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Functional Element
Technology

1Functional Element Technology........................................................................................................................................................

This functional element punches
through sheet metal and the cold
forming process forms a tightconnection.

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More Function in Sheet Metal
In many industries components are equipped withelements such as nuts, bolts and screws for special
functions. Most of these so-called functional elements
can be integrated into workpieces by means ofpressing, punching, riveting or clinching processes.
The predominantly automated connections that canbe made by means of cold joining technologies are
significantly more cost-effective than conventional
connections like welding, as no rework caused bycontamination or component distortion is required.
The connections provide good retention, particularly
with regard to torque and press-out force, and theconsistent quality can be easily monitored throughsimple measurement procedures. The continuous
documentation of the connection parameters is valued
by users worldwide across a wide range of different
industries.
The use of functional elements has already been provenin a wide range of applications. For each element there
is a safe, fast and cost-effective procedure.

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Advantages of the Functional Element Technology........................................................................................................................................................

Versatile and full of options
Functional elements are available from various
manufacturers. They differ in function, method offastening and dimensions. Most elements can be pressed into common materials such as steel, stainlesssteel, high strength steel (boron), aluminum and fiber
composite materials of 0.6 – 10 mm thickness.

Parts of the functional element
Functional partfor the defined purpuse of the element
Joining partfor insertion into the workpiece

The insertion of functional elements by cold joining
process offers numerous technical advantages:

Advantages:
 Fast work processes
 High precision positioning Energy-saving technology
 Joining without heat: No heat development
at the workpiece or element
 Automatic and precise monitoring anddocumentation of the process Very good dynamic joining properties Flexible positioning on components due tohigh accessibility of the systems
 Wide range of applications

Clinching Studs
The Clinching Stud is particularly suitable for workpieces that have to be gas- or liquid-tight, because
the sheet metal is not pierced. For the processingof these elements we have held the patent for many
years and are the technology experts.
Versions:- Lens head 1- Coarse thread- Fine thread 3

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Application materials:- Steel sheet metal thickness 0.8 mm up to 1.2 mm-Aluminum sheet metal thickness 1.2 mm up to
2.0 mmRetention forces:- Maximum pulling force: up to 2,200 N- Maximum torque: up to 20 Nm

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17

mm

mm

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White goods and consumerPierce
electronics
bolts

Self piercing bolts in a back light housing

Medical equipment
Trunk lid

Spoiler / Spoiler Attachment
Hood

Back shelf

Door sill /Door seal carrier
Heating elements and door frames

Fender5

Process competence........................................................................................................................................................

The best technical solution for every application
We provide you with the best technological solutions and complete turnkey systems from one source. In addition to themost widely used processes, our employees also work on individualized solutions.

Process without pre-punching
Self-Clinching
The element meets an unpunchedcomponent and is pressed in with highpressure. The component deforms andcreates a solid clinch
connection.

Self-Piercing
The functional element punches throughthe unpunched component. A solid
connection that is resistant to twistingand pressing out is created by the flowof material into the element.

Process with pre-punching
Press Fitting
The functional element is pressed into a
pre-punched and formed component.
The material flows behind the element
and ensures a solid connection.

Riveting
The element is inserted into a prepunched component. It gets deformed
and a solid connection is created.

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Proven Process Quality
Continuous Quality Monitoring
A significant advantage of inserting functional elementswith our technology is the simple quality control in series
production. By continuously measuring the force-travelcurve, each connection can be checked. An additional
analysis can be carried out using cross sections (cutthrough the element) push out, pull through and torquetests can be confirmed through testing.
Preliminary tests in the TOX® Technical Center
Prior to collaboration, we will work on the most effective
solution for you in our lab. Here we will perform
preliminary joining tests on your samples, which wetest and analyze afterwards. We will also determine allparameters for your application, including the requiredpress force and suitable tools, and we will establish
which system can be used for your joining application.
Final Check of the Machine Parameters
Before we deliver a system, we check the real processing results. We will create a cross section andanalyze the joining process and the retention forces ofthe element. Everything will be documented in a detailed test report. The initial set-up of the delivered system
is based on these determined values and parameters.

Advantages
 Demonstrated joining quality in pre-tests
and during series production
 Measurement and documentation of pushout, pull through and torque-out Documentation of the joining quality
 Production of pre-production parts

7 mm
With a cross section (cut through the element), theexact formation can be examined under a microscopefor analysis. If necessary, optimizations can be made.

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System competence........................................................................................................................................................

The technology for element insertion
TOX® PRESSOTECHNIK, with its decades of experience, provides you with competent know-how
of systems. Regardless of the manufacturer of yourfunctional elements, we are able to customize yourapplication using a wide range of components andmodules. Your customer-specific requirements are
met down to the last detail utilizing standard systemcomponents thanks to our modular design.

Stationary TOX® Tong
Setting equipment and tools 1
We determine the correct setting tools for every
functional element. The centerpiece is the setting head
and the die.

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Frame 2The high forces occurring during inserting are absorbed
by a low deflection frame.
TOX® Drives 3
The forces required are generated by electromechanicalservo drives or pneumohydraulic Powerpackages.

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1

Stationary TOX® Tong
with setting tooling forfunctional elements

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TOX® Element
feeding

TOX® Control andprocess monitoring4.........................
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Customer
Network

TOX® Element feeding
TOX FeedingUnit 4
Preparation of the element occurs in our compact enclosure. The hopper, vibratory bowl, escapement andblow feed prepare the element for delivery to the setting
head.

TOX® Control andprocess monitoring5®

 Ranging from external impulse to complete PLC
controls built to the highest safety standards
 Multi-technology controls available for additional
processes
 Monitoring of process and machine parameters

9System competence........................................................................................................................................................

Automatic Element Delivery for Tong Systems
Stationary BlowFeed System
The element will be directly
delivered to the setting
head through a chute. The
robot positions the part
inside the press for theelement to be set.

Robot-carried BlowFeed System
The element will be directly
delivered to the setting
head through a chute. The
robot will position the tong
to the part for the element
to be set.

DockFeed System (Magazine)
The element will be delivered by chute to the docking
station. The robot carries
the tong to the dock to fill
the magazine. It then positions the tong to the part toset the elements until themagazine is empty.

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Advantages
 Simple Safe and reliable Cost effective

Advantages
 For large workpieces
 Safe and reliable FastAdvantages
 For multi-technology
applications
 Flexible
 Chute-free robot dresspack........................................................................................................................................................

Versions
Different basic designs are possible for systems
that process functional elements. Crucial factors forchoosing one system over another include the potential
integration into production lines, optimum feed-in, thedesired working speed and the size of the components.
Stationary tongs
For integration in production lines and equipment,
stationary machine tongs are suitable. The workpiece
will be presented by a robot and the element will beinserted by the press.
Robot tongs
A mobile tong is moved and controlled by a robot. The
elements are either supplied by a docking station or
through a feed chute.

Hand tong
For low volume production a hand-held tong can beutilized. The element can be delivered form the chute, amagazine or be hand loaded.
Presses / Machines
Machines can be designed as fully automatic, semiautomatic or purely manual workstations. The workpiece is manually loaded into the machine. The machine
will then insert element(s) per a customized plan.
TOX® PRESSOTECHNIK is certified to build safety
rated work stations.

Versions

Robot tong

Machine11Components........................................................................................................................................................

TOX® Setting heads
The requirements of the setting technique, particularlyof the setting head, are crucial for the different types offunctional elements. Based on our years of experienceand laboratory tests for each application TOX®
PRESSOTECHNIK can select and develop the suitablesetting head.
The design of the setting head will be determind by themethod of part positioning, press force required anddrive type. The setting direction (up, down, free, etc.).

Advantages
 Die and setting head as an integrated solution
 Process-reliable separation of elements
 Slim tool design for tight spaces
 Maintenance-friendly design
 High guide accuracy
 Components with low wear

Versions
TOX® Setting Headfor nuts

TOX® Setting Headfor elongated bolts

TOX® Setting Headfor clinch rivet elements

Designed for special nuts that arepunched into thick sheet metal.
An additional stroke removes theslug.

Processes individually blown inelements with internal travel tosecure the element and drive withthe required press force.

For elements that are blown
individually, indexed and clinched
into the component in a downward movement.

TOX® Dies

Feeding hoses

The die is the crucial counterpart of the setting headand ensures the correct formation of the joint.

The elements will be delivered to the setting headthrough special chuting. Depending on the element
shape, they are round, rectangular or profiled.

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TOX® FeedingUnit
The TOX® FeedingUnit includes the sorting and delivery
equipment for safe and reliable element delivery. Thissystem is outside of the robot cell for easy refill. It
includes:Hopper: This is the fill location that holds large
quantities of elements. The feeder bowl receives its
elements form here.
Feeder Bowl: This feature orients and delivers theelement to the escapement for delivery.

Escapement:
The oriented elements are singulated here for delivery
to the setting head. From here the element is typicallyblown through a chute to the setting head.
The TOX® FeedingUnit can fit many processes thanks
to our modular system. We also validate our designs
for each systems offered to ensure that manual
manipulation is not required.

HopperFeeder Bowl

Escapement

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Flexible control-software for the integrated production
Flexible Multi-Technology-Control
One system - many possibilities! Our multi-technology-control operates and monitors all functions. It is driveindependent and can be used for any technology. Whena robot changes its tong, the system recognizes theparameters and can continue working immediately. This
yields the highest degree of flexibility.

TOX® Multi-Technology-Control
TOX® Clinching

Riveting

Additionally, the intuitive TOX® HMI software allows easy
installation and operation of the system. It is clearlystructured and internationally understandable.

Insertionof functional
elements

Integrated Production
Using numerous interfaces, it is easy to connect the
TOX® Equipment to a company network. The systemcomponents communicate with each other via fieldbus.
Processes can be continuously monitored andimproved with the data collected here. Feedback from the production process can be used to
optimize the technology parameters. Unnecessary
maintenance work and downtime can be avoided
thanks to predictive maintenance.

Advantages
 One control for different application technologies
 Import of process parameters from customer
network
 Auto-configuration of system components
 Condition Monitoring: Storage of operating hours,
maintenance counter, tool information etc.
 Preventive Maintenance avoids downtime
 Dynamic process monitoring Numerous interfaces for connecting periphery units(e. g. measurement sensors, feeding systems etc.)
 Network communication via OPC UA / MQTT

Process Monitoring Devices
The quality parameters of
the element insertion can be
examined and documented
by a sperate device.

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TOX® HMI
Control andProcess unit

Customer
NetworkSensors
Optional sensor systems canbe used to check and display
fill levels, process progress andalso quality characteristics ofthe elements.

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Frames and Columns
The forces that occur during insertion of functional
elements are absorbed by a C-frame or the columnsof a column press. The design takes into accountinterfering contours, total weight, piece part accessibility,
working conditions and occupational safety.

Tong frame

Press frame

FramesRobust frames are used for tongs and presses. We
respond to the specific requirements with standard
frames or individual designs.
Column presses
Column presses are particularly useful for multi-point
tools. They can be manufactured in various sizes, but
all have the same precision and ease of access.

Column press

TOX® Drives
The insertion of elements requires high forces on
the setting head. This forces are generated byelectromechanical servo drives or pneumohydraulicPowerpackages.
TOX® ElectricDrive
The modular electromechanical servo drive systems generate press forces up to 1000 kN.
TOX® Powerpackage
The strong pneumohydraulic drive, which is alreadyused worldwide in thousands of machines. Available
with press forces of 2 – 2000 kN. A special Powerpackage version X-KSD is used for pierce elements todamp the break trough.

Additional Components
Information about additional components like controls,part fixtures, safety devices and accessories can befound on our website www.tox.com.

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Individual Solutions for our Customers........................................................................................................................................................
TOX® PRESSOTECHNIK designs process flows more
economically – with special systems, intelligent assembly
systems and fully automatic feeds with integrated
additional functions. We possess long-standing
experience and comprehensive know-how in thedevelopment and design of these systems.
We look to create highly efficient systems to match ourcustomer’s designated work flow. We are committed
to finding the best solution for optimizing the
manufacturing processes according to our customer’s
requirements.
For this reason, our machines are the product of close
cooperation between our customers and our project
managers. Our service team will also be on handquickly and reliably at all times following delivery.

Identify demand
An extensive consultation forms the basis of eachconcept for us – for special machines as well as
production systems. We use our experience andhigh level of expertise to identify the basic needs,
determine the required components, and sketchout an initial layout. In our lab we can produce
samples with original materials, components andelements in parallel.

Development process
The specific system concept is forwarded to ourdesign department, which creates the machinelayout and generates detailed drawings for
production. We produce or procure the mechanicalcomponents according to the design and assemble
the system. There after the electrical components
are installed and the controller is configured.

Commissioning
Once complete, a trial run of the system isperformed. Once everything meets customer
expectations, the customer approves the system.
Following delivery, set-up and installation of thesystem, commissioning is performed by our
qualified personnel.

After-sales service
We train the operating personnel extensively –either at our premises or on site using the delivered
system. Often, we also support initial production
and provide advice and assistance. When everything is running smoothly, we are happy to perform
regular maintenance tasks on request.

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Application examples........................................................................................................................................................

Stationary Tongsfor pressing in selfpiercing nuts.

4-Column-Press
with multi-point toolfor car body parts.

Machine with 4 C-frames
as a manual workstation forpressing in nuts.

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Stationary Tongfor pressing in pierce
nuts in an axle support.

Stationary Tongthat presses in selfpiercing studs.

C-Frame Press
as a manual workplace.
It presses in rivet bolts in apart of a car hood.

4-Column-Manual Press,
which presses in grounding
studs into the unpunchedwheel arch of a car.

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TOX® PRESSOTECHNIK GmbH & Co. KG
Riedstrasse 488250 Weingarten / Germany
Find your local contact partner at:
www.tox.com
840194 / 85.202309.en Subject to technical modifications.

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