Joining processes in the TCO check

Throughout industry, the Total Cost of Ownership (TCO) principle is a critical factor in decisions on procuring new machinery or plant. The actual procurement costs are not the only factor that a business must consider if it aims to manufacture competitively in the long term. It's equally important to factor in all the direct and indirect costs incurred before, during and after the procurement. This is the way to identify solutions that are most favorably priced and cost-effective. This principle also applies to joining and press-fit processes in industrial manufacturing: investments in electromechanical joining systems can pay off in the long run here – in terms of energy balance and maintenance expense as well as product scrap costs.

In May 2012, the University of Kassel published a study that compares the energy efficiency of hydraulic, pneumatic and electromechanical processes. The results highlight and emphasize the savings potential of electromechanical joining systems. With conventional hydraulic applications, the energy required is 4.4 times more than for electromechanical technology – and pneumatic processes actually use up to ten times more energy. With an electromechanical solution, greater efficiency means that savings of 77 percent are possible as compared to hydraulic systems; in relation to pneumatic applications, as much as 90 percent can be saved.

Reduce operating costs

Maintenance and servicing outlay on electromechanical joining systems is minimal. Why? Because there is no need to change the oil or dispose of the hydraulic oil – so there is no risk of potential leaks like those that can occur in pneumatic processes. In the case of compressed air applications, such incidents can cause high additional costs. Users of electromechanical joining systems can also eliminate the costs of oil and compressed air. Low maintenance and follow-up costs increase available production time and plant productivity. The result: the investment is quickly amortized – in less than two years, depending on the specific application case.

Increase production efficiency

Thanks to the servo amplifier, the process can be controlled very accurately – it is measurable and reproducible because positioning is exact, speeds are constant and accurate, and press-in forces can be precisely defined. This also enhances safety and reliability, and it can significantly reduce the scrap rate. Electromechanical systems that visualize and evaluate production processes are used for consistent, process-integrated quality assurance. The benefits: errors are detected in good time and the relevant product parts are separated out promptly, so they undergo no further processing. In all these ways, electromechanical systems boost production efficiency across the board.

Avoid extra investment costs

More and more often, manufacturers are opting for joining systems that have the ability to perform different joining steps on one and the same plant. Here too, electromechanical applications offer major advantages: rapid setup and flexible adaptation to different measuring ranges. This means that different components can be produced on one single machine. The benefits: fewer assembly machines are needed, and investment costs on additional machines are saved.

Be equipped to face the future

So that manufacturers can take full advantage of these savings potentials, Kistler offers coordinated electromechanical NC joining systems with integrated force sensors and high-performance force-displacement evaluation – for end-to-end monitoring and documentation of all measured values. Thanks to user-friendly visualization and intuitive operation, manufacturers can optimize their production by detecting faulty parts at an early stage. The maXYmos NC monitoring system evaluates and documents XY curves for joining and press-fit processes, in conjunction with NC joining modules and the matching IndraDrive servo amplifier. A high degree of control and the advantages of process monitoring mean that optimal cycle times and maximum process repeatability can be achieved. Exact positioning ensures consistently precise results.


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