Compact servo press instead of pneumatic: with force-displacement monitoring for joining

Winterthur, March 2026 – Electromechanical joining is becoming much more effortless. For the first time, the new Integrated Joining System (IJSys) with force-displacement measurement by Kistler combines all the components of a servo press in a single housing. Process monitoring and control remain the only components that must be connected separately via the maXYmos NC system. Thanks to its compact design, the new joining system is an energy-saving alternative to pneumatic systems.

Electromechanical joining systems are precise, flexible, and energy-saving. Yet external components such as the drive, safety or measurement technology need to be positioned in a separate control cabinet, which increases the integration effort. Kistler developed the IJSys in response to the need for a space-saving and easy-to-integrate solution. The new joining module combines all components in one unit. It integrates the servo drive, the sensor, data digitization and the safety technology directly into the module. As with other electromechanical joining systems from Kistler, a precise force sensor is integrated. The system digitizes the force-displacement data internally and transmits it via an EtherCAT interface. Users can evaluate the data with the proven maXYmos NC process monitoring system from Kistler. Alternatively, they can process the data directly in a higher-level system.

During the development of the new servo press, Kistler reduced space requirements and integration effort by minimizing the number of cables. The system supplies power, logic and data transmission via a single hybrid cable. Only the integrated safety technology requires an additional cable to connect the module to an emergency stop system, for example. The power supply is designed for 48 volts instead of the usual 230 or 400 volts. This protective low voltage eliminates the need for a licensed electrician to connect the system.

Kistler and Cyltronic developed an all-in-one servo press as energy-saving alternative to pneumatic systems.

Connecting the Integrated Joining System to industrial machinery and plants is simple via two cables only.

The force-displacement monitoring of each joining cycle is supported by the process monitoring system maXYmos NC.

Precise force-displacement control for stable joining processes is based on parameters like force, position, and speed.

Kistler developed the all-in-one servo press, the Integrated Joining System, in collaboration with Cyltronic AG. Thanks to its compact design, it serves as an energy-efficient alternative to pneumatic systems and is well-suited for compact machine designs. Cyltronic contributed its expertise in integrating components into electric cylinders.

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Compact joining system – also as an alternative to pneumatics

The Integrated Joining System has a joining force of up to 2.5 kN, a stroke of 200 millimeters, and a travel speed of 250 millimeters. The mechanical interface is designed in accordance with ISO standard 15552. This makes the servo press particularly suitable for applications in electronics and automotive manufacturing, where pneumatic systems have previously been used primarily due to space constraints or cost reasons. Electromechanical technology offers a number of advantages: on the one hand, it is more energy-efficient in operation, and on the other hand, electromechanical systems are more flexible. While pneumatic systems usually move only between start and end positions and require considerable effort to reach intermediate positions, electromechanical systems can be controlled continuously. Equally, the force ranges and speeds required for the process can also be achieved much more precisely and flexibly with an electromechanical system than with pneumatic solutions.

Expert in force-displacement monitoring Kistler cooperates with integration specialist Cyltronic

Kistler developed the compact all-in-one joining system in collaboration with Cyltronic AG. “Our colleagues at Cyltronic bring valuable experience in integrating components for electric cylinders. This expertise was essential for implementing our new system quickly and successfully,” explains Dr. Bastian Telgen, who was responsible for the development of the Integrated Joining System at Kistler. “We look forward to working with our customers on many projects and to developing further solutions and functions in line with market requirements and user feedback.”