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Brochure UFM Precision5

Because of its high accuracy, the press series UFM Precision5 is well suited for applications in the lower load range, requiring the highest precision. The whole press concept is adapted to increase the accuracy of the units. For many years, the UFM Precision5 has been used successfully in the field of medical technology, the watch industry, the electronic industry and other industrial sectors.
Anfragen
UMF
Precision5
The UFM Precision5 units are suitable
for assembly and joining applications
with force-distance monitoring requiring
small forces and high precision.
For more efciency.
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
worldwide.
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 solv-
ing the individual and complex assembly
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
Ireland
Italy
Korea
Malaysia
Mexico
Netherlands
Norway
Poland
Romania
Singapore
Slovakia
Spain
Sweden
Switzerland
Thailand
Turkey
USA
PROMESS UMF Precision5 3
2 PROMESS UMF Precision5
Because of its high accuracy, the press series
UFM Precision5 is well suited for applications in the
lower load range, requiring the highest precision.
The whole press concept is adapted to increase
the accuracy of the units. For many years, the
UFM Precision5 has been used successfully in
the eld of medical technology, the watch industry,
the electronic industry and other industrial sectors.
Advantages
n Standard model includes absolute encoder
that eliminates the need for referencing
(except 200 N unit)
n Digital force measurement with 24 Bit resolution
n Multi range calibration for force input optional
n High repeatability
n High guiding accuracy of the press ram
n No rotation backlash of the press ram
n Sensor system can be easily extended using
versatile PROMESS-Bus
n Utilization of window and envelope technology
n No PLC knowledge required
n Movement and monitoring as an integrated
solution
n PLe for STO by default
UFM Precision5
Type Force (kN) Stroke (mm) Speed (mm/s)
1 0.2 60 250
2 1 100 400
3 1 200 300
4 3 200 250
Overview of
Press Types
The units of the series UFM Precision5
can be congured differently: with or
without holding brake and with piezo or
strain gauge force transducer, except
the 200 N unit which is equipped with
a piezo force transducer by default.
Additionally the following types are
available:
PROMESS UMF Precision5 5
4 PROMESS UMF Precision5
Mechanics
The UFM Precision5 series features a
high precision design. The non-rotating
press ram runs in a precision guidance
without any rotation backlash.
The radial offset of the press ram is
extremely small over the full stroke.
Also the force transducer is mounted
non-rotating at the press ram.
The linear design of the press allows
for high speeds due to the spindle, that
is directly driven by the aligned servo-
motor. The integrated absolute encoder
(except 200 N unit) ensures precise
positioning and eliminates the need for
referencing at the start of a cycle. The
robust design makes it well suited for
long periods of use.
System Design
The mechanical system is controlled by
a power amplier with an integrated NC
module. The internal RISC processor
coordinates the assembly press and can
be easily programmed and operated
using a conventional PC/display.
The controller coordinates the me-
chanical motion of the press as well as
monitoring the force and distance. The
force-distance characteristic can be
monitored using envelopes and/or win-
dow methods. The data can be edited
numerically and graphically so that each
individual process can be easily moni-
tored. 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.
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)
Mechanical design:
1. AC servomotor with absolute
encoder (except 200 N unit)
2. Direct drive
3. Steel housing
4. Non-rotating press ram with
precision guidance
5. Piezo- or strain gauge force
transducer
6. Tool holder
1
2
3
4
6
5Basic version
Power cable
Field bus
PLC
Ethernet
PROMESS-BUS
UFM Precision5
PDM-S/PDM-P
Position encoder (optional)
Server / Network
Standard or
Industrial-PC
- Visualization
- Database
- Program Memory
Power amplier
PROMESS UMF Precision5 7
6 PROMESS UMF Precision5
The system utilizes a digital preampli-
er. This transfers the force signal at a
resolution of 24-bit. When the character-
istics are calibrated, the assembly press
achieves a system accuracy of 0.3 %
from the nal value.
The characteristic 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 calibration report and can be print-
ed out.
PLC
Ethernet
PROMESS-BUS
UFM Precision5
PDM-S/PDM-P
PDM-S/PDM-P
Ethernet
UFM Precision5
PDM-S/
PDM-P PROMESS-BUS
Extension/Options
Standard or
Industrial-PC
- Visualization
- Database
- Program Memory
Power cable
Field bus
PROMESS-BUS
Ext.
Force Transducer
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
Power amplier
Line conguration
Field bus
PLC
Server / Network
Standard or Industrial-PC
Power amplier
PROMESS UMF Precision5 9
8 PROMESS UMF Precision5
Software
As standard, the UFM Precision5 range
of presses comes 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).
Highlights for
demanding
applications:
n Positioning on force slope:
Joining components until a
denite slope (increasing
force) or relatively once a
click 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., spin-
ning 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 achie-
ving 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
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 UMF Precision5 11
10 PROMESS UMF Precision5
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.
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 Assembly press UFM Precision5
n Power amplier incl. application module and UFM V5 rmware
n Digital preamplier PDM-S respectively PDM-P
n Cable, eld bus and more accessories on demand
Envelopes can be edited and reloaded
into the press. The data can also be ex-
ported in Excel format at any time.
The standard models include the data-
base software package and DB viewer.
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
ONLY WITH
US
PROMESS UMF Precision5 13
12 PROMESS UMF Precision5
PROMESS has developed extensive accessories for
the UFM Precision5 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:
Connecting cables have to be ordered separately.
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
Frames
PROMESS provides different frames on request.
Sensors
(Displacement
Transducers)
The PROMESS NC controller allows
you to connect various additional
sensors for measuring force, distance,
temperature or other variables.
Technical Data
Precision sensor
PROMESS UMF Precision5 15
14 PROMESS UMF Precision5
PSB
Ethernet
PROMESS-BUS
UFM Precision5
PDM-S/PDM-P
System Design
Power cable
Field bus
Standard or
Industrial-PC
- Visualization
- Database
- Program Memory
Position encoder (optional)
PLC
As an option to our assembly presses
UFM Precision5 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
PSB010G2
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
UFM Precision5 1 kN 3 kN
Item no. PSB010G2
Connection voltage 3 AC 380 V - 480 V, +/- 10 %, 48-65 Hz
Connected load at 400 V 8.7 kVA
Protection class IP 54
Weight 17 kg
Recommended protection IEC 20 A class gG
Temperature range 0 °C ... +40 °C
Power loss 368 W
PC Interface Ethernet
Option PLC, eldbus interface Probus, Pronet, EtherCAT (add. on request)
Technical Data
Power switch Emergency stop button
Reset buttonFieldbus intake
Motor feedbacksystem
Safety break
Ethernet
PC
Motor supply
Power supply
Overview connections
System Design
PROMESS UMF Precision5 17
16 PROMESS UMF Precision5
PSD
System Design
Technical Data
The PSD safety module is delivered
tested and ready to install. It contains
the power electronics and
safety controller for the assembly
press. 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.
The safety module eases and acceler-
ates the installation procedure for the
joining unit. The PSD is suitable for our
UFM Precision5 units with and without
brakes. As a prerequisite, it must be
controlled using eld bus.
Mounted Components
n AC servo amplier with NC module
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
ISO 13849-1
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
Ethernet
PROMESS-BUS
UFM Precision5
PDM-S/PDM-P
Safety Module PSD
System Design
Power cable
Field bus
Standard or
Industrial-PC
- Visualization
- Database
- Program Memory
Position encoder (optional)
PLC
UFM
Precision5 Item no. WxHxD
(mm)
Supply -
voltage
Fre-
quency
Operating tem-
perature range
Control
voltage
200 N 23200500G2
354x475x300
230 VAC
+/- 10 %, 1ph
50-60 5-40 °C 24 V
+/- 10 %
1 kN
23400250G2
380-480 VAC
+/- 10 %, 3ph
3 KN
PROMESS UMF Precision5 19
18 PROMESS UMF Precision5
Input Force Transducer
Accuracy class 0.1 %
Sensitivity 0.1 ... 5 mV/V
Analogue bandwith 10 kHz typ. (-3dB)
Resolution A/D
converter 24 bit
Housing Aluminium die-cast
Protection class
EN 60529 IP 40
Dimensions LxBxH
125x80x57 mm (height
without connectors)
Input Encoder
Tracks A+, B+, A-, B-
Level Rectangle TTL 5V
Counter 16 bit
Input Force Transducer
Accuracy class 0.1 %
Analogue bandwith 10 kHz typ. (-3dB)
Resolution A/D
converter 24 bit
Housing Aluminium die-cast
Protection class
EN 60529 IP 40
Dimensions LxBxH
125x80x57 mm (height
without connectors)
Input Encoder
Tracks A+, B+, A-, B-
Level Rectangle TTL 5V
Counter 16 bit
PROMESS Digital Modules PDM
PROMESS offers four different multifunction ampliers PDM. The modules are
digitally connected to the UFM control via the PROMESS-Bus. They feature the
following charateristics:
PDM-S
Item no. 14650
Digital preamplier for strain
gauge force transducer, multi
range calibration optional
PDM-P
Item no. 14655 / 56
Digital preamplier for piezo
force transducer, multi range
calibration optional
Analogue Inputs
Precision class 0.25 %
Analogue bandwith 10 kHz typ. (-3dB)
Resolution A/D
converter 24 bit
Housing Aluminium die-cast
Protection class
EN 60529 IP 40
Dimensions LxBxH
125x80x57 mm (height
without connectors)
Supply voltage 24 VDC
Input Encoder
Tracks A+, B+, A-, B-
Level Rectangle TTL 5V
Counter 16 bit
PDM-A
Item no. 14711
Four analogue inputs
+/- 10 VDC
Inputs
Input protection Electrically isolated
Output protection Electrically isolated
Eingangsspannung 24 VDC
Ausgangsstrom 24 VDC
Case mounting Cap rail
Protection class
EN 60529 IP 40
Dimensions LxBxH 165x109x55 mm
PDM-IO
Item no. 14700
16 digital in- and outputs
PROMESS UMF Precision5 2120 PROMESS UMF Precision5
Display and PC
As a programming unit for editing NC programs and for visualizing signals,
PROMESS offers industrial and panel PCs as well as different displays.
Additional PCs and
displays are available on
request, e.g. PCs with 17”
or 19” display.
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 provides various
eld busses for communicating
between the PLC and NC con-
troller of the press.
Industrial 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,
n 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
Panel PC 15“
Item no. 2601080230
n 15“ Display
n Resistive touchscreen
for production use
n Frontcase IP 65 rated
n Silent fanless operation –
no mobile parts
n Consumer and industrial
interfaces
n 2x10/100/1000 mbps
network-ports, integrated
Wi-Fi (Intel 533AN)
n Flexible DC connection
n Audio amplier with 2x2w speakers
n VESA 100 bracket for mounting
Additional eld busses on request.
UFM Precision5 Item no.
200 N 750200PR
1 kN
753000PR
3 kN
UFM Precision5 Item no.
200 N 750205PR*
1 kN
753005PR*
3 kN
UFM Precision5 Item no.
Probus 3302005550
Pronet 3302005585
EtherCAT 3302005595
Ethernet IP 3302005590
PROMESS UMF Precision5 2322 PROMESS UMF Precision5
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
digital PROMESS preamplier PDM
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 UMF Precision5 25
24 PROMESS UMF Precision5
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
(accreditation by DAKKS on 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
Calibration Set 1 kN 5 kN
Item no. 5106 5107
Force transducer KAM/1kN/0.2 KAM/5kN/0.2
Base plate XKM 096 XKM 096
Diameter/height
Ø40 / 12 Ø40 / 12
Plug XKC 041 XKC 041
Display KT-V5 KT-V5
Factory calibration
XKW 221 XKW 221
PROMESS UMF Precision5 27
26 PROMESS UMF Precision5
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.
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 UMF Precision5 29
28 PROMESS UMF Precision5
F1
F2
L1 L2
Application Examples
Precision Joining
n Precision joining
< 0.002 mm, colli-
sion-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 shut-
down once absolute
shoulder position has
been reached.
Stamping/Forming
n Stamping and
forming with
detection of part
height and relative
forming distance.
Surface
Checks
n Logging of
force-distance
data for multiple
switch points. Press-tting
n Press-tting with
controlled force
for relative dis-
placement.
Testing/Measuring
n Logging of force-
distance data for
multiple positions.
Bending
n Monitored ben-
ding of straps,
brackets etc.
on safety com-
ponents. Clipping
n Joining of plastic
and medtech
parts with moni-
toring of snapping
force.
Calibrating
n Calibration
with quality
assurance
through moni-
tored force.
Position s [mm]
Force f [kN]
Position s [mm]
Force f [kN]
Position s [mm]
Force f [kN]
Position s [mm]
Force f [kN]
Position s [mm]
Force f [kN]Force f [kN]
Position s [mm]
Force f [kN]
Position s [mm]
Position s [mm]
Force f [kN]
Position s [mm]
Force f [kN]
Position s [mm]
Force f [kN]
Our assembly presses UFM Precision5 are used in the medical sector,
the electronic production, the watchmaking industry and other sectors
of the micro technology since many years.
PROMESS UMF Precision5 31
30 PROMESS UMF Precision5
PROMESS
Gesellschaft für Montage-
und Prüfsysteme mbH
Nunsdorfer Ring 29 | D-12277 Berlin
Fon +49 (0)30 / 62 88 72 - 0
Fax +49 (0)30 / 62 88 72 - 59
promess@promessmontage.de
PROMESS. For more efciency.
www.promessmontage.de