Embed Size (px)
Citation preview
Pneumatic Forces from 2 – 2000 kN
TOX®-Powerpackage
2 www.tox-en.com 10.201203.en
TOX®-PowerpackageIdeal Source for Forces from 2 – 2000 kN
TOX®-Powerpackage - the energysaving Pneumatic intensifier withintegrated oil system and automa-tic activated power stroke. Ourtechnology combines Pneumaticsand Hydraulics providing you withthe following advantages:
– Lower energy consumption– Compact, clean design– High stroke frequency– Soft-touch: easy on your tooling– Reduced noise level
The TOX®-Powerpackage operatesonly on shop air, without hydraulicpower units. The controls are verysimple, the same as for any doubleacting pneumatic cylinder.
The operating stroke is divided intothree stages:– air-operated approach stroke– pneumohydraulic power stroke– air-operated return stroke
The simple design, with few movingparts, assures you of trouble-freeoperation for many years. The lowapproach forces protect your toolingand reduce the noise level.
High stroke frequencies are easilyachieved with minimal air consump-tion. In addition, small air connectionsallow the use of small, compact, moreeconomical valves.
Application:Any manufacturing operation requiringpressing forces from 2 – 2000 kN withpower stroke up to 80 mm and totalstroke up to 400 mm.
The “Logical”AlternativeOur compact, integrated system putsthe pressure on all mechanical, tog-gle, hydraulic, and air-guzzling pneu-matic systems. Simple installation andcontrols make it the ideal alternative.
The advantages in detailThe thoroughly thought out design ofour TOX®-Powerpackage is proved bythe patented details. So, for example,the oil refill system is equipped withan anti-overfill safety for trouble-freemaintenance. Overfilling is avoided.
Our patented intensifier with absoluteair/oil separation is unique in its sim-plicity. Due to the intensifier pistonbeing equipped with spring reset,savings of 85% of the energy neededfor the power stroke of a double-acting cylinder are realized.
Stroke Frequency Diagram at 70% Force Capacity
Power stroke (mm)
Str
okes
/min
Type
TO
X®-
Pow
erpa
ckag
e
Note: Precise stroke frequency and air consumption figures are available on request.
3www.tox-en.com10.201203.en
• Standard features onS Series, from S 4 on: integrated hydraulic endposition cushion, patented
• Central power bypass version ZLB can be retrofittedon all TOX®-Powerpackages,patented.
Reliable Power, Day In and Day OutDue to the double supported workingrod a bearing length to diameter ratioup to 10:1 can be achieved.
The TOX®-Powerpackage cylinderscan be mounted in any orientation.
ClinchingTOX®-sheet metaljoining
Punching, Piercing Coining, Marking,Stamping
Pressing,Compressing,Straightening
Riveting, Crimping,Flaring
Assembling,Press-Fitting,Mounting
Bending, Edging Clamping,Tensioning, Peening
4
e
1
1
www.tox-en.com 10.201203.en
TOX®-Powerpackage – Simple to handle like a Pneumatic
The Power in DetailThe TOX®-Powerpackage is a com-pletely integrated power drive. Thedifferent configurations and the spe-cially developed accessories make ituniversally adaptable. In special appli-cations, such as spotwelding, theTOX®-Power package is optimizedaccording to your requirement.
Developed to the smallest detail:More than 150.000 successfulworldwide applications have pro-ven it.
1. The pilot mounting gives preciselocation, and the standard boltpattern allows for quick and easymounting.
2. The working rod is cushioned inboth end positions with long-lifecushions; this is the key to smoothoperation, even at high frequencies.
3. The seals have been optimizedthrough extensive endurance testing.
4. Special seals allow for operationwith non-lubricated compressed air.
5. The TOX®-Powerpackage delivershigh forces in a compact design. Thedouble supported working rod hasenormous significance for toleratingthe most rugged working environ-ments.
6. The absolute air/oil separation isthe reason for low maintenance, highstroke frequencies and trouble-freeoperation. An annular groove, bet-ween the seals separating the air andoil sections and vented to the atmo-sphere, prevents the air from mixingwith the oil.
Fast approach - the main control valve “a” isswitched. The working piston 1 extends athigh speed until it meets resistance at anypoint of the stroke. This resistance causes thechangeover of the included power strokesequence valve “d”.
Power stroke - the intensifier plunger 3 pas-ses the high pressure seal and compressesthe oil in the working area 5 up to 400 bar.This oil pressure acts on the back of workingrod 1 and generates the power stroke.
Return stroke - switching the main controlvalve “a” again results in switching of thepower stroke valve “d” and venting of cham-ber “e”. The working piston 1 and the intensi-fier piston 2 return to their initial position.
Functioning of the TOX®-Powerpackage
PowerValve1.2
4 2
1 53
Flow ControlForward Stroke
Flow ControlRetract Stroke
F
21
3
7654
16
Oil Level Indicatorpneumatic or electric
Flow Control “X”
Retracted position
Air operated fast approach
Pneumatic hydraulic power stroke
Resistance activates powerstroke independent of travelposition
fastapproach
start of
powerstrokereturn stroke
power stroke
5www.tox-en.com10.201203.en
7. Each TOX®-Powerpackage featuresa standard high pressure measuringconnector. The following functions canbe performed:– constant press force independent
of the supply air pressure by acti-vating the return stroke when a preset oil pressure has been rea-ched
– monitoring supply pressure to aidin quality control
– activation of subsequent operati-ons
– pressure gauge, etc.
8. Oil level indicator. Accessoriesinclude pneumatic and electric moni-toring, also available with remote con-trols.
9. Oil refill connection.
Cylinder, powerful like a Hydraulic Cylinder
Flow ControlPower Stroke
Back Pressure Line
1310
8
9 11
11
12 1514
Air Supply Intensifier
ZDO
Indicatoric or electric
F
The components shown in green are included with each unit.
The components shown in red are optional and available as accessories.
10. Constant pressure, closedsystem, oil reservoir for extended refillintervals.
11. The patented anti-overfill systemeliminates problems when refilling thecylinder with oil. The snap ring moun-ted inside the intensifier barrel limitsthe travel of the feed piston. If thecylinder is overfilled, the excess oil isremoved by the integrated pressurerelief valve.
12. The intensifier spring serves adual function, the return of the intensi-fier piston and provide a constantpressure on the oil reservoir withoutany pneumatic hookup. This results ina trouble-free operation of the TOX®-Powerpackage in any mounting orien-tation, e.g. in robotic applications. Inaddition, the patented spring provides
savings in air consumption of theTOX®-Powerpackage. The return stro-ke does not require a high consumpti-on pneumatic supply.
13. The intensifier piston generatesthe high force during the power stro-ke. Different power stroke require-ments can be easily achieved bychanging the dimensions of the plun-ger on the intensifier piston.
14. The change-over from approachstroke to power stroke takes placeautomatically as soon as the workingrod meets resistance. The change-over time can be adjusted with theflow control valve “X”.
15. The complete controls are eithermounted to the TOX®-Powerpackageor have been integrated into the flan-ge for an even more compact design.What this means to you: the TOX®-Powerpackage is controlled like anydouble acting pneumatic cylinder witha 4/2- or a 5/2-way directional valve.
16. From cylinder size S 4 upwardsall TOX®-Powerpackages are equip-ped with the integrated, patented,hydraulic end position cushion.Thus an optimal dam pening in theretracted position is guaranteed –especially in case of applicationswith high tool weight.
Other functions can be easily done,e.g., travel dependent activation of thepower stroke, approach or power stro-ke at different air pressures, or use ofproportional valves.
6 www.tox-en.com
TOX®-Powerpackage:Comparison with other Systems
1. Costs- Investment
- Processspeed
- EnergyConsumptionper Stroke
- Maintenance
2. Quality
3. SystemFlexibility
4. Environment
5. Disadvan-tages
The TOX®-Powerpackage
Relatively low to medium costs; inexpensivepneumatic controls: simple mounting (examples).
24 kN € 1.900,-80 kN € 2.270,-
300 kN € 4.040,-1000 kN € 10.600,-
Based on cycle rates:for 24 kN 100 strokes/minfor 80 kN 80 strokes/minfor 300 kN 50 strokes/minfor 1000 kN 30 strokes/min
in liters (CF) normal air:for 24 kN 4.75 l (.17 CF)for 80 kN 16.00 l (.57 CF)for 300 kN 59.00 l (2.08 CF)for 1000 kN 198.00 l (7.00 CF)
Easy to exchange; compact design; minimal wear;seals last many millions of cycles. Simple mainte-nance consists of oil refilling and bleeding when lowoil level indicator pops out.
Easy on tooling due to soft touch during approachstroke. Independent speed controls for approach,retract and power strokes. Force can be preciselycontrolled with a pressure switch and monitored witha gauge. Workpiece tolerance stackups are com-pensated automatically by the resistance activatedpower stroke. Stroke adjustment is not required whenchanging tooling. Precise rod guidance is providedby supporting it on both ends.
Very flexible: units available in many stroke lengths.In special cases, the units can be stroked repeatedlyto achieve longer power strokes.
Ideal for clean room applications. Low noise due tosoft touch. Low air consumption also provides lownoise levels of exhausts.
Units are long for very long power stroke require-ments (split execution can be used in such cases).
Alternative 1Toggle with pneumatic cylinder
Low to medium costs. Limited force range.
24 kN € 2.659,-80 kN not available
300 kN not available1000 kN not available
60 strokes/min- - -
in liters (CF) normal air:17.0 l (60 CF)- --
Large ports and connections requirements. Proneto linkage wear and excessive play affecting endproduct quality.
The force curve rises parabolically and is not adjusta-ble. Therefore, ram position must be adjusted for pro-per force output. Power stroke adjustment is notpossible. The force is position dependent. Parttolerances are critical. External ram guidance isrequired.
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 air pressure, 60 mm total stroke, 3 mm included power stroke, press force 24 kN / 80 kN / 300 kN / 1000 kN
Fastapproachstroke
Forward stroke
Power stroke
Return stroke
Retract force
App
roac
hfo
rce
Pre
ss-
f orc
e
Retractstroke
Forwardstroke
For
ce o
utpu
t
10.201203.en
7www.tox-en.com10.201203.en
Alternative 2Pneumatic cylinder
Low costs. Limited force range.
24 kN € 1.023,-80 kN € 2.250,-
300 kN not available1000 kN not available
60 strokes/min30 strokes/min--
in liters (CF) normal air:35.0 l (1.24 CF)
117.0 l (4.13 CF)--
Large ports and connections requirements. Large in size. Lowwear.
High impact forces. Forward and retract strokes are adjustablein speed and force. No possibility for power stroke adjustments.Power throughout stroke. No compensation for variations inpart tolerances.
Force available throughout stroke.
High air consumption. High noise level due to exhaust of largeports.
Large bores result in large mounting envelopes and high airconsumption.
Alternative 3Hydraulic system
Medium to high costs. Complicated controls andinstallation.
24 kN € 3.426,-80 kN up to
300 kN1000 kN € 21.730,-
80 strokes/min60 strokes/min30 strokes/min20 strokes/min
Depending on controls.For simple controlsand small loads,up to 80 kN/80 strokes/min.
Very complicated controlsrequired for large units.
Change of oil and filters required periodically. Oil leakage,contamination requires continuous maintenance. Complica-ted installation and plumbing.
Low-force approach stroke is possible only with specialsystems. Approach and retract speeds are adjustable;power stroke can be controlled with pressure switch. Forceavailable throughout stroke, compensates for variations inpart tolerances.
Force available throughout stroke.
High noise levels. Contamination, oil leakage. Heat gener-ated by pump.
High energy consumption. Leakage.
Retract stroke
Retract forceApproach force
Press force
Approachstroke Power stroke
For
ce o
utpu
t
Forward stroke
Retract stroke
Retract forceApproach force
Press force
Approachstroke Power stroke
For
ce o
utpu
t
Forward stroke
8 www.tox-en.com 10.201203.en
TOX®-Powerpackage –the Complete Power Source Program
Type S (Standard)Application: generalFast Approach/Return StrokesHigh Stroke FrequenciesPneumatic Forces: 2 – 1000 kNTotal Stroke: up to 400 mmPower Stroke: up to 80 mmOperating Pressure: up to 10 bar(Version .30 up to 6 bar)
Preferred series Q-SPneumatic Forces: 10 – 300 kN
Type K (Compact)Application: generalFast Approach/Return StrokesHigh Stroke FrequenciesShort Design - Side by SidePneumatic Forces: 2 – 500 kNTotal Stroke: up to 400 mmPower Stroke: up to 50 mmOperating Pressure: up to 10 bar(Version .30 up to 6 bar)
Preferred series Q-KPneumatic Forces: 10 – 150 kN
Type KTPneumatic Forces: 2 – 2000 kNTotal Stroke: up to 400 mmPower Stroke: up to 400 mmOperating Pressure: up to 10 bar
Type RP (Marking Cylinder)Application: MarkingPneumatic Force: up to 150 kNTotal Stroke: 32 mmPower Stroke: 3 mm
Type T (Turbo)Application: high-speed frequenciesup to 550 strokes/min.Pneumatic Force: up to 120 kNPower Stroke: 6 and 12 mm
Type P/K/VH(Spot Welding Cylinders)Application: Welding engineeringfor portable and robotic tongs aswell as for stationary fixtures.
Types S and Q-S
Types K and Q-K
Type RP
NEW
NEW
9www.tox-en.com10.201203.en
Type Swith long power strokes
Type S 50with power stroke limiter
Type T (Turbo)
Type K 51with total stroke limiter
A drive from the TOX®-ElectricDrive Program.A Servo-System with 0.25 – 500 kN press force.
The alternative:
Type EPMK
Type KTwith separate booster formultiple working cylinders
Special versions upon request.
10 www.tox-en.com 10.201203.en
TOX®-Powerpackage in Industrial Applications
The TOX®-Powerpackage can be easi-ly mounted on linear tracks, therebyproviding a simple, flexible customi-zed machine. Simplicity is further pro-vided by the lack of hydraulics andthe use of simple controls.
TOX®-Powerpackage PressesThe functional building-block principleof the TOX®-Presses simplifies thematch to the individual applicationand results in an efficient, economicalsolution. The power is supplied by theTOX®-Powerpackage, the ideal solu-tion for efficiency and trouble-freeoperation.
The TOX®-Powerpackage is the idealdrive for sheet metal joining tasksusing the innovative TOX®-Clinch orTOX®-ClinchRivet technologies,invented by and patented for TOX®
PRESSOTECHNIK, whether used inportable tongs, robot tongs or insingle and multipoint fixtures.
With TOX®-Clinching all types of sheetmetal can be joined, replacing spotwelding, forming a strong, burr-freeconnection. TOX® also joins galvani-zed and prepainted materials. Dissi-milar materials of different thicknes-ses, even sandwiched layers are easi-ly joined with TOX®-Clinch technology.
The picture below shows a 6-pointTOX®-Clinching machine to join elec-tric cable channels, with 3 S-typeTOX®-Powerpackage cylinders of80 kN press force each.
11www.tox-en.com10.201203.en
Extract from our customer list:AGFA, AUDI, BASF, Bauknecht,BMW, Bosch-Siemens, Buderus,Daimler, FAG, Ferrari, Fiat, Ford,GEZE, GM, Kienzle, Mann & Hummel, Metabo, Michelin, MTU, Olympia, Opel, Peugeot, Philips,Phoenix, Porsche, Renault, Siemens, Thyssen, VARTA, VDO,VW, etc.
In the countries:Argentinia, Austria, Belgium, Brazil, China, Czechia, Denmark,Egypt, Finland, France, Great Britain, Hungary, India, Italy, Japan, Korea, Malaysia, Mexico, Netherlands, Poland, Portugal,Romania, Russia, Saudi Arabia,Singapore, Slowakia, Slowenia, Spain, South Africa, Sweden, Switzerland, Thailand, Turkey andUSA we are present either withdaughter companies, joint ven-tures or representatives.
Application of 3 TOX®-Powerpackagecylinders in a series valve production.High frequencies, compactness andreliability over millions of cycles arethe basis for satisfied customers.
TOX®-Robot Tongs andTOX®-Machine Mount TongsAre designed for universal use. Theunits are supplied complete andready to run. The TOX®-Powerpacka-ge features hydraulic cushion for thereturn stroke for smooth operation.
12
Our Worldwide Sales and Service Network
10.201203.en Subject to technical alterations.
TOX®-ProductionSystems
TOX®-Press-Fitting
TOX®-Punching
TOX®-Coining
TOX®-Tongs
TOX®-Joining-Systems
TOX®-Controls
TOX®-Monitoring
TOX®-Presses
TOX®-FinePress
TOX®-ElectricDrive
TOX®-PowerKurver
TOX®-Powerpackage
Product Range
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
