Quality Joining & Testing News 2/12 - Kistler

maXYmos BL Keeps Quality and
Costs under Control
> Page 2
Torque Measuring Flange Now
in Three New Sizes
> Page 5
&
Fast ROI after Switching to Electric
Joining Systems
> Page 6
NEWS
Important news for our customers in manufacturing and assembly Issue 2/2012
XY monitor with powerful evaluation techniques replaces CoMo and DMF-P product series
maXYmos TL for Challenging Monitoring Applications
Building on the positive response to the
XY monitor maXYmos BL for process monitoring
and product testing, Kistler is now
offering this proven successful concept
in the maXYmos TL Type 5877A… with
extended functionality. The maXYmos TL
can be used for simple force-displacement
monitoring through challenging applications
in assembly and product testing.
Starting in 2013, the top-level version will
incrementally replace the ControlMonitors
CoMo Logic, CoMo Sys, CoMo View
and CoMo Net as well as the DMF-P
A300 and DMF-P A400.
maXYmos TL with powerful evaluation
techniques
The extensive functionality and straightforward
operating concept using an intelligent
menu system are based on the
maXYmos BL. Key features of this highend
XY monitor are more powerful evaluation
techniques, a larger selection of
connectable sensors, unrestricted choice
of fi eldbus types, expandability up to 8
pairs of XY-channels and a large (10,4"),
high-resolution, color touch screen display.
Using the additional evaluation
objects (GRADIENT, HYSTERESIS and
CALCULATE), the maXYmos TL ensures
optimal evaluation of even complex curve
criteria. CALCULATE, for example, allows
calculation and evaluation of the distance
between two breakover (snap-in) points
on a force-displacement curve. GETREF
objects provide CALCULATE with the positions
of these points in advance.
The maXYmos TL offers an array of useful
functions to professionals in the fi eld
of process monitoring. The monitor detects
tool breakage with the aid of gradient
monitoring and responds in real time.
The short evaluation time allows moni-
The new high-end XY monitor maXYmos TL provides
powerful functions and evaluation techniques for
process monitoring and product testing

toring of up to 20 parts/second, and the
X- and Y-thresholds can generate switching
signals for control purposes in real time.
128 measurement programs with 10 eval-
uation objects each ensure flexibility in
terms of the evaluation criteria and vari-
ety of parts. A curve memory for NOK
diagnosis provides access to the last 500
curves for analysis using the filter and
bundle function.
Flexible integration into the machine
environment
The maXYmos TL consists of a measuring
and evaluation module (MEM) and a dis-
play module (DIM). The two components
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can either be installed separately from each
other, so that they are only connected via
the monitor cable, or they can function as
a single compact mechanical and electrical
unit. The latter configuration is achieved
by inserting the MEM into the rear slot
of the DIM. This combination already
provides one pair of measuring channels
(1x XY) and all of the interfaces required
for control, data export and remote main-
tenance. If continual visualization is not
required, the MEM can also function as
a black box module: setup and process
visualization are then handled using VNC
access via the EtherNet or USB interface
in conjunction with the maXYmos PC
Unbeatable value for money for 100 % quality in joining and assembly
The XY monitor maXYmos BL now offers
extended functionality and a still unbeat-
able price-performance ratio as part of
Kistler’s product portfolio. With its ad-
ditional capabilities, it is redefining XY
monitoring for joining and assembly
processes as well as product testing. Key
features of the maXYmos BL includes
its intelligent menu system using a 3,5"
color touch screen, highly practical eval-
uation and diagnostic functions, and
universal, modern case concept based
on a modular approach for desktop, wall
and front panel mounting.
The maXYmos BL also includes a large
measurement curve memory for nearly
continuous monitoring of the curve along
with 16 measurement programs for 16
different types of part, each with 4 eval-
uation objects. Automatic trend tracking,
which can be activated for the band of
the envelope curve, tracks the set point
limits, for example with progressive
tool wear, and matches the evaluation
function to the actual process situation.
The internal curve memory and the abil-
ity to display stored families of curves
considerably simplify fault analysis for
the process.
New features are fast data transmission
via serial EtherNet/IP and USB interfaces
as well as the ±10 V input. Fast data
software available as an accessory. The
maXYmos TL is designed to support all
common mounting configurations such
as desktop, wall and front panel mount-
ing. The flexible case concept gives the
machine designer plenty of options. The
MEM is always equipped with Profibus
DP, ProfiNet, EtherNet/IP and Modebus/
IP. Interfaces for all common sensor
types are standard features. Kistler’s
product line includes a large selection of
suitable force and torque sensors as well
as displacement and angle sensors. The
maXYmos TL will be available starting in
January 2013.
Get Better. With Kistler.
XY Monitor maXYmos BL Keeps Quality and Costs under Control
The maXYmos BL Type 5867B… now also for sensors with 10 V output,
with EtherNet/IP bus and USB interface
transmission also enables documenta-
tion of process data for traceability down
to the individual part. The new maXYmos
PC software allows direct transfer of
the test record from the maXYmos BL
to the PC and offers many functions for
visualizing, measuring and analyzing
measurement curves and process values
as well as for evaluating the process
capability.
The maXYmos BL records and interre-
lates all of the measurands that can
be supplied, for example, by force or
torque sensors on the Y-channel and
potentiometric displacement or rotation
angle sensors on the X-channel. It uses
evaluation objects such as BOX, LINE
and ENVELOPE to analyze quality-relevant
sections of the recorded measurement
curves. In this manner, the
maXYmos BL can monitor and evaluate
the quality of a product or production
step. In press-fit processes, for example,
it monitors the force vs. the displacement
or time, and in screw tightening
processes the torque vs. the rotation
angle or time.
XY monitoring can also be used to en-
able very early elimination of rejects from
the process, boost the product and pro-
cess quality, reduce downtime and allow
early detection of tool and system wear.
The measurement results can be fed
back into the process to facilitate pinpoint
process optimization.

Regensburg University of Applied Sciences uses torque measuring flange for Formula Student Electric
KiTorq Sensor Proves its Worth on Electric Motor Test Stand
Regenics e.V. is the Formula Student
Electric team at the Regensburg University
of Applied Sciences. Since 2010, the
student team has used its electric vehicle
to take part in Formula Student Electric
Germany, a competition for young engineers.
In August 2012, the 50 students
went with their RP12e vehicle to the
German racing track Hockenheimring
for a test run.
Josef Engl, a student at Regensburg and
the team leader for electric drive trains at
Regenics, is in charge of the race car’s
electric motors. In his development work,
he uses a test stand which is equipped
with the new KiTorq torque measuring
flange from Kistler with a measuring
range of 500 N·m. "Thanks to the new
design of the torque flange along with
its very short construction, we were able
to make do without a bearing system
between the two motors on our test
stand", reported Engl. "Since we could
bolt the two motors close together on
the flange using the coupling, we were
able to use smaller dimensions for the
shafts with a correspondingly lower
weight."
Since the CoMo Torque evaluation unit
is mobile, the unit that had already been
available at the university for some time
could also be used for the measurement
with the new KiTorq. The stator’s sensor
outputs were connected to a power ana-
lyzer with additional analog and digital
inputs in order to read out the speed
E-motor test stand with KiTorq torque measuring flange from Kistler
Premiere for the RP12e electric vehicle built by the team from Regensburg University of Applied Sciences
and torque and display it with a separate
LabView interface. This online tool helps
to configure the measuring flange and
Kistler’s CoMo Torque evaluation unit for torque
sensors in operation (photos: Regenics e.V.)
also to store the torque alarm limits and
various measuring ranges. In this manner,
it was possible to verify the actual
speed using the measuring flange. "Other-
wise, we were only able to measure the
speed via CAN with the power electron-
ics. However, it is a very important control
measuring instrument when setting
up the test stand. Measurement of the
torque on the shaft using the measuring
flange replaces the purely computational
determination of the torque. Based on
the torque and speed, we can automat-
ically compute the power too", reported
Engl.
The motor torque constant (k = torque
t/phase current I) actually acts as a con-
stant over a wide range. "However, a
small non-linearity does creep in especially
for larger values of the torque",
observed Engl. Using the measuring
flange, he was able to determine when
the current no longer behaves directly
proportionally to the torque. Then, he
could create a characteristic and store it
in the power electronics. By measuring
the delay between the specified torque
value (via CAN to the power electronics)
until reaching the torque on the shaft, it
was possible to test various parameters
in the power electronics and obtain ideal
settings.
Based on the comparison between the
electric power and the measured torque
(conversion to power using the speed)
on the mechanical shaft, it was possible
to determine the efficiency of the motor,
the inverter and ultimately the overall
system. Furthermore, the torque/speed
characteristic was recorded at load steps.
www.regenics.de
www.kistler.com

Torque measuring fl ange with integrated speed measurement for precision measurements
KiTorq System Now Covers Full Range from 100 to 5 000 N·m
The KiTorq system torque measuring fl ange
Type 4540A…
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The KiTorq system torque measuring
fl ange now covers the entire commonly
used measuring range from 100 to
5 000 N·m. The rotor Type 4550A…
now comes in three new sizes with
measuring ranges of 100, 200
and 5 000 N·m to round out the
portfolio for applications on test
stands for internal combustion
engines, electric motors, gearboxes
and drive trains. The new
sizes can also be used in a fully
modular manner in the KiTorq
system: they can be combined with
the same stator, making it possible
to test different assemblies
without test unit modifi cations.
The ringless design simplifi es
the installation process.
With seven sizes, fully digital
transmission, an accuracy
of 0,05 %, a signal
bandwidth of up to 10 kHz
and integral speed measurement at
60 pulses per revolution, the KiTorq system
offers maximum dynamic response
and precision. The measuring fl ange is
extremely robust and maintenance-free.
It has been tested to EN 60068-2-27 for
Torque measuring fl ange for direct integration into control systems
Fieldbus Interfaces for the KiTorq Stator
For the fi rst time at SPS/IPC/DRIVES
2012, Kistler is presenting its new KiTorq
stator torque measuring fl ange Type
4542A with fi eldbus and industrial
EtherNet interfaces. The familiar analog/
frequency, USB and RS232 interfaces
from Type 4541A… are also found in
the new stator. It is fully compatible with
all KiTorq rotors Type 4550A… . In this
manner, the KiTorq system can now be
directly integrated into the control system.
For the market launch, the fi eldbus
interfaces Profi net, Profi bus and
CANopen are available. Kistler plans to
develop further interfaces in the future
to suit customer requirements.
Like the overall KiTorq system, the new
stator type is also characterized by mod-
ularity, fl exibility, an unbeatable priceperformance
ratio and very simple installation
including the free SensorTool
software that is supplied. For a slightly
higher price than the existing Type
4541A, it allows direct integration into
the customer’s test stand environment
using the fi eldbus interfaces. This saves
time during installation and eliminates
the need for expensive additional
equipment for acquiring
and evaluating measurement data.
In addition to the new digital interfaces,
it still has an analog
output for fault diagnostics
and external monitoring of
measurement data. The stator
is offi cially certifi ed by interface
mechanical shock, to EN 60068-2-6 for
triaxial vibration and to EN 61326-1 for
interference immunity.
The KiTorq system in operation on an electric motor
test stand
and is available individually or – in conjunction
with a KiTorq rotor Type 4550A
– as a complete measuring system.
KiTorq rotor system Type 4542A…

Testing of springs subject to highly dynamic loading using measuring chains from Kistler ensures 100 % quality
Technical Spring Manufacturer Uses maXYmos BL
The company Technische Federn GmbH
Otto Joos from Ditzingen, Germany, man-
ufactures technical springs to meet ex-
tremely demanding requirements in the
automotive industry. These components
are built to withstand highly dynamic
forces and are used in injection pumps
for automobile and truck engines as well
as in drive assemblies for locomotives and
ships – i.e. in technical fields with an im-
pact on our everyday lives.
Many technical processes would be entire-
ly inconceivable without springs. More-
over, spring failure often has severe consequences.
In order to provide guaranteed
safety based on product dependability,
Joos performs exhaustive testing of its
springs so they can withstand, for exam-
ple, one billion load cycles with no dam-
age when used in a diesel injection pump.
Since springs must have the correct length
in order to ensure a defined restoring force,
Joos measures the length of its springs
prior to delivery. Here, the force-displace-
ment monitoring system maXYmos BL was
chosen for use in a new sorting system.
The maXYmos BL monitors and evaluates
XY curves in which two measurands (force
and displacement in this case) are required
to exhibit a certain relationship with re-
spect to one another. Using two switching
Sorting system with force-displacement monitoring system maXYmos BL (left, top) for measuring the length of springs
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At the point where the press ram makes contact with the spring, the force signal exhibits a steep rise (left). If the eval-
uation object (EO-01 = LINE-X) is crossed accordingly, the spring length is within the specified tolerance. The evaluation
object EO-01 provides the position at the point of intersection in the form of a process value to the table of values (right).
thresholds and the UNI-BOX evaluation
object, the maXYmos BL records the three
possible states of the springs under test –
spring too short, spring in tolerance and
spring too long – and reports the result to
the sorting chute via the PLC. Thanks to
100 % testing of its springs, Joos can guar-
antee exact conformance with the custom-
er’s requirement profile, enabling consistent
delivery and 100 % quality assurance.
Moreover, the compression springs must
undergo mechanical processing in addi-
tion to testing. A grinding process ensures
optimal faces for a dependable bearing
surface and also guarantees the exact
spring length. The maXYmos BL also supports
this process: based on the threshold
X for the defined force of approx. 0,5 N,
the monitor outputs the spring length at
this point via its table of process values.
The force of 0,5 N defines the initial contact
between the force sensor and the
spring: the associated increase in force at
this position thus precisely indicates the
length of the spring under test.
For Managing Director Jürgen Marx and
Head of Quality Management Dirk
Retzlaff, the maXYmos BL has opened up
a new range of test possibilities. Thanks
to the 100 % quality assurance, they can
continue to satisfy the growing requirements
imposed by the automotive industry
for complete production monitoring
– without increasing their staffing levels.

300-740e-09.12 Fri1100 ©2012, Kistler Group
Electrical systems save energy and operating costs
Norbert Bäuml: "Fast ROI with
Electromechanical NC Joining Systems"
Norbert Bäuml is the Global Sales Manager for
Joining Systems at Kistler (photo: private source)
Energy savings is a hot topic nowadays –
and clearly not just for private households
and consumers. For example, Volkswagen
CEO Martin Winterkorn is seeking to lower
energy consumption at his company’s
factories by 25 % by the year 2018. If electromechanical
joining systems are installed
in place of hydraulic or pneumatic systems
for press-fit applications, they tend to pay
for themselves quickly. Norbert Bäuml,
Global Sales Manager for Joining Systems
at Kistler, explains why and how fast.
Mr. Bäuml, you’re advising users to opt
for electromechanical NC joining systems.
Why?
We very commonly see hydraulic joining
systems on transmission and gearbox
assemble time, for example, where gears
are pressed onto shafts or bearings and
bushings. Several such systems are each
supplied by a hydraulic unit. Hydraulic
systems generate cost pools related to
energy usage, maintenance, oil changes
and space requirements. They need oil
lines, a means to collect any fluid leakage
as well as satisfying the cooling require-
ment. Moreover, there is the regular expense
of changing the oil for the hydraulic
units. Of course, they also consume
significantly more energy than electrical
systems.
What are the benefits of electromechanical
NC joining systems?
Electromechanical joining systems only re-
quire energy when they are actually performing
pressing operations. They do not
use any oil and they have very low main-
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tenance requirements. Technical planners
eagerly deploy electrical systems because
they are more flexible, quieter and cleaner.
But electrical systems have a reputation
for higher cost …
The initial investment into electrical tech-
nology is greater than hydraulic or pneumatic
technology. However, there are
other important factors besides the initial
investment. Production planners tend to
look ahead and also take into account
the lower energy and operating costs of
electrical systems.
Aren’t these savings difficult to calculate?
In a concrete example involving about
60 press-fit processes on a production
line, total savings were generated for the
energy consumption, operating technology
and maintenance expense of over
EUR 60 000 (USD 78 700) per year. The
payback period of about a year and a half
was also enough to win over the customer’s
purchasing department.
How much energy is the customer saving
now?
The energy savings added up to several
times 100 000 kWh per year, i.e. about
2 million kWh over the usual system ser-
vice life.
Do these same calculations apply in other
countries too?
In emerging countries like China and India,
the energy costs might not be as high
as ours, so the ROI is somewhat slower.
There, however, many planners of new
installations are encouraged to concentrate
on minimizing energy consumption since
the supply is simply not as secure as in
Western industrial nations.
Apart from low energy consumption:
what else do customers really like about
your joining systems?
Electromechanical NC joining systems
from Kistler are coordinated systems with
integrated sensor technology and powerful
force-displacement evaluation for
complete process monitoring and documentation
of all measurement results, for
example, for usage in higher-level quality
systems.
Who is my contact person for this area?
That would be the JSB sales supporters
at Kistler. Please consult your sales representative.
Kistler Worldwide
Austria
Tel. +43 1 867 48 67 0
sales.at@kistler.com
Australia
Tel. +61 3 9560 5055
sales.au@kistler.com
Brasil
Tel. +55 11 50520308
sales.br@kistler.com
China, People's
Republic of
Tel. +852 25 915 930
sales.cn@kistler.com
Czech Republic/Hungary/
Poland/Slovakia
Tel. +420 296 374 878
sales.cz@kistler.com
Denmark
Tel. +45 70 20 85 66
info.dk@kistler.com
Finland
Tel. +358 9 612 15 66
info.fi@kistler.com
France
Tel. +33 1 69 18 81 81
info.fr@kistler.com
Germany
Tel. +49 711 34 07 0
info.de@kistler.com
India
Tel. +91 129 4113 555
sales.in@kistler.com
Italy
Tel. +39 02 481 27 51
sales.it@kistler.com
Japan
Tel. +81 3 3769 9501
sales.jp@kistler.com
Visit our stand:
Korea, Republic of
Tel. +82 31 465 6013
sales.kr@kistler.com
Motek 2012, Stuttgart
Hall 5, Stand 5535
Mexico
Tel. +52 81 4170 8075
sales.mx@kistler.com
Netherlands
Tel. +31 182 304 444
sales.nl@kistler.com
Singapore
Tel. +65 6570 5377
sales.sg@kistler.com
Spain
Tel. +34 93 860 33 24
info.es@kistler.com
Sweden/Norway
Tel. +46 31 871 566
info.se@kistler.com
Switzerland/Liechtenstein
Tel. +41 52 224 12 32
sales.ch@kistler.com
Taiwan
Tel. +886 2 7721 2121
sales.tw@kistler.com
Thailand
Tel. +66 2678 6779-80
sales.thai@kistler.com
United Kingdom
Tel. +44 1256 74 15 50
sales.uk@kistler.com
USA/Canada
Tel. +1 248 668 6900
sales.us@kistler.com
Other Countries
Tel. +41 52 224 11 11
sales.export@kistler.com
Switzerland
(Headquarters)
Tel. +41 52 224 11 11
info@kistler.com
SPS/IPC/DRIVES 2012, Nuremberg
Hall 4A, Stand 451
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