........................................................................................................................................................

TOX Powerpackage®

Pneumohydraulic drives with press forces of 2 – 2000 kN

1

For forces of 2 – 2000 kN........................................................................................................................................................

If high forces need to be generated efficiently in asmall space, pneumo-hydraulics come into play.
TOX® PRESSOTECHNIK knows how to effectively
combine the benefits of compressed air and oil.
The result is the TOX® Powerpackage – powerful pneumohydraulic drive cylinders, providing apress force of up to 2000 kN.

Advantages
 High stroke frequency
 Long service life
 Low energy consumption
 Low noise level Minimal maintenance costs

Inside the TOX® Powerpackage is a double guided working piston, working hand in hand with an intensifier piston. While the pneumatic control ensures high speeds,
the pneumohydraulic process step is responsible for
accurate application of force. Compressed air and oil
are reliably separated here, preventing any risk of contamination. The TOX® Powerpackage is controlled like anormal, double acting pneumatic cylinder.

Measuring andcontrol connection

Working piston

The functional design, with few movable parts, reduces wear and increases the service life. The low
impact forces of the fast stroke protect the tool and reduce the noise level. A mechanical spring with dual
function ensures low energy consumption: No air isrequired for the return stroke of the intensifier piston,and the constant pressure on the oil reservoir enables
assembly of the cylinder in any alignment. The low
energy usage in the unit allows for a significant
increase of the speed when using the smallest valve
cross-sections. This saves cost and space for the
installation.
Unrivalled quality
The pneumohydraulic TOX® Powerpackage impresses
compared to mechanical drives, toggle systems, hydraulic drive systems or large-volume pneumatic cylinders with its high power density, flexibility and simplicity.
It was developed for combined force-displacement motion sequences, which require forces of up to 2000 kN
and standard powerstrokes up to approx. 80 mm. The
standard total stroke is a maximum of 400 mm.

2

www.tox.com

Flow control X

Patented separationof oil and air

........................................................................................................................................................

Intensifier piston
Hydraulic end position damping
for quieter operation

Powerstroke valve

Depending on the version
mechanical or pneumatic spring

Central power bypassYour competent partner
 Close partnership from planning tooperation of the system
 Strong support for commissioning
and process optimization
 Worldwide customer service
 Personal 24/7 Hotline exclusively for ourcustomers
 Training at TOX® PRESSOTECHNIK or
at your premises
 Factory calibration and repair service
 Efficient remote maintenance3

Design........................................................................................................................................................

Highly detailed design
The TOX® Powerpackage is a pneumatic cylinder withintegrated hydraulic system. It uses the practical benefits of both media and supplements them with numerous technical innovations.

1

The TOX® Powerpackage is attached by meansof the flange with tight tolerance pilot and simple
mounting option.

2

The end positions of the moveable pistons areequipped with durable damping elements – thekey to smooth running at the highest stroke frequency.

3

All sealing components have been optimized incomprehensive long-term tests.

4

Special seals enable operation with oil-free air.

5

The double guided working piston directly transmits the force to the workpiece or tool.

6

Absolute separation of air and oil through two
seals with an annular groove in-between. This reliably prevents contamination of the hydraulic oil withair.

7

The high pressure and control connection enables subsequent functions like press force control,
and process pressure monitoring.

8

Oil level indicator

9Permanent pressure oil reservoir for infrequent
refilling intervals.

10

The patented anti-overfill safety device prevents
the oil reservoir from overfilling. If too much oil is filled in, it can drain off through its check valve.

1

4

2

3

6

5

7

11 The spring (depending on the version: mechanicalor pneumatic spring) meets two functions: resetof the intensifier piston and generation of pressure
on the reservoir. This means the oil in the reservoir
is under constant pressure. This way, operation ispossible in any installation position, for example ona robot.
12 The intensifier piston generates the force during

the powerstroke. It is single-acting and is equippedwith a spring reset, thus saving 85 percent of theenergy of a double-acting cylinder in the powerstroke.

4

www.tox.com

........................................................................................................................................................

15

16

9

8

10

11

13

The automatic switch from fast approach to powerstroke occurs when the working piston meets resistance at any point of the stroke. The powerstroke
valve is controlled by to the return stroke chamberand functions according to the dynamic pressure
procedure. The changeover time is controlled withthe flow control X.

14

The complete control is either mounted to or has
been integrated into the flange. This ensures a compact design. The TOX® Powerpackage is controlled
like any double-acting pneumatic cylinder with a
4/2- or a 5/2-way directional valve.

12

4

2

13

14

15

The TOX® Powerpackages line-Q and line-X as wellas the special types S (from size S 4) are equippedwith a patented, integrated, hydraulic end position
damping. This guarantees optimum damping in
the return stroke – especially in case of applications
with high tool weight and high retract speeds.

16

The patented central power bypass (ZLB) prevents
vacuum formation in the oil system, which can occur during punching or during high stroke speeds.

5The patented functional principle........................................................................................................................................................

Original position
In the home position, the drive is held by the main
control valve (H) in the return stroke. The working piston(1) is retracted.

1

H

Fast approachK

1

Air-operated fast approach: The main control valve(H) is actuated. The working piston (1) extends in fast
approach, until it meets resistance at any point. It stops
and the powerstroke valve (K) switches. Air now streams into the intensifier chamber (E).

E

H

PowerstrokeK

5

1

Pneumohydraulic powerstroke: The intensifier piston(2) closes the high pressure chamber (5) and builds theoil pressure in the working area to up to 400 bar. This oilpressure acts on the rear of the working piston (1) andgenerates the powerstroke.

E

2

H

Return stroke
K

1

H

6

www.tox.com

2E

Air-operated return stroke: After switching the main
control valve (H), the powerstroke valve (K) vents thechamber (E) automatically. The intensifier piston (2) ispressed back by spring force and the working piston (1)returns to the original position pneumatically.

........................................................................................................................................................

TO ®
lity Xp
10 m romise:istro llion
kes
in
12 m
onth
s!
qua

Power for daily use
The TOX® Powerpackage is a complete drive system.
With its various designs and comprehensive accessories it is universally applicable. It can be installed in any
position and usually does not require external tool guidance.

Ideal for use in various applications

Clinching,
TOX® Sheet
Metal Joining

Assembling,press-fitting

Punching,
piercing

Coining,
marking

Pressing-in,
Insertion offunctional
elements

Tensioning,clamping

Riveting

Pressing,
compressing

7

The pneumohydraulic drive family........................................................................................................................................................

The line-Q series Available in common standard sizes Shortest delivery times
 Attractive price Mechanical return spring

Design S (standard)Press forces: 2 – 300 kN
Total stroke: up to 200 mm
Powerstroke: up to 52 mm
Compressed air: 2 – 6 bar

Type Q-S

The line-X series
 Most configurable
 Can be configured according to the applications
 Precisely controllable and adjustable High stroke speeds
 Pneumatic spring
Press forces: 2 – 1700 kN
Total stroke: up to 400 mm
Powerstroke: up to 69 mm
Compressed air: 2 – 6 bar
Type X-S

Special types
 Application-specific design Complete range of types
 Compatible with the whole range of accessories
 Mechanical spring or air spring (depending on
the version)
Press forces: 2 – 1740 kN
Total stroke: up to 400 mm
Powerstroke: up to 80 mm
Compressed air: 2 – 10 bar
Type S

8

www.tox.com

........................................................................................................................................................

Design K (compact)

The series RP (marking cylinder), T (turbo
cylinder) and RZ (robot tongs cylinder)
Press forces: 2 – 160 kN
Total stroke: up to 200 mm
Powerstroke: up to 12 mm
Compressed air: 2 – 10 bar

Type Q-K
Type RZKX-KT system With separate intensifier for one or several working
cylinders For long powerstrokes
 Working cylinders can be activated individually Compact design, flexible mounting
Press forces: 2 – 2000 kN
Total stroke: up to 400 mm
Powerstroke: up to 100 mm
Compressed air: 2 – 10 bar
Type X-K

X-KT system

Type K

9®
TOXPowerpackage line-Q........................................................................................................................................................

The standardized basic system
The line-Q drives are designed for a large number ofstandard applications and are available in two designs:
a straight, slim type Q-S and a compact type Q-K. Thispreferred series is available in most standard sizes. Thismeans it can be delivered quickly at an attractive price.
The line-Q series is equipped with a sturdy mechanicalreturn spring for constant pressure on the storage piston and is equipped with hydraulic end position damping and power bypass ZLB as standard. This prevents
vacuum formation in the oil system, i.e. during faststroke speeds. Furthermore, this series has a magnetic
piston for external sensing.

Advantages
 Short delivery times due to standardized sizes
 Good value for money
 Low air consumption
 Medium maintenance intervalTechnical details:
 Central power bypass ZLB
 Hydraulic end position damping ZHD
 Fixed stop with elastomer damping in the forward
stroke FUD
 Prepared for stroke request ZHU and externallinear position sensor ZHW
 Mechanical return spring

Type Q-S

Type Q-K

10

www.tox.com

®
TOX
Powerpackage line-X........................................................................................................................................................

The individual high-end system
The drives of the line-X series enable high fast approach
stroke forces and fast stroke speed. They have very low
maintenance and repair costs. Furthermore, we can
individually adapt them to you application. The line-X
drives have a central power bypass as standard, as well
as a pneumatic spring instead of the mechanical springfor the intensifier return.
The line-X series is available as type X-S (slim design)and type X-K (compact design). Pneumatic spring,
powerstroke valve and fast stroke support are alreadyintegrated. Additional components include a pneumatic spring pressure regulator with maximum air flow for
maximum cycle times, and an OR valve for fast stroke
support.
All line-X drive cylinders are equipped with dynamic
pressure control (flow control X). Optional control versions including a pressure regulator in the powerstrokeline, external powerstroke connection or external
powerstroke release are available. Three pneumaticconnections are required: one each for forward andreturn strokes and one for the pneumatic spring.

Advantages
 Maximum capacity and variability Individually adaptable Maximum speed
 Long maintenance intervals

Technical details:
 Pneumatic spring Central power bypass ZLB
 Hydraulic end position damping ZHD
 Fixed stop with elastomer damping in the forward
stroke FUD
 Prepared for stroke request ZHU and externallinear position sensor ZHW up to X-S / X-K 030
 Type X-K with patented ring buffer version on theintensifier for significantly shortened installation
length Option: Distance transducer ZKW on X-K 050
and larger

Type X-K

Type X-S

11

®
TOX
Powerpackage X-KT system........................................................................................................................................................

The separated pneumohydraulic power unit
The TOX® X-KT system consists of the pressure intensifier X-ES and one or several working cylinders. Depending on press force, installation dimensions and cycle
time, it is tailored to customer requirements.
Either TOX® Hydraulic Cylinders HZL or pneumatic
TOX® Working Cylinders X-AT are used as working cylinders.

Advantages
 Compact installation dimensions
 Long powerstrokes
 Simple control
 Maximum capacity and variability
 Modular concept
X-KT system integrated in special machineTechnical details:
 Use of up to 6 working cylinders per pressure
intensifier Optimum system separation by TOX® Hydro Split
Coupling
 Simple color-coded pneumatic plug system Optional: selected cylinders can be driven withswitchable hydro split coupling
Pressure intensifier X-ES with TOX® Hydraulic
Cylinder HZL
 Short design
 Working piston with simple bearing Absolute separation of air and oil Fixed stop in forward stroke (elastomer damping
optional) Options: Stroke request ZHU and distancetransducer ZKW Cost-effective drive solution
Pressure intensifier X-ES with TOX® Working Part
X-AT
 High fast and return stroke forces Short cycle times
 Fixed stop with elastomer damping in the forward
stroke Prepared for stroke request type ZHU and externallinear position sensor ZHW up to X-AT 030
 All sizes with bypass ZLB incl. hydraulic end
position damping ZHD
 Option: Distance transducer ZWK on X-AT 50
and larger
12

www.tox.com

®
TOX
Powerpackage RZK, RZS, RZH........................................................................................................................................................

The specialist for robot tongs
The TOX® Powerpackages RZ are ideal for applications
on robot tongs and handheld tongs. These drives canbe precisely adjusted with a special flange. This enables
highest precision and production quality, even without
additional guide for the tool. The robot tong drives areready for operation in all installation positions.
The TOX® RZ series is available in three different designs: The type RZK is the weight-optimized compact
design for robot-controlled and mobile handheld tongs.
The particularly slim design of the TOX® Powerpackage
RZS is ideal for the press drive, which does not requirea guide carriage on the tool. The RZH system is suitablefor use on particularly light handheld tongs, or if several
hydraulic cylinders are to be used on one intensifier. The
hydraulic cylinder RZH(x) in turn is available in two basic
versions. Here, the pressure medium used for the returnstroke determines the cylinder type: RZHL for pneumatic return stroke and RZHO for hydraulic return stroke.

Advantages
 Simple and accurate adjustments of tongs with our
special flange Short cycle times
 Maximum maintenance intervals
Powerpackage type RZK Compact design
 With pneumatic spring High stroke rates, short cycle times
 Stroke lengths standardized for TOX® Tongs
 Integrated total stroke adjustment

Powerpackage type RZS Long design
 With pneumatic spring High stroke rates, short cycle times
 Cost-effective

Precise flange connection
The drive can be precisely aligned in both directions
perpendicular to the stroke direction by means ofcustom-fit grooves on the mounting surface of the
TOX® Powerpackage type RZ. The height and position of the drive can be adjusted with shims and the
key on the mounting surface.

Powerpackage type RZHL / RZHO Compact
 Working cylinder RZHL for combination withpressure intensifier X-ES
 Working cylinder RZHO for combination withhydraulic pump
 With special flange for TOX® Tongs
 High stroke rates, short cycle times
 Integrated total stroke adjustment

13

®
TOX
Powerpackage special types S, K, T and RP........................................................................................................................................................

Whether extremely fast or powerful, with marking tool
mounting or defined stroke: In case of unique applications, the special versions of the TOX® Powerpackage S,
K, T or RP come into play.
The TOX® Powerpackage S 50 / 80 provides high fast
approach and retraction forces and is available with apowerstroke adjustment. The length of the powerstroke
can be set independent of the length of the total
stroke. This is why this special type is particularly suited
to marking of numbers with consistant marking depth atdifferent piece part heights.
Alternately, with series K 51 / 81, the total stroke can becontinuously adjusted – independent of the length ofthe powerstroke and the cylinder length. This is ideal for
any forming and joining applications, especially if tools
without end stop are used. All designs are also available with flanges and air connections rotated to fit yourmounting area.

Type SType S .50 / S .80

Type K

Technical details:
 Individual stroke lengths, press forces anddimensions possible
 Optionally with pneumatic or mechanical spring Available as 6 bar and 10 bar drives
 All accessories available
Type K .51 / K .81

The high-speed TOX® Powerpackage T operates withup to 550 strokes per minute. Due to the high speed,
the turbo cylinder is particularly suited to punching andnibbling machines.

Designed with a working piston with anti-rotation device, the marking cylinder TOX® Powerpackage RP is
ideally suited to stamping and labelling of components.

Type T Only powerstroke Up to 550 strokes / min With pneumatic spring and integrated power bypass
 Constant press force
 Compressed air: up to 10 bar

Type RP With anti-rotation device
 With clamping chuck for tool holding fixture Setting of stamping depth With pneumatic spring Compressed air: up to 10 bar

14

www.tox.com

Special versions........................................................................................................................................................

Version for usage in the food sector (ZLM)
All TOX® Powerpackages can be filled with food grade
oil and grease (both USDA-H11 approved). These units
are suited to usage in the food, pharmaceutical andcosmetics industry, where contact with the lubricant
cannot be avoided.
Rust-protected versions (ZRO)
If desired, the TOX® Powerpackages are available asrust-protected version. All individual parts are then galvanized, painted or made of stainless steel. These units
are particularly suited to usage in the food and packaging industry.

TOX® Powerpackage for the battery production(Cu / Zn / Ni - optimized)
Drives to be used in battery production must meet special requirements. All components such as bearings or
guides which can show wear must be designed to prevent short circuits. They should also prevent conductive
or interfering particles from getting into the production
process. For these drives, some attachment parts andcomponents were designed almost completely without
copper, nickel and zinc, some entirely without. The proven pneumohydraulic TOX® Powerpackage is available in this special version in different designs (type S
and K; other types on request) and with comprehensive
accessories.

Powerstroke servo control ZKPr
Precisely adjustable
The powerstroke servo control ZKPr is a new control
with proven mechanics. Based on the precise control
in the powerstroke, it optionally provides accurate processes for the TOX® Powerpackages of series line-X or
the special types S, K and RZ with integrated pneumatic
spring. It can control press forces of up to 150 kN and issuited to all applications with a counterforce.
The powerstroke servo control is useful for applications
which have a counterforce such as: Riveting Mounting
 Caulking
 Joining Flaring Insertion of Bending
functional elements
 Pressing Pressing
 Marking
Functionality of the control
The fast stroke is controlled with a 5/2-way valve. The
powerstroke is controlled by means of an intensifier
piston and only occurs once the working piston is extended during fast stroke. For controlling the powerstroke, the intensifier piston is controlled with a 5/3-way
servo valve, independent of the working piston.

Advantages
 Powerstroke control by means of a servo valve
 Speed, displacement and progression adjustable in
the powerstroke
 Stop is optional in absolute or relative position
 Reduced air consumption
 Robust control behaviour by means of hydraulicreduction
 Software protects against overload
 Simple and reliable control
 Can be retrofitted

PLC

15

Stroke controls and damping systems........................................................................................................................................................

Stroke controls

Stroke damping systems

The stroke of the TOX® Powerpackages can be adapted to individual requirements. The following control
units can be used for this:With the stroke damping ZED, the speed of the working piston can be controlled across the entire stroke.
This is useful for pressing applications to overcome thestick-slip-effect. The damping ensures a gentle app-roach to the piece part, good pressing results, noise reduction, and avoids high mechanical stresses.

The pressure control of the powerstroke line ZDKenables individual adaptation of the press force bymeans of a manual pressure
valve. The pressure valve canalso be installed further away(e.g. in the switch cabinet).

The external powerstroke activation ZKHZ realizes
the connection of the powerstroke valve by means of anelectrically actuated 3/2-way
valve. This is recommended
for travel-dependent powerstroke connection or for application-related
interrupted
approach stroke. The ZKHZ isalso ideal when using the TOX® Powerpackage with thepiston rod pointing upwards and large tool weight.

The cutting impact damping ZSD dampens the working piston when the counterforce ceases, for example
during punching applications. As purely mechanicaldamping it can also be used as stroke damping withlimitations.

With the powerstroke deactivation ZKHD, thepowerstroke can be deactivated through an electricalsignal (e. g. during setup mode).
The external powerstroke release ZKHF securesthe activation of the powerstroke valve by means ofdynamic pressure control byrequesting the release via an
additional electrical signal.

The stroke frequency optimization ZHO is an optional additional assembly for improving the cycle time
(time gained approx. 20 percent) and replaces the existing powerstroke valve with avalve of the next size.

16

www.tox.com

The holding brake “Safety Lock” ZSL takes effect incase of pressure loss and prevents the working piston
from extending. It works with mechanical clamping jaws
and can only be released again through application ofpressure. The holding brake is certified by the professional association.

Accessories........................................................................................................................................................

C

D
B

C
Mounting positions for accessories:
A
B
C

E

D
E

Press force sensor ZPS
Stroke request for forward / return stroke ZHU
Analog position sensor ZHW and ZKWElectronic pressure switch ZDOOil level monitoring ZU

AWith a large number of useful accessories, you can also
expand your TOX® Powerpackage abilities and opti-mize it for your application.
The press force sensor ZPS is screwed onto theworking piston and measures press forces in pull andpush directions. It is protected against dust and dirt,
sturdy, compact and impresses with its high measuring
accuracy.

The electronic pressure switch ZDO
detects the oil pressure in the high-pressure section as system pressure and indicates this as a 4-digit LED display. Two
output signals are created according to
the switching function set.

All TOX® Powerpackages of the types line-Q and line-X
up to size 030 are equipped with a special barrel anda magnetic disk on the working piston. The stroke request for forward and return stroke ZHU deter-mines their position via a sensor. This allows
you to sense any position relaventto your application.

The coupling ZWK connects the TOX® Powerpackage(press) and tool flexibly so that the TOX® Powerpackage
is not affected by lateral forces. It is screwed directly onto
the TOX® Powerpackage piston rod
and is available in lengths from 60 to
320 mm.

The distance transducer indicates the absolute actual
position of the TOX® Powerpackage piston. The travel measuring system ZHW / ZKW can be installed
externally (ZKW) as well as internally (ZHW). It operates
contact free and is thus wear-free and resistant to contamination and interference fields.

The oil pump ZP enables filling up and lowering of
the oil volume of the TOX® Powerpackages without
the formation of bubbles. It ensures the optimum
maintenance procedure and long operating intervals.
The transparent container and filler hose facilitate the oillevel monitoring.

ZHW

ZKW

17

Possible applications........................................................................................................................................................

Presses
The functional design of the TOX® Presses based on
the modular principle enables simple and economic
adaptation to your individual specifications, from standard
presses to individual special machines as a systemsolution.

18

www.tox.com

........................................................................................................................................................

Tongs
The TOX® Robot Tongs and TOX® Machine Tongs areindividually configured using our standard C-frame,
drive, tool and control components and are suppliedcompletely ready for connection. The TOX® Powerpackages used here are equipped with retract damping
as standard. This enables extremely high frequencies
while protecting the attached elements from shock.

Special machines
TOX® Powerpackages are also used in many special
machines: for pressing in elements, punching, joiningof sheet metal with the TOX® Clinch Technology, rivet
technology and many more assembly processes. The
drives meet all process requirements here. They are
powerful, economical, easy to maintain, and simple toimplement.

19

........................................................................................................................................................

TOX® PRESSOTECHNIK GmbH & Co. KG
Riedstrasse 488250 Weingarten / Germany
Find your local contact at:
www.tox.com
313535 / 10.202309.en Subject to technical modifications.

20

www.tox.com