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Brochure UFM Line5

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UFM Line5
PROMESS assembly presses for
assembly and joining applications
with force-distance monitoring
Gerhard Lechler founded the company
PROMESS in 1977 as an engineering of-
ce in the eld of technical measurement
in Berlin. Initially, the company distributed
handmade patented measuring bearings
for tool condition monitoring before the
electro-mechanical assembly press (UFM)
with integrated NC control was born at the
end of the 1980s. Right from the begin-
ning it was the strength and the passion
From process development to pre-
liminary testing, from initial installation
to daily production, PROMESS offers
holistic expertise from a single source.
Our specialist teams have comprehen-
sive knowledge of our products and
offer prompt and effective advice world-
wide.
Today PROMESS is one of the global
leaders in the manufacturing of elec-
of Gerhard Lechler to develop technical
solutions for his customers. And this has
not changed until today. This passion has
continued so that the core competence
of PROMESS is still the development of
complete technological systems for sol-
ving the individual and complex assem-
bly and testing tasks and requirements of
our customers.
tro-mechanical assembly presses with
the widest range of presses in this eld.
Currently, more than 15,000 presses are
operating in heavy industrial applica-
tions.
In almost 30 countries all over the world
our sales and service partners are
looking forward to your enquiries and
questions.
Your partner in the eld of assembly and testing technology
Austria
Argentina
Belgium
Brazil
Canada
China
Czech Republic
Denmark
France
Germany
Great Britain
Hungary
India
Italy
Korea
Malaysia
Mexico
Netherlands
Norway
Poland
Romania
Singapore
Slovakia
South Africa
Spain
Sweden
Switzerland
Thailand
Turkey
USA
PROMESS UFM Line5 32 PROMESS UFM Line5
UFM Line5
The UFM Line5 range includes
standard press designs with an optimum
price/performance ratio. They are well
suited for assembly and joining applications
with force-distance monitoring and can be
integrated in automated assembly lines,
test stations or manual workstations.
Overview of Press Types
Advantages
n Standard model includes absolute encoders that
eliminate the need for referencing
n Only the power amp is required, no need for an
additional external monitoring system
n Multi measurement with 24-bit resolution
n Multi range calibration for force input (optional)
n Sensor system can be easily extended using
versatile PROMESS-BUS
n Field busses can be optionally expanded using
plug-in modules
n Utilization of window and envelope technologies
n No PLC knowledge required
n Movement and monitoring as an integrated solution
n Slim internal micrometer
n Automatic grease unit optionally available
n Integrated program memory
n PLe for STO by default
TyPE fORcE STROkE SPEEd
Type 1 10 kN 350 mm 300 mm/s
Type 2 30 kN 350 mm 250 mm/s
Type 3 60 kN 350 mm 250 mm/s
Type 4 100 kN 350 mm 200 mm/s
Type 5 200 kN 350 mm 100 mm/s
PROMESS UFM Line5 54 PROMESS UFM Line5 PROMESS UFM Line5 54 PROMESS UFM Line5
Mechanics
The Line5 universal joining module
is robustly designed thus making it
well suited for heavy duty cycles.
The mechanical system consists of
the following components:
AC servo motor with integrated
absolute encoder, precision gearbox
(except type 1), integrated force
transducer, robust steel enclosure,
screw assembly, non-rotating press
ram
The units use an inline design, i.e.,
the shaft is driven by a motor spindle
in line with the shaft. The excellent
rotational characteristics of this sys-
System Design
The mechanical system is controlled by
a power amplier with an integrated NC
module. The internal RISC processor
coordinates the joining module and can
be easily programmed and operated
using a conventional PC/display.
The controller coordinates the
mechanical motion of the press as well
as monitoring the force and distance.
The force-distance characteristic can
be monitored using envelopes and/
or window methods. The data can be
edited numerically and graphically so
tem provide excellent dynamic response.
However for compact installation spaces,
we recommend joining the modules using
an angled motor spindle.
The integrated absolute encode
ensures precise positioning and
eliminates the need for referencing
at the start of a cycle.
that each individual process can be
easily monitored. The automatic learning
function allows customers to eliminate
the need for custom programming and
simply learn the processing limits using
a good part. Quality assurance data is
stored using the database plugin and
can be re-used at any time.
The system utilizes a digital preamplier,
PROMESS digital module PDM-S. This
transfers the force signal at a resolution
Design basis for all
mechanical parts:
fNominal = 2.5 x CDyn
This guarantees an
extremely long life cycle
(min. 12 million strokes on
average for standard
assembly processes)
Set-up of the mechanics
1. Servo motor with absolute encoder
2. Gearbox
3. Integrated strain-gauge force transducer
4. Steel housing
5. Mounting ange
6. Non-rotating press ram
1
2
3
4
5
6
Basic version
Power cable
Field bus
SPS
Ethernet
PROMESS-BUS
UFM Line5
PDM-S
Position encoder (optional)
Server / Network
Standard or
Industrial-PC
- Visualization
- Database
- Program Memory
Power amplier
PROMESS UFM Line5 76 PROMESS UFM Line5
Extension/Options
Line conguration
of 24-bit almost trouble-free. When the
characteristics are calibrated, the joining
system achieves a system accuracy of
0.3 % from the nal value. The characte-
ristic calibration process is comparable
to a multispan calibration for 10 spans.
The characteristic map is created
automatically using the UFMR Calibrate
plugin. The results are stored in a cali-
bration report and can be printed out.
The PROMESS Digital Module PDM-S
contains an input for connecting a force
transducer (strain gauge) as well as
an encoder input for connecting digital
sensors. The PDM-S is digitally connec-
ted to the UFM control via the PROMESS
BUS.
Standard or
Industrial-PC
- Visualization
- Database
- Program Memory
Power cable
Field bus
PLC
Ethernet
PROMESS-BUS
UFM Line5
Ext.
Force Transducer
PDM-S
PDM-S
Server / Network
Can be expanded as
desired
PDM-IO 16 Inputs/Outputs
PDM-A 4 Analogue inputs
PDM-P Force (Piezo) + Distance
PDM-S Force (DMS) + Distance
Field bus
PLC
Ethernet
UFM Line5
Server / Network
Standard or Industrial-PC
Power amplier
PDM-S PROMESS-BUS
Power amplier
PROMESS UFM Line5 98 PROMESS UFM Line5
Highlights for
demanding
applications:
n Positioning on force slope:
Joining components until a
denite slope (increasing force)
or relatively once a knee-point
has been detected.
n Controller module:
This module allows you to
easily solve processes by
controlling the process
variables and maintaining
constant signals, e.g., spinning
operations with constant force
controlling.
n Measurement data system:
Measurement data can be
captured relative to positions
and force, but also relative to
freely denable reference points
(e.g., relative to achieving a
specic threshold).
n Bending compensation:
Not only customizable for
separate systems, also for
specic processes and
components.
Main window
Entry screen Move
Entry screen Press to Signal
Entry screen Tare
Software
As standard, the UFM Line5 range of
presses come with the UFM V5.xx
programming software. This software
is intuitive to operate and does not
require any PLC expertise. It can be
used to create simple or advanced
joining processes.
The integrated User Administration
feature offers multiple permission levels
and logging for process safety. The
log documents who makes which
changes to the program. Each user
prole can be exported and then
imported to another station. Thus it is
possible to integrate a user administ-
ration system and also to connect the
system to a higher-level permission
system using the .Net interface or eld
bus (e.g., Euchner EKS system).
The transparent and concise program
surface allows users to quickly create
programs. The main window lists all
programming steps together with their
functions. The function screens can
be opened successively to enter the
process values. Thus the force, displa-
cement, time, speed, acceleration and
braking rate can be easily programmed
for each step. Once the required input
screens have been dened, the joining
program is completed and the steps
are processed automatically.
PROMESS UFM Line5 1110 PROMESS UFM Line5
Modern Database Structure
All process data including the curves
can be stored in a database.
All common database formats such as
Oracle, MS SQL and Access are sup-
ported. A separate database is created
for each station. Programs can be
stored and re-used at any time.
Since the program changes can be
traced, this provides 100% traceability
throughout the entire production.
The database can be analyzed using
the DB Viewer with its extensive
querying and ltering options. Graphs
can be superimposed on each other for
comparisons and analyses. Envelopes
can be edited and reloaded into the
Trigger Technology by PROMESS
The triggers are “pulse points”. Up to seven trigger points can
be dened in order to react to processing events during movement.
These reactions can include:
n Smooth speeds
n Set the outputs in real time
n Change target parameters during movement
n Correct process tolerances during movement
DB Viewer
Software Highlights:
n
Press to signal, press to force, press to an external signal
(e.g., analogue or TTL signals)
n
Force and speed can be programmed individually during the
joining process
n
Variables can be used to transmit setpoints, perform calculations
using PLC and generate counters
n
100 % quality control using window and/or envelope methods
n
100 % process documentation using modern database structure
n
100 % process analysis using standardized interface to QS-STAT
(optional), alternative to process data management software IPM
(optional) – can be expanded using .net interface
n
Trigger function for demanding applications
n
High controller accuracy (minimization of overshoot in control processes)
n
Display of two graphs in one diagram
n
Quick printout of a graph report (screenshot)
Scope of Delivery for Components:
n Universal joining module Line5
n Power amplier incl. application module and UFM V5 rmware
n Brake resistance
n Ethernet module
n Digital preamplier PDM-S
n Cable, eld bus and more accessories on demand
press. The data can also be exported in
Excel format at any time.
The standard models include the data-
base software package and DB viewer.
ONLY WITH
US
PROMESS UFM Line5 1312 PROMESS UFM Line5
PSB010G1
UFM Line5 10 kN 30 kN 60 kN 100 kN
Item no. PSB010G1 PSB030G1 PSB060G1 PSB100G1
Connection voltage 3 AC 380 V - 480 V, +/- 10 %, 48-65 Hz
Connected load at 400 V 8,7 kVA 10 kVA 18,3 kVA 19,0 kVA
Protection class IP 54
Weight 17 kg 18 kg 28 kg 28 kg
Recommended protection IEC 20 A class gG IEC 40 A class gG
Temperature range 0° C … +40° C
Power loss 368 W 493 W 654 W 756 W
PC Interface Ethernet
Option PLC eldbus interface Probus, Pronet, EtherCAT (add. on request)
Technical Data
PROMESS has developed extensive accessories for
the UFM Line5 range of presses that provide them
with additional functionality. Together with our many
years of expertise, we provide you with complete
technologies for solving your own complex assembly
and testing tasks.
Accessories/Options
As an option to our assembly presses
UFM Line5 we offer our PROMESS
Safety Box PSB as an alternative to the
integration in electrical cabinets. The
device features all safety and power
components for this purpose.
It can easily and quickly be connec-
ted by plug & play. All cables are
pluggable. Due to the compact
design, the PSB can be mounted next
to the assembly press so that cable
lengths can be reduced and wiring
becomes unnecessary. By using the
PSB your assembly press will be ready
for production instantly.
Safety Box PSB
Advantages
n No integration in electrical
cabinets
n Reduction of cable lengths
n No wiring work
n No adaption of electrical
diagrams
n Short connection time:
plug & play
n PLe for STO by default
n Extention on SLS, SS1,
SS2 possible
n IP Code 54
n Extremely compact design
Safety Box PSB
PROMESS UFM Line5 1514 PROMESS UFM Line5
System Design
Technical Data
System Design
The PSD safety module is delivered
tested and ready to install.
It contains the power electronics and
safety controller for the joining unit. It
offers the following safety functionality:
STO in PLe in accordance with DIN ISO
13849-1; optional: SSx and SLS in PLd
in accordance with DIN ISO 13849-1
(for UFM Line5 with safety brake).
The safety module eases and
accelerates the installation procedure
for the joining unit.
The PSD is suitable for our UFM Line5
units with and without brakes. As a
prerequisite, it must be controlled using
eld bus.
Connected Components
n AC servo amp with NC module
n Brake resistance
n EMC components, main power lter
n Safety controller: Safety functionality
n STO in PLe in accordance with
DIN ISO 13849-1; optional: SSx and
SLS in PLd in accordance with
DIN ISO 13849-1 (for UFM Line5
with safety brake)
n Field bus interface (must be
ordered separately)
n Set of cables (must be ordered
separately)
n Required connectors (connected
to pins): Power supply
n 24-volt emergency stop circuit
Advantages
n Short installation times
n No wiring necessary
n Completely inspected
and tested
n EMC tested
PSD 010G1
Power cable
Field bus
Standard or
Industrial-PC
- Visualization
- Database
- Program Memory
Ethernet
PROMESS-BUS
UFM Line5
PDM-S
PSD Safety Module
Position encoder (optional)
UFM Line5 Item no. WxHxD
(mm)
Supply -
voltage
Frequency
Operating
temperature
range
Control
voltage
10 kN PSD010G1 354x475x300
380-480 VAC
+/-10%, 3 ph 50-60 Hz +5-40 °C 24 VDC
+/-10%
30 kN PSD030G1 500x500x300
60 kN PSD060G1 500x500x350
100 kN PSD100G1 500x500x350
200 kN PSD200G1 500x500x350
PLC
PSD
PROMESS UFM Line5 1716 PROMESS UFM Line5
Item no.
UFM Line5 Item no.
10 kN 850104LN
30 kN 850304LN
60 kN 850604LN
100 kN 850604LN
200 kN 852004LN
Item no.
UFM Line5 Item no.
10 kN 850106LN
30 kN 850305LN
60 kN 851602LN
100 kN 851602LN
200 kN 852005LN
Four-Column Frame
Four-column frames are suitable
for applications with central axial
application of force. They offer low
bending that is solely parallel.
By default, the lower plates are
equipped with a center hole and
2-T grooves as optimum tool
mounts. The upper plates are
pre-fabricated to hold a specic
joining module.
Four-Column Frame
Frames
PROMESS offers matching C- and
four-column frames for each type
of press in the UFM Line5 range.
C-Frames
The robust C-frames are easily
accessible from the front and sides
and provide high stiffness. The max.
bending is 0.2 mm under nominal
load. They are mainly suitable for
use in assembly lines or machines.
By default, the lower plates are
equipped with a center hole and 2-T
grooves as optimum tool mounts.
The upper plates are pre-fabricated
to hold a specic joining module.
C-Frame
PROMESS UFM Line5 1918 PROMESS UFM Line5
Article no. Capteur / Accessoires Câble
Course
Résolution
3647 Capteur précision
ST 1278 axial 12 mm, extension neutre +/- 0.001 mm
3640 Capteur précision
ST 1278 radial 12 mm, extension neutre +/- 0.001 mm
4103003080 Capteur précision
ST 1277 axial 12 mm, rétraction
pneumatique +/- 0.001 mm
4103003078 Capteur précision
ST 3078 axial 30 mm, extension neutre +/- 0.001 mm
Item no.
Art.-Nr.
Technical Data
UFM Line5 Item no.
10 kN 850103LN
30 kN 850303LN
60 kN 851601LN
100 kN 851601LN
200 kN 852003LN
Item no.
Connecting cables have to be ordered separately.
UFM Line5 Item no.
10 kN 850102LN
30 kN 850301LN
60 kN 850603LN
100 kN 851001LN
200 kN 852001LN
UFM Line5 Item no.
10 kN 850002LN
30 kN 850005LN
60 kN 850003LN
100 kN 850003LN
200 kN 852002LN
External Force
Transducer
The force transducers in the Line5
range are designed to measure tension
and compression forces both statically
and dynamically. They offer high
measurement precision and a low
installation height.
Sensors (Displacement Transducers)
The PROMESS NC controller allows you to connect various additional sensors
for measuring force, distance, temperature or other variables.
Cable Track
Module
PROMESS offers different modules
for towing the force transducer cable
safely without wear and tear.
External Force Transducer
Flange Plate
PROMESS offers corresponding
ange plates for fastening the joining
modules.
Flange Plate
Item no. Sensor / Accessory Cable
Stroke
Resolution
3647 Precision sensor ST 1278 axial 12 mm, neutral position
extended +/- 0.001 mm
3640 Precision sensor ST 1278 radial 12 mm, neutral position
extended +/- 0.001 mm
4103003080 Precision sensor ST 1277 axial 12 mm, pneumatic
retracted +/- 0.001 mm
4103003078 Precision sensor ST 3078 axial 30 mm, neutral position
extended +/- 0.001 mm
PROMESS UFM Line5 2120 PROMESS UFM Line520 PROMESS UFM Line5
Display
PROMESS offers different displays
on request.
Additional eld busses on request.
UFM Line5 Item no.
10 kN 750100LNM
30 kN 750300LNM
60 kN 750600LNM
100 kN 751000LNM
200 kN 752000LNM
UFM Line5 Item no.
10 kN 750105LNM*
30 kN 750305LNM*
60 kN 750605LNM*
100 kN 751005LNM*
200 kN 752005LNM*
UFM Line5 Item no.
Probus 3302005550
Pronet 3302005585
EtherCAT 3302005595
Connector Sets
If a cable set is not ordered,
a connector set will be required.
Cable Sets
The cable sets are available
in lengths of 5*, 10, 15 and 20 m.
Field Busses
PROMESS offers various eld busses
for communicating between the PLC
and NC controller of the press.
Display and PC
As a programming unit for editing NC programs and for visualizing signals,
PROMESS offers an industrial PC and different displays.
Industrie PC
Item no. 2601002060
n Industrial PC for installation in
control cabinets – multilingual
n Compact enclosure made of sheet
steel, W*H*D = 140*230*257mm
n Interfaces: 2 x Ethernet RJ45,
1 x RS232, 1 x RS-232/422/485
Serial, 2 x PS/2 for keyboard and
mouse, 2 x USB, 1xIrDA,
n Hard drive 100GB IDE 2,5“ HDD,
24h7d
n Windows Win7 ultimate MUI
PROMESS UFM Line5 2322 PROMESS UFM Line5
URMR XML-Writer
Plugin
PROMESS offers a range of custom
plugins for its powerful UFM V5.xx
programming software. These can be
connected to the software through the
.net interface. This allows the software
to be modied on a case-by-case basis
and optimized for specic applications
without having to update or change the
rmware. The expanded database is
also linked to the plugin.
Excerpt from the plugin library:
n UFMR Calibrate
The UFMR Calibrate plugin was de-
veloped for calibrating force
transducers in the joining modules.
The integrated range calibration of
the PROMESS PDM-S digital preamp
supports 2-point calibration as well as
characteristic diagram calibration.
Calibration can be performed most
simply using the PROMESS calibra-
tion set that contains a reference force
transducer and the KT-V5 evaluation
unit with display.
The KT-V5 is connected to the USB
port of the computer and operated
using the UFM in order to read in the
values of the reference force. The
characteristics of the reference force
transducer are automatically detected
by the integrated TED5 and written to a
calibration log that can be exported in
Excel format.
However, the calibration can also be
performed using external calibration
equipment. In this case, the base point
values of the reference transducer are
entered manually.
n UFMR Barcode
The UFMR Barcode plugin can be used
to change the program within the UFM
software using a barcode scanner. While
the program runs, the barcode scanner
can be used, for instance, to transfer a
Part ID using the UFM dialog function.
n UFMR QDE
The UFMR QDE plugin
allows quality assurance
data to be exported to the QS-STAT
statistics software from Q-DAS
and supports process monitoring
and optimization. Measurement,
auxiliary and description data can
be exported from each joining
program as characteristic data.
n UFMR IPM
The UFMR IPM plugin
makes it possible to
export process and measurement data
to the IPM process data management
from CSP and thus supports process
monitoring and optimization.
Calibration plugin
n URMR XML-Writer
PROMESS developed the XML
Writer plugin for exporting process,
measurement and graph data as well
as other variables. The XML les can
be subjected to further processing and
analyses.
URMR XML-Writer
Calibration protocol
PROMESS UFM Line5 2524 PROMESS UFM Line5
Calibration Set 1 kN 5 kN 10 kN 20 kN 50 kN 100 kN 200 kN
Item no. 5106 5107 5104 5101 5103 5105 5108
Force transducer KAM/1kN/0,2
KAM/5kN/0,2 KAM/10kN/0,2 KAM/20kN/0,2
KAM/50kN/0,2 KAM/100kN/0,2 KAM/200kN/0,2
Base plate XKM 096 XKM 096 XKM 096 XKM 094 XKM 094 Without Without
Diameter/height Ø40 / 12 Ø40 / 12 Ø40 / 12 Ø90 / 25 Ø90 / 25 Ø90 / 25 Ø90 / 25
Plug XKC 041 XKC 041 XKC 041 XKC 041 XKC 041 XKC 041 XKC 041
Display KT-V5 KT-V5 KT-V5 KT-V5 KT-V5 KT-V5 KT-V5
Factory calibration XKW 221 XKW 221 XKW 221 XKW 221 XKW 221 XKW 221 XKW 221
Our maintenance contract contains:
n 1 x annual maintenance checkup including following services:
– Re-greasing of all lubricated areas
Transmission oil change when necessary
Inspection of mechanical and safety-relevant parts
Replacement of worn parts when necessary
Software update
Creation of machine status report and offer to eliminating
any deciencies or faults
Calibration of force transducer
Adjustment work
Issuing of calibration certication
n 12-month extension to guarantee following maintenance
n Express delivery with no additional charges
n 10% discount on single parts
n 10% discount on additional services and training
Calibration &
Maintenance
Avoid expensive repairs
Preventative maintenance is
the simplest means of reducing
costly standstills in production,
increasing machine life and
boosting productivity. Our services
offer exible maintenance for your
plant with minimum downtime.
Calibration Set
Easily perform a quick calibration or
test of the UFM joining unit in your
machine using the PROMESS
calibration set.
The process can be automated using
the optionally available software.
On completion, a log le is created
that can be exported to Microsoft
Excel.
PROMESS Calibration Sets consist of:
n Reference transducer
n Evaluation unit for the reference transducer with
display and USB port for connecting to a PC
n Factory calibration log
(or DKD calibration by request)
n PROMESS Software UFMR Calibrate (optional)
n Suitcase
Special Features:
n Simple operation
n Robust battery-driven display
n Industrial strength suitcase
n Nominal forces from 500 N to 200 kN
n With factory calibration certicates
Calibration plugin
PROMESS UFM Line5 2726 PROMESS UFM Line5
CUSTOMER SERVICE
Our Service Competence
PROMESS universal joining modules have been used for many years in
heavy industrial applications. This is made possible through the solid quality
of the products as well as our extensive, sustainable worldwide service.
From process development to preliminary testing, from initial installation
to daily production, PROMESS offers holistic product expertise from
a single source and thus provides sustainably
rapid service and competent consulting.
Training
PROMESS has developed
various training modules
to simplify, as much as
possible, the installation,
operation, maintenance and
handling of our joining
modules. The modules are based on core knowledge for introducing NC joining
technologies that, after consultation, can be individually modied or adapted.
Training can be held on site or at our premises and are performed by
experienced and qualied training personnel.
Express Delivery
On request and for an additional charge, we can deliver within two weeks by
express delivery for up to ve units.
Our services include:
n Process development
n Preliminary testing
n Rental units
n Installation
n Extensive documentation
n Training
n Local and remote maintenance
n Calibration services
n Emergency repairs and spare part delivery
n Consignment warehouse
n Worldwide distribution and service network
Range of Services
PROMESS UFM Line5 2928 PROMESS UFM Line5
F1
F2
L1 L2
Application Examples
Precision Joining
n Precision joining < 0.002 mm,
collision-free due to electronic
bending compensation.
Riveting
n Rivet press with programmable press
force and control of power press.
Join on Contact
n Joining on contact with
precise shutdown once
absolute shoulder position
has been reached.
Stamping/Forming
n Stamping and forming with
detection of part height
and relative
forming.
Surface Checks
n Logging of force-distance data for
multiple switch points.
Press-tting
n Press-tting with
controlled force for
relative displacement.
Testing/Measuring
n Logging of force-
distance data for multiple
positions.
Bending
n Monitored bending of straps,
brackets etc. on
safety components.
Clipping
n Joining of plastic and
medtech parts with
monitoring of snapping
force.
Calibrating
n Calibration with quality assurance
through monitored force.
Position s
Force f [kN]
Position s
Force f [kN]
Position s
Force f [kN]
Position s
Force f [kN]
Position s
Force f [kN]
Force f [kN]
Position s
Force f [kN]
Position s
Position s
Force f [kN]
Position s
Force f [kN]
Position s
Force f [kN]
Adaptive window
PROMESS UFM Line5 3130 PROMESS UFM Line5
PROMESS. For more efciency.
www.promessmontage.de
PROMESS
Gesellschaft für Montage-
und Prüfsysteme mbH
Nunsdorfer Ring 29 | D-12277 Berlin
Phone +49 (0)30 / 62 88 72 - 0
Fax +49 (0)30 / 62 88 72 - 59
promess@promessmontage.de