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TOX Joining Technique
- the leading clinching system with many advantages:
- economic - Clinching is significantly more cost efficient than spot welding
- reliable - We guarantee joint strength values
- versatile - Clinching is usable for numerous material combinations
- environmentally friendly - Clinching is energy saving, clean, quiet
- user oriented - TOX = technology + production equipment from one source
The TOX Joining Technique combines two closely related technologies,
already well established and proven since many years in mass production,
and finding new and innovative clinching applications every day in the sheet metal joining industry:
TOX Clinching
also known as riveting without rivets, usually using the solid die cavity patented by TOX.
Due to its cost effectiveness and reliability, TOX Clinching is a process highly acknowledged
and highly regarded by the whole sheet metal working industry.
A patented spin-off development of Clinching is the TOX ClinchRivet:
TOX ClinchRivet
A simple, symmetrical rivet is used as the joining element to produce a clinch connection with higher
strength values than those obtained with a pierce rivet and without cutting the material.
Applications in the crash zone of passenger cars are a testament to the capabilities of this versatile joining method.
The TOX Principle
The Clinching process (DIN 8593) produces a button-type, positive connection of two or three layers of sheet metal using a cold-forming process. The process joins sheet metals of different thicknesses or materials, even with adhesives or other intermediate layers.
In industrial applications clinching is being applied for single sheet thicknesses of 0.1 mm up to a total layer thickness of 12 mm / .47" and up to 800 N/mm2 / 5.7 lbf/in2 tensile strength. In laboratory tests significantly higher values have already been achieved!
TOX offers all the components needed for the TOX Joining Technique: from technical support provided with the TOX Test Report, as far as complete turnkey cells. Many satisfied customers in the automobile, white goods and computer industries, as well as machine integrators confirm: "You can rely on TOX!"
TOX Force Fitting
- applying standard moduls from the TOX program and in close co-operation with the system suppliers
for pierce and force fit elements we are your competent turnkey partner.
TOX Punching
- using, for example, the Punch-Robot / Machine Tongs SHR with hydraulic
drive HZ.
TOX Marking
- for this specific task a number of purpose developed products is available, from the TOX PowerKurver down to the single marking element.
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TOX-Drives - Pneumatic-hydraulic
The TOX-Powerpackage – the energy saving pneumatic operated cylinder with integrated oil system and
automatic activated power stroke. Capacities from 2 to 2000 kN, total strokes up to 400 mm, power strokes
up to 80 mm (longer power strokes available with the split KT system)
Patented: bypass system, hydraulic return stroke dampening, absolute air-oil separation.
We also supply the Powerpackage in various customised executions.
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New: line-Q, the advantageous preferential series
Technical Data:
Straight (Q-S-) and compact (Q-K-) versions available
Press forces 10 - 277 kN at 6 bar air pressure
Total stroke 100-200 mm
Power stroke up to 52 mm
High cycle speed, high approach and retract forces
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Series S - Standard
Inline version
High cycle speed, high approach and retract forces
Pressforce from 2-1740 kN
Total stroke up to 400 mm
Power stroke up to 80 mm
Standard features from size S4 and larger: power bypass and hydraulic dampening in retract
All units available with pneumatic spring: Series EL
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Series K - Compact
Short design
High approach and retract forces
High cycle speed
Pressforce from 2-500 kN
Total stroke up to 400 mm
Power stroke up to 50 mm
All units available with pneumatic spring: Series EK
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Series KT - with remote mounted intensifier
The split version of the Powerpackage - flexible and expandable
Pressforce from 2-2000 kN
Total stroke up to 400 mm
Power stroke up to 400 mm
Operating air pressure up to 10 bar
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Series RP - marking cylinder
Special marking cylinder
Pressforce up to 150 kN
Total stroke 32 mm
Power stroke 3 mm
Working rod with integrated antirotation and tool clamping collet.
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Series T - Turbo cylinder
The fast "Turbo cylinder"
Up to 550 strokes / min
Pressforce up to 120 kN
Power stroke 6 & 12 mm
Application in punch and nibbling machines
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TOX-Drives - Electro-mechanic
TOX-ElectricDrive - modular Servo-Spindle Drives, with well-proven accessories. Prepared for all standard interfaces. Capacities from 0,5 to 400 kN, standard stroke length up to 300 mm. Axis controller in two executions, including the user friendly "TOXsoftWare" for parametering, controlling, operating, monitoring. Safety category 4 resp. 3.
Custom versions, built from standard modules, can rapidly be realised.
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Series EPMS - Standard
Pressforce from 0,5 to 200 kN, 5 types
Standard stroke 250/300mm
Must be used in a properly guarded work area
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Series EPMK - Compact
Pressforce from 0,5 to 400 kN, 7 types
Standard stroke 250/300mm
Meets safety category 4 with optional holding brake
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Series EPMR - Ultra Compact
Pressforces 55 and 100 kN
Standard stroke 100mm
Meets safety category 4 with optional holding brake
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Series EPC - PowerKurver 90 kN
Pressforce 90 kN
Operating angle 90°
Drive: ElectricDrive EPMK 25
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Modular electromechanical servo spindle system with press force up to 400 kN, from standalone systems
to complex machines: the solution for all applications in all variations.
The drive system consists of the following components: servo spindle EPMx, a servo controller, cables and the TOXsoftWare.
The modular and easy to configure system provides for a wide spectrum of applications, such as forming or press fit operations,
safety oriented applications and sheet metal joining processes like TOX Clinching, even with adjustable and controllable remaining point bottom thickness.
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TOX-Presses
Power progression from 2 - 2000 kN
TOX Presses – the performancers of your production
Modular concept : from the standard press up to the individual plant – everything is possible.
Rugged and economic, long-lived and versatile, CE-conform and in line with UVV (German Accident Prevention Regulations),
including comprehensive accessories. Type-tested safety controls and process monitoring systems – everything is available.
Three drive variants are available:
- TOX-Powerpackage, the ideal press drive, combining the advantages of pneumatics with those of hydraulics
- TOX-ElectricDrive, with most-precise mechanics and user-friendly software
- TOX-Hydraulic Cylinder, the working cylinder with separate pressure intensifier
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TOX®-Powerpackage
TOX®-Powerpackage-Presses
work substantially more efficiently than conventionally driven presses.
Because, after all, the presses incorporate the unique TOX®-
Powerpackage with patented end position dampening and power
bypass. An energy saving power cylinder, which combines the
advantages of pneumatics and hydraulics: the total stroke is divided
into an air operated, low consumption, fast approach stroke,
and an automatically activated pneumo-hydraulic power stroke.
While pneumatic cylinders and many hydraulic systems consume
a lot of energy during the approach stroke, the TOX®-Presses
use the power stroke only when needed.
TOX®-Powerpackage: Total strokes up to 400 mm, power strokes
up to 200 mm.
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TOX®-ElectricDrive
Electromechanical servo drives
with planetary roller screw and
push-pull force sensor. Highly precise,
guided and anti-rotating working
rod. Modular drive concept
with or without mechanical brakes.
Thus providing redundancy according
to safety category 4.
Simple, operator-friendly programming
of spindle motions. The included
free TOX®-Works software
contains force-travel monitoring.
TOX®-ElectricDrive: Total strokes
up to 500 mm, power strokes
according to customer’s requirements.
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TOX®-Hydraulic-Cylinder
The working cylinder HZ with the
same proven seal technology of
the TOX®-Powerpackage. Driven
by the pneumatic operated TOX®-
Intensifier ES, which converts air
pressure into hydraulic pressure.
The approach stroke is hydraulic,
the return stroke pneumatic, an
absolutely reliable system, thanks
to the patented air/oil separation.
For higher approach speeds and
larger retract forces, select the
TOX® Hydraulic cylinder type AT
with an air-to-oil intensifier ES as
drive. The hydraulic cylinder AT
also features patented air/oil separation
for a safe, reliable function.
Available also in the HZ version for
use with a hydraulic pump, providing
hydraulic approach and return
stroke.
Stroke lengths:
HZ up to 200 mm
AT up to 400 mm
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The Press Controls
Only a machine which has been well
matched to the job can provide the
required efficiency and desired cost
effectiveness. This can be accomplished
by a well thought-out control
system, which on the one hand is as
simple and safe to operate as possible,
and on the other hand offers
maximum use of its functions.
Select the best suited controls for your
press from the vast TOX® standard
program: prototype tested, CE-conforming
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Intelligent Monitoring
The TOX® Pressing Monitoring System
EPW provides for monitoring of
processes requiring documentation
of precisely defined functional correlations
between force and travel.
The consistent check of your pressing
operations guarantees a full
quality assurance.
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TOX Tongs Information
Our modular concept for handheld-, machine- and
robotic tongs provides you with ample freedom to match these TOX tongs to
your parts and handling equipment. Custom models are available. We provide
solutions to your application and quality assurance requirements with a
clearly defined interface.
Tong drives: specially designed hydraulic cylinders with absolute air/oil
separation for hydraulic fast/power strokes and pneumatic return stroke. The
pressure for these cylinders is generated by a TOX pneumohydraulic
intensifier type ES. Pressure can also be supplied by a conventional
hydraulic power unit. Or, with our pneumatic operated TOX Powerpackage
cylinder.
An alternative to the pneumohydraulic drives are our electromechanical servo
spindles TOX ElectricDrive coupled with our user-friendly
TOXsoftWare.
A TOX stripper is always integrated.
The punch and the die position can be interchanged in special tongs
executions, e.g., if difficult accessibility to the joint location makes
this necessary.
TOX supplies specially developed Process Monitoring Systems, which help you
to check and document your quality control requirements.
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TOX Handheld/Machine Tongs
The TOX Handheld Tongs have been designed with the
operator in mind:
- robust and durable
- excellent handling due to:
- flexible hose connection to the pressure intensifier
- well thought-out rotary coupling for oil, air and electric
- sturdy, swivelling hanging bracket for attachment of a balancer
- service friendly
Some of the Handheld Tongs shown here can also be used as machine mounted
units, which are supplied with tapped mounting holes in place of the
handles.
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TOX Robot / Machine Tongs
The modular system of the TOX Robot /
Machine Tongs was developed together with
our customers mainly for clinching
applications and therefore has these
application oriented features:
- Modular design
- 3 drive variants available
- TOX Quality Dimension "X" adjustable and controlable
- y – z axis adjustable
- indirect press force measuring
- power stroke can be switched off for setting
TOX tongs are designed for tough volume production, still providing best
serviceability.
The design concept allows for a large variety of component combinations, which
are at best explained during a consultation meeting with a TOX expert.
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Pneumo-Hydraulic Pressure Intensifier
The working cylinder on the TOX Tongs requires hydraulic pressure of 250 bar or
470 bar depending on the unit. The simplest way to generate this hydraulic
pressure is with a pneumo-hydraulic TOX-Pressure Intensifier, which boosts the
compressed air pressure from 6 bar to the required hydraulic pressure. The tong
controls are integrated in the intensifier unit. We offer two intensifier
versions in different variations:
Compact-Pressure Intensifier BES
For TOX-Handheld Tongs CMH 01.45 and CMH 02.30, TOX-Mini-Handheld Tongs CMH
03.45 and CMH 04.45 version 12. With pneumatic controls, including a pressure
relief valve.
Tong-Pressure Intensifier PHA
For TOX-Handheld Tongs TZ and CHH (250 bar) or for TOX-Mini-Handheld Tongs CMH
04.45 (470 bar); version with 1- and 2-Hand controls with safety valve, in
rolling or pedestal mounted models.
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Applications
TOX Production Cells - standard components can be
used to create your production line
Standard components, such as our drives, tongs and pressframes, controls,
safety elements, process monitoring, as well as clinching, marking or
piercing tools, can be used to design and produce ideal customized solutions
to your individual requirements. Thanks to our vertical manufacturing
structure, we are independent, prompt and cost efficient – for your benefit!
Send us your requirements and we will find the best solution for you!
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Production cell for car window lifter
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Pressing cell for bushings
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Production unit for washing machine cabinets
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