Joining with even greater intelligence and precision

Kistler presents electromechanical joining systems that wirelessly transmit measurement data using advanced telemetry—delivering even more accurate results and precise process monitoring. With the new Type 2164A NCFx Pro joining modules, users can choose between two sensor technologies: a piezoelectric force sensor featuring an exceptionally wide, flexible measuring range and enhanced overload protection, or a strain gauge-based force sensor. Both sensors are integrated directly into the servo press’s tool mount—precisely where the joining force is applied. Compared to their predecessors, the new joining modules are slimmer, faster, and optimally designed for future functional expansions such as predictive maintenance. These electromechanical NC joining modules are also available as standard in an angled configuration for use in confined spaces.

A fundamental principle of metrology is that the closer the measurement is taken to the point of action, the more accurate the results. This applies equally to joining systems, where sensors verify that the system is applying the correct amount of force. Thanks to telemetry, the force sensor in Kistler’s new NCFx Pro series electromechanical joining modules is integrated into the front of the tool mount—specifically on the ram—right where the joining force is generated. Data transmission from the sensor to the electronics within the joining module housing is entirely digital. Data is transferred to the maXYmos NC process monitoring system via an EtherCAT interface.

This digital communication offers several advantages: it is less susceptible to interference, provides extensive diagnostic capabilities, and allows direct access to additional sensor data, such as readings from integrated temperature sensors. Furthermore, cable length no longer affects measurement accuracy, system stability is further enhanced, and potential sources of error are minimized. Thanks to the new sensor position and digital data transmission, these energy-efficient servo presses achieve a new level of precision for applications in the electronics, medical technology, and automotive industries. "Precision and reliability are key requirements for our customers, particularly when assembling steering systems, chassis components, axles, and other safety-critical parts. This is where the new product family offers decisive advantages," reports Alexander Müller, who is responsible for these joining systems at Kistler.

Flexibility through piezoelectric measurement technology

Strain gauge (DMS) force sensors cover measurement ranges from 2 to 120 kN, while piezoelectric force sensors cover ranges from 0.05 to 120 kN. Depending on the specific model, piezoelectric sensors allow the use of seven predefined measurement ranges via the maXYmos NC process monitoring system. This selection capability enables more accurate measurements while simultaneously offering high overload protection, especially in the lower measurement ranges. Users also benefit from reduced spare parts inventory requirements ("one-fits-all" approach) and flexible system adaptation without the need for recalibration.

Both joining module variants—featuring either piezoelectric or strain gauge force sensors—are designed with a 20 percent overload reserve. This reserve provides added safety should the actual joining force exceed the planned value. Furthermore, both sensor types are mechanically compatible; they can be easily swapped or reordered for capacities of 2 kN and up, and can be sent in for calibration. Optional DAkkS calibration is currently in preparation. Thanks to plug-and-play functionality, the sensors—including their sensitivity and measurement range data—are automatically detected. This prevents errors during commissioning and significantly simplifies handling. Simplified integration and commissioning of new electromechanical joining systems thanks to compact design

With speeds ranging from 250 to 500 millimeters per second, Kistler’s new NCFx Pro series electromechanical joining modules achieve significantly faster cycle times, thereby boosting productivity in automated manufacturing processes. They also feature a more compact design that allows for tighter axis spacing and a reduced footprint, facilitating integration into existing machine layouts. Another advantage: for models up to 60 kN, only a single cable is required to connect the motor for commissioning. The new ctrlX Drive servo amplifiers are also more compact, saving additional space in the control cabinet. A safety zone box for SMES, SMST2, and safely reduced speed functions is no longer required.

The joining module itself also features a plug-and-play architecture, allowing users to commission it quickly without complex parameterization. An external lubrication port enables easy maintenance and connection to a central lubrication system.

Forward-looking: acceleration sensor for future predictive maintenance function already integrated

When developing the NCFx Pro series of electromechanical joining systems, Kistler placed special emphasis on future-proofing. Consequently, a further sensor-based enhancement is already under development, as Alexander Müller reveals: "An acceleration sensor for upcoming predictive maintenance functionality is already integrated into the NCFx Pro joining modules. This feature can be activated later via a software license through the maXYmos NC process monitoring system—without requiring any further modifications."