0004 mm 0,0005 mm 0,0003 mm 0,0015 mmElectrical

Protection class Drive IP54 (as component)


Climatic conditions + 10 to + 40°C, from 40° C performance loss, max. 55° C; air moisture < 75%**, without condensation

Order No.

TypeStro-ke

Nomi-nalforce[kN] A A1 A2 B C D Ff7 G H I J K L M N P R T U Vg6 W X Y

Weightapprox.

kg

EPMK 010.030. 250 10 70 92 76 657 8xM8x16 60 50 10 30 15° 75° 20 M12x1,5 32 24 211 300 390 568 – – 24 59 22

EPMK 025.030. 250 25 70 92 76 657 8xM8x16 60 50 10 30 15° 75° 28,5 M22x2 48,5 24 211 300 390 568 18 7 24 59 26

EPMK 055.030. 300 55 95 120 105,5 761 8xM10x20 83 70 10 40 15° 75° 35 M30x2 60 34 245 316 456 678 26 7 28 60 46

EPMK 100.030. 300 100 115 156 122 854 8xM12x25 98 75 15 50 15° 75° 36 M30x2 61 41 280 343 483 750 26 7 28 62 78

EPMK 200.030. 300 200 145 170 146 973 8xM16x25 125 100 18 70 15° 75° 46 M39x2 81 60 327,5 385 525 838 – – 52 94 154

EPMK 400.030. 300 ±400 250 276 250 1260 8xM24x40 200 150 20 100 30° 60° 60 M64x2 120 85 525 432 552 1074 – – 60 114 543


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Data sheetTOX®-Electric Power Module EPMR 55, 100 kN

Dimensions

*Recommended operating range 5-100%**Specials on request. (colour, stroke, speed, ..)***Zero position of drive is the reference (marked) position + 3 mm****in thermal transient condition

Order no.Type Stroke K L M N P Q R T U Vg6 W X Y

EPMR 055.030. 100 18 M24x1,5 37 24 245 83 182 262 484 22 6 28 60

EPMR 100.030. 100 17 M24x1,5 36 30 274 120 218 298 565 22 6 28 62

Order no.

Type Stroke

Nomi-nalforce[kN] A A1 A2 A3 B C C1 C2 C3H7 C4H7 D1 D2 E1 E2 F F1±0,02 F2 F3 F4 G H J

Weightapprox.

kg

EPMR 055.030. 100 55 95 120 105,5 39 567 27 13 9 14 14 15 21 60 62 92,5 45 62,5 6 9 4 40 28 38

EPMR 100.030. 100 100 115 144 121,5 57 668,5 33 17,5 11 14 14 17 25 85 84 115,5 58 75,5 6 10 4 50 33 68

The tightly toleranced (H7) keywayson the mounting flange provide forprecise alignment of the drive withrespect to the direction of travel.The height and position of the drivecan be precisely adjusted usingspacer plates and keys.

Specifications EPMR 055.030.100 EPMR 100.030.100MechanicalRated force* push 55 kN 100 kN

Rated force pull 16,5 kN 30 kN

Stroke** 100 mm 100 mm

Max. speed** 120 mm/s 120 mm/s

Max. short-term overload 10% of rated force

Positional repeatability underload****

< ± 0,01 mm

SensorsLoad cell 2,75 – 55 kN 5 – 100 kNRated force 55 kN 100 kN

Accuracy < +/- 0,5 % of rated force,pressing

Resolver x xResolution 0,00025 mm 0,0003 mm

ElectricalProtection class Drive IP54 (as component)


Climatic conditions + 10 to + 40°C, from 40° C performance loss, max. 55° C;air moisture < 75%**, without condensation


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Applications:• Clinching• Clamping• Marking• Robot Applications

Advantages:•Part accessibility•Top loading•Clamping and Clinching at thesame time

TOX®-Electric PowerKurver EPC 90 kN

Accessories such as for TOX®-PowerKurver type KK are possible(see TOX®-PowerKurver catalog).

Ordering example:EPC 90.090.000

Version numberOpening anglePress force (kN)Electric Power Curver

Servo-Drive-Unit with planetary rollerscrew in combination with our provenTOX®-PowerKurver cam activatedpress design. The large openingangle allows for easy access to too-ling.

• Self-locking• Long lifetime• Freely programmable opening

angles, up to 90°.

The Servo Spindle in operation

Robot guided clinching tongsEPMR 55 used in TOX®-Robotic tongs TZ for joining sheet metal

EPMR 55

Option:Terminal box for starting thecompensating slide and thespray lubrication equipment, andmanual initiation for spraying alubricant on to the joining area, ifrequired.

TOX®-Robot tongs TZ (see brochure: TOX®-Tongs)

Option:Robot coupling

Application:Metal joining withTOX®-Round Joint(see brochure: TOX®-Joining Systems)

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Ethernet

Servo motor

Load cell signal

Axis-Controller (Ill.: line-X)

Fieldbus

I/O

Resolver signal

Option:24 V DC brake

PC/Laptop or IPCfor operating andprocess monitoring

Control for parameter settingand commissioning

TOX®-Axis-Controllerline-Q

TOX®-Axis-Controllerline-X

TOX®softWare

EthernetInterbus/ServiceNet/Profibus

RS 232/485PLCNETWORK

The line-Q and line-X idea

Between the servo drive and the servicing, parameter setting and visualization, there is always an axis-controller.The functions and interfaces available depend on the type of the axis-controller.

For the TOX®-ElectricDrive, one mayselect between two single axis con-trollers, line-Q or line-X. Both linesare identical in their mechanicaldesign and differ only with regards tothe number of features.

Complete program line-Q• Short lead time• Limited in the number of functions

and customer interfacesThe first choice if the extensivelist of functions is sufficient.

Complete program line-X• Nearly unlimited number of

functions with custom interfaces possible.

The best choice if the extensivelist of functions is already suffi-cient or can be expanded by theTOX® service experts.

StandardData bus • RS 232 / RS 485

• Ethernet TCP / IPFieldbus • Profibus-DP

OptionalInterbus instead of Profibus

Other Fieldbus available over Gateway, e.g. DeviceNet,ControlNet, Ethernet IP

Analog0-10 V, alternative to Profibus

Digital8 inputs / 8 outputsexpandable to 32

StandardData bus • Ethernet TCP/IP Fieldbus • Profibus-DP

• CanOPEN

OptionalOther Fieldbus available over Gateway, e.g. Interbus, DeviceNet,ControlNet, Ethernet IP

Analog0-10 V; two available with one free

Digital8 inputs / 4 outputsexpandable to 255

Spindle (Ill.: EPMK)

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TOX®-Axis-Controller line-Q and line-X

Configuration and Programmingwith the TOX®

SoftWareAll parameters, configuration and pro-gram functions residing inside thecontroller will be accessed with thesoftware module TOX®-Worx in thesoftware package TOX®

softWare. TheTOX®

softWare is delivered with eachTOX®-ElectricDrive. The followingsystem requirements are necessaryto access the TOX®

softWare in the axiscontroller:TOX®

softWare in the axis controller:• (Industrial) PC (Pentium III)• Operating system WIN2000 or

higher • Java Runtime

The circuit diagrams are includedwith the operating manuals. Onrequest, we can provide an info CDincluding wiring examples, TOX®

soft-

Ware, PLC building blocks and theoperating manual immediately afterreceipt of the order.

TOX®-Axis-Controller:the central intelligenceBoth freely programmable axis con-trollers are single axis controllers withintegrated logic and servo amplifier.They control and monitor all functionsof the TOX®-ElectricDrive system.Advantages include the highly dyna-mic processing of pressing programsand fast reaction to variations in theprocess. During and after production,the process data can be taken fromthe controller for further processing ordocumentation.

Common Characteristics:• Faster commissioning,

Plug and Work• Extensive programming and

diagnostic functions• Parameter programming of

processes (online and offline)• Pre-configured and pre-calibrated• Maintenance-free• Display and monitoring of force-

travel progressions• Graphical process analysis• Display of process results including

status, date and time stamp• Target position with monitoring of

force limits• Target force with monitoring of

position limits• Window monitoring• Sequential control• Run according to PLC standard

values• PLC function blocks e.g.

Siemens S7• Deflection compensation• Abstract from the standard function

library:- Force and/or travel controlled

commands- Functions for process control and

process data recording- Graphical displays

- Processing of input signals as wellas definition and setting of output signals

- Taring and continuous monitoringof force sensors

• Quality data management overEthernet and Fieldbus

• Commissioning function without PLC

• Input and allocation of calibration values of the force sensors

• Integration of external force sensors(DMS and 0-10 V are possible)

• Functional test of load cells• Highest safety category possible

(see page 2)• Axis controller and ballast resistor

can be installed in any applicable standard enclosure

• Electric connections are provided with plugs

• Integrated overload functions for motor and servo amplifier

• Electrical isolation betweencontroller and amplifier

• 3-cable technology• Protection degree IP20, can be

extended to IP54• Compact design with direct AC

supply and integrated resolver andmotor connection

• For spindle operation, includingprocess monitoring a PC is not required

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TOX®-Axis-Controller line-Q

Status displays LED

Status displaysLED I/O

X2-com-TerminalProgramming port

COM 2/3 RS 232(e.g. barcode input)

X10 Profibus/Interbus

X7 Ethernet

X6 I/O Expansion

X4/X5 Encoder input

X13/X14 Active/passivetransducer

X3 Encoder output

X1 Servofeedback

X50/X51 DigitalInput/Output

X40 Category 3 safety

X20 Motor plug

X31 Ballast resistorX30 AC Input

Complete panel in IP54.Customer specific solutionspossible on request.

Special solutionsSpecial properties of line-Q• Stores last 1000 process data sets• Memory for about 25 processes

(for TOX® standard workflows)• Digital force regulation with

0.5 ms sample rate of 0,5 ms • Four controllers are allocated

according to spindle sizes and arespecially matched to their capacityranges

• Customized interfaces are possible within a limited scope

General data and installation requirementsOperating conditionsCircuit type with grounded star-circuit unlimited use

IT-net Follow instructions for special measures!

StandardsConformity CE Low voltage directive (73/23/EWG)

Approvals UL 508C Power Conversion Equipment (File-No. 32659)

EnclosureEnclosure type IP20 not in the connecting area of the

motor side connectors.Contact protectionaccording to type 1

Climatic conditionsOperation* IEC/EN 60721-3-3 3K3 (+5 ... +40°C)

Derating of rated output current +40 ... +60°C: 1,5%/°C

air moisture max. 95%, without condensation*Attention: In case of an installation at 1000 m above sea level the reduction of the nominal current will be 15%/1000 m.

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125,6118

55,5

7

2,5

10,5

53,257

273,5

243,

9

277,

4

285

310,

8

206,5

+ UB

Rext

line-Q

X31

X10

X11/X12

X40

X2

X7

X13

X1

X20I/O

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TOX®-Single Axis Controller line-Q

Green: Scope of delivery TOX®-ElectricDrive SetRed: supplied by customer

Block diagramUse of the TOX®-ElectricDrive SystemSimplified presentation.

Ballastresistor

Emergency switch box with adelay of approx. 150 – 500 ms.as per risk analysis and after-running test

Emergency switch button light grille/protective door

PC

Servodrive

Ethernet, programming,process data

Motor

Control, digital, PLCEmer-gencyswitch

Resolver

RS 232 programmingprocess data

Standard Interface, Profibus

Optional interface, Interbus

Easy installation due tocompact cabinet designThe TOX®-Axis-Controller has beendesigned for optimized integration.

- Standard industrial power input:3 x 480 V (+5% ; -25%) =360 ... 504 V AC 50/60 Hz

- Dimensions of controller W/H/D:273.5/310.8/ 125.6 mm

- Dimensions of ballast resistor W/H/D: 30/60/355 mm

- Built-in depth of switch cabinet:300 mm

Force sensor

Standard interfaces• Ethernet• Profibus or Interbus• RS 232• RS 485

delayed

undelayed

to category 3switching-off

Ordering description: EDC2See offer or order confirmation forprecise description.

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TOX®-Axis-Controller line-X

Special solutions

Complete panel in IP54. Custo-mer specific solutions possible onrequest.

By plugging the axis-controller to oroff the mounting base, it can bequickly connected or replaced.

The plug-in system of the modulesmakes them easy to select and tochange:• Safety• Bus (communication)• Intelligence

Special properties of line-X• Storage of the last 500 process data

records• Digital force regulation with

sampling rate of 1ms• Memory for about 270 processes

(for TOX® standard workflows) • Six controllers are allocated

according to spindle sizes and arespecially matched to their capacityranges

• Customized interfaces are generallypossible

Pluggable modulesPluggable Axis controller Pluggable I/O connections

Mounting socket

Axis controller

Mains filter

Profibusmodule

EthernetTCP/IP module

Memorymodule

Safety module

Motorconnection

Basic applianceMainsconnection

Digital I/O

Diagnosticinterface

Resolver-connection

Analog Inputs/Outputs

CANonBOARD

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Functions and possibilites of line-X

General data and installation requirements

Exclusive properties of line-X• Integrated PLC functionality,

IEC 61131• Envelope curve monitoring• Controlling remaining bottom

thickness for clinching (quality dimension X)

• Integration of external distancesensorics

• All modules are pluggable• Customized fault diagnostics are

possible• Customized functions are possible

Current volume of special functionlibraryProcess jumps: process calling, sub-process calling• With process jumps it is possible to

define jumps into other processes during and/or at the end of aprocess.

Spindle data• By adding this function, you can

change the spindle data “on the fly”while the process is running. At the end of the process, the spindle data will be reset to the default value.This gives you the possibility to work with additional force sensors on one spindle.

Stopping the process• By adding this function, the process

is stopped. This is useful in combi-nation with the “conditional check”function.

Conditional check function (start-,target-, end condition)• Based on a selectable source (IO,

Fieldbus, variable). This function gives you the possibility to define multiple conditional targets within aprocess.

Set and evaluate integer and/or realvariables• This function is used to define an

integer and/or real variable for the “conditional check” function.

Operating conditionsCircuit type with grounded star-circuit unlimited use

IT-net Follow instructions for special measures!

StandardsConformity CE Low voltage directive (73/23/EWG)

Approvals UL 508C Power Conversion Equipment (File-No. 32659)

EnclosureEnclosure type EN 60529 IP20 not in the connecting area of the

motor side connectors.NEMA 250 Contact protectionaccording to type 1

Climatic conditionsOperation* IEC/EN 60721-3-3 EN 50178 3K3 (-10 ... +55°C)

Derating of rated output current +45 ... +55°C: 2,5%/°C

air moisture max. 85%, without condensation*Attention: In case of an installation at 1000 m above sea level the reduction of the nominal current will be 15%/1000 m.

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line-X

X105

MXI1

MSI

MMI

MXI2

X3

X7

X105I/O

X4, X5

a

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green: Scope of delivery TOX®-ElectricDrive Setred: supplied by customer

Blocks diagramUse of the TOX®-ElectricDrive-System.Simplified diagram.

Ballastresistor

Emergency switch box with adelay of approx. 150 – 500 msas per risk analysis and after-running test

Emergency switch button light grille/protective door

PC

Servodrive

Ethernet, programming,process data

Motor

Control, digital, PLCEmer-gencyswitch

undelayed

Resolver

Force sensor

Standard Interface, Profibus

approx. 150-500 msdelaySafety category 3

TOX®-Axis-Controller line-X

Size of the TOX®-ElectricPower Module

Dimensions a(mm)

Weight(kg)

EPMx 010 90 5,3

EPMx 025EPMx 055EPMx 100

120 8,1

Size ofthe TOX®-Electric PowerModule

Dimensions (mm)Wei-ght(kg)

a b b1 b2 e c1 d g mEPMx 200EPMx 400

206 606 556 630 294 170 585 6,5 12,5 26,5

Mounting dimensions Mounting plate Mains filter for EPM x 10-100

- Standard industrial power input: 3 x 180 - 550 V (+0% ; -0), Nominal power at 400 V AC 50/60 Hz- Dimensions of ballast resistor W/H/D: 30/60/355 mm- Built-in depth of switch cabinet: 400 mm

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Worx Diagram line-X

Worx-Project management line-X

CommissioningAn online mode enables the user tomonitor all controller functions andI/O in real time for commissioningand troubleshooting purposes.

Curve mappingI/O DisplayJog function

ProgrammingThe process cycle is configured byselecting process specific functionblocks from a menu, building a presssequence. No CNC code program-ming knowledge is required.

Click on the Menu function blockEnter the required parametersStart the processControl the process

TOX®SoftWare Facts and Features for line-Q and line-X

�� User friendly�� Easy configuration�� Integrated documentation�� Designed for touch screen use

�� Platform independent�� Supports all common interfaces�� Several user levels

Project environmentThe WORX-Module has pre-configu-red, ready to use press functionblocks which can be customized tothe individual application. A dialogbased project-wizard will aid in theinitial setup and assist in the projectlayout. Projects can be saved andcopied as templates for future use.

The Windows based user interfacehas a familiar look and feel enablingquick and easy navigation throughthe projects. The Explorer-style menulayout supports easy administrationof press programs and file handling.

Abstract from the function library line-X

TOX®SoftWare WORX

The TOX®SoftWare consists of the pro-

grams: Server (connection from thePC to the axis controller), WORX andHMI.

TOX®SoftWare is a new, interactive

Software Suite with completely inte-grated controls and monitoring functi-ons specifically designed for all appli-cations.

The user will be able to quickly defineand configure new projects withoutthe knowledge of any programminglanguage. Operating interface andsoftware are programmed by TOX®

and may be adapted in conformitywith customer’s request.

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TOX®SoftWare HMI

• Adaptable screen surface• Messages can be freely defined

(errors, information, status, etc.)• Manual / Automatic screen• Diagnostic screen with logbook• Process data export in Excel-compatible CSV

format for quality management• Counter (total, IO ,NIO, maintenance intervals)• Protected against unlicensed change access by

authorization• Special screens with additional information can be

integrated (e.g. temperature indicators, travelmeasuring systems and the like)

• Backup of all parameters by pressing a button

Manual operation picture line-Q

TTM(TOX® Touch Menue) line-Q

Diagnostic module line-Q

HMI-communication environment(HMI = Human-Machine-Interface)The TOX®

SoftWare includes an HMI for the operator tocontrol and visualize the process. The user platformcan be adapted by the user. It is also possible toconfigure a data export in this part of the software.

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Graphics module line-Q

Sequence module line-Q

Process data export in graphics module line-Q

TOX®SoftWare HMI with line-Q

Process control using the window technique

Monitoring of a force/travel progression ofa process with defined windows.

+ An almost unlimited number of force/travelwindows can be defined.

Sequential control – expanded process admini-stration and simplified conversion scenario

+ Piecepart-specific parameter change by pressing a button and selection of another sequence

+ Maximum number of processes limited only by thehard drive capacity

+ Dynamically controlled process flow with IO/NIO statement

+ Highly efficient manual workplaces thru single cycle control possibility

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Clinching module with envelope curve line-Q

Pressing module process parameter line-Q

Clinching module process parameter line-Q

MonitoringThe HMI collects the complete force/travel diagramsand evaluates them with the help of freely program-mable windows and/or envelope curves. The valuescan be zoomed and displayed in different ways.SPC Data can be archived (SPC: statistic processcontrol).

TOX®SoftWare HMI with line-X

Simple teach-in mode+ Automatic teaching of the processes and the force

limits in the target window and the envelope+ no programming, just parameter setting+ automatic scaling of diagrams

Process monitoring using envelope curvesThe envelope curve determines by two limit curvesthe path of the force/travel progression+ Full monitoring within the set point and target

windows, i.e. the force/travel characteristics curvecan not fall outside the upper and lower limits

+ Selection possibility!For curves deviating from the envelope, theseoptions apply:

process will continue until targetwindow is reachedstop process

Pressing module for highly flexible pressingprocedures+ Cockpit function due to complete parameter setting

on one screen+ High precision possible, for example, by the

integration of different piecepart specific deflectionvalues in the process flow

+ High repetitive accuracy, for example, by thepossible compensation of dimensional fluctuations of piecepart lengths

+ Complex process flows can be realized(several jump function, sub-process calling etc.)

Clinch module for the modern sheet metaljoining technologyPrecise control of the quality dimension X (remai-ning bottom thickness after the clinching process) inconsideration of the machine deflection. Irregulari-ties in production (fluctuations in sheet metal thick-ness, fluctuations in surface condition ...) could other-wise cause fluctuations of the dimension X.

+ active stabilization of variancestechnical optimum achieved with an accuracy of± 0,04 mm

+ the X dimension is assured independent ofmaterial combination and properties

Point diameter

Controldimension "X"Controldimension "X"

ePunch sideDie side

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Control Options for line-Q and line-X

IP54 enclosure

For axis controller package, includingfan or cooling unit. Specificationsaccording to TOX® Standards. Specialexecutions available on request(Example see picture page 12 and14).

Safety Controls

All the following control variants aretype-examination tested.

Basic Controls:

• Cycle initiation over 2-hand buttons.Both switches must be held down during the complete cycle.

• Visualization over IPC with swivel arm to be mounted on pressframe with flange selectively from aboveor below.

Light Curtain Controls:

• Safety guarding and controlling versionTwo operating modes are available:1. The light curtain has no control-

ling function. Cycle initiation over 1-hand switch or foot switch.

2. The light curtain has a controlling function. Cycle initiation after endof light curtain interruption(so-called Talot control)

Special executions (on request):• Software integration of external

components, e.g. sensors fortemperature, travel, etc.

• Activation of additional motions, e.g.for a sliding table, a guarding door, etc.

Industrial PC from TOX®:the sturdy alternative to usual PC systems

Options to Basic Controls:• Function safe return stroke.

The return stroke of a press takes place automatically after completingthe press cycle. The switches do nothave to be held down during the return stroke.

• Function safe speed. The drive extends with a maximum speed of 10 mm/s. The controls can beactivated with a 1-hand switch or foot switch.

Control with protective door:• Cycle initiation by 1-hand switch or

foot switch• The pressing process is only started

if the protective door is closed

Execution IPC with stainlesshousing, rack mount

version

High speed IPC in panel mount version Terminal: embeddedIPC rack aspanel mount

Touchscreen 12.1 inch TFT (SVGA) 12.1 inch TFT (SVGA) 17 inch TFT (SXGA) 12.1 inch TFT (SVGA)

Operating system Windows XP TOX® Linux

Software TOX®softWare TOX®

softWare Terminalwith reduced function, forline-Q only

Mass storage 40 GB HD 512 MB CF Card

Interfaces 2x USB (one front con-nection), 1 x Ethernet10/100 Base- T RJ-45,2 x PS/2,1 x COM1 RS232,1 x VGA-CRT, 1 x LPT

2 x USB (one front connection)1 x Ethernet 10/100 Base- T RJ-45

2 x PS/21 x COM1 RS232

1 x VGA-CRT1 x LPT

4 x USB (two front connections)

1 x Ethernet 10/100 Base-T RJ-45

Ambient temperature +5°C...+40°C +5°C...+45°C +5°C...+50°C

In contrast to a terminal, the Industri-al PC (IPC) allows additional pro-grams to be installed.

Particularly ruggedbased on solid statecircuitry. Offline opera-tion is not possiblewith this terminal.

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www.tox-de.com

For the re-calibration of the TOX®-ElectricPower Module. The intervalfor the re-calibration is fixed by cus-tomer’s quality management.

Calibration equipment type ZKEIncludes:- Precision force sensor

10, 50, 100 or 200 kN- Digital display unit- Shockproof power cord- Calibration certificate- Aluminum case

Planning and design of completepresses and special machines.

TOX® PRESSOTECHNIK helps yousolve your production demands withthe application of specific solutionsmade with components from ourstandard product line.

Realization of electro-mechanic pres-ses of utmost safety level (see page2) and tested by the GermanEmployer’s Liability Insurance Asso-ciation.

ApplicationsFrom the TOX building blocks to special machines

Possible on request.

Accessories

Grease gun for re-greasing the TOX®-ElectricDrive Systems

Greasing intervals and amountaccording to the manual,suitable for 400g TOX®-Spindlegrease cartridge.

It is a must for the reliable operationof the spindle.Order no.: ZFP

400g TOX®-Special greasecartridgeOrder no.: ZFE

Automatic lubrication forTOX®-ElectricPower Module

40.0804.02

TOX®-Press series PCWith 2-column ram guide, EPMK100 with brake, protective hood withexhaust fan, safety 2-hand controls,function “safe direction” with opera-tor guarding and touch screen IPCwith TOX®

softWaresee picture page 3

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www.tox-de.com

Applications

TOX®-Press series MBwith 2-column ram guide, baseUUM, EPMK 55 with brake, safetycontrol with protective door and1-hand key with function “safespeed” for inching operation withopen protective door andTOX®

softWare

TOX®-Automatic stationC-frame type CEJ with CERstand, EPMR 55, TOX®-Clinchingtools and TOX® lube sprayequipment

TOX®-Press series MAGWith 4-column ram guide,EPMK 100 with holding brake,slide table with locking cylinder,UUM of welded construction,safety control with protectivedoor and 1-hand key or footpedal, with touch screen IPCwith TOX®

softWare

TOX®-Automatic stationC-frame type CEB with CER stand,EPMK 55 positioning cylinder forCEB, EPMK 55 for pressing andpulling operation, EPMK 10 pre-load axis with external force sensor

TOX®-Press series PCWith 2-column ram guide, forpressing and pulling operation,EPMK 400 with brake, protectivehood with exhaust fan, safetycontrols with function “safespeed”, stroke initiation via1-hand key or foot pedal

TOX®-Automatic stationseries CMBWith linear guided ram mountedin the C-frame, UUM table,EPMK 100, control for automaticoperation with touch screen IPCwith TOX®

softWare

40.0804.02

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Our Worldwide Sales and Service Network

TOX® PRESSOTECHNIKRiedstraße 4D-88250 WeingartenTel. +49 (0) 7 51 / 50 07-0Fax +49 (0) 7 51 / 5 23 91E-Mail: [email protected]

GMBH &CO. KG

40.0804.02 Subject to technical alternations.

TOX®-Production

Systems

TOX®-Fastener-

Insertion

TOX®-Piercing

and Marking

TOX®-Tongs

TOX®-Joining-

Systems

TOX®-Controls,

TOX®-Monitoring

TOX®-Presses

TOX®-FinePress

TOX®-ElectricDrive

TOX®-PowerKurver

TOX®-Powerpackage

Product Range

electricdrive electro-mechanical servo systems · 3 qx l i n e - the electro-mechanical servo...

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