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www.ADandP.media AD&P; ∕ JANUARY 2016 ASSEMBLY Integrating sensors, powerful software and data analysis tools is not only taking place in robotics, but also with precision presses. This brings the ability to gather data and generate numerous signature curves to clinching, riveting and other pressworking assembly tasks. "Press-and-hope" followed by "sort-and-toss" gives way to establishing parameters for perfect parts (at times with looser tolerances or less press force necessary than originally thought) and then pressing them with regularity. Promess ( promessinc.com ) has been refning and improving its EMAP (electro-mechanical assembly press) system which combines servo-controlled ballscrew press technology with a multi-axis motion control system to provide a high-precision, closed-loop press system. The servo system is sized so that no gearbox is required. This contributes to system durability (i.e., lower maintainance) and performance stability, as opposed to the standard industry practice of using low-torque, high-speed motors in conjunction with high-ratio gearboxes to obtain the required torque, according to Promess. Sensors and electronics contribute the ability to perform the assembly operations with precision. Piezoelectric sensors for measuring force, pressure and acceleration along with strain gauges and analog and digital position sensors are wired into master modules containing high-speed analog and encoder inputs with high sampling rates. The resulting capabilities for advanced data analysis include unlimited gauging points and integrated programming language with complete math functions for generating signature curves and analyzing them. Check valves for anti-lock braking systems (ABS) are an example of how rethinking the assembly process based on the information one can gather while pressing pays of. Promess describes the requirement to build a check valve with a pressure tolerance of ±200 psi, tolerances that were later tightened to ±50 psi. To ordinarily achieve that, it would be necessary to have a precision spring, a precision ball, and a precision bore that are pressed and assembled and then tested at a separate test station. But through EMAP's ability to monitor the force of the valve insertion, it became possible to do two things: (1) generate a press signature of a good pressure relief valve with standard components, and (2) precision-test each valve to the 1,000 psi performance level during assembly at a tolerance of ±2 psi. "Pressing to function" with a lower-tolerance "standard" spring, ball and bore, while at the same time generating a press signature that assures each and every valve functions as required, lowered the costs for components and also eliminated the need for a separate test station with its related equipment and labor. Quality, consistency, and through- put go up while signifcant costs are removed from the production process.. It's so cool, it's scary. New ACR or automotive applications. Evonik. Power to create. From clear to uniform illumination with ACR . Sleek and thrilling to behold, ACR ings a new dimension to automotive lighting design. Using LED edge lighting, ACR ransforms from crystal clear to uniform illumination in any color—no more unsightly LED "hot spots." The design possibilities will take your breath away. Evonik Cyro LLC www.acrylite-polymers.com See for yourself with an in-person demo! Call 1-800-631-5384 LEFT: Learning by doing. Robots enabled with LVC (Learning Vibration Control) shave up to 15% in spot-welding time. 39