Operating manual

TOX®softWare Worx

line-X Reference Manual

Version 2.2.7 03/2017

TOX® PRESSOTECHNIK GmbH & Co. KG  Riedstraße 4  D - 88250 Weingarten

Tel. +49 (0) 751/5007-0  Fax +49 (0) 751/52391  www.tox-de.com  E-Mail: [email protected]
 Table of contents

Table of contents
1 Project/Adapter ................................................................................................ 5
1.1 Synchronise clock ..................................................................................... 7
1.2 Device control ........................................................................................... 8
1.3 Parameter Logger – Configuration .......................................................... 10
1.4 Produce report ........................................................................................ 12
1.5 Project Statistics ..................................................................................... 13
1.6 Properties ............................................................................................... 14
2 Device data ..................................................................................................... 15
3 Spindle data ................................................................................................... 21
4 Diagrams ........................................................................................................ 29
5 Final values .................................................................................................... 40
6 Variable status ............................................................................................... 45
7 Processes ....................................................................................................... 47
7.1 The 'Processes' tab................................................................................. 47
7.2 Editing a process .................................................................................... 60
7.3 Summary of the function groups and functions ....................................... 64
7.4 Explanation of the functions .................................................................... 66
7.4.1 'Stroke' function............................................................................ 66
7.4.2 'Relative stroke' function .............................................................. 71
7.4.3 'Press' function ............................................................................. 75
7.4.4 'Pressing with bending compensation' function ............................ 80
7.4.5 'Return stroke' function................................................................. 83
7.4.6 'Jog forwards' function.................................................................. 85
7.4.7 'Jog backwards' function .............................................................. 87
7.4.8 'Sluggishness drive' function ........................................................ 89
7.4.9 'Clinch pre-position' function......................................................... 90
7.4.10 'Clinching adhesive' function ........................................................ 93
7.4.11 'Clinching' function ....................................................................... 95
7.4.12 'Clinching return stroke' function .................................................. 98
7.4.13 'Tongs code' function ................................................................. 100
7.4.14 'Riveting pre-position' function.................................................... 100
7.4.15 'Riveting adhesive' function ........................................................ 102
7.4.16 'Riveting return stroke' function .................................................. 104
7.4.17 'Rivet type' function .................................................................... 105
7.4.18 'Clinch riveting pre-position clinch'.............................................. 106

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 Table of contents

7.4.19 'Clinch riveting' function.............................................................. 108

7.4.20 'Self-piercing riveting' function .................................................... 111
7.4.21 'Rivet monitoring' function .......................................................... 112
7.4.22 'Self-piercing riveting' function .................................................... 114
7.4.23 'Semi-hollow punch riveting' ....................................................... 116
7.4.24 'External target value' function ................................................... 117
7.4.25 'Inflexion point detection' function with inflexion point analysis ... 120
7.4.26 'Inflexion point detection' function without inflexion point analysis123
7.4.27 'Press to force difference' function.............................................. 127
7.4.28 'Pressing to PLC default values' function.................................... 130
7.4.29 'Stroke 7th axis' function ............................................................ 131
7.4.30 'Reference run' function ............................................................. 132
7.4.31 'Time delay' function .................................................................. 133
7.4.32 'Process call' function ................................................................. 133
7.4.33 'Sub-process call' function .......................................................... 134
7.4.34 'Start multiple condition' function ................................................ 135
7.4.35 'Target multiple conditions' function............................................ 136
7.4.36 'End multiple condition' function ................................................. 136
7.4.37 'Reworking' function ................................................................... 136
7.4.38 'Define abort contact' function .................................................... 137
7.4.39 'Acceleration' function ................................................................ 138
7.4.40 'Deceleration' function ................................................................ 139
7.4.41 'Spindle data' ............................................................................. 140
7.4.42 'End process' function ................................................................ 144
7.4.43 'Stop process' function ............................................................... 144
7.4.44 'Set integer variable' ................................................................... 145
7.4.45 'Set real variable' function .......................................................... 145
7.4.46 'Home position reached' function ............................................... 145
7.4.47 'Home position not reached' function.......................................... 146
7.4.48 'Working position reached' function ............................................ 146
7.4.49 'Working position not reached' function ...................................... 146
7.4.50 'Technology process complete' function ..................................... 146
7.4.51 'Technology process not complete' function ............................... 147
7.4.52 'Target value reached' function .................................................. 147
7.4.53 'Target value not reached' function............................................. 147
7.4.54 'Process repeat possible' function .............................................. 147

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 Table of contents

7.4.55 'Process repeat not possible' function ........................................ 148

7.4.56 'Save intermediate values 1' function ......................................... 148
7.4.57 'Save intermediate values 2' function ......................................... 148
7.4.58 'Save final values' function ......................................................... 148
7.4.59 'Curve tracing' function ............................................................... 149
7.4.60 'Stop curve tracing' function ....................................................... 149
7.4.61 'Start envelope monitoring' function............................................ 150
7.4.62 'Stop envelope monitoring' function ............................................ 151
7.4.63 'Wait for input' function ............................................................... 151
7.4.64 'Set output' function .................................................................... 152
7.4.65 'Initialise force sensor' function................................................... 153
7.4.66 Check force sensor .................................................................... 153
7.4.67 'Comment' function .................................................................... 153

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 Project/Adapter

1 Project/Adapter

A connected line-X device is displayed in the file system with the name defined in the
TOX®softWare server when it was created.
Icon for line-X devices

For the examples listed here, the adapter name 'EPzAdapter' is used, which is created on
installation as the default target device.
In the structure of the file system, the entries are assigned to the main adapter groups under
the adapter.

Note
The TOX®softWare offers many functions via the second (right-hand)
mouse button. Use this mouse button to open context menus.

Note
Boxes with a white background can be edited. If a box has a grey back-
ground, it cannot be edited (Either you are not permitted to edit it or it
must not be edited generally).

• Context menu 'Adapter' in the file system

Update adapter Updates the selected adapter, for example if it is dis-
played as unavailable but a connection exists again
via the TOX®softWare server.
Cancel all changes All changes made since last saved are cancelled.
Cut (CTRL+X) Places the selected adapter in the buffer.
Note: After pasting, the adapter is no longer availa-
ble in its previous position.
Copy (CTRL+C) Copies the selected adapter to the buffer.
Paste (CTRL+V) Pastes the adapter in the buffer to the place marked
in the file system. This command is only available if
an adapter is available in the buffer and the point at
which it is pasted is a valid destination.
Delete (DEL) Deletes the currently selected adapter after acknowl-
edging the security message with the 'Yes' button.
Rename This command cannot be enabled in the context
menu of the TOX®softWare Worx. An adapter must
be renamed in the TOX®softWare server (see manual
TOX®softWare server).
Synchronise clock Synchronises the time of the controller (description in
section 1.1 Synchronise clock).

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 Project/Adapter

Device control Opens the 'MONITOR' application to move a spindle

via an Ethernet connection in the TOX®softWare
Worx (description in section 1.2 Device control).
Axis mode: Automatic Switches the axis mode to 'Automatic'. This com-
mand is only available of the axis is not in Automatic
mode. Programs can be changed in this mode.
Axis mode: Remote Switches the axis mode to 'Remote'. This command
is only available if the axis is not in Remote mode. In
this mode, the device does not accept program
starts.
Set process release Sets the process release on the controller. This com-
mand is only available if the process release is
blocked.
Block process release Blocks process release on the controller. This com-
mand is only available if the process release is set.
Without process release, the device does not carry
out any movement commands.
Reset error Re-sets existing errors on the controller.
Parameter logger configuration Opens the configuration window of the parameter
logger (description in section 1.3 Parameter Logger
– Configuration).
Produce report Opens the window 'Save file' to define the memory
location for the report file (description in section 1.4
Produce report).
Project statistics Opens the window 'Project information' (description
in section 1.5 Project).
Properties Opens the window 'Properties (description in section
1.6 Properties).

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 Project/Adapter

1.1 Synchronise clock

In the window 'Time synchronisation', the data and time of the controller can be changed.
• 'Connection' category
The current server and the device are displayed here. It is not possible to change the server
or the device here. .

• 'Current' category
Here, the date and the time read out by the controller are displayed. Both values can be
changed either via the arrow buttons or by direct input. The up arrow increases the value
by 1 and the down arrow decreases the value by 1.
With the button 'Local time', the date and time of the workstation are read out and the entries
in the boxes adapted accordingly.
 With the 'Cancel' button, the window is closed without adopting the changes.
 With the 'OK' button, the values entered in the boxes for date and time are written to the
controller.

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 Project/Adapter

1.2 Device control

For commissioning or checking functions, you can move a spindle with the function 'Device
control' from the TOX®softWare Worx via an Ethernet connection without an existing PLC or
other program- or start-based I/O connection.

Device control
The device control can only be used if the start signal source and the pro-
cess number source are set to 'Ethernet' in the 'device data'.
The connection to the device must also be active. This function is not
available in offline mode.

After selection of the entry 'Device control' in the context menu, the following confirmation
prompt appears:

With the 'Cancel' button, the window is closed without adopting the changes.
 Enter the word 'MONITOR' (in capital letters) in the input box.
 Then open the device control with the 'OK' button:

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 Project/Adapter

• 'Data' category
The server and target device are displayed here. The box 'Current program' displays the
selected program number. The selection list 'Program pre-selection' contains the processes
which are actually stored on the controller. By selecting an entry in the selection list, this
process number is selected on the controller.
• 'Process' category
Here the current force and the current travel are displayed with progress bars. At the end
of the process, the force and travel values from the final values are displayed in the box
'Final values'. In the box 'Cycle time', the processing time of the process is specified. With
the LEDs 'Ready' and 'Reference', a message is issued stating whether the controller is
ready to run the process and whether the axis has already been referenced.
The process is started with the safety button 'Start'. The button is enabled with the first click
(flashing green border) and start-up is triggered with the second click. If the button is re-
leased, start-up is immediately cancelled and the axis stops. If the button is held, the pro-
cess is run until the end of the process is reached.
The connection icon (in the status bar bottom left) shows the connection status of the target
device. If necessary, error messages are displayed in the output box to the right of this.

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 Project/Adapter

1.3 Parameter Logger – Configuration

In the 'Parameter Logger' window, you can log changes in the devices and process config-
uration.

In the 'Active' checkbox, logging of data changes can be enabled or disabled.

• Local
The data packages generated are stored locally or on the network drive.
• ProFeP
Only use this function after consulting TOX® PRESSOTECHNIK.
In the 'Connection' panel, the server which is used as the destination for the data telegrams
is defined. The address or the alias and the port are to be specified here. UDP-compatible
software (server service) must run on the server, which receives data telegrams and
acknowledges them accordingly.
• Silent mode
When the 'Silent mode' checkbox is enabled, data transmission is carried out in the back-
ground. Pop-up messages are suppressed in 'Silent mode'.

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 Project/Adapter

The data of the 'Parameter Logger' are generated in telegram form. The data should be
delivered as soon as possible. Until acknowledged delivery to the server, the data are stored
in the 'offline cache'. If the server cannot be reached after several tests, transmission is
interrupted for 5 minutes before it is attempted to set up a connection again, in order to
minimise the load on the system. Until then, the accumulated data are stored in the 'offline
cache'. Once the connection is restored, the accumulated data are transmitted.
• Category 'AKZ' (system codes)
The settings to identify the system are configured here.
The AKZ is a character string for identification of the system:
WORKS DEPT. SYSTEM MACHINE
For configuration of the categories in the fields under the category 'AKZ', the selection but-
tons 'Fixed' and 'Variable' are available, which define a fixed or a variable character string
for this field.
– Fixed
When 'fixed' is selected, the sub-character string is directly read out of the input box for
the relevant character string of the AKZ and used as the designation.

– Variable
When 'Variable' is selected, the sub-character string for the relevant character string of
the AKZ is derived from the PC name. The value in the input box 'Index from' is the start
index and the value in the input box 'Index to' is the end index of the sub-string from the
PC name. The value '-1' in an index input box indicates that the character string is read
up to the end.

Works In the 'Works' category, assignment of the sub-string for the AKZ is defined via
the selection switches 'Fixed' and 'Variable'. Depending on the position of the
selection switches, a fixed designation or a start and end index is expected.
DEPT. In the 'Department' category, assignment of the sub-string for the AKZ is defined
via the selection switches 'Fixed' and 'Variable. Depending on the position of
the selection switches, a fixed designation or a start and end index is expected.
Station In the 'Station' category, the sub-string for the AKZ is defined via the selection
buttons 'Fixed' and 'Variable'. Depending on the position of the selection
switches, a fixed designation or a start and end index is expected.
Device In the 'Device' category, assignment of the sub-string for the AKZ is defined via
the selection switches 'Fixed' and 'Variable'. Depending on the position of the
selection switches, a fixed designation or a start and end index is expected.

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 Project/Adapter

• Category 'Paramlogger folder'

In the ' Paramlogger folder' category, the offline data logger for the data of the 'Parameter
Logger' are configured. Here you define the path for buffering telegrams which are ready
but have not been sent yet.
 In the input box 'Path', enter the target directory of the offline data buffer.
 Press the button 'Select' to open the window to select the memory location in the file
system.
 In this window, select the required path and click on the button 'Open'.
With the 'Cancel' button, the configuration of the path is ended.

1.4 Produce report

With the 'Produce report' function, you can produce written documentation
on the current status of your device. The report is generated in PDF format and is already
formatted. The sub-division is based on the allocation of the categories under the device.
After selection of the menu entry, a "Save file window“ is opened, in which the memory
location and the file name of the PDF document is defined.
With the 'Cancel' button, the window is closed without a report being produced. With the
'OK' button, the report is produced and stored under the entered name at the selected
memory location.
While the PDF is being created, this information window is displayed:

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 Project/Adapter

1.5 Project Statistics

In the ’Project Statistics’ window, you can obtain information on the memory status and
scope of the current project:

In the 'Connection' category, the server and the target device are specified.
The 'Info' category specifies the number of processes and functions on the device and the
current project ID via which the comparison of the online and offline project is processed.
In the category 'Memory requirement in the device', the current load of the memory in the
device is displayed both numerically in [%] and via a slide bar.
 Close the window with the 'Close' box.

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 Project/Adapter

1.6 Properties
The window 'Attributes of EPzAdapter' contains information on the current adapter:

• Name
Name of the adapter
• All files
Name of the assigned offline file
• File size
Current size of the assigned file
• Revision date
Date of the last revision in the assigned file
• Status description
Status of the online adapter (available/blocked/not available)
• Device mode
Mode of the online adapter. The mode is generally specified in plaintext in the file system
in square brackets after the adapter name.
The modes are: Init, Remote, Invalid and Automatic

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 Device data

2 Device data

The device data are displayed and defined in this window. Available device data can
be loaded from the controller, modified and written to the controller again (online
project). Device data from offline projects are modified in the offline file and can be
loaded into the system later.
 In the 'File systems' window, select the project whose device data are to be displayed.
 Double-click on the icon in front of 'Device data':
Icon for device data

The window 'Device data' appears on the desktop. In the tab, the adapter name is also
displayed in front of the entry 'Device data':

Changes in device data

All changes carried out in the device data only become effective after the
project is saved with an enabled checkbox 'Device data'.

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 Device data

Context menu 'Device data' in the file system

Open Opens the device data in the working area of the TOX®softWare
Worx.
Copy (CTRL+C) Copies the device data to the buffer.
Paste (CTRL+V) Pastes the data from the buffer.
The function is only available if the device data are available in
the buffer.
Produce report Produces a report of the current device data in PDF format. A
file name and the memory location
can be selected in the window 'Save as'.
Properties Opens the window 'Properties of the device data, the contents of
which are the same as those of the window in the working area.

'Properties' tab (right-hand window)

'General' group
• TOX®softWare version
Here you can find the exact software version.
• Firmware version
In the 'Firmware version' window, a unique version number of the firmware is displayed,
which must always be specified when contacting TOX® PRESSOTECHNIK:

The box cannot be edited and is set directly from the controller.
• Application version
In the 'Application version' window, a unique version number of the application is displayed,
which must always be specified when contacting TOX® PRESSOTECHNIK:

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 Device data

The box cannot be edited and is set directly from the controller.
• Start signal source
Selection of the source of the start signal. In the selection box, the options 'Input', 'Fieldbus'
and 'Ethernet' are available.

Input The start is triggered via a digital input.

Fieldbus The start comes via the Fieldbus, e.g. from a PLC.
Ethernet The start comes via Ethernet, e.g. via 'MONITOR' from the TOX®softWare
Worx or from the TOX®softWare HMI.

• Process number source

Selection of the source of program pre-selection. In the selection box, the options 'Input',
'Fieldbus' and 'Ethernet' are available.

Input The program number is pre-selected via digital input signals.

Fieldbus The program number comes via the Fieldbus, e.g. from a PLC.
Ethernet The program number comes via Ethernet, e.g. via 'MONITOR' from the
TOX®softWare Worx or from the TOX®softWare HMI.
• Start input program number
The entry defines from which input the program number is formed.

Start input program number

The entry is only evaluated when the entry 'Input' is selected in the list
box 'Process number source'.
 Confirm the input of a new port number with the 'Enter' button.

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 Device data

• Number of bits Program number

The entry defines how many bits are to be used by the program number selection byte for
the program number. The entry can be edited directly in the display panel in authorisation
level 3.

Number of bits Program number

The entry is only evaluated when the entry 'Input' is selected in the list
box 'Process number source'.

 Confirm the input of a new port number with the 'Enter' button.
• Reduced number of diagram points
With this function, only 100 instead of 500 points per diagram are plotted. This may be
useful if processes have a cycle time of less than 4 seconds and one wishes to reduce the
download time.
The diagram points not used are then filled in with 0 to correctly fill the buffer of 500 points.
The filler data have no effect on the display and evaluation of the diagram.
Omitting the unused diagram points therefore leads to faster processing of the diagram data
both by the controller and by the PC system.
 Enable this function by selecting the checkbox.
• Mains voltage
In some countries, the controller must be adapted to the local mains voltage. In the default
setting, this value is 'undefined', which means that the voltage value is not taken into ac-
count.
In the selection box, you can select a different default value:

'Ethernet' group
• IP address
Input of the IP address of the controller (for further information on the IP address, see the
documentation of the TOX®softWare server).

Changes to the IP address

Changes to the IP address of the controller must also be updated in the
TOX®softWare server in order to maintain the connection to the target de-
vice.

With the button on the right-hand side of this box, a text input box is opened, in which you
can change the IP address:

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 Device data

With the 'Cancel' button, the window is closed without adopting the changes. With the 'OK'
button, the new IP address is entered in the box.
• Subnet mask
Display of the active subnet mask. The subnet mask can be edited at access level 3.

Changes to the subnet mask

A change in the subnet mask must correspond with the topology of the
network, i.e. it must be selected such that the controller is available in the
accessible subnet of the PC.

 Confirm the input of a new subnet mask with the 'Enter' button.
• Gateway
If the PC and the controller are in a network controlled by a gateway, the entry of the gate-
way IP address is required. When using a gateway, communication is not carried out be-
tween address A and address B but via the gateway. With a gateway, nodes can be made
"invisible" although they are in the same network/subnet.

Changes in gateway
Whether a gateway must be entered and the address of the gateway
must be clarified with the person responsible for the network.
• Mac address
The MAC address (Media-Access-Control address) is the hardware address of each indi-
vidual network adapter, which serves as the unique identifier of the device in a computer
network.

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 Device data

'PLC' group
• Interface type
Select the interface type: default or PLC
Default: TOX® default interface, e.g. in direction of robot
PLC: Siemens function module for "Moving to PLC default values“
• PLC data type
Select the PLC data type: "Swapped", "Not swapped" or "customized". "Swapped" and "Not
Swapped" define whether data with more than one byte must be interpreted from the highest
to the lowest or vice versa. The interpretation can be adapted in cooperation with TOX®
PRESSOTECHNIK and activated via "Customized".
'Input/Output' tab
• DO1, DO2, DO3 enabled for users
Generally, the outputs DO1 – DO3 on the controller are occupied with default feedback
messages. When activated, these outputs can be enabled for the user, i.e. the default as-
signment is then disabled.
• Enable external inputs/outputs
For activation, an input/output module must be integrated as hardware. Activation releases
this module for the application (e.g. the CAN bus).
• I/O to TOX® standard
Enables use and assignment of input/output interfaces to TOX® standard peripheral equip-
ment.
Peripheral equipment
• Door active
Enables use of an integrated safety door.

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 Spindle data

3 Spindle data

In the spindle data, the specific data of the complete spindle are specified. These include,
for example, the motor, gearbox, control and force sensor data. The spindle data are deter-
mined by TOX® PRESSOTECHNIK and saved in a spindle data record. You only have to
load the data belonging to your spindle to the axis controller.
Most values are used to check the plausibility of the input values, e.g. whether an entered
position can be reached at all with the length from the spindle data.
 In the 'File systems' window, select the project of which the spindle data are to be dis-
played.
 Double-click on the icon in front of 'Spindle data'.
Icon for spindle data

The data can be loaded from a file or from the axis controller. New spindles can be set up
with the aid of a template or by copying data of an existing project with a spindle of the same
type.
The window 'Spindle data' appears on the desktop. In the tab, the project name is also
displayed in front of the 'Spindle data' entry:

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 Spindle data

Changing the spindle data

Most of the spindle data ´displayed here can only be changed with au-
thorisation level 4.
All data entered here must correspond with the actual system values.
All changes in the spindle data only become effective after the project has
been saved with the enabled checkbox 'Spindle data'.

The spindle data are contained in several categories.

'Control' group
• Spindle type
The setting of the spindle type is necessary if a controller controls more than one spindle
by re-docking which differ in terms of hardware. The spindle-specific values are parameter-
ised with the aid of the spindle type. The spindle type can be set via the selection boxes
(authorisation level 4).
In the default setting, the type 'unknown spindle type' is set. This informs you that for this
project no spindles are re-docked. The type does not have to be entered in this case.
• Spindle serial no.
Input of the serial number of the spindle is optional and is used for assignment of the pro-
ject/adapter to a certain spindle.
With the button on the right-hand side of this box, an input window is opened in which the
serial number of a spindle can be changed.

 With the 'Cancel' button, the window is closed without adopting the changes.
 With the 'OK' button, the new serial number is added to the spindle data.
• Maintenance counter
Here the number of strokes is specified which can be operated until the next lubrication is
to be carried out. The entered value is used again when the maintenance counter in the
HMI is re-set.

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 Spindle data

• Output stage permanently on

If this checkbox is enabled, control of the controller is maintained independently of whether
the target force or -position is reached. Control of this force or position is then always main-
tained.
'Motor' group
• Maximum acceleration/deceleration [mm/s2]
Maximum permissible acceleration/deceleration speed of the spindle. The value can be
changed directly in the input box.
• Minimum acceleration/deceleration [mm/s2]
Minimum permissible acceleration/deceleration speed of the spindle. The value can be
changed directly in the input box.
• Reversal of direction
Reversal of the counting direction of the encoder switch-over between S and K – spindles.
• Current with nominal force
Current value required for a pressing process in the nominal force range. This value is used
to monitor the signal of the force sensors with the motor current. The value can be changed
directly in the input box.

Caution
This value must not be changed without consulting TOX® PRESSOTECH-
NIK. Changing this value may result in a fault when the spindle starts up
or even damage to the spindle if the Emergency-Stop function reacts too
late.

'Gearbox' group
In the 'Gearbox' group, the transmission of the gearbox is defined as the input/output ratio.
The information is always displayed in the form 'Factor Input: Factor Output'. Here the val-
ues must always be given as integers. The ratio may have to be extended according to the
rules of fractions.
• Factor input
Input factor of the gearbox.
• Factor output
Output factor of the gearbox.

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 Spindle data

'Force sensor' group

• Source analogue input
In this selection list, the source of the analogue input signal is selected (analogue input 1 or
2). If no analogue input is used, the entry 'No analogue input’ appears.

Changes in source analogue input

CAUTION! In the event of an incorrect setting, the spindle may be dam-
aged, as the force transmission may be switched off.

Calculation of the force via the motor current

In later applications, the force can be calculated via the motor current with
'No analogue input'.

If the function is used (newer applications), the pressing speed should be 3 mm/s. The
higher the selected speed is, the less accurate the result. When pressing at high speed and
close to the nominal force, the maximum force may be exceeded due to the measuring
accuracy at high speed. An overload of the spindle may lead to damage or even destruction
of the drive and tool.
Continuous, hard impacts on the material or continual overloading of the drive may lead to
a considerable reduction in the service life of the spindle.
• Analogue input mode
With the selection buttons it is defined whether the analogue input value is to be interpreted
as current or as voltage.
This function is pre-set by TOX®-Pressotechnik.
• Force sensor test active
This function is pre-set by TOX®-Pressotechnik.

24 OM 100.Worx-lineX-Reference.201703.en
 Spindle data

'Spindle' group
• Maximum length [mm]
Length of the spindle in mm.
• Maximum force
Maximum press force of the spindle at 10 % of the nominal value in kN.
• Nominal force:
Maximum physically possible force of the spindle or of a press frame in kN.

Adjust nominal force for application

It is possible that the press, tongs or the external sensor is designed for a
lower load than the nominal force of the spindle. In this case, the nominal
force of the mechanical system must be adjusted so that unintentional ap-
plication of excessive force in the functions is prevented. If the limit is set
too high, this may lead to damage to the tool or the drive.

• Pitch [mm]
Pitch of the spindle in mm per revolution.
• Maximum speed [mm/s2]
Maximum possible speed of the spindle.
• Minimum speed [mm/s2]
Minimum possible speed of the spindle.
• Maximum software limit [mm]
Limitation of the maximum length by the software, for example to protect a tool in the work-
ing area. This value is smaller than or equal to the maximum spindle length.
• Minimum software limit [mm]
Limitation of the minimum position of the spindle by the software, for example to protect a
structure in the lower working area. This value is greater than or equal to the internal block
position of the spindle.
• Maximum safe speed [mm/s2]
Limitation of the maximum speed for reasons of safety. The maximum safe speed is, for
example, the highest possible speed which allows the spindle to be stopped in time before
damage to the component and/or tool occurs in the context of time optimisation.
The safe speed can only be ensured with additional elements (e.g. encoder). If this is also
installed, the speed is reduced.
• Bending constant [kN/mm]
Based on the bending constant, special functions can compensate for the mechanical bend-
ing which occurs when a force is exerted in a clinching frame or on a station.
The bending constant (kN/mm) is used, for example, with the functions "Clinching" and
"Pressing with bending compensation".
The axis moves to the target position. When it arrives there, the currently available force is
permanently used to calculate an additional compensation travel delta_s.

OM 100.Worx-lineX-Reference.201703.en 25
 Spindle data

The axis thus moves on to a new target position = target position (without compensation) +
delta_s.
The bending constant can be calculated, for example, from the return movement curve of a
force/distance characteristic using two points of this for the following calculation:
Bending constant (kN/mm) = force_1 - force_2 / distance_1 - distance_2 (delta force / delta
distance)

Determine bending constant

The bending constant must first be determined. An incorrect bending con-
stant can lead to damage to the tool or the spindle.
• Tong weight index
This parameter is used as a calculation factor for the compensating slide with the die-side
drive.
'Calibration' group
• Factor
The factor determined by TOX®-Pressotechnik during factory calibration is listed at this
point.
Every axis is calibrated by TOX®-Pressotechnik. The factor in the software must corre-
spond with that on the axis and documented in the TOX®-Pressotechnik factory calibration
report, so that the force accuracy of the axis is observed!
The axis can be re-calibrated with the aid of a suitable test set-up and experience.
Open the window to calculate the calibration factor with the button on the right-hand side of
this line.

Incorrect calibration factor

In the event of an incorrect change in the calibration factor, the accuracy
of the axis may no longer be within your specification.
If the factor is incorrectly altered (e.g. from 1.2 to 0.2), this may lead to
damage to the axis!

26 OM 100.Worx-lineX-Reference.201703.en
 Spindle data

In the 'Measurement series' category, the measured values and the associated target val-
ues are entered line by line. With every further pair of values, the calibration factor is refined.
In the 'Calibration factor' category, in the upper box 'Current', which cannot be edited, the
currently set calibration factor is specified. In the 'New' box, the calibration factor calculated
from the measurement series is given.
 With the 'Cancel' button, the window is closed without adopting the changes.
 With the 'OK' button, the new calibration factor is adopted.
'Clinch' group
• Zero position [mm]
Is the mechanical distance from the punch tip to the die base in mm.

Determine the zero position:

If the zero position is unknown or if it was entered approximately and in-
correctly (> 0.5 mm), e.g. due to conversions, the clinching process may
lead to damage to the tool or to the drive.

• Die depth [mm]

Distance from the zero point to the die surface in mm. Generally, zero position – die depth
(e.g. 1.2 mm).

OM 100.Worx-lineX-Reference.201703.en 27
 Spindle data

'Point number' group

• Start position process no.
The 'Start position point number' defines a process number which is evaluated as the start
process number for clinching or pressing processes. In the clinching or pressing application
of the TOX®softWare HMI, only those processes from this number upwards are evaluated
and displayed.
• Point number active
If the checkbox 'Point number active' is selected, the processes are not selected by number
(position in the process sequence) but by name. The designation is numerical and consists
of a defined number of places which identify the process.
• Number of places for the point number
Specification of the number of places for the point number is only relevant if the option 'Point
number active' is selected. This value defines the number of places which the numerically
interpreted process name contains. If the function 'Point number active' is selected and the
value for the number of places is limited, e.g. to 5, a valid point number appears, for exam-
ple, as follows. The maximum number of characters is nine places.
'Brake' group
• Brake active
With the checkbox 'Brake active' it is defined whether a brake feedback message is to be
evaluated in the hardware structure or not. This option is especially useful for commission-
ing.
• Brake type
Here it is possible to select which brake type (stop brake or safety brake) is installed on the
spindle.
• Brake category
Here it is possible to select whether the brake test is only to be carried out in connection
with the reference run or before each process.
• Application delay [ms]
The brake requires a period of x ms to apply. To ensure that the TOX® Servo Drive with the
tool does not sag after the process ends, the motor is actuated for x ms longer to ensure
that the brake is properly applied and can hold the weight.
Context menu 'Spindle data' in the file system
Open Opens the spindle data in the working area of the TOX®softWare
Worx.
Copy (CTRL+C) Copies the spindle data to the buffer.
Paste (CTRL+V) Pastes the spindle data from the buffer.
Produce report Produces a report of the current spindle data in PDF format. A
file name and the memory location can be selected in a window
'Save as'.
Properties Opens the 'Properties' window of the spindle data, the contents
of which are the same as the window in the working area.

28 OM 100.Worx-lineX-Reference.201703.en
 Diagrams

4 Diagrams

If diagram recording is enabled, the diagrams pertaining to the adapter are managed under
the diagram node.
 In the 'File systems' window, select the project of which the diagrams are to be dis-
played.
 Double-click on the icon in front of 'Diagrams'.
Icon for diagrams

The 'Diagrams' tab appears on the desktop. Here the project name is also displayed in front
of the entry 'Diagrams'. On opening for the first time, no curve is yet displayed in the 'Dia-
grams' tab.

The desktop is described in the section 'Individual diagrams'.

OM 100.Worx-lineX-Reference.201703.en 29
 Diagrams

• Context menu 'Diagrams' in the file system

Open Opens the 'Diagrams' window in the working area. The last rec-
orded diagram is displayed with the attachment '[active]'.
Add curve chart Combines several diagrams in one chart.
Paste (CTRL+V) Pastes diagrams from the buffer to the node.
Produce report Produces a report of the current diagrams in PDF format. A file
name and the memory location
can be selected in the window 'Save as'.
Export to CSV format Produces a file with the current final values in CSV format. A file
name and the memory location can be selected in a window
'Save as'.
Properties Opens the window 'Properties' for the diagrams.

'Attributes of diagrams' window

The diagram recording for the current project and the display of the diagrams is configured
here. The settings apply to all diagrams generated for this adapter.

30 OM 100.Worx-lineX-Reference.201703.en
 Diagrams

'General' group
• Record
With this checkbox, diagram recording is switched on. After enabling, the 'Mode' group is
displayed in the 'Attributes of diagrams' window.
• Diagram name
Basic name of the diagram entries. This name basis is extended by the following values in
order to clearly identify the diagram entries:
process number; process name; date; time stamp
With the button on the right-hand side of this box, an input window is opened in which the
name of the diagram can be changed:

 With the 'Cancel' button, the window is closed without adopting the changes.
 With the 'OK' button, the new serial number is added to the spindle data.
'Mode' group
The 'Mode' group is displayed if diagram recording is enabled.

• Record permanently
Diagram recording is not limited by the end of a process but by the recording time. The
function is not currently available.

OM 100.Worx-lineX-Reference.201703.en 31
 Diagrams

• Individual diagrams
The function 'Individual diagrams' cannot be changed as long as the function 'Record per-
manently' is selected. If 'Record permanently' is disabled, one entry per diagram is produced
when this function is enabled. If the option is disabled, the option 'Number of diagrams per
curve' is displayed. The function is not currently available.
• Number of curves
The maximum number of diagram entries in the diagram element is defined here. When the
maximum number of diagrams is reached, the oldest diagram is always removed from the
list.
'Displays' group
• Show function names
Enables the display of the function names in the diagram.
• Display function limits
Enables the display of the function limits in the diagram.
• Display spindle limits
Enables the spindle limits in the diagram.
• Display diagram with co-ordinate values
Activates the co-ordination values in the displayed diagram. The coordinates are displayed
as a tool tip when pointing to a point on the curve.
'Colours' group
With the button on the right-hand side of the individual line, the window to select the colour
is opened here (example: colour for displaying spindle limits). When selecting the colours,
ensure that the colours of all lines contrast well with the background colour.

Selection of the colours corresponds to the procedure for standard applications under Win-
dows.

32 OM 100.Worx-lineX-Reference.201703.en
 Diagrams

• Spindle limit colours

Colour selection for displaying spindle limits.
• Function colours
Colour selection for displaying the functions.
• Envelope colours
Colour selection for displaying the envelopes.
• Background colour
Colour selection for displaying the background
• Grid colour
Colour selection for display of the grid.
• Diagram colour
Colour selection for display of the diagram.
 With the 'Cancel' button, the window is closed without adopting the changes.
 With the 'OK' button, the displayed colours are adopted.

OM 100.Worx-lineX-Reference.201703.en 33
 Diagrams

Individual diagrams
The individual diagram entries are displayed in the project under the icon 'Diagrams' as
follows.

By double-clicking on a diagram entry, the selected diagram is opened and displayed in the
'Diagrams' tab.

In the upper half of the desktop, the final values pertaining to the diagram are displayed.
The graphical display is situated in the lower half.
You can zoom freely in the diagram window. For this, the mouse pointer must be placed at
the required point in the diagram. ´Move the mouse, keeping the mouse button pressed,
down and to the right to zoom into the diagram. The display is re-set to the previous setting
if you move the mouse up and to the left, keeping the mouse pointer pressed.

34 OM 100.Worx-lineX-Reference.201703.en
 Diagrams

The diagram offers three views for the process evaluation:

− Force over distance [kN/mm],
− Force overtime [kN/ms]
− Distance over time.
All three views can be shown or hidden independently of each other. The views can be
switched over with the corresponding buttons above the diagram display panel.

OM 100.Worx-lineX-Reference.201703.en 35
 Diagrams

• Force over distance

• Force over time

36 OM 100.Worx-lineX-Reference.201703.en
 Diagrams

• Distance over time

Depending on the selected diagram type, the labelling and scaling of the Y-axis change.
In the upper half on the left above the diagram display panel, the navigation and operating
buttons for the diagram window are situated:

Up Moves the diagram view up.

Down Moves the diagram view down.

Left Moves the diagram view to the left.

Right Moves the diagram view to the right.

Zoom in Zooms into the diagram, the visible section becomes more
detailed.
Zoom out Zooms out of the diagram, the visible section becomes larger.

Optimum Displays the complete diagram.

zoom

OM 100.Worx-lineX-Reference.201703.en 37
 Diagrams

• Context menu ’Diagram’

Activate Opens the selected diagram in the display window 'Diagrams'
in the working area. The entry of the diagram in the file system
is extended with '[active]'.
Cut (DEL) Places the selected diagram in the buffer.
Note: the source diagram is no longer available after pasting at
this point.
Copy (CTRL+ C) Copies the selected diagram to the buffer.
Delete Deletes the selected diagram from the diagram list.
Rename Used to rename the diagram entry.
Produce report Produces a report of the current diagrams in PDF format. A file
name and the memory location can be selected in a window
'Save as'.
Properties Opens the window 'Properties' for the diagrams.

• Rename
When the menu entry 'Rename ...' is selected, this window is opened:

The name of the diagram can be changed in the text box as required.

Changing diagram names

If, for example, the process number, process designation, date or time
are to be retained in the name, this must be taken into account when re-
naming.

 With the 'Cancel' button, the window is closed without adopting the changes.
 With the 'OK' button, the new name for the diagram is adopted.

38 OM 100.Worx-lineX-Reference.201703.en
 Diagrams

• Properties
When the 'Properties' menu entry is selected, the window 'Attributes of diagram' is
opened.

Here, information is given on the date of the recording and the number of curves contained
therein. The colour of the curve can be changed with the aid of the window 'Colour selec-
tion'. This is opened with the button on the right.
 Close the window with the 'Close' box.

OM 100.Worx-lineX-Reference.201703.en 39
 Final values

5 Final values

With this menu item, the final values in a project are viewed.
 In the 'File systems' window, select the project of which the final values are to be dis-
played.
 Double-click on the icon in front of 'Final values'.
Icon for final values

The 'Final values' tab appears on the desktop. In the tab, in front of the entry 'Final values' the
project name is also displayed. Under this tab, an empty table appears with the column titles
of the final values:

 Press the button top left on the desktop to retrieve the current final values from the
controller.
Button to retrieve the final values (transmission of the final values from the con-
troller to the project)

40 OM 100.Worx-lineX-Reference.201703.en
 Final values

After transmission, the final values of this project last determined are displayed in the col-
umns of the table:

When the button is pressed again you are asked whether the final values of the project are
to be overwritten:

 With the 'Cancel' button, the window is closed without adopting the changes.
 With the 'OK' button, the final values are retrieved again and replace the view displayed
so far.

OM 100.Worx-lineX-Reference.201703.en 41
 Final values

• Context menu 'Final values' in file system

Open Opens the tab 'Final values' on the desktop.

Update Retrieves the final values again. If final values have already
been retrieved, a message is displayed asking whether the
final values are to be accepted.
Automatic Automatically reads in new final values and displays them in
the table.
Cut (CTRL+X) Without function.
Copy (CTRL+C) Copies the final values to the buffer.
Paste (CTRL+V) Pastes the final values from the buffer.
The function is only active if there are final values in the
buffer.
Delete Deletes the final values. The 'Final values' tab is again dis-
played as it was when first opened.
Export to CSV format Produces a file with the current final values in CSV format. A
file name and the memory location can be selected in a win-
dow 'Save as'.
Produce report Produces a report of the current final values in PDF format.
A file name and the memory location can be selected in a
window 'Save as'.
Properties Opens the properties windows of the final values. The attribute
window is described in the following section.

42 OM 100.Worx-lineX-Reference.201703.en
 Final values

Window 'Attributes of final values'

The final values for the current project are configured here.

'Properties' group
• Number of data records
Specifies the current number of final value data records which are currently displayed in the
working area.

OM 100.Worx-lineX-Reference.201703.en 43
 Final values

'Update' group
• Automatic
With this checkbox, automatic retrieval of the final values is enabled.
• Maximum number of data records
The maximum number of data records limits the number of final value records to retrieve.
The final value data records last measured are retrieved up to the maximum number of data
records.
'Sort' group
• Column
Selection of which column is to be sorted. Here, any available column from the list box can
be used as the sorting key:

• Order
With the selection buttons 'Ascending' and 'Descending', you define whether the table be-
gins with the first or last data record of the final values. Sorting is based on the configured
sorting key.
'Column display' group
All available columns of the table are listed. If the checkbox after these column headers is
enabled (check mark is visible), these columns are displayed on the desktop under the tab
'Final values'. If this checkbox is not enabled, these columns are hidden. With this function
you can display the final values which are relevant for the individual evaluation.
By pressing the button 'Close' or by closing the window with the icon [x] in the title bar, the
changes are adopted without further prompts.

44 OM 100.Worx-lineX-Reference.201703.en
 Variable status

6 Variable status

With the variables table, signals or values available on the controller can be compiled and
displayed. It is not possible to change the data.
The variable status is only available for the devices connected online online under rmi://lo-
calhost, as the sources for the offline adapters are not available. The information displayed
helps with commissioning and with trouble-shooting in the area between the controller and
the hardware or the controller and the PC.
'Digital IO' group
The 'Digital IO' group represents the input/output extensions connected to the controller. This
extension must be physically available and addressed in the application. The display can be
defined as 4 bytes or 32 bits for input and output. Due to the ability to check the signals, a
missing signal or an incorrect signal sequence, for example, can be detected. The display
corresponds to the HMI menu 'toxappio'.

OM 100.Worx-lineX-Reference.201703.en 45
 Variable status

'Fieldbus' group
The 'Fieldbus' group represents the interface between the controller and the robot/PLC pe-
riphery. This interface must be physically available and accessed in the application. The
display can be defined as 8 words (2 bytes), 16 bytes or 128 bits for input and output. Due
to the ability to check the interface, errors in the signal sequences/communication can be
detected, for example. The display corresponds with the HMI screen 'iffbs'.
'Firmware' group
With the 'Firmware' group, various values can be directly read out from the controller, for
example the current force or position, the selected process or the status can be visualised.
The information corresponds to the information of the status bar on the lower edge of the
screen of Worx or HMI.
'Byte Array' group
The byte array is the communication interface between the controller and the TOX®softWare.
It comprises 500 bytes, the data type of which can only be determined by the position in the
byte array. This definition is partly defined in the TOX®softWare and the application. These
areas cannot be influenced externally. Other areas are used to implement application- or
customer-specific integrations. In this case, the type or the position may vary. It may be
necessary to check certain signals against the expected or required reaction in the software
or on the controller. The data are provided for analysis as 500 bytes.

46 OM 100.Worx-lineX-Reference.201703.en
 Processes

7 Processes

7.1 The 'Processes' tab

In the processes, the specific program sequences assigned to the axis are listed. There it
is possible to configure the sequences and load them to the controller.

Caution
The first 19 processes are already configured by TOX® PRESSOTECH-
NIK. The parameters of these processes can be modified depending on
the function, but they must not be deleted. Deletion of these processes
may lead to errors, which permanently prevent start-up of the axis.

 In the window 'File systems', select the project of which the processes are to be dis-
played or edited. Open the process node with the 'Plus' icon.
Icon for processes

 Select one of the processes

 Double-click on the icon in front of the selected process.
Icon for process

The 'Processes' tab is displayed:

OM 100.Worx-lineX-Reference.201703.en 47
 Processes

The tab consists of four segments:

• Messages
If an input value does not pass the plausibility test, this error is displayed in the 'Messages'
window. These messages are used for fast trouble-shooting and de-bugging.

In addition to the display of the error in the message window, the relevant sub-item (in this
case: processes) and the program with the erroneous value are marked with a red icon on
the adapter. The process is also marked accordingly in the process selection list in the
sequence window and in the tab of the index card.

With the messages, a differentiation is made between process warnings and process errors:

Process warning Refers to problems in the parameterisation logic. Neverthe-

less, the process can be saved in the controller.
Process error Refers to problems in parameterisation. The process can-
not be saved in the controller.

48 OM 100.Worx-lineX-Reference.201703.en
 Processes

• Sequence
In the 'Sequence' window, a process is configured. The process is either selected by dou-
ble-clicking on the process node in the file system or with the selection list in the top right-
hand panel of the 'Sequence' window. The selected functions of this process are displayed
directly below the selection list.

Selection list

Functions

After selecting the function in the function list, its parameters are listed in the properties
window below it. These can be edited according to the authorisation level.
The left-hand window contains a selection tree divided into areas in which all available func-
tions are listed. In this selection tree, as in the file system, you can navigate with the plus
and minus icons. The individual functions can be added to the current function list with a
double-click.

OM 100.Worx-lineX-Reference.201703.en 49
 Processes

• Info
In the 'Info' window, information on the currently selected function is displayed. In the upper
section, the function is described, in the lower section the parameters.
This example shows the info window for the 'Stroke' function:

• Diagram
In the 'Diagram' window, the functions of the process are displayed in graph form if possible.
The diagrams facilitate planning and optimisation of function monitoring.
In the example, a process is displayed which contains the following functions:
− Stroke (function 3)
− Press (function 4)
− Return stroke (function 6)

The windows show the force or distance limits of the functions. A current function (selection
via function list of the process) is shown in white. An active window can be moved in the
diagram display panel by keeping the mouse button pressed. The moved parameters are
directly added to the function.

50 OM 100.Worx-lineX-Reference.201703.en
 Processes

In the diagram folder of the individual processes, diagrams can be copied which were rec-
orded for the connection in the diagram folder of the adapter. For example, parameterisation
of the process can be optimised via the information from the diagram.
• Context menu 'Processes'
Paste (CTRL+V) Pastes the process from the buffer at the selected position in the
process sequence.
Paste process Adds a new empty process at the end of the process list. Adds a
new empty process at the end of the process list.
Start teach-in all Sets the teach-in mode for all processes in the process se-
quence for which envelopes can be taught in.
Stop teach-in all Re-sets the teach-in mode for all processes in the process se-
quence which are currently in teach-in mode.
Produce report Produces a report on the current processes in PDF format.
Properties Opens the properties window of the processes. The attribute
window is described in the following section.

OM 100.Worx-lineX-Reference.201703.en 51
 Processes

• Attributes of processes

'Teach-in' group
• Status
Displays the current status of the teach-in.
• Number of teach-in cycles
Here, the number of IO executions of the processes is defined which are to be used for
processing the results in an envelope.

Number of teach-in cycles

The number of teach-in cycles must be more than 1 for the 'teach-in' func-
tion to be available.

After teach-in, the processes in the file system and in the process selection box are
marked with a green dot:

The icon of all processes which can be taught in are marked with a green dot. After the
process name, the entry is extended with the status '[Teach-in running ...]' and the current
processing status. '0/2', for example, means 0 of 2 teach-in cycles completed.
Process
The process is the smallest selectable unit in the process sequence. It contains one or more
functions which are processed in sequence when called.

52 OM 100.Worx-lineX-Reference.201703.en
 Processes

• Context menu 'Processes'

Open Opens the selected process in the 'Processes' tab on the
desktop.
Add process (CTRL+Plus) Adds a new empty process at the end of the process list.
Adds a new empty process at the end of the process list.
Cut (Cut) Copies the marked process to the buffer and removes the
process from the process list.
Note: After pasting, the adapter is no longer available in its
previous position.
Copy (Copy) Adds the process to the buffer.
Copy Opens the dialogue for the extended copying action.
Paste (CTRL+V) Pastes the process from the buffer at the selected position
in the process sequence.
Delete (Del) Deletes the selected process from the process list.
Rename Opens a window to rename the process.
Up Moves the process up one position in the sequence.
Down Moves the process down one position in the sequence.
Produce report Produces a report on the current processes in PDF format.
Delete envelope Deletes the created envelope from the process list.

• Copy ...
In the extended copy action, you can choose between two copy functions:
• Multiply a process
The checkbox 'Several processes' is not enabled.
In the category 'Copy processes', a source process is selected in the list box 'Source pro-
cess' which serves as a basis for the copying action.
In the 'Options' category, in the list box 'Paste process after', a destination for the copy
action is defined in the process list. In the default setting, the destination is specified after
the last entry in the process list.
In the input box 'Number copies', you define the number of copies of the source process.
With the checkbox 'Replace', it is defined whether the processes are added (in which case
all subsequent processes in the process list are moved back by the number of copies) or
replaced. In the case of replacement, the overwritten processes in the process sequence
are no longer available.

OM 100.Worx-lineX-Reference.201703.en 53
 Processes

 With the 'Cancel' button, the window is closed without adopting the changes.
 With the 'OK' button, the copying process is started with the selected settings.
• Copy part of the process list
The checkbox 'Several processes' is enabled.
In the category 'Copy processes', a range is selected from the current process list as source
processes in the list boxes 'Source process from' and 'Source process to' which serves as
the basis for the copy action.
In the 'Options' category, in the list box 'Paste process after', a destination for the copy
action is defined in the process list. In the default setting, the destination is specified after
the last entry in the process list.
With the checkbox 'Replace', it is defined whether the processes are added (in which case
all subsequent processes in the process list are moved back by the number of copies) or
replaced. In the case of replacement, the overwritten processes in the process sequence
are no longer available.

54 OM 100.Worx-lineX-Reference.201703.en
 Processes

 With the 'Cancel' button, the window is closed without adopting the changes.
 With the 'OK' button, the copying process is started with the selected settings.
• Delete
After selection of the 'Delete' menu entry, a confirmation prompt is issued before deleting:

Caution
The first 19 processes are already configured by TOX® PRESSOTECH-
NIK. The parameters of these processes can be modified depending on
the function, but they must not be deleted. Deletion of these processes
may lead to errors, which permanently prevent start-up of the axis.

 With the 'No' button, the window is opened without carrying out the deletion process.
 The deletion process is acknowledged with the 'Yes' button.

OM 100.Worx-lineX-Reference.201703.en 55
 Processes

Zipping of the process list

Zipping of the process list has effects on the numerical selection of the
processes which follow the deleted process.

The process numbers can be adapted with the checkbox 'Zip process list': If the checkbox
is enabled, all process numbers following the process to be deleted are adapted to the
actual position in the process list. If the checkbox is not enabled, the process numbers
remain unchanged and the deleted process is excluded from numbering.
 With the 'Cancel' button, the window is closed without deleting the process.
 With the 'OK' button, the delete process is finally acknowledged. Process numbering is
adjusted according to the checkbox "Zip process list".
• Rename
After selecting the menu entry 'Rename', a window is opened to enter the new name.

 With the 'Cancel' button, the window is closed without renaming the process.
 With the 'OK' button, the new process name is adopted.

56 OM 100.Worx-lineX-Reference.201703.en
 Processes

Program
The program contains the functions of the process.
• Context menu 'Program'
Open Opens the selected process in the 'Processes' tab on the
desktop. From there, the individual functions can be ac-
cessed.
Adding a function from the Adds the function selected from the function selection list to
pallet the end of the sequence.
Copy (CTRL+C) Copies the selected program to the buffer.
Paste (CTRL+V) Pastes a program from the buffer.
Change order Opens the window to change the order of the functions in the
sequence.
Rename Function not available.
Produce report Produces a report on the current program in PDF format. A
file name and the memory location can be selected in a win-
dow 'Save as'.

OM 100.Worx-lineX-Reference.201703.en 57
 Processes

• Change order
In the 'Change order' window, the order of the functions can be adapted to the required
sequence.
With the 'Up' and 'Down' buttons, the selected function is moved up or down respectively.
These buttons are only available if moving by one space is possible from the current posi-
tion.

 With the 'Cancel' button, the window is closed without adopting the changes.
 With the 'OK' button, the new order is adopted.
Diagram
In the 'Diagram' folder, diagrams can be stored in the diagram node of the assigned adapter.
This enables assignment to the process run and the diagrams are still available after a
system re-start.
• Context menu 'Diagram'
Paste (CTRL+V) Pastes diagrams from the buffer to the node.
Produce report Produces a report of the current diagrams in PDF format. A file
name and the memory location can be selected in a window 'Save
as'.
Properties Opens the 'Properties' window of the diagrams. The attribute win-
dow is described in the following section.

58 OM 100.Worx-lineX-Reference.201703.en
 Processes

Function
'Function' refers to the sub-actions which result in the process and therefore the required
sequence in the complete sequence. The individual functions are described in detail in sec-
tion 7.4 Explanation of the functions.
• Context menu 'Function'
Open Opens the selected process in the 'Processes' tab on the
desktop. From there, the individual functions can be ac-
cessed.
Cut (CTRL+X) Copies the marked function to the buffer and removes the
function from the sequence list.
Copy (CTRL+C) Copies the selected function to the buffer.
Delete Deletes the function after a confirmation prompt.
Up Moves the function up one position in the sequence.
Down Moves the function down one position in the sequence.
Produce report Produces a report of the function in PDF format. A file name
and the memory location can be selected in a window 'Save
as'.
Properties Opens the 'Properties' window of the function.
The contents correspond with the individual properties win-
dow of the function on the desktop.

• Delete
After selecting the menu entry 'Delete', a confirmation prompt is displayed before the deletion
process:

 With the 'Cancel' button, the window is closed without adopting the changes.
 With the 'Yes' button, the deletion process is acknowledged and the function is removed
from the function list.

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 Processes

7.2 Editing a process

The 'Processes' window contains the core of the TOX®softWare Worx: here, process se-
quences can be compiled which can be transmitted to the controller and stored there. To
configure and create processes, you require authorisation level 3.
 In the 'File systems' window under the level 'Processes', select an existing process
which is to be edited – e.g. 24120 (20).
 On the desktop, open the tab 'Processes' by double-clicking on the 'Process' icon.
A tab appears on the desktop '[Name of the adapter]: Processes':

In this tab, under 'Functions', you can select the work step to be run next in the selected
process.

60 OM 100.Worx-lineX-Reference.201703.en
 Processes

Select available process

 Select a process in the 'File systems' window.
Processes not yet in use are identified by opening the item 'Program' in the 'File systems'
window under 'Processes' under the name of the program. If no functions are listed
there, this program has not yet been used.

 Double-click on the icon in front of the entry 'Program'.

The 'Processes' tab appears on the desktop:

If you wish to make changes, you can

− change the order of the program steps:
click on the entry, keep the mouse button pressed and drag the entry to the required
position,
− delete program steps:
either mark the entry and press the button 'Del', remove the marked entry with the
menu command 'File\Edit\Delete' or click on the entry with the right-hand mouse but-
ton and remove with the 'Delete' command,

OM 100.Worx-lineX-Reference.201703.en 61
 Processes

− paste new functions:

in the 'Processes' tab of the sequence window under 'Functions', drag a program
step to the required point in the compilation window with the mouse using drag &
drop.
In the 'Properties' window, all parameters of the selected function are displayed. To change
the parameters, click on the box after the property of which the value is to be changed. In
the description under the 'Properties' window, the designation and the physical unit of the
property are displayed. This description panel can be enabled or disabled with the right-
hand mouse button via the command 'Display description panel'.
If the 'Properties' window is not displayed, you can open it by clicking on the 'Up arrow' icon
on the lower edge of the working area.
Create new process (functions)
 Select a process in the 'File systems' window.
Processes not yet in use are identified by opening the item 'Program' in the 'File systems'
window under 'Processes' under the name of the program. If no functions are listed
there, this program has not yet been used.

 Double-click on the icon in front of the entry 'Program'.

The 'Processes' tab appears on the In the window under 'Sequence', the 'Functions'
folder appears. In the function list, the name of the program is given at the top. The
display panel below it is empty.
 Open the 'Functions' folder in the left-hand selection box.
In this list box, further folders are displayed in which the individual functions are grouped
together.

 Drag a program step from the list under 'Functions' with the mouse using drag & drop to
the required point in the compilation window (to the right of the 'Functions' window, under
the program name. By double-clicking on the icon in front of the function, the function is
automatically pasted after the last entry).
 Change the order of the program steps by clicking on the entry in the compilation win-
dow, keep the mouse button pressed and drag the entry to the required position.

62 OM 100.Worx-lineX-Reference.201703.en
 Processes

 Delete a program step: either mark the entry and press the button 'Del', remove the
marked entry with the menu command 'File\Edit\Delete' or click on the entry with the
right-hand mouse button and remove with the 'Delete' command,
If not all changes have been saved during a session, a window appears when closing the
program in which all elements edited and not saved are displayed. There you are asked if
you wish to accept all changes to the elements or only parts thereof or whether you want to
close the program without changes.

 With the 'Save' button, the marked element is saved and the TOX®softWare Worx is
closed. With the shift or CTRL key, more than one element can also be marked.
 With the 'Save all' button, all elements listed in this window are saved and the TOX®soft-
Ware Worx is closed.
 With the button 'Cancel all', no element listed in this window is saved and the TOX®soft-
Ware Worx is closed.
 With the 'Cancel' button, you return to the TOX®softWare Worx without saving the data.

OM 100.Worx-lineX-Reference.201703.en 63
 Processes

7.3 Summary of the function groups and functions

To simplify the overview of individual functions, these are divided into function groups, which
are displayed in the following list:

 Movement Default: Stroke

Stroke relative
Press-fitting
Press-fitting with bending compensation
Return stroke
Jog forwards
Jog backwards
Sluggishness drive

Clinching Clinching pre-position

Clinching adhesive
Clinching
Clinching return stroke
Tongs code:

Riveting Riveting pre-position

Riveting adhesive
Riveting return stroke
Rivet type

Clinch riveting Clinch riveting pre-position clinching

Clinch riveting

Self-piercing riv- Double rivet monitoring

eting Rivet monitoring
Self-piercing riveting
Semi-hollow self-piercing riveting

Extended External setpoint

Inflexion point detection
Pressing to force difference
Pressing to default PLC values
Stroke 7th axis

 Process Control Reference run

Time delay
Process call
Sub-process call
Start multiple condition
Target multiple condition
End multiple condition

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 Processes

Re-working
Define abort contact
Acceleration
Deceleration
Spindle data
End process
Stop process

Variables Set integer variable

Set real variable

Status Home position reached

Home position not reached
Working position reached
Working position not reached
Technology process complete
Technology process not complete
Setpoint reached
Setpoint not reached
Process repeat possible
Process repeat not possible

Data Save intermediate value 1

Save intermediate value 2
Save final values

Diagram Start curve tracing

Stop curve tracing
Start envelope monitoring
Stop envelope monitoring

 I/O Input/output wait

Set output

 Force sensor Initialise force sensor

Check force sensor

 Utilities Comment

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 Processes

7.4 Explanation of the functions

7.4.1 'Stroke' function
This function is used for fast positioning of the drive. It greatly depends on the properties
entered. Generally with the 'Stroke' function, an absolute position is moved to without force
at high speed.

• Target value
Select here whether to move to an absolute position or to force. If the spindle is moved at
high speed, the stroke should not be moved to force. The parameters in this list change
according to the selection.
• Position (with selection 'Target value to position')
Here the absolute target position is entered which is based on the reference position.

Upper force limit at high speed

At high speed, the upper force limit should be selected as low as possi-
ble. This should be < 20 % of the nominal drive force in order to detect
unintentional contact at an early stage. With too high a maximum force
limit, the maximum force of the spindle may be exceeded. An overload of
the spindle may lead to damage or even destruction of the drive and tool.
Continuous, hard impacts on the material or continual overloading of the
drive may shorten the service life of the spindle.

66 OM 100.Worx-lineX-Reference.201703.en
 Processes

• Force (with selection 'Target value to force')

The target force moved to is entered here. With this function, the spindle only brakes when
moving at very high speed when the target force is detected. This leads to the target force
being exceeded.

Risk of overloading
At high speed and with high target force, the maximum force of the spin-
dle may be exceeded. An overload of the spindle may lead to damage or
even destruction of the drive and tool.
Continuous, hard impacts on the material or continual overloading of the
drive may shorten the service life of the spindle.

• Maximum force value

This value defines the upper limit of the force value which must not be exceeded in a pro-
cess.
• Minimum force value
This value defines the lower limit of the force value which must be reached in a process.
• Position monitoring
With a stroke to a target force, it is checked whether the target force is reached within the
position values.
• Force check position
If 'Target value to force' is selected (only has an effect on the final value entry)
Selection: - Target window
Here with "Final value entry force", the maximum force value reached within this function
is entered, even if the force value decreases after stopping.
Selection: - Target position
Here with "Final value entry force", the force value at standstill is entered, even if the
force value was higher before standstill.
If 'Target value to position' is selected (has an effect on the OK/NOK evaluation)
Selection: - Target window
The pressing process is assessed as OK if at least at one point the force within the
window was greater than or equal to the minimum value and the force has never ex-
ceeded the maximum value.
Selection: - Target position
The pressing process is assessed as OK when the force at the parameterised position
was greater than or equal to the minimum value and had never exceeded the maximum
value.

OM 100.Worx-lineX-Reference.201703.en 67
 Processes

• Maximum position value

If position monitoring is enabled, the upper limit of the range to be monitored is specified.
• Minimum position value
If position monitoring is enabled, this value specifies the lower limit of the range to be mon-
itored.
• Position (with selection 'Target value to position')
The line value to which positioning takes place is entered here.
• Check min./max. warning limits.
If the warning limit is enabled, the values entered in the warning limits are monitored.
• Warning limit max.
If warning limit monitoring is enabled, this value specifies the upper limit of the range to be
monitored.
• Warning limit min.
If warning limit monitoring is enabled, this value defines the lower limit of the range to be
monitored.
• Speed
In the case of a stroke without counter-force, a high speed (up to the maximum spindle
speed) is generally used.
• Time monitoring
With the aid of time monitoring, the 'Stroke' function can also be checked again. If the time
entered in 'Time monitoring [ms] ' is exceeded, the spindle is stopped and a general error
message is issued. With the aid of user variables, a fault message which is only valid for
this time monitoring can be defined.
• Time monitoring [ms]
Time in milliseconds which may be required by the function until complete processing.
• User variables
The user variables are comprised of four figures, which can be freely selected from 0 to
255. With reference to these variables, it is possible to create a clear error message espe-
cially for this time monitoring in the HMI, e.g. with reference to a digital sensor, the function
of which has to be checked.

68 OM 100.Worx-lineX-Reference.201703.en
 Processes

• Transition speed
The transition speed enables an even transition to the next function. With this parameter,
the spindle is not braked to 'zero' when switching to a new function to then accelerate to the
new speed value again but instead it is only braked to the speed set in this parameter. This
speed should be identical to the value of the subsequent speed.

Y Y
1 2 1 2

3 4

X X

X Travel [mm] 2 Function X + 1

Y Speed [mm/s] 3 without transition speed
1 Function X 4 with transition speed

Combination of functions
The transition speed may only be used in combination with a further move-
ment function. The only exceptions to this are the functions 'Save final val-
ues' and 'Save intermediate values'. If this is not observed, this may lead to
damage to or even destruction of the drive and tool.
Exceeding the mechanical limits is possible with the transition speed. The
transition speed must not be used close to mechanical limits and is done at
your own risk. Exceeding the mechanical limits may lead to damage to or
even destruction of the drive and tool.

• Transition speed [mm]

The value for the transition speed is entered here.

OM 100.Worx-lineX-Reference.201703.en 69
 Processes

• Abort contact
With the aid of the abort contact, this function can be cancelled prematurely. After the abort,
this function is deemed to be ended and the process is continued with the next function. If
this is the last function in a process, the process is evaluated as 'OK'. In order to use this
command, an abort contact must be defined in the process.

1
Y

6 2

5
3

4
X

X Travel [mm] 3 max. force value

Y Force [kN] 4 min. force value
1 Target position value 5 monitored range
2 max. position value 6 min. position value

70 OM 100.Worx-lineX-Reference.201703.en
 Processes

• Window evaluation

On selection of this parameter, a diagram opens in which it can be defined from which side
the force/travel may reach the target value.
In this example, the force may only exceed the minimum force after the minimum position
has been reached.
7.4.2 'Relative stroke' function
The 'relative stroke' can be used for both slow pressing and fast movement. This function
enables relative positioning independently of the pre-positioning. This function is used in
particular for pressing to a defined travel if great component tolerances occur on the work
piece. With the 'Pressing' function, for example, the component can be with low force and
then, based on this variable pre-position, moved to a relative value, which is entered in the
function as the position.

• Min/max force active

This value activates the values entered in Min./max. force value.
• Maximum force value
This value defines the upper limit of the force value which must not be exceeded in a pro-
cess.

OM 100.Worx-lineX-Reference.201703.en 71
 Processes

• Minimum force value

This value defines the lower limit of the force value which must be reached in a process.
• Position monitoring
Here it is checked whether the target position is reached within the specified relative limits.
The relative limits must be entered on the basis of the relative stroke value. With a move-
ment of X millimetres, the value X minus the negative tolerance is entered, as the maximum
limit the value X plus the positive tolerance.
• Absolute position monitoring
If this function is enabled, the values entered in max./min. position value with reference to
the absolute zero point then apply.
• Maximum position value
If position monitoring is enabled, the upper limit of the range to be monitored is specified.
• Minimum position value
If position monitoring is enabled, this value specifies the lower limit of the range to be mon-
itored.
• Position
The relative target position of the travel is entered here. This relative target position is added
to or deducted from the current position value of the previous function. Example: at the start
time of the function, the spindle is at the current absolute position of 95 mm. The relative
travel should be 3 mm. These 3 mm are entered in this function as the position. The spindle
therefore moves to 98 mm (95 mm + 3 mm).

Upper force limit at high speed

At high speed, the upper force limit should be selected as low as possi-
ble. This should be < 20 % of the nominal drive force in order to detect
unintentional contact at an early stage. With too high a maximum force
limit, the maximum force of the spindle may be exceeded. An overload of
the spindle may lead to damage or even destruction of the drive and tool.
Continuous, hard impacts on the material or continual overloading of the
drive may shorten the service life of the spindle.

• Speed
The speed depends on the use of the function: to move long distances, select a higher
speed, for pressing select a low speed. A speed of approx. 3 mm/s is specified as a refer-
ence value for most pressing processes. This value may vary greatly depending on the
application.

Pressing speed
The more insensitive a component is against force peaks (tolerance force
limits), the faster pressing can be carried out.

72 OM 100.Worx-lineX-Reference.201703.en
 Processes

• Time monitoring
With the aid of time monitoring, the function can also be checked again. If the normal se-
quence time is not observed, the spindle is stopped and an error message is issued.
• Time monitoring [ms]
Time in milliseconds which may be required by the function until complete processing.
• User variables
Four user variables can be specified here, which are used to generate a specific error mes-
sage. For each value, a number between 0 and 254 can be specified. The user variables
are given in this form:
xxx_xxx_xxx_xxx
• Transition speed
The transition speed enables an even transition to the next function. With this parameter,
the spindle is not braked to 'zero' when switching to a new function to then accelerate to the
new speed value again but instead it is only braked to the speed set in this parameter. This
speed should be identical to the value of the subsequent speed.

Y Y
1 2 1 2

3 4

X X

X Travel [mm] 2 Function X + 1

Y Speed [mm/s] 3 without transition speed
1 Function X 4 with transition speed

Combination of functions
The transition speed may only be used in combination with a further
movement function. The only exceptions to this are the functions 'Save fi-
nal values' and 'Save intermediate values'. If this is not observed, this
may lead to damage to or even destruction of the drive and tool.
Exceeding the mechanical limits is possible with the transition speed. The
transition speed must not be used close to mechanical limits and is done
at your own risk. Exceeding the mechanical limits may lead to damage to
or even destruction of the drive and tool.

• Transition speed [mm/s]

The value for the transition speed is entered here.

OM 100.Worx-lineX-Reference.201703.en 73
 Processes

• Abort contact
With the aid of the abort contact, this function can be cancelled prematurely. After the abort,
this function is deemed to be ended and the process is continued with the next function. If
this is the last function in a process, the process is evaluated as 'OK'. To be able to use this
command, an abort contact must be defined in the process (see function 'Define abort con-
tact').To be able to use this command, an abort contact must be defined in the process (see
function 'Define abort contact').

1 3
Y
2

8 4

7
5

6
X

X Travel [mm] 4 max. position value

Y Force [kN] 5 max. force value
1 any position value 6 min. force value
2 relative position value 7 monitored range
3 Target position value 8 min. position value

74 OM 100.Worx-lineX-Reference.201703.en
 Processes

7.4.3 'Press' function

This function is used to press parts at a low speed. Pressing can be carried out to a target
force or to an absolute position.

• Target value:
Here you select whether pressing is carried out to an absolute position or to force. Depending on
the selection, the parameters in this list change.
− Position (with selection 'Target value to position')
Here the absolute target position is entered which is based on the reference position.

Upper force limit at high speed

At high speed, the upper force limit should be selected as low as possi-
ble. This should be < 20 % of the nominal drive force in order to detect
unintentional contact at an early stage. With too high a maximum force
limit, the maximum force of the spindle may be exceeded. An overload of
the spindle may lead to damage or even destruction of the drive and tool.
Continuous, hard impacts on the material or continual overloading of the
drive may lead to a reduction in the service life of the spindle.

− Force (with selection 'Target value to force')

The target force moved to is entered here. With this function, the spindle only brakes
when moving at very high speed when the target force is detected. This leads to the
target force being exceeded.

Risk of overloading
At high speed and with high target force, the maximum force of the spin-
dle may be exceeded. An overload of the spindle may lead to damage or
even destruction of the drive and tool.
Continuous, hard impacts on the material or continual overloading of the
drive may shorten the service life of the spindle.

OM 100.Worx-lineX-Reference.201703.en 75
 Processes

• Maximum force value

This value defines the upper limit of the force value which must not be exceeded in a pro-
cess.
• Minimum force value
This value defines the lower limit of the force value which must be reached in a process.
• Position monitoring
When pressing to a target force, it is checked whether the target force is reached within the
position values.
• Force check position
If 'Target value to force' is selected (only has an effect on the final value entry)
Selection: - Target window
Here with "Final value entry force", the maximum force value reached within this function
is entered, even if the force value decreases after stopping.
Selection: - Target position
Here with "Final value entry force", the force value at standstill is entered, even if the
force value was higher before standstill.
If 'Target value to position' is selected (has an effect on the OK/NOK evaluation)
Selection: - Target window
The pressing process is assessed as OK if at least at one point the force within the
window was greater than or equal to the minimum value and the force has never ex-
ceeded the maximum value.
Selection: - Target position
The pressing process is assessed as OK when the force at the parameterised position
was greater than or equal to the minimum value and had never exceeded the maximum
value.
• Maximum position value
If position monitoring is enabled, the upper limit of the range to be monitored is specified.
• Minimum position value
If position monitoring is enabled, this value specifies the lower limit of the range to be mon-
itored.
• Speed
Select a low speed for pressing. A speed of approx. 3 mm/s is specified as a reference value
for most pressing processes. This value may vary greatly depending on the application.

Pressing speed
The more insensitive a component is against force peaks (tolerance force
limits), the faster pressing can be carried out.

76 OM 100.Worx-lineX-Reference.201703.en
 Processes

• Time monitoring
With the aid of time monitoring, the function can also be checked again. If the normal se-
quence time is not observed, the spindle is stopped and an error message is issued.
• Time monitoring [ms]
Time in milliseconds which may be required by the function until complete processing.
• User variables
Four user variables can be specified here, which are used to generate a specific error mes-
sage. For each value, a number between 0 and 254 can be specified. The user variables
are given in this form:
xxx_xxx_xxx_xxx
• Transition speed
The transition speed enables an even transition to the next function. With this parameter,
the spindle is not braked to 'zero' when switching to a new function to then accelerate to the
new speed value again but instead it is only braked to the speed set in this parameter. This
speed should be identical to the value of the subsequent speed.

Y Y
1 2 1 2

3 4

X X

X Travel [mm] 2 Function X + 1

Y Speed [mm/s] 3 without transition speed
1 Function X 4 with transition speed

Combination of functions
The transition speed may only be used in combination with a further move-
ment function. The only exceptions to this are the functions 'Save final val-
ues' and 'Save intermediate values'. If this is not observed, this may lead to
damage to or even destruction of the drive and tool.
Exceeding the mechanical limits is possible with the transition speed. The
transition speed must not be used close to mechanical limits and is done at
your own risk. Exceeding the mechanical limits may lead to damage to or
even destruction of the drive and tool.

• Transition speed [mm/s]

The value for the transition speed is entered here.

OM 100.Worx-lineX-Reference.201703.en 77
 Processes

• Abort contact
With the aid of the abort contact, this function can be cancelled prematurely. After the abort,
this function is deemed to be ended and the process is continued with the next function. If
this is the last function in a process, the process is evaluated as 'OK'. To be able to use this
command, an abort contact must be defined in the process (see function 'Define abort con-
tact').To be able to use this command, an abort contact must be defined in the process (see
function 'Define abort contact').

• Reversal of direction
Reverses the direction of the spindle.

• Dwell time (target value to force)

With the aid of the dwell time, the force is maintained over the period of time specified here.

Relation between dwell time and force

Low forces can be maintained over longer periods, high forces only over
a shorter period (up to 3 seconds). Within this period, in the event of a de-
crease in force, the spindle readjusts from 0.5 % of the nominal force to
the target force.

7 1
Y

X Travel [mm] 4 monitored range

Y Force [kN] 5 Target position value
1 max. position value 6 Target force value
2 max. force value 7 min. position value
3 min. force value

78 OM 100.Worx-lineX-Reference.201703.en
 Processes

• Speed control
If the target value is set to 'Force', the 'Speed control' can be enabled. Here the speed is
already reduced when a percentage of the target value is not reached in order to prevent
over-shooting at the end of the movement.
The percentage of the target force used as the starting point for the speed control is entered
in the box.
• Starting point in % of force
Percentage of target force used as the starting point for the speed control.
• Window evaluation

On selection of this parameter, a diagram opens in which it can be defined from which side
the force/travel may reach the target value.
In this example, the force may only exceed the minimum force after the minimum position
has been reached.
• Force holding speed [mm/s]
After the target force has been reached (when the dwell time amounts to > 0 ms) the spec-
ified speed is used to hold the force value stable. This means that the drive regulates for-
wards or backwards depending on whether the target force (see force accuracy max/min)
exceeds or drops below the set value.
• Max. force accuracy [%]
This value refers to the specified target force (when the dwell time amounts to > 0 ms), e.g.
at 60 kN of this, 0.5% corresponds to 0.3 kN, which counts as the upper hysteresis for the
force regulation.
• Max. force accuracy [%]
This value refers to the specified target force (when the dwell time amounts to > 0 ms), e.g.
at 60 kN of this, 0.5% corresponds to 0.3 kN, which counts as the lower hysteresis for the
force regulation.

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7.4.4 'Pressing with bending compensation' function

With the aid of this function, pressing is carried out to an absolute position with very high
pressing accuracy.
Every machine is subject to bending, which may vary greatly depending on the design. With
high bending of the machine, this function is used to compensate for this bending, so that
pressing can be carried out to the actual position. The bending of the machine must first be
determined and stored in the spindle data.

• Maximum force value

This value defines the upper limit of the force value which must not be exceeded in a pro-
cess.
• Minimum force value
This value defines the lower limit of the force value which must be reached in a process.
• Position monitoring
When the function is selected, it is possible to enter the min. and max. position values.
• Force check position
With selection 'Target window':
The pressing process is assessed as OK if at least at one point the force within the window
was greater than or equal to the minimum value and the force has never exceeded the
maximum value.
With selection 'Target position':
The pressing process is assessed as OK when the force at the parameterised position was
greater than or equal to the minimum value and had never exceeded the maximum value.
• Maximum position value
If position monitoring is enabled, the upper limit of the range to be monitored is specified.

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 Processes

• Position
Here the absolute target position is entered which is based on the reference position. A
correction factor is added to this position internally, which depends on the bending and the
force (bending correction).A correction factor is added to this position internally, which de-
pends on the bending and the force (bending correction).

Upper force limit at high speed

At high speed, the upper force limit should be selected as low as possi-
ble. This should be < 20 % of the nominal drive force in order to detect
unintentional contact at an early stage. With too high a maximum force
limit, the maximum force of the spindle may be exceeded. An overload of
the spindle may lead to damage or even destruction of the drive and tool.
Continuous, hard impacts on the material or continual overloading of the
drive may shorten the service life of the spindle.

• Minimum position value

If position monitoring is enabled, this value specifies the lower limit of the range to be mon-
itored.
• Speed
Select a low speed for pressing. A speed of approx. 3 mm/s is specified as a reference value
for most pressing processes. This value may vary greatly depending on the application.

Note
The softer and the more insensitive a component is to force peaks (toler-
ance force limits), the faster pressing can be carried out.

Note on pressing accuracy

The slower pressing is carried out, the higher the accuracy is of the actual
values achieved.

• Time monitoring
With the aid of time monitoring, the function can also be checked again. If the normal se-
quence time is not observed, the spindle is stopped and an error message is issued.
• Time monitoring [ms]
Time in milliseconds which may be required by the function until complete processing.
• User variables
Four user variables can be specified here, which are used to generate a specific error mes-
sage. For each value, a number between 0 and 254 can be specified. The user variables
are given in this form:
xxx_xxx_xxx_xxx

OM 100.Worx-lineX-Reference.201703.en 81
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• Abort contact
With the aid of the abort contact, this function can be cancelled prematurely. After the abort,
this function is deemed to be ended and the process is continued with the next function. If
this is the last function in a process, the process is evaluated as 'OK'. In order to be able to
use this command, an abort contact must be defined in the process (see function 'Define
abort contact' on page 137).

7 1
Y
6
2

X Travel [mm] 4 monitored range

Y Force [kN] 5 Target position value
1 max. position value 6 Bending compensation
2 max. force value 7 min. position value
3 min. force value

• Speed control
If the target value is set to 'Force', the 'Speed control' can be enabled. Here the speed is
already reduced when a percentage of the target value is not reached in order to prevent
over-shooting at the end of the movement.

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7.4.5 'Return stroke' function

The return stroke is used to rapidly return the spindle to any position up to the reference
position.

• Maximum force value

This value defines the upper limit of the force value which must not be exceeded in a pro-
cess. The value should normally correspond to the nominal spindle force.
• Position
The target position of the return stroke is entered here. This is an absolute position, starting
from the reference position.

Target position
The target position must be outside of the component or force range. If
this is not the case and movement to the component is carried out at high
speed and high maximum force limit, the maximum force of the spindle
may be exceeded. An overload of the spindle may lead to damage or
even destruction of the drive and tool.
Continuous, hard impacts on the material or continual overloading of the
drive may shorten the service life of the spindle.

• Speed
On the return stroke, a high speed is generally used (up to the maximum spindle speed).
• Time monitoring
With the aid of time monitoring, the 'Stroke' function can also be checked again. If the normal
sequence time is not observed, the spindle is stopped and an error message is issued.
• Time monitoring [ms]
Time in milliseconds which may be required by the function until complete processing.
• User variables
Four user variables can be specified here, which are used to generate a specific error mes-
sage. For each value, a number between 0 and 254 can be specified. The user variables
are given in this form:
xxx_xxx_xxx_xxx

OM 100.Worx-lineX-Reference.201703.en 83
 Processes

• Abort contact
With the aid of the abort contact, this function can be cancelled prematurely. After the abort,
this function is deemed to be ended and the process is continued with the next function. If
this is the last function in a process, the process is evaluated as 'OK'. To be able to use this
command, an abort contact must be defined in the process (see function 'Define abort con-
tact').To be able to use this command, an abort contact must be defined in the process (see
function 'Define abort contact').

Y 1

3
X

X Travel [mm] 2 Press final position

Y Force [kN] 3 Min. force value
1 Max. force value 4 Target position value

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7.4.6 'Jog forwards' function

This function is used for manual movement of the spindle without load in positive direction
(= extend spindle). One typical application is teaching in processes to move to the compo-
nent slowly and determine the position. When moving the spindle, the start button must be
pressed, independently of its activation (TOX®softWare, inputs, BUS systems) until the re-
quired position is reached. The spindle keeps moving until the start is cancelled.

• Maximum force value

This value serves process reliability and a suitably small value should be selected to prevent
damage to the tool or the component in the event of a malfunction. As soon as the maximum
force value is reached, the function is aborted and the spindle stops. Generally, forces be-
tween 1 and 3 kN are recommended.

Do not move under load

This function is not designed for moving under load. A high speed with a
high maximum force may lead to hard impacts and/or exceeding of the
maximum spindle force. An overload of the spindle may lead to damage
or even destruction of the drive and tool.
Continuous, hard impacts on the material or continual overloading of the
drive may shorten the service life of the spindle.

• Position monitoring
When position enabling is enabled, the movement range can be limited.
• Maximum position
The maximum position represents the limit value for the movement range and must not be
exceeded. As soon as it is reached, the spindle stops.
• Minimum position
The minimum position marks the second limit value for the permissible movement range.
This position must be reached. As soon as it is reached, the spindle stops.

OM 100.Worx-lineX-Reference.201703.en 85
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• Speed
Speed at which the drive is to be moved.

Caution
The speed for jog mode must not be greater than 10 mm/s, so that the
operator of the machine can react in time when the required position is
reached or in the event of a hazardous situation.
• Time monitoring
The movement time can be limited with the aid of time monitoring:

1 2
Y

4
X

X Travel [mm] 2 max. position value

Y Force [kN] 3 max. force value
1 min. position value 4 min. force value

• Time monitoring [ms]

Time in milliseconds which may be required by the function until complete processing.

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 Processes

7.4.7 'Jog backwards' function

This function is required for manual movement of the spindle without load in negative direc-
tion (= retract spindle). One typical application is the teaching in of processes to retract the
spindle slowly. When moving the spindle, the start switch must be pressed independently
of its activation (TOX®softWare, inputs, BUS systems) until the required position is reached.
The spindle keeps moving until the start is cancelled.

• Maximum force value

This value serves process reliability and a suitably small value should be selected to prevent
damage to the tool or the component in the event of a malfunction. As soon as the maximum
force value is reached, the function is aborted and the spindle stops. Generally, forces of
between 3 and 5 kN are recommended. The force value should be selected higher than for
'Jog forwards' in order to be able to move in jog mode without a fault abort if the force is
exceeded.
• Position monitoring
When position enabling is enabled, the movement range can be limited.
• Maximum position
The maximum position represents the limit value for the movement range and must not be
exceeded. This limit value should always be slightly higher than for the 'Jog forwards' func-
tion. As soon as the position is reached, the spindle stops.
• Minimum position
The minimum position marks the second limit value for the permissible movement range.
This position must be reached. As soon as the position is reached, the spindle stops.
• Speed
Speed at which the drive is to be moved.

Caution
The speed for jog mode must not exceed 10 mm/s, so that the machine
can react in time when the required position is reached or in the event of
a hazardous situation.

OM 100.Worx-lineX-Reference.201703.en 87
 Processes

• Time monitoring
The movement time can be limited with the aid of time monitoring:

4 1
Y

3
X

X Travel [mm] 2 max. force value

Y Force [kN] 3 min. force value
1 max. position value 4 min. position value

• Time monitoring [ms]

Time in milliseconds which may be required by the function until complete processing.

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 Processes

7.4.8 'Sluggishness drive' function

This function can be called at regular intervals in order to check the system for sluggishness
and to detect wear or faults. The value of the current required for a defined positioning is
tested. If the value of the current is too high due to friction or other causes, a warning or
fault message is issued depending on the setting. The default setting must not be changed
without first consulting TOX® PRESSOTECHNIK.

• Maximum force value

This value defines the upper limit of the force value which must not be exceeded in a pro-
cess.
• Position monitoring
With this command it is checked whether the target force is reached within the limits.
• Maximum position value
If position monitoring is enabled, the upper limit of the range to be monitored is specified.
• Minimum position value
If position monitoring is enabled, this value specifies the lower limit of the range to be mon-
itored.
• Position (target value to position)
The target position is entered here. This is an absolute position, starting from the reference
position.
• Speed
The speed is permanently set to 3 mm/s.
• Warning limit
As soon as the value of the current reaches or exceeds the warning limit, a warning is issued
in the final values.
• Error limit
If the value of the current entered is reached or exceeded, an error message is issued in
the final values.

OM 100.Worx-lineX-Reference.201703.en 89
 Processes

• Time monitoring
With the aid of time monitoring, the function can also be checked again. If the normal se-
quence time is not observed, the spindle is stopped and an error message is issued.
• Time monitoring [ms]
Time in milliseconds which may be required by the function until complete processing.
• User variables
Four user variables can be specified here, which are used to generate a specific error mes-
sage. For each value, a number between 0 and 254 can be specified. The user variables
are given in this form:
xxx_xxx_xxx_xxx
• Abort contact
With the aid of the abort contact, this function can be cancelled prematurely. After the abort,
this function is deemed to be ended and the process is continued with the next function. If
this is the last function in a process, the process is evaluated as 'OK'. To be able to use this
command, an abort contact must be defined in the process (see function 'Define abort con-
tact').To be able to use this command, an abort contact must be defined in the process (see
function 'Define abort contact').

7.4.9 'Clinch pre-position' function

This function is used for fast pre-positioning of the spindle with a clinch application.
The function 'Clinch ´pre-position' is absolutely necessary for a clinching process and must
be used for a clinching application instead of the 'stroke' function. With clinching processes,
the positioning is not absolute from the reference position but instead from the zero position
in the spindle data. The position value entered therefore corresponds to the opening dimen-
sion of the clinching tong: with a position value of 0 mm, the tongs are closed.

1 Zero dimension = opening 2 Die 3 Punch

dimension
• Check target value/maximum limits
The parameters are permanently set and cannot be changed.
• Maximum force value
This value defines the upper limit of the force value which must not be exceeded in a pro-
cess.

90 OM 100.Worx-lineX-Reference.201703.en
 Processes

• Position
The target position of the travel is entered here. This absolute target position corresponds
to the opening dimension of the clinching tongs.

Upper force limit at high speed

At high speed, the upper force limit should be selected as low as possi-
ble. This should be < 20 % of the nominal drive force in order to detect
unintentional contact at an early stage. With too high a maximum force
limit, the maximum force of the spindle may be exceeded. An overload of
the spindle may lead to damage or even destruction of the drive and tool.
Continuous, hard impacts on the material or continual overloading of the
drive may shorten the service life of the spindle.

• Speed
In the case of a stroke without counter-force, a high speed (up to the maximum spindle
speed) is generally used.
With clinching tongs, movement to the pre-position is generally carried out at high speed
(up to the maximum spindle speed).
• Time monitoring
With the aid of time monitoring, the 'Stroke' function can also be checked again. If the normal
sequence time is not observed, the spindle is stopped and an error message is issued.
• Time monitoring [ms]
Time in milliseconds which may be required by the function until complete processing.
• User variables
Four user variables can be specified here, which are used to generate a specific error mes-
sage. For each value, a number between 0 and 254 can be specified. The user variables
are given in this form:
xxx_xxx_xxx_xxx
• Transition speed
With the clinching process, the transition speed is permanently set.

OM 100.Worx-lineX-Reference.201703.en 91
 Processes

• Abort contact
With the aid of the abort contact, this function can be cancelled prematurely. After the abort,
this function is deemed to be ended and the process is continued with the next function. If
this is the last function in a process, the process is evaluated as 'OK'. In order to use this
command, an abort contact must be defined in the process.

1 2

X Travel [mm] 2 Zero dimension = Position 0

Y Force [kN] 3 max. force value
1 (Pre-)position 4 max. opening dimension

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 Processes

7.4.10 'Clinching adhesive' function

This function is required to press the adhesive out of the clinching point with an additional
adhesive bond before the 'clinching' function.

• Target value
The target value is permanently set to 'Force' and cannot be changed.
• Force
The force required to press the adhesive out of the clinching point is specified here. The
required force is determined by the TOX® test and specified in the TOX® inspection report
of the tool. This value must not be changed without consulting TOX® Pressotechnik.
• Speed
With the clinching process, the speed is pre-set. This value can only be changed by TOX®
PRESSOTECHNIK.
• Dyn. X-dimension
Only use this function after consulting TOX® PRESSOTECHNIK.
• Time monitoring
The function can be additionally checked with time monitoring. If the time entered in 'Time
monitoring [ms]' is exceeded, the spindle is stopped and a general error message is issued.
With the aid of the user variables function, an error message valid only for this time moni-
toring can be generated.
• Time monitoring [ms]
Time in milliseconds which may be required by the function until complete processing.
• User variables
Four user variables can be specified here, which are used to generate a specific error mes-
sage. For each value, a number between 0 and 254 can be specified. The user variables
are given in this form:
xxx_xxx_xxx_xxx
• Transition speed
The transition speed is set to 'deactivated' and cannot be altered.

OM 100.Worx-lineX-Reference.201703.en 93
 Processes

• Abort contact
With the aid of the abort contact, this function can be cancelled prematurely. After the abort,
this function is deemed to be ended and the process is continued with the next function. If
this is the last function in a process, the process is evaluated as 'OK'. To be able to use this
command, an abort contact must be defined in the process (see function 'Define abort con-
tact').To be able to use this command, an abort contact must be defined in the process (see
function 'Define abort contact').

• Dwell time
The dwell time must be adapted to the flow rate of the adhesive. This time is determined by
the TOX® test.

X Travel [mm] 2 (Target) force

Y Force [kN] 3 max. opening dimension
1 Zero dimension = Position 0

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 Processes

7.4.11 'Clinching' function

This function is used to combine metal sheet pairs to one residual plate thickness (X dimen-
sion). This X dimension is actively controlled during clinching. This compensates for both
bending and different sheet thicknesses. With clinching processes, positioning is not abso-
lute in relation to the reference position but instead absolute in relation to the zero position
in the spindle data. The position value entered therefore corresponds to the opening dimen-
sion of the clinching tongs: With a position value of 0 mm, the tongs are closed.

1 Zero dimension = open- 2 Punch 3 Die

ing dimension

• Target value
The target value is permanently set to 'Position' and cannot be changed.
• Maximum force value
This value defines the upper limit of the force value which must not be exceeded in a pro-
cess.
• Minimum force value
This value defines the lower limit of the force value which must be reached in a process.
• Position
Here the target position (= X-dimension) from the TOX® inspection report is entered here.
• Speed
The speed is permanently set.
• Time monitoring
The function can be additionally checked with time monitoring. If the time entered under
'Time monitoring [ms]' is exceeded, the spindle is stopped and a general fault message.
With the aid of the user variables, an error message which is only valid for this time moni-
toring can be defined.

OM 100.Worx-lineX-Reference.201703.en 95
 Processes

• Time monitoring [ms]

Time in milliseconds which may be required by the function until complete processing.
• User variables
Four user variables can be specified here, which are used to generate a specific error mes-
sage. For each value, a number between 0 and 254 can be specified. The user variables
are given in this form:
xxx_xxx_xxx_xxx
• Abort contact
With the aid of the abort contact, this function can be cancelled prematurely. After the abort,
this function is deemed to be ended and the process is continued with the next function. If
this is the last function in a process, the process is evaluated as 'OK'. To be able to use this
command, an abort contact must be defined in the process (see function 'Define abort con-
tact').To be able to use this command, an abort contact must be defined in the process (see
function 'Define abort contact').

• Text
Here a comment can be entered, for example to clearly describe the process or the material.
• Speed control/control speed
When speed control is enabled, first movement is carried out with the value parameterised
under control speed and only reduced to the value parameterised under speed towards the
end of the clinching process.
'Teach-in' function
• Upper force limit + [kN]
A clinching process must be taught into the relevant application (material). Here, the upper
force limit is relative to the final force value measured. After teach-in, this value is added to
the upper force limit and automatically adopted as the maximum force value. With the final
force value of a clinch joint of 40 kN and an upper force limit of 1 kN, the value of 41 KN is
automatically adopted for the maximum force value.
• Lower force limit - [kN]
During teach-in, the input of the lower force limit is relative to the measured final force value.
After teach-in, this value is subtract from the lower force limit and automatically adopted as the
minimum force value. With the final force value of a clinching joint of 40 kN and a lower force
limit of 1 kN, after the teach-in process the value of 39 KN is automatically adopted for the min-
imum force value.

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 Processes

• Teach-in lower force limit - [kN]

Minimum force which must be reached with teach-in. This parameter guarantees that no
movements are taught-in without material.

7 1
Y

6
2

3
5

X Travel [mm] 4 monitored range

Y Force [kN] 5 Lower force limit
1 Zero dimension = Position 0 6 Upper force limit
2 max. force value 7 Position = X-dimension
3 min. force value 8 max. opening dimension

OM 100.Worx-lineX-Reference.201703.en 97
 Processes

7.4.12 'Clinching return stroke' function

The clinching return stroke is used for rapid return of the spindle. With clinching processes,
the positioning is not absolute from the reference position but instead from the zero position
in the spindle data. The position value entered therefore corresponds to the opening dimen-
sion of the clinching tong: with a position value of 0 mm, the tongs are closed.

1 Zero dimension = open- 2 Punch 3 Die

ing dimension

• Target value
The target value is permanently set to 'Position' and cannot be changed.
• Position
The target position is entered here. This absolute position corresponds to the opening di-
mension of the clinching tongs.

Target position
The target position must be outside of the component or force range. If
this is not the case and movement to the component is carried out at high
speed and high maximum force limit, the maximum force of the spindle
may be exceeded. An overload of the spindle may lead to damage or
even destruction of the drive and tool.
Continuous, hard impacts on the material or continual overloading of the
drive may shorten the service life of the spindle.

• Speed
On the return stroke, a high speed is generally used (up to the maximum spindle speed).
• Time monitoring
With the aid of time monitoring, the function 'Clinching return stroke' can also be checked
again. If the normal sequence time is not observed, the spindle is stopped and an error
message is issued.
• Time monitoring [ms]
Time in milliseconds which may be required by the function until complete processing.

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 Processes

• User variables
Four user variables can be specified here, which are used to generate a specific error mes-
sage. For each value, a number between 0 and 254 can be specified. The user variables
are given in this form:
xxx_xxx_xxx_xxx
• Abort contact
With the aid of the abort contact, this function can be cancelled prematurely. After the abort,
this function is deemed to be ended and the process is continued with the next function. If
this is the last function in a process, the process is evaluated as 'OK'. To be able to use this
command, an abort contact must be defined in the process (see function 'Define abort con-
tact').To be able to use this command, an abort contact must be defined in the process (see
function 'Define abort contact').

• Return stroke via Fieldbus

If 'Return stroke via Fieldbus' is enabled, positioning is not carried out to the value defined
in 'Position' but instead to the value entered in the Fieldbus interface.

1 2
Y
3

X Travel [mm] 3 X-dimension

Y Force [kN] 4 max. force value
1 (Return stroke) position 5 max. opening dimension
2 Zero dimension = Position 0

OM 100.Worx-lineX-Reference.201703.en 99
 Processes

7.4.13 'Tongs code' function

It is possible to control several tongs alternately with a controller. With this function it is
checked whether the right tongs for the process are docked. If several tongs are controlled,
the 'Tongs code' function must be placed at the beginning of a process by the controller.

• Indexing slide enabled

Enabling of this parameter informs the controller that an indexing slide without a position
sensor is available. Only enable this function after consulting TOX® PRESSOTECHNIK.
• Tong angle
Deviation of the tongs from the zero position in degrees.
7.4.14 'Riveting pre-position' function
The function 'Riveting pre-position' is used for rapid pre-positioning of the spindle with a
riveting application.
The function is essential for a riveting process and must be used in the sequence before
the actual riveting function. With the function 'Riveting pre-position', positioning is not abso-
lute with regard to the reference position but instead relative to the zero position in the
spindle data. The position value entered therefore corresponds to the opening dimension
of the clinching tongs: With a position value of 0 mm, the tongs are closed.

1 Zero dimension = open- 2 Punch 3 Die

ing dimension

• Target value
The target value is permanently set to 'Position' and cannot be changed.
• Maximum force value
This value defines the upper limit of the force value which must not be exceeded in a pro-
cess.
• Position
The target position is entered here. This absolute position corresponds to the opening di-
mension of the clinching tongs.

100 OM 100.Worx-lineX-Reference.201703.en
 Processes

• Speed
When moving to the pre-position, movement is generally carried out at high speed (up to
the maximum spindle speed).
• Time monitoring
The function can be additionally checked with time monitoring. If the time entered in 'Time
monitoring [ms]' is exceeded, the spindle is stopped and a general error message is issued.
With the aid of user variables, a fault message which is only valid for this time monitoring
can be defined.
• User variables
The user variables are composed of four integers, which can be freely selected from 0 to
255. With reference to these variables, a clear message can be projected with the flex mes-
sages in the HMI specifically for this time monitoring, e.g. with a reference to a digital sensor
whose function must be checked.
• Transition speed
The transition speed enables an even transition to the next function. With this parameter,
the spindle is not braked to 'zero' when switching to a new function but instead it is only
braked to the speed set in this parameter. This speed should be identical to the value of the
speed in the next function.

Y Y
1 2 1 2

3 4

X X

X Travel [mm] 2 Function X + 1

Y Speed [mm/s] 3 without transition speed
1 Function X 4 with transition speed

Combination of functions
The transition speed may only be used in combination with a further
movement function. The only exceptions to this are the functions 'Save fi-
nal values' and 'Save intermediate values'. If this is not observed, this
may lead to damage to or even destruction of the drive and tool.
Exceeding the mechanical limits is possible with the transition speed. The
transition speed must not be used close to mechanical limits and is done
at your own risk. Exceeding the mechanical limits may lead to damage to
or even destruction of the drive and tool.

OM 100.Worx-lineX-Reference.201703.en 101
 Processes

• Abort contact
With the aid of the abort contact, this function can be cancelled prematurely. After the abort,
this function is deemed to be ended and the process is continued with the next function. If
this is the last function in a process, the process is evaluated as 'OK'. In order to use this
command, an abort contact must be defined in the process.
7.4.15 'Riveting adhesive' function
This function is required to press the adhesive out of the clinching point with an additional
adhesive bond before the next 'clinching' function.

• Target value
The target value is permanently set to 'Position' and cannot be changed.
• Force
The force with which the adhesive is to be pressed out of the clinching point is entered
here.
• Speed
With 'Riveting adhesive', movement is generally carried out at low speed (3 mm/s).
• Time monitoring
With time monitoring, the 'Stroke' function can also be checked again. If the time entered in
'Time monitoring [ms]' is exceeded, the spindle is stopped and a general error message is
issued. With the aid of user variables, a fault message which is only valid for this time mon-
itoring can be defined.
• User variables
The user variables are composed of four integers, which can be freely selected from 0 to
255. With reference to these variables, a clear message can be projected with the flex mes-
sages in the HMI specifically for this time monitoring, e.g. with a reference to a digital sensor
whose function must be checked.
• Transition speed
The transition speed enables an even transition to the next function. With this parameter,
the spindle is not braked to 'zero' when switching to a new function but instead it is only
braked to the speed set in this parameter. This speed should be identical to the value of the
speed in the next function.

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 Processes

Y Y
1 2 1 2

3 4

X X

X Travel [mm] 2 Function X + 1

Y Speed [mm/s] 3 without transition speed
1 Function X 4 with transition speed

Combination of functions
The transition speed may only be used in combination with a further
movement function. The only exceptions to this are the functions 'Save fi-
nal values' and 'Save intermediate values'. If this is not observed, this
may lead to damage to or even destruction of the drive and tool.
Exceeding the mechanical limits is possible with the transition speed. The
transition speed must not be used close to mechanical limits and is done
at your own risk. Exceeding the mechanical limits may lead to damage to
or even destruction of the drive and tool.

• Abort contact
With the aid of the abort contact, this function can be cancelled prematurely. After the abort,
this function is deemed to be ended and the process is continued with the next function. If
this is the last function in a process, the process is evaluated as 'OK'. In order to use this
command, an abort contact must be defined in the process.

• Dwell time
With the aid of the dwell time, a force can be maintained over a long period.

Note
Low forces can be maintained over longer periods, high forces only over
a shorter period (up to 3 seconds). Within this period, in the event of a de-
crease in force, the spindle readjusts from 0.5 % of the nominal force to
the target force.

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 Processes

7.4.16 'Riveting return stroke' function

The 'Riveting return stroke' function is used for rapid return of the spindle. The positioning
is not absolute to the reference position but instead relative to the zero position in the spindle
data. The position value entered thus corresponds to the opening dimension of the riveting
tongs: With a position value of '0' mm, the tongs are closed.

1 Zero dimension = open- 2 Punch 3 Die

ing dimension

• Target value
The target value is permanently set to 'Position' and cannot be changed.
• Position
The target position of the return stroke is entered here. This is an absolute position, starting
from the reference position.

Target position
The target position must be outside of the component or force range. If
this is not the case and movement to the component is carried out at high
speed and high maximum force limit, the maximum force of the spindle
may be exceeded. An overload of the spindle may lead to damage or
even destruction of the drive and tool.
Continuous, hard impacts on the material or continual overloading of the
drive may shorten the service life of the spindle.
• Speed
On the return stroke, a high speed is generally used (up to the maximum spindle speed).
• Time monitoring
The function can be additionally checked with time monitoring. If the time entered in 'Time
monitoring [ms]' is exceeded, the spindle is stopped and a general error message is issued.
With the aid of user variables, a fault message which is only valid for this time monitoring
can be defined.
• User variables
The user variables are composed of four integers, which can be freely selected from 0 to
255. With reference to these variables, a clear message can be projected with the flex mes-
sages in the HMI specifically for this time monitoring, e.g. with a reference to a digital sensor
whose function must be checked.

104 OM 100.Worx-lineX-Reference.201703.en
 Processes

• Abort contact
With the aid of the abort contact, this function can be cancelled prematurely. After the abort,
this function is deemed to be ended and the process is continued with the next function. If
this is the last function in a process, the process is evaluated as 'OK'. To be able to use this
command, an abort contact must be defined in this process (see also function 'Define abort
contact').

• Return stroke via Fieldbus

If 'Return stroke via Fieldbus' is enabled, positioning is not carried out to the value defined
in 'Position' but instead to the value entered in the Fieldbus interface.
7.4.17 'Rivet type' function
With this function, removal of the rivet is initiated before riveting.

When 'Rivet system active' is selected, important information on the rivet system is entered
in the spindle data as a function in program 9.

• Rivet type number

A number between 1 and 7 is entered here, with which it is defined from which magazine
the rivet is taken.
• Time monitoring
The function can be additionally checked with time monitoring. If the time entered in 'Time
monitoring [ms]' is exceeded, the spindle is stopped and a general error message is issued.
• Rivet system active
This checkbox is enabled if the function 'Spindle data' is used in program 9.
• Rivet system
The number of rivet systems is entered here.
• Active magazine
The magazines which are active are entered here. If magazines 1 and 3 are active, for
example, '13' is entered here.
• Counter slug box
Here it is entered when the counter should indicate that the slug box is full. When the value
is reached, the robot can be activated to empty the slug box.

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 Processes

7.4.18 'Clinch riveting pre-position clinch'

This function is used for rapid pre-positioning of the spindle with the clinch riveting applica-
tion.
The function 'Clinch riveting pre-position clinch' is essential for a clinch riveting process and
must be situated in the process before the clinch riveting function. With the function 'Clinch
riveting pre-position clinch', positioning is not absolute with regard to the reference position
but instead relative to the zero position in the spindle data. The position value entered there-
fore corresponds to the opening dimension of the clinching tongs: With a position value of
0 mm, the tongs are closed.

1 Zero dimension = open- 2 Punch 3 Die

ing dimension

• Target value
The target value is permanently set and cannot be changed.
• Maximum force value
This value defines the upper limit of the force value which must not be exceeded in a pro-
cess.
• Position
The target position is entered here. This value corresponds with the opening dimension of
the clinching tongs.

Upper force limit at high speed

At high speed, the upper force limit should be selected as low as possi-
ble. This should be < 20 % of the nominal drive force in order to detect
unintentional contact at an early stage. With too high a maximum force
limit, the maximum force of the spindle may be exceeded. An overload of
the spindle may lead to damage or even destruction of the drive and tool.
Continuous, hard impacts on the material or continual overloading of the
drive may shorten the service life of the spindle.

• Speed
When moving to the pre-position, movement is generally carried out at high speed (up to
the maximum spindle speed).

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 Processes

• Time monitoring
The function can be additionally checked with time monitoring. If the time entered in 'Time
monitoring [ms]' is exceeded, the spindle is stopped and a general error message is issued.
With the aid of user variables, a fault message which is only valid for this time monitoring
can be defined.
• User variables
The user variables are composed of four integers, which can be freely selected from 0 to
255. With reference to these variables, a clear message can be projected with the flex mes-
sages in the HMI specifically for this time monitoring, e.g. with a reference to a digital sensor
whose function must be checked.
• Transition speed
The transition speed enables an even transition to the next function. With this parameter,
the spindle is not braked to 'zero' when switching to a new function but instead it is only
braked to the speed set in this parameter. This speed should be identical to the value of the
speed in the next function.

Y Y
1 2 1 2

3 4

X X

X Travel [mm] 2 Function X + 1

Y Speed [mm/s] 3 without transition speed
1 Function X 4 with transition speed

Combination of functions
The transition speed may only be used in combination with a further
movement function. The only exceptions to this are the functions 'Save fi-
nal values' and 'Save intermediate values'. If this is not observed, this
may lead to damage to or even destruction of the drive and tool.
Exceeding the mechanical limits is possible with the transition speed. The
transition speed must not be used close to mechanical limits and is done
at your own risk. Exceeding the mechanical limits may lead to damage to
or even destruction of the drive and tool.

OM 100.Worx-lineX-Reference.201703.en 107
 Processes

• Abort contact
With the aid of the abort contact, this function can be cancelled prematurely. After the abort,
this function is deemed to be ended and the process is continued with the next function. If
this is the last function in a process, the process is evaluated as 'OK'. In order to use this
command, an abort contact must be defined in the process.

7.4.19 'Clinch riveting' function

This function is used to combine metal sheet pairs to one residual plate thickness (X dimen-
sion). Unlike clinching, with clinch riveting a rivet is also pressed. The X-dimension is ac-
tively controlled with clinch riveting. In this way, both bending and different plate thicknesses
are compensated for. With clinching processes, positioning is not absolute in relation to the
reference position but instead absolute in relation to the zero position in the spindle data.
The position value entered therefore corresponds to the opening dimension of the clinching
tongs: With a position value of 0 mm, the tongs are closed.

1 Zero dimension = open- 2 Punch 3 Die

ing dimension

• Target value
The target value is permanently set to 'Position' and cannot be changed.
• Maximum force value
This value defines the upper limit of the force value which must not be exceeded in a pro-
cess.
• Minimum force value
This value defines the lower limit of the force value which must be reached in a process.
• Position
Here the target position (= X-dimension) from the TOX® inspection report is entered here.
This value corresponds with the opening dimension of the clinching tongs.
• Speed
The speed is permanently set and cannot be altered.

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 Processes

• Time monitoring
The function can be additionally checked with time monitoring. If the time entered in 'Time
monitoring [ms]' is exceeded, the spindle is stopped and a general error message is issued.
With the aid of user variables, a fault message which is only valid for this time monitoring
can be defined.
• User variables
The user variables are composed of four integers, which can be freely selected from 0 to
255. With reference to these variables, a clear message can be projected with the flex mes-
sages in the HMI specifically for this time monitoring, e.g. with a reference to a digital sensor
whose function must be checked.
• Abort contact
With the aid of the abort contact, this function can be cancelled prematurely. After the abort,
this function is deemed to be ended and the process is continued with the next function. If
this is the last function in a process, the process is evaluated as 'OK'. To be able to use this
command, an abort contact must be defined in the process (see function 'Define abort con-
tact').To be able to use this command, an abort contact must be defined in the process (see
function 'Define abort contact').

• Text
Here a comment can be entered, for example to clearly describe the process or the material.
• Speed control/control speed
With the enabled speed control, operation is first carried out with the value parameterised
under control speed and only reduced to the value parameterised under speed towards the
end of the clinching process.

OM 100.Worx-lineX-Reference.201703.en 109
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Teach-in
• Upper force limit
A clinching process must be taught into the relevant application (material). Here, the upper
force limit is relative to the final force value measured. After teach-in, this value is added to
the upper force limit and automatically adopted as the maximum force value. With the final
force value of a clinching joint of 40 kN and an upper force limit of 1 kN, after the teach-in
process the value of 41 KN is automatically adopted for the maximum force value.
• Lower force limit
During teach-in, the input of the lower force limit is relative to the measured final force value.
After teach-in, this value is subtracted from the lower force limit and automatically adopted as
the minimum force value. With the final force value of a clinching joint of 40 kN and a lower force
limit of 1 kN, after the teach-in process the value of 39 KN is automatically adopted for the min-
imum force value.

1 2
Y

7
3

4
6

X Travel [mm] 4 min. force value

Y Force [kN] 5 monitored range
1 Position ( = X-dimension) 6 Lower force limit
2 Zero dimension ( = Position 0) 7 Upper force limit
3 max. force value 8 max. opening dimension

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 Processes

7.4.20 'Self-piercing riveting' function

'Double rivet monitoring'
With this function, movement to a pre-position is carried out and it is checked via the pa-
rameterised force limits that there is no second rivet present.

• Target value
The target value is permanently set to 'Position' and cannot be changed.
• Maximum/minimum force value
The force limits are entered here which are only fallen short of or exceeded if a second rivet
is present.
• Position
The target position is entered here. This is an absolute position, starting from the reference
position.
• Speed
A high speed (up to the maximum spindle speed) is generally used here.
• Time monitoring
The function can be additionally checked with time monitoring. If the time entered in 'Time
monitoring [ms]' is exceeded, the spindle is stopped and a general error message is issued.
With the aid of the user variables, an error message which is only valid for this time moni-
toring can be defined.
• User variables
The user variables are composed of four integers, which can be freely selected from 0 to
255. With reference to these variables, a clear message can be projected with the flex mes-
sages in the HMI specifically for this time monitoring, e.g. with a reference to a digital sensor
whose function must be checked.
• Abort contact
With the aid of the abort contact, this function can be cancelled prematurely. After the abort,
this function is deemed to be ended and the process is continued with the next function. If
this is the last function in a process, the process is evaluated as 'OK'. To be able to use this
command, an abort contact must be defined in this process (see also function 'Define abort
contact').

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 Processes

7.4.21 'Rivet monitoring' function

With this function, the force limit in the riveting process are monitored.

• Target value
The target value is permanently set to 'Position' and cannot be changed.
• Maximum/minimum force value
The force limits are entered here which are only fallen short of or exceeded if a second rivet
is present.
• Position
The target position is entered here. This is an absolute position, starting from the reference
position.
• Speed
A high speed (up to the maximum spindle speed) is generally used here.
• Time monitoring
The function can be additionally checked with time monitoring. If the time entered in 'Time
monitoring [ms]' is exceeded, the spindle is stopped and a general error message is issued.
With the aid of user variables, a fault message which is only valid for this time monitoring
can be defined.
• User variables
The user variables are composed of four integers, which can be freely selected from 0 to
255. With reference to these variables, a clear message can be projected with the flex mes-
sages in the HMI specifically for this time monitoring, e.g. with a reference to a digital sensor
whose function must be checked.
• Transition speed
The transition speed cannot be changed with rivet monitoring.

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 Processes

• Abort contact
With the aid of the abort contact, this function can be cancelled prematurely. After the abort,
this function is deemed to be ended and the process is continued with the next function. If
this is the last function in a process, the process is evaluated as 'OK'. To be able to use this
command, an abort contact must be defined in this process (see also function 'Define abort
contact').
'Teach-in' function
• Upper force limit + [kN]
A clinching process must be taught into the relevant application (material). Here, the upper
force limit is relative to the final force value measured. After teach-in, this value is added to
the upper force limit and automatically adopted as the maximum force value. With the final
force value of a clinching joint of 40 kN and an upper force limit of 1 kN, after the teach-in
process the value of 41 KN is automatically adopted for the maximum force value.
• Lower force limit - [kN]
During teach-in, the input of the lower force limit is relative to the measured final force value.
After teach-in, this value is subtracted from the lower force limit and automatically adopted as
the minimum force value. With the final force value of a clinching joint of 40 kN and a lower
force limit of 1 kN, after the teach-in process the value of 39 KN is automatically adopted
for the minimum force value.
• Teach-in lower force limit - [kN]
Minimum force which must be reached with teach-in. This parameter guarantees that no
movements are taught-in without material.

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 Processes

7.4.22 'Self-piercing riveting' function

With this function, a self-piercing rivet is set and pressed.

• Target value
The target value is permanently set to 'Force' and cannot be changed.
• Maximum/minimum force value
Minimum and maximum limits which must be observed even when taking the position limits
into account.
• Force
The target for self-piercing riveting is the force. With self-piercing riveting, movement is car-
ried out until this force is reached.
• Position monitoring
Position monitoring cannot be changed during self-piercing riveting.
• Maximum/minimum position value
The position values which must be observed when the force is reached.
• Speed
The speed for self-piercing riveting is permanently set and cannot be changed.
• Transition speed
The transition speed cannot be altered with self-piercing riveting.

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 Processes

• Time monitoring
The function can be additionally checked with time monitoring. If the time entered in 'Time
monitoring [ms]' is exceeded, the spindle is stopped and a general error message is issued.
With the aid of user variables, a fault message which is only valid for this time monitoring
can be defined.
• User variables
The user variables are composed of four integers, which can be freely selected from 0 to
255. With reference to these variables, a clear message can be projected with the flex mes-
sages in the HMI specifically for this time monitoring, e.g. with a reference to a digital sensor
whose function must be checked.
• Abort contact
With the aid of the abort contact, this function can be cancelled prematurely. After the abort,
this function is deemed to be ended and the process is continued with the next function. If
this is the last function in a process, the process is evaluated as 'OK'. To be able to use this
command, an abort contact must be defined in this process (see also function 'Define abort
contact').
• Text
The material pairs to be combined, for example, can be entered here.
• Dwell time
With the aid of the dwell time, a force can be maintained over a long period.

Note
Low forces can be maintained over longer periods, high forces only over
a shorter period (up to 3 seconds). Within this period, in the event of a de-
crease in force, the spindle readjusts from 0.5 % of the nominal force to
the target force.

• Speed control/starting point in % of force

When speed control is enabled, movement is first carried out with the value parameterised
under speed. After the value parameterised under starting point in % of force is reached,
the speed is reduced so that the value projected under force is exceeded by as little as
possible. Thus, in order to save time, a considerably higher speed can be used.
• Teach-in, upper/lower force limit, upper/lower position limit
Here, the values are entered which are to be added to or subtracted from the values deter-
mined during teach-in in order to define the final limits.

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 Processes

7.4.23 'Semi-hollow punch riveting'

With this function, a semi-hollow punch rivet is set and pressed.

• Target value
The target value is permanently set to 'Position' and cannot be changed.
• Maximum/minimum force value
Minimum and maximum limits which must be observed even when taking the position limits
into account.
• Position
Here the target position (= X-dimension) from the TOX® inspection report is entered here.
• Compression
Here, the position is corrected by the value entered (in mm) as the target setting for the
servo drive.
• Speed
The speed for semi-hollow punch riveting is permanently set and cannot be altered.
• Time monitoring
The function can be additionally checked with time monitoring. If the time entered in 'Time
monitoring [ms]' is exceeded, the spindle is stopped and a general error message is issued.
With the aid of user variables, a fault message which is only valid for this time monitoring
can be defined.
• User variables
The user variables are composed of four integers, which can be freely selected from 0 to
255. With reference to these variables, a clear message can be projected with the flex mes-
sages in the HMI specifically for this time monitoring, e.g. with a reference to a digital sensor
whose function must be checked.

116 OM 100.Worx-lineX-Reference.201703.en
 Processes

• Abort contact
With the aid of the abort contact, this function can be cancelled prematurely. After the abort,
this function is deemed to be ended and the process is continued with the next function. If
this is the last function in a process, the process is evaluated as 'OK'. To be able to use this
command, an abort contact must be defined in this process (see also function 'Define abort
contact').
• Text
The material pairs to be combined, for example, can be entered here.
• Speed control/control speed
If speed control is enabled, first movement is carried out with the value parameterised under
control speed and only reduced towards the end of the clinching process to the value pa-
rameterised under speed.
• Teach-in, upper/lower force limit
Here, the values are entered which are to be added to or subtracted from the values deter-
mined during teach-in.
7.4.24 'External target value' function
The external target value is used mainly for external pre-positioning (it is also possible to
move to an external force value). With this function, for example, robot tongs can be indi-
vidually pre-positioned according to the position of the next clinching point. This minimises
the cycle time when moving the robot. The function 'External target value' is only available
in process 6.

• Target value
Select here whether pressing is to be carried out to an absolute position or to a force. The
parameters displayed in this list change according to the selection made.

Target position
The target position must be outside of the component or force range. If
this is not the case and movement to the component is carried out at high
speed and high maximum force limit, the maximum force of the spindle
may be exceeded. An overload of the spindle may lead to damage or
even destruction of the drive and tool.
Continuous, hard impacts on the material or continual overloading of the
drive may shorten the service life of the spindle.

OM 100.Worx-lineX-Reference.201703.en 117
 Processes

• Maximum force value

This value defines the upper limit of the force value which must not be exceeded in a pro-
cess.
• Minimum force value
This value defines the lower limit of the force value which must be reached in a process.
• Maximum position value
With this value, the upper limit of the range to be monitored is defined.
• Minimum position value
With this value, the lower limit of the range to be monitored is defined.
• Speed
The speed can be freely selected and individually adapted to the time available, for example
to the travel time of the robot to the next clinching position.
• Time monitoring
The function can be additionally checked with time monitoring. If the time entered in 'Time
monitoring [ms]' is exceeded, the spindle is stopped and a general error message is issued.
With the aid of user variables, a fault message which is only valid for this time monitoring
can be defined.
• User variables
The user variable comprises four integers, which can be freely selected from 0 to 255. With
reference to these variables, a clear message can be projected with the flex messages in
the HMI specifically for this time monitoring, e.g. with a reference to a digital sensor whose
function must be checked.

118 OM 100.Worx-lineX-Reference.201703.en
 Processes

• Abort contact
With the aid of the abort contact, this function can be cancelled prematurely. After the abort,
this function is deemed to be ended and the process is continued with the next function. If
this is the last function in a process, the process is evaluated as 'OK'. In order to be able to
use this command, an abort contact must be defined in the process (see function 'Define
abort contact' on page 137).

1 2

Y
3

X Travel [mm] 4 Min. force value

Y Force [kN] 5 Monitored range
1 Min. position value 6 External target position value
2 Max. position value 7 External target force value
3 Max. force value

OM 100.Worx-lineX-Reference.201703.en 119
 Processes

7.4.25 'Inflexion point detection' function with inflexion point analysis

With this function, movement is carried out until the increase in force becomes greater than
the value parameterised in the inflexion point or becomes smaller if a negative value is
entered for the inflexion point.

• Check maximum limits

Maximum/minimum force value is displayed/hidden.
• Position monitoring
The values to be monitored are displayed/hidden.
• Maximum position value
If position monitoring is enabled, the upper limit of the range to be monitored is specified.
• Minimum position value
If position monitoring is enabled, this value specifies the lower limit of the range to be mon-
itored.
• Speed
Select a low speed for pressing. A speed of approx. 3 mm/s is specified as a reference value
for most pressing processes. This value may vary greatly depending on the application.

Note
The softer and the more insensitive a component is to force peaks (toler-
ance force limits), the faster pressing can be carried out.
• Time monitoring
The function can be additionally checked with time monitoring. If the time entered in 'Time
monitoring [ms]' is exceeded, the spindle is stopped and a general error message is issued.
With the aid of user variables, a fault message which is only valid for this time monitoring
can be defined.

120 OM 100.Worx-lineX-Reference.201703.en
 Processes

• Abort contact
With the aid of the abort contact, this function can be cancelled prematurely. After the abort,
this function is deemed to be ended and the process is continued with the next function. If
this is the last function in a process, the process is evaluated as 'OK'. To be able to use this
command, an abort contact must be defined in the process (see function 'Define abort con-
tact').To be able to use this command, an abort contact must be defined in the process (see
function 'Define abort contact').
• Reversal of direction
Reverses the direction of the spindle.
• Inflexion point
The increase in force at which the axis should stop is entered here.
• Inflexion point filter factor
Number of points which are used as the basis for calculation of the increase.
Example function sequence with inflexion point detection:

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 Processes

Example of inflexion point detection:

2
3
4

For example, if you want to detect this inflexion point (2) within certain force and position
limits, the axis must first move to pressing (4) with a function (to force, e.g. 5 kN), the gra-
dient progression (3) at position 263.70 mm is approx. 22 kN/mm.
The function "Inflexion point detection" is then carried out (before the actual. pressing func-
tion (1) with 17.5 kN) with the values:
inflexion point -2 kN/mm / filter factor 5 / min force 6,0 / max. force approx. 20 kN /min
position 263.00 / max. position 266.20 (see diagram).
This means that as soon as the pitch of 20 kN/mm decreases to less than 2 kN/mm (within
the pos. and force limits), the OK function is fulfilled.
A pressing function to force and reverse stroke is then carried out.

122 OM 100.Worx-lineX-Reference.201703.en
 Processes

7.4.26 'Inflexion point detection' function without inflexion point analysis

This function is used to press to a fixed stop. Pressing is carried out as for the command
'Pressing' with a pre-set force. However, here the final values of the pressing process can
be defined at a position X before the end of the function. Generally, this position lies just in
front of the end of the pressing process, as the force increases rapidly when pressing to a
fixed stop. In this way, the actual pressing force can be displayed which is decisive for the
strength of the component.

• Target value
Here you can select whether pressing is to be carried out to an absolute position or to force.
The parameters displayed in this list change according to the selection made.
− Position (with selection 'Target value to position')
Here the absolute target position is entered which is based on the reference position.

Upper force limit at high speed

At high speed, the upper force limit should be selected as low as possi-
ble. This should be < 20 % of the nominal drive force in order to detect
unintentional contact at an early stage. With too high a maximum force
limit, the maximum force of the spindle may be exceeded. An overload of
the spindle may lead to damage or even destruction of the drive and tool.
Continuous, hard impacts on the material or continual overloading of the
drive may shorten the service life of the spindle.

− Force (on selection of 'Target value to force')

The target force moved to is entered here. With this function, note that when moving
at very high speed the spindle only breaks when the target force is detected. This
leads to the target force being exceeded in proportion to the increase in speed.

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 Processes

Risk of overloading
At high speed and with high target force, the maximum force of the spin-
dle may be exceeded. An overload of the spindle may lead to damage or
even destruction of the drive and tool.
Continuous, hard impacts on the material or continual overloading of the
drive may shorten the service life of the spindle.

• Check maximum limits

Maximum/minimum force value is displayed/hidden.
• Maximum force value
This value defines the upper limit of the force value which must not be exceeded in a pro-
cess.
• Minimum force value
This value defines the lower limit of the force value which must be reached in a process.
• Position monitoring
Position monitoring should only be used for a stroke to the target value 'Force'. Here it is
checked whether the target position is reached within the defined limits. Position monitoring
is parameterised on the basis of the absolute value of the final force. Due to the relative
displacement of the delta inflexion point position, the limits are also moved relatively and
also apply there accordingly (formula: value of the limits - value of the delta inflexion point
position).
• Maximum position value
If position monitoring is enabled, the upper limit of the range to be monitored is specified.
• Minimum position value
If position monitoring is enabled, this value specifies the lower limit of the range to be mon-
itored.
• Speed
Select a low speed for pressing. A speed of approx. 3 mm/s is specified as a reference value
for most pressing processes. This value may vary greatly depending on the application.

Note
The softer and the more insensitive a component is to force peaks (toler-
ance force limits), the faster pressing can be carried out.

• Time monitoring
The function can be additionally checked with time monitoring. If the time entered in 'Time
monitoring [ms]' is exceeded, the spindle is stopped and a general error message is issued.
With the aid of user variables, a fault message which is only valid for this time monitoring
can be defined.

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• Abort contact
With the aid of the abort contact, this function can be cancelled prematurely. After the abort,
this function is deemed to be ended and the process is continued with the next function. If
this is the last function in a process, the process is evaluated as 'OK'. To be able to use this
command, an abort contact must be defined in the process (see function 'Define abort con-
tact').To be able to use this command, an abort contact must be defined in the process (see
function 'Define abort contact').
• Reversal of direction
Reverses the direction of the spindle.
• Maximum relative position press in window
The position in relation to the position at which the value parameterised in maximum inflex-
ion point force may not yet be exceeded.
• Minimum relative position press in window
The point in relation to the inflexion point position at which the value parameterised in min-
imum inflexion point force must already have been exceeded.
• Delta inflexion point position
The delta inflexion point position is a relative position based on the final value of the function.
The total travel minus the delta inflexion point position results in position X, which is to be
checked.
• Maximum inflexion point force
The maximum inflexion point force is an absolute value which refers to the delta inflexion
point position.

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• Minimum inflexion point force

The minimum force value at the delta inflexion point position forms the lower force limit at
position X. This is the minimum value which must be reached.
This minimum inflexion point force is an absolute value which refers to the delta inflexion
point position.
Example of inflexion point detection without inflexion point analysis:

∆ Inflexion point position

e.g. 2 mm

Here the inflexion point

was detected.

Max. inflexion point force

Min. relative position press-
ing in window, e.g. 2.5 mm
Max. relative position press-
ing in window, e.g. 1.5 mm
OK
Monitoring window
Min. inflexion point force

NOK

S
This function looks at the inflexion point but observes the running window ret-
rospectively.

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7.4.27 'Press to force difference' function

This function is used to press to a relative force. The initial position is the current force which
is present at the beginning of this function. The relative force is now added to the current
force and results in the final force. If, for example, a force of 11 kN is present at the beginning
of this function and the force is to be increased by 10 kN, the target force is 21 kN.

• Maximum force value

This value defines the upper limit of the force value which must not be exceeded in a pro-
cess.
• Force difference [kN]
Force difference refers to the increase in forced by which the currently active force on the
component is to be increased (formula: current force + force difference = final force).

Risk of overloading
At high speed and with high target force, the maximum force of the spin-
dle may be exceeded. An overload of the spindle may lead to damage or
even destruction of the drive and tool.
Continuous, hard impacts on the material or continual overloading of the
drive may lead to a reduction in the service life of the spindle.

• Minimum force value

This value defines the lower limit of the force value which must be reached in a process.
• Position monitoring
Position monitoring should only be used with a stroke to target value 'Force'. Here it is
checked whether the target position is reached within the defined limits. Position monitoring
is recommended when pressing to a force difference.
• Maximum position value
If position monitoring is enabled, the upper limit of the range to be monitored is specified.
• Minimum position value
If position monitoring is enabled, this value specifies the lower limit of the range to be mon-
itored.

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• Speed
Select a low speed for pressing. A speed of approx. 3 mm/s is specified as a reference value
for most pressing processes. This value may vary greatly depending on the application.

Note
The softer and the more insensitive a component is to force peaks (toler-
ance force limits), the faster pressing can be carried out.

• Time monitoring
The function can be additionally checked with time monitoring. If the time entered in 'Time
monitoring [ms]' is exceeded, the spindle is stopped and a general error message is issued.
With the aid of user variables, a fault message which is only valid for this time monitoring
can be defined.
• User variables
The user variable comprises four integers, which can be freely selected from 0 to 255. With
reference to these variables, a clear message can be projected with the flex messages in
the HMI specifically for this time monitoring, e.g. with a reference to a digital sensor whose
function must be checked.
• Abort contact
With the aid of the abort contact, this function can be cancelled prematurely. After the abort,
this function is deemed to be ended and the process is continued with the next function. To
be able to use this command, an abort contact must be defined in the process (see function
'Define abort contact').
• Dwell time
With the dwell time, a force can be maintained over a longer period of time.

Relation between dwell time and force

Low forces can be maintained over longer periods, high forces only over
a shorter period (up to 3 seconds). Within this period, in the event of a de-
crease in force, the spindle readjusts from 0.5 % of the nominal force to
the target force.

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1 2

Y
3

7
4

5
6

X Travel [mm] 4 min. force value

Y Force [kN] 5 Force difference +
1 min. position value 6 Pre-load
2 max. position value 7 previous process sequence
3 max. force value

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7.4.28 'Pressing to PLC default values' function

This function is not parameterised in the controller but directly in the PLC. All values (target
force/target position and limits) are written to the controller via the PLC. Up to five different
travel commands can be used in a process.

• PLC Data record No.

The data record to be used in the PLC must be selected in this box.

Note
Parameterisation of the data records and control are described in the doc-
umentation 'Move to PLC default values' on the INFO-CD TOX®-Elec-
tricDrive.

• Speed control/control speed

If speed control is enabled, first movement is carried out with the value parameterised under
control speed and only reduced towards the end of the clinching process to the value pa-
rameterised under speed.
• Min. / max. force active
If this tick is set, the maximum and minimum values achieved during pressing are entered
in the final values and not the values parameterised for pressing.
• Absolute position monitoring
Position monitoring is as viewed from the absolute zero point (reference point), also with
relative positioning.

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7.4.29 'Stroke 7th axis' function

Robot tongs (with TOX®-ElectricDrive and tool) are controlled as a 7th axis of the robot. The
pliers are positioned with the aid of the external setpoint value (see function external set-
point value), which changes dynamically with the position of the robot. Here, depending on
the position of the robot, a new position is written to the controller by the robot and then
moved to.

• Maximum force value

This value defines the upper limit of the force value which must not be exceeded in a pro-
cess.
• Minimum force value
This value defines the lower limit of the force value which must be reached in a process.
• Maximum position value
With this value, the upper limit of the range to be monitored is defined.
• Minimum position value
With this value, the lower limit of the range to be monitored is defined.
• Speed
The speed can be freely selected and individually adapted to the time available, for example
to the travel time of the robot to the next clinching position.
• Acceleration
Maximum permissible acceleration speed of the axis. The value can be changed directly in
the input box.
• Time monitoring
The function can be additionally checked with time monitoring. If the time entered in 'Time
monitoring [ms]' is exceeded, the spindle is stopped and a general error message is issued.
With the aid of user variables, a fault message which is only valid for this time monitoring
can be defined.
• User variables
The user variable comprises four integers, which can be freely selected from 0 to 255. With
reference to these variables, a clear message can be projected with the flex messages in
the HMI specifically for this time monitoring, e.g. with a reference to a digital sensor whose
function must be checked.

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• Abort contact
With the aid of the abort contact, this function can be cancelled prematurely. To be able to
use this command for this function, an abort contact must be defined in the process (see
function 'Define abort contact' on page 137).
7.4.30 'Reference run' function
In the case of servo motors with a resolver as a position measuring system, the system
must be referenced once every time the supply voltage is switched on at the controller so
that the absolute mechanical zero position can be determined. All absolute position func-
tions refer to this mechanical zero position.

• Referencing method
When 'Fixed stop' is selected, the spindle nut moves back in the EPM until the rear mechanical
final position is reached. This is detected by an increase in current.
When 'Reference switch' is selected, a backwards movement is carried out until the digital
input D I4 returns a signal '1'. When the mechanical final position or the limit switch is de-
tected, the direction is reversed and the spindle is positioned 3 mm in front of the limit stop.
The reference marker is now set at this position.

Note
If the spindle is equipped with a brake and the controller does not have a
Can or I/O extension, the input DI 4 is already assigned and cannot be
used for referencing.

• Limit switch
When "Fixed stop" is selected, it can be decided whether referencing is carried out with or
without a sensor. If "with sensor" is selected, the system assumes that when the limit stop
is reached, the limit switch signal is also connected. If this is not the case, an error message
is issued. An incorrect reference point is thus also prevented from being set in the case of
a sluggish spindle.
• Position
Distance travelled forward after the fixed stop is reached before the position scale is set to
zero.
• Acceleration
Acceleration of the axis during referencing.
• Speed
Speed to be moved at after accelerating

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• Current limit
If the current has reached the limit entered here, the spindle nut has arrived at the rear
mechanical stop.

Safety
The values are defined by TOX® PRESSOTECHNIK and may only be al-
tered with permission.

7.4.31 'Time delay' function

This function enables a defined pause in the process. The position of the spindle is not
changed for the defined period.

7.4.32 'Process call' function

With this function, the current process is ended and a new process started. This can be
used for example in combination with multiple conditions.
• Process number
Here the process to be started can be selected.

Order of the process numbers

If new processes are added, the order is changed. All subsequent pro-
cess numbers are added to the number of processes inserted. Ensure
that the selected process is correct after a change in order to prevent un-
wanted axis movements. Otherwise, damage to or destruction of the drive
and tool may occur.

1 Function X 4 Function 1
2 Process call 5 Function 2
3 Process X

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7.4.33 'Sub-process call' function

With this function it is possible to change to a different process (= sub-process) and then,
after ending the sub-process, the first process can be resumed from the point where it was
left.

Order of the process numbers

If new processes are added, the order is changed. All subsequent pro-
cess numbers are added to the number of processes inserted. Ensure
that the selected process is correct after a change in order to prevent un-
wanted axis movements. Otherwise, damage to or destruction of the drive
and tool may occur.

1 Function X 4 Function 1
2 Process call 5 Function X (process end)
3 Process X 6 Function X + 1

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7.4.34 'Start multiple condition' function

The multiple condition corresponds to the 'case function' in the high level programming lan-
guage. A case function is a case distinction which depends on the input and the number of
bits (size). The multiple condition works here with a bi-linear code, from which the branch
targets are determined. The search is continued until the function 'End multiple condition' is
found in the process.
Example:
Two bits are defined as a start condition, with which four cases can be distinguished:
00 = 0 = Case 0
01 = 1 = Case 1
10 = 2 = Case 2
End multiple condition
In this example, no case is defined for combination 11. With this combination, an error
message is issued.

• Source
Here the source is selected via which the start condition is sent. Digital inputs and outputs,
Fieldbus and variables can be used as the source.
• Byte number
Here the byte number is entered in which the expected information is transmitted.
• Start bit number
Here, a start bit can be defined in the selected byte.
• Number of bits
Depending on the start bit, the number of bits can be set of which the decimal values are
composed.
• Variable type
The real or integer variables are evaluated here.
• Variable number
Variable number of the internal variables.

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7.4.35 'Target multiple conditions' function

This function corresponds to a defined case that is changed to when a certain branch con-
dition is fulfilled. The defined process is resumed at this point. An example is listed in the
function 'Start multiple condition'.

• Value
The value corresponds to the converted decimal value from the bi-linear code of the start
multiple condition.
7.4.36 'End multiple condition' function
This function marks the end of the multiple condition. Up to the point at which this function
is entered, a suitable value is searched for. If no suitable value is found up to then, a fault
is generated. An example is listed in the function 'Start multiple condition'.
7.4.37 'Reworking' function
This function enables an automatic reaction to a process error. If an error occurs in a work
process and the component is assessed as NOK, a change to a reworking process takes
place, which can be individually configured. The condition for this change is that the 'Re-
working' function was defined before the error. Therefore, this function should already be
set before the first travel command.
One example of reworking is the return to home position (by default process 2). As soon as
a monitoring parameter (force limits, position limits, time-out,...) signals an infringement, a
change to process 2 takes place, the spindle returns to the home position and the NOK
component can be removed.

Do not use 'Save final values' function

With a reworking process, the function 'Save final values' must not be
used.

Order of the process numbers

If new processes are added, the order is changed. All subsequent pro-
cess numbers are added to the number of processes inserted. Ensure
that the selected process is correct after a change in order to prevent un-
wanted axis movements. Otherwise, damage to or destruction of the drive
and tool may occur.

Example:
20 processes are saved in the controller. If an additional process is added after process 10
(process 11), all subsequent process numbers are increased by 1. The previous process
11 becomes process 12 etc. Check whether the specified process number is assigned to
the correct process.

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• Process number
Number of the process selected for re-working.
7.4.38 'Define abort contact' function
With this function, an input can be defined as an abort contact, which can then be used by
all subsequent functions of the process if the command 'Define abort contact' is enabled in
the relevant function. In addition, it is defined whether a transition from 'Low' to 'High' (0 to
1) or from 'High' to 'Low' (1 to 0) is to trigger a reaction. As soon as the abort contact is
detected, the corresponding function is ended.

• Source
The source via which the start condition is sent can be selected here. Digital inputs and
outputs, Fieldbus and variables can be specified as the source.
• Byte number
Here the byte number is entered in which the expected information is transmitted.
• Bit number
The corresponding bit in the selected byte is indicated here.
• Signal level
The switching level (edge) is defined here. The marked level corresponds with the normal
state. If the contact is now connected, a change to a different state occurs.
1–24 V / 0–0 V
• Variable type
The real or integer variables are evaluated here.
• Variable number
Variable number of the internal variables.

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7.4.39 'Acceleration' function

With the aid of this function, the acceleration of the subsequent function can be reduced.
Normally, movement is always carried out with maximum acceleration from the spindle data.
This function only changes the acceleration to the target speed, the braking process is car-
ried out with maximum negative acceleration from the spindle data. The time until the target
speed is reached can thus be increased. The maximum acceleration from the spindle data
cannot be exceeded.

• Acceleration
The acceleration is given in mm/s2 as an absolute value. The acceleration entered there
also corresponds with the acceleration actually applied.

Y
1 2

X Time [t] 1 Acceleration time spindle data

Y Speed [mm/s] 2 Acceleration time function

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7.4.40 'Deceleration' function

Deceleration is equivalent to acceleration and reduces the negative acceleration (braking
time). Normally, movement is always carried out with the maximum negative acceleration
from the spindle data. This function only changes deceleration from the target speed to a
lower speed (e.g. 0 mm/s), positive acceleration is still carried out with maximum accelera-
tion from the spindle data. The maximum negative acceleration from the spindle data cannot
be exceeded.

• Deceleration
Deceleration is given in mm/s2 as an absolute value. The deceleration entered there also
corresponds with the deceleration actually applied.

1 2

X Time [t] 1 Deceleration time function

Y Speed [mm/s] 2 Deceleration time spindle data

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7.4.41 'Spindle data'

This function contains all important basic settings which vary from spindle type to spindle
type. The spindle data serve as the basis for all functions and as the basis for all calcula-
tions.

Incorrect spindle data

If incorrect spindle data are entered, this may lead to damage to the tool
or to the spindle. To prevent damage to the tool or spindle, these values
may not be changed without consulting TOX® PRESSOTECHNIK.

The function 'Spindle data' is used when work is carried out on a robot with several tongs.
This function is only used in process 9. A comment with spindle data must be stored in
process 9, whereby the comment must always be placed in front of the 'Spindle data' func-
tion. When docking the relevant tong, the tong code is transmitted to the controller and the
spindle data relating to this tong are loaded. The tong code must correspond with the posi-
tion of the spindle data in process 9: for example, if tong code 1 is found, the spindle data
listed first are loaded in program 9.

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Force sensor
• Source analogue input
By default, the force sensor signal is transmitted to the controller via the analogue input 1.
An additional force sensor can be connected via the analogue input 2.

Replacement of a force sensor

If another force sensor is used, this may lead, for example in the event of
incorrect connection or incorrect calibration of the force sensor, to dam-
age to the tool or spindle, as the measured force values do not corre-
spond with the real force values.

Spindle
• Spindle type
The spindle type ´describes the properties of the spindle used. With the selection of the
spindle type, all other spindle data are loaded internally in the controller which are not listed
separately in the 'Spindle type' function. If you select the spindle type in the list box, ensure
that you select the type of the correct spindle. The description of the spindle used here is
based on the name, the nominal force and the stroke length, e.g. EPMR (Name)/55 (Nomi-
nal force)/100 (Stroke length).

Incorrect spindle data

If incorrect spindle data are entered, this affects all control parameters.
This may lead to damage to the tool or spindle.

The exact designation of the spindle can be found on the type plate:
EPM K 200. 001. 300. 00
Version number
Stroke [mm]
Version number
Coefficient pressing force [kN]
Design
(Standard, compact, robot tongs)
Electric Power Module

• Spindle serial no.

The serial number for identification of the spindle is engraved on the type plate. The serial
number is made up of the six digit material number and a serial device number, e.g.
123456.99.
• Maximum length [mm]
Length of the spindle in mm.

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• Maximum force
The maximum force is the highest available force limit. The maximum force corresponds to
the nominal force of the spindle plus an overload capacity of 10 %. If 100 % of the nominal
force of the spindle for pressing or clinching, the tolerance window can be set up to the
maximum force. If no tolerance window was generated in a function, the maximum force
applies as the upper force limit.

Observe maximum force

The maximum force corresponds to the nominal force of the spindle with
approx. 10 % overload. This is the last shut-off point to protect the spindle
mechanism and corresponds to the maximum force display. This entry
may only be changed with the agreement of TOX® PRESSOTECHNIK. If
the limit is set too high, this can lead to damage to the tool or spindle
If an external sensor with a lower nominal or ultimate load is used, this is
decisive and the maximum force value must be reduced accordingly to
prevent damage to or destruction of the sensor.
• Nominal force:
The nominal force denotes the maximum operational force which is available for this spindle
type. The value entered cannot be higher than the nominal force of the spindle.

Limitation of load
In some cases, the press, the tongs or the external sensor can be de-
signed for a lower load than the nominal force of the spindle. In this case,
the nominal force of the mechanical system must be adjusted so that un-
intentional application of excessive force in the functions is prevented. If
the limit is set too high, this may lead to damage to the machine.
• Bending constant [kN/mm]
The bending constant refers to the degree of bending of the press or tongs. Every material
has an expansion coefficient. In addition, bending depends on the shape of the machine. If
a value of 22 kN/mm is specified for robot tongs, for example, the tongs expand by exactly
1 mm with a force of 22 kN. If the spindle is operated, for example for clinching, with the
function 'movement with bending compensation', this constant is used as the basis for cal-
culation. If a value of 22 kN/mm is specified for robot tongs, for example, the tongs expand
by exactly 1 mm with a force of 22 kN. If the spindle is operated, for example for clinching,
with the function 'movement with bending compensation', this constant is used as the basis
for calculation.

Determine bending constant

The bending constant must first be determined. An incorrect bending con-
stant can lead to damage to the tool or the spindle.
• Maximum software limit [mm]
With this maximum software limit, the stroke is generally limited for all functions. The me-
chanical stroke limit can thus be reduced, for example to protect the tool against overload-
ing.
• Minimum software limit [mm]
With this minimum software limit, the return stroke is generally limited for all functions.

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• Tong weight index

This parameter is used as a calculation factor for the compensating slide with the die-side
drive.
Calibration:
• Factor
The calibration factor is individually measured for every spindle with its controller at TOX®
PRESSOTECHNIK. The calibration factor is specified on every spindle and can be entered
directly. This refers to calibration of the force sensor system.

Observe calibration factor

If you enter an incorrect calibration factor in the spindle data, the internal
and external forces no longer correspond with each other. This may lead
to damage to the tool or spindle.

Clinching
• Zero position [mm]
The zero position corresponds to the opening dimension of the complete spindle and is only
used for clinching. When clinching, movement is carried out to a certain X-dimension (re-
sidual plate thickness). The zero dimension corresponds with the closed tongs, in which
case the X-dimension (residual plate thickness) is zero. Every tool is subject to a low pro-
duction tolerance and therefore the zero position must be adjusted with each tool change.
To determine the zero dimension, first carry out a clinching process and compare the en-
tered X-dimension with the actual X-dimension. Then you must add the difference between
the actual X-dimension and the calculated X-dimension to the zero dimension (X-dimension
greater than the entered target value) or subtract it (X-dimension less than the target value).
Repeat the process until the entered X-dimension corresponds with the actual X-dimension.
This zero position refers to all clinching processes and therefore no further adjustments
have to be made in the processes.

Incorrect zero position

If the zero position is not known or entered incorrectly (>0.5 mm), for ex-
ample due to conversions, this may lead to damage to the tool and drive.

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• Die depth [mm]

The die depth is specified in the TOX® inspection report of the tool. The value to be set
corresponds to the zero dimension minus the die depth specified in the TOX® inspection
report. This value is only used for the automatic plate thickness detection and otherwise
has no further effect.

1 2 3 4

1 Die 4 Punch
2 Die depth (tool inspection report) 5 Die depth (spindle data)
3 Zero dimension = opening dimension

7.4.42 'End process' function

This function ends the current process. This command can be used in combination with the
functions of the multiple condition.
7.4.43 'Stop process' function
This function stops the current process. This command can be used in combination with the
functions of the multiple condition.

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7.4.44 'Set integer variable'

With the aid of the function, integer variables can be written to the controller. This function
is intended for customised applications, where the integer values are evaluated accordingly
or used in a multiple condition as a step variable.

• Variable number
The variable number refers to the corresponding internal address of the individual integer
variables.
• Variable value
Value to be entered in the corresponding integer variables.
7.4.45 'Set real variable' function
With this function, real variables can be written to the controller. This function is intended
for customised applications for which the real values are evaluated accordingly.

• Variable number
The variable number refers to the corresponding internal address of the individual real var-
iables.
• Variable value
Value to be entered in the corresponding real variables.
7.4.46 'Home position reached' function
With this function, a bit is set in the Fieldbus interface if the home position has been reached.
With the aid of this status, this information is output via the Fieldbus interface (e.g. from a
spindle to the robot).

Default interface
This status applies to the default interfaces, which must be set at the cor-
rect position by the creator of the process. With customised interfaces,
this status can be automated internally in the application.

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7.4.47 'Home position not reached' function

With this function, a bit is set in the Fieldbus interface until the home position is reached. With
the aid of this status, this information is output via the Fieldbus interface (e.g. from a spindle to
the robot).

Default interface
This status applies to the default interfaces, which must be set at the cor-
rect position by the creator of the process. With customised interfaces,
this status can be automated internally in the application.

7.4.48 'Working position reached' function

With this function, a bit is set in the Fieldbus interface when the working position has been
reached. With the aid of this status, this information is output via the Fieldbus interface (e.g.
from a spindle to the robot).

Default interface
This status applies to the default interfaces, which must be set at the cor-
rect position by the creator of the process. With customised interfaces,
this status can be automated internally in the application.

7.4.49 'Working position not reached' function

With this function, a bit is set in the Fieldbus interface until the working position is reached.
With the aid of this status, this information is output via the Fieldbus interface (e.g. from a spindle
to the robot).

Default interface
This status applies to the default interfaces, which must be set at the cor-
rect position by the creator of the process. With customised interfaces,
this status can be automated internally in the application.

7.4.50 'Technology process complete' function

With this function, a bit is set in the Fieldbus interface when the machining process has been
completed. With the aid of this status, this information is output via the Fieldbus interface (e.g.
from a spindle to the robot).

Default interface
This status applies to the default interfaces, which must be set at the cor-
rect position by the creator of the process. With customised interfaces,
this status can be automated internally in the application.

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7.4.51 'Technology process not complete' function

With this function, a bit is set in the Fieldbus interface until the machining process is com-
pleted. With the aid of this status, this information is output via the Fieldbus interface (e.g. from
a spindle to the robot).

Default interface
This status applies to the default interfaces, which must be set at the cor-
rect position by the creator of the process. With customised interfaces,
this status can be automated internally in the application.

7.4.52 'Target value reached' function

With this function, a bit is set in the Fieldbus interface when the target value has been
reached. With the help of this status, this information is output via the Fieldbus interface
(e.g. from a spindle to the robot).

Default interface
This status applies to the default interfaces, which must be set at the cor-
rect position by the creator of the process. With customised interfaces,
this status can be automated internally in the application.

7.4.53 'Target value not reached' function

With this function, a bit is set in the Fieldbus interface until the target value has been reached.
With the aid of this status, this information is output via the Fieldbus interface (e.g. from a
spindle to the robot).

Default interface
This status applies to the default interfaces, which must be set at the cor-
rect position by the creator of the process. With customised interfaces,
this status can be automated internally in the application.

7.4.54 'Process repeat possible' function

With this function, a bit is set in the Fieldbus interface as long as a repeat of the process is
still possible. This is generally permissible as long as no pressing or clinching command
has been carried out. With the help of this status, this information is output via the Fieldbus
interface (e.g. from a spindle to the robot).

Default interface
This status applies to the default interfaces, which must be set at the cor-
rect position by the creator of the process. With customised interfaces,
this status can be automated internally in the application.

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7.4.55 'Process repeat not possible' function

With this function, a bit is set in the Fieldbus interface if a repeat of the process is no longer
possible. This is generally possible as long as no pressing or clinching command has been
issued. With the help of this status, this information is output via the Fieldbus interface (e.g.
from a spindle to the robot).

Default interface
This status applies to the default interfaces, which must be set at the cor-
rect position by the creator of the process. With customised interfaces,
this status can be automated internally in the application.

7.4.56 'Save intermediate values 1' function

With this function, intermediate values can be saved at any position in the process. This
command is set directly after any function. The final values of this function are then saved.
The position reached and the force of the previous function including the minimum and
maximum limits are entered in the lines 'ZW1' in the final values (for further information on
the final values, see chapter 5 Final values).
7.4.57 'Save intermediate values 2' function
With this function, intermediate values can be saved at any position in the process. This
command is set directly after any function. The final values of this function are then saved.
The position reached and the force of the previous function including the minimum and
maximum limits are entered in the lines 'ZW2' in the final values (for further information on
the final values, see chapter 5 Final values).
7.4.58 'Save final values' function
With this function, final values can be entered at any position in the process. This function
is required if final values and intermediate values are to be saved. An exception to this is
the clinching process, where the final values are saved automatically and do not have to be
additionally set in a process. When using a reworking process, the final values must not be
stored there if no process-related operations are carried out there, e.g. moving top home
position. In this case, the final values from the faulty pressing are overwritten and the final
values saved there are lost. This command is set directly after any function. The final values
of this function are then saved. The position reached and the force of the previous function
including the minimum and maximum limits are entered in the final values (for further infor-
mation on the final values, see chapter 5 Final values).

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7.4.59 'Curve tracing' function

This function is used for process monitoring and records the process within the specified
parameters. This may be a defined period of time or a defined distance. A diagram can only
be recorded once in a process and all relevant data should be within the recording range.
To achieve high accuracy, the recording range should be as large as necessary but as small
as possible. After expiry of the time or after exceeding the distance range, diagram record-
ing is automatically ended.

• Active:
Curve tracing is enabled or disabled here.
• Mode
Here it is selected whether a certain time period or a certain travel range is to be recorded.
• Maximum position value (in 'Position' mode)
This position defines the maximum absolute value – based on the reference position – up
to which the curve is traced. If this value is exceeded, the curve is no longer traced.
• Minimum position value (in 'Position' mode)
This position defines the maximum absolute value – based on the reference position – from
which curve tracing is started or ended.
• Recording period (in 'Time' mode)
Specifies the period with which the time should be recorded in the diagram.
• Stop recording at end of process
If this command is enabled, the recording is ended at the latest at the end of the process.
7.4.60 'Stop curve tracing' function
With this function, curve tracing is stopped prematurely. This function should be used if the
return stroke is not relevant when recording the time or in particular when recording the
travel. Simultaneous recording of the return travel may lead to interpretation errors, as at
first sight it is not clearly visible which is pressing and which is the return stroke. This clearly
shows when the pressing process is ended and the return stroke begins.

• Active
Curve tracing is enabled or disabled here.

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7.4.61 'Start envelope monitoring' function

This function enables monitoring with an envelope. This is based on the curve tracing. A
curve is produced with a defined number of teaching processes. If possible all parameters
of the teaching process (internal parameters but also external parameters such as the com-
ponent, component tolerance etc.) should remain constant. The envelope is a type of toler-
ance band around the curve. The more constant the external parameters (tolerances) are,
the tighter the envelope can be selected. If the envelope is exceeded or not reached with
one or more values, the function is aborted and an error message is issued. The envelope
allows monitoring of a process range or of the complete process.

• Active
Curve tracing is enabled or disabled here.
• Process abort with error
A process can be directly aborted here and – if defined – a reworking process opened (see
'Reworking' function). If the command 'Process abort with error' is not enabled, the process
is run to the end and then an error message is generated.
• Abort with input force greater than upper envelope
If this parameter is enabled, the input force of the initial position of the envelope is checked.
If the force is above the envelope monitoring, the process is aborted.
• Upper force limit + [kN]
The upper force limit describes the average curve with a positive force offset. Each force at
each point of the envelope is added to the value of the upper force limit (calculation basis
Y-axis).
• Lower force limit - [kN]
The lower force limit describes the average curve with a negative force offset. The value of
the lower force limit is subtracted from every force at every point of the envelope (calculation
basis Y-axis).
• Upper position limit
The upper position limit describes the average curve with a positive travel offset. Each travel
point of the envelope is added to the value of the upper position limit (calculation basis X-
axis).

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• Lower position limit - [mm]

The lower position limit describes the average curve with a negative path offset. The value
of the upper position limit is subtracted from each path point of the envelope (calculation
basis X-axis).

Displacement of the axis

With simultaneous input of force and travel limits, the curve is displaced in
two axes.

7.4.62 'Stop envelope monitoring' function

With this function, envelope tracing can be stopped prematurely. This can be carried out,
for example, before the return stroke, as monitoring of the return stroke is generally not
necessary for the process. Tracing of the return travel may lead to interpretation errors, as
it cannot be clearly seen when the pressing process ends and the return stroke begins.

• Active
The function is enabled or disabled here.
7.4.63 'Wait for input' function
This function interrupts the process until a clearly defined input is set. It is possible to react
from a transition from 'Low' to 'High' (0 to 1) or from 'High' to 'Low' (1 to 0). The position of
the spindle is not changed during the waiting period.

• Source
The source via which the start condition is sent can be selected here. Digital I/O or Fieldbus
can be specified as the source.
• Byte number
Here the byte number is entered in which the expected information is transmitted.
• Bit number
The corresponding bit in the selected byte is indicated here.
• Signal level
The switching level (edge) is defined here.

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• Time monitoring
The function can be additionally checked with time monitoring. If the time entered in 'Time
monitoring [ms]' is exceeded, the spindle is stopped and a general error message is issued.
With the aid of user variables, a fault message which is only valid for this time monitoring
can be defined.
• Abort contact
With the aid of the abort contact, this function can be cancelled prematurely. To be able to
use this command for this function, an abort contact must be defined in the process (see
function 'Define abort contact' on page 137).
• User variables
Four user variables can be specified here, which are used to generate a specific error mes-
sage. For each value, a number between 0 and 254 can be specified. The user variables
are given in this form:
• xxx_xxx_xxx_xxx
7.4.64 'Set output' function
With this function, a defined output is set via the digital I/O or the Fieldbus interface.

• Source
The source via which the start condition is sent can be selected here. Digital I/O or Fieldbus
can be specified as the source.
• Byte number
Here the byte number is entered in which the expected information is transmitted.
• Bit number
The corresponding bit in the selected byte is indicated here.
• Signal level
The switching level (edge) is defined here. The marked level corresponds with the normal
state. If the contact is now connected, a switch to the other state occurs (1 = 24 V; 0 =
0 V).The switching level (edge) is defined here.

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7.4.65 'Initialise force sensor' function

The 'Initialise force sensor' function is only used in the 'reference run' process. With the aid
of this function, the force transducers are checked, a reference value is saved and the force
is set to zero.

Only use for reference run

This function is only to be used in the reference run process. It must
never be used together with the transition speed! In these functions, no
monitoring is active and the drive continues operating with the entered
transition speed. This may lead to damage to or even destruction of the
drive and tool.

7.4.66 Check force sensor

This function checks the force sensor and sets the force value to zero. It is recommended
to use this function at the beginning of each process to achieve optimum process reliability
and prevent possible damage.

Combination of functions
This function must not be used together with transition speed. With transi-
tion speed, monitoring is not active and the drive continues to operate
with the transition speed entered. This may lead to damage to or destruc-
tion of the drive and tool.

• Channel 1/2 comparison

The signals connected to the two analogue inputs are monitored for deviation < 5%. This
function is only useful if an additional (external) force sensor has been connected to the
analogue input.
7.4.67 'Comment' function
With this function, a comment (brief description) can be added, which is created in the pro-
cess as a full function (with a function number and corresponding memory location).

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