Pneumatic Press with Force Monitoring
Streamline Your Assembly Process with A-Tech’s Pneumatic Press Systems
At A-Tech, we specialize in providing turnkey pneumatic assembly press solutions that deliver precision, reliability, and 100% quality control. Our robust Mader Pneumatic Presses, paired with the Burster Digiforce monitoring system, offer an easy-to-use, fully pneumatic system—no PLC required—ensuring every cycle is repeatable, accurate, and secure.
Our presses are designed to meet the demands of industries like automotive, aerospace, electronics, and medical, offering consistent performance that scales with your needs. With A-Tech, you're choosing a solution that’s not only customizable but also integrated with the highest quality components from trusted German manufacturers.
Why Choose A-Tech's Pneumatic Presses?
Integrated Monitoring for Absolute Precision
Our presses feature the Burster Digiforce monitoring system for real-time feedback on force and distance, ensuring 100% control over the assembly process. No guesswork—just precision in every operation.
Fully Assembled for Quick Implementation
Each unit comes with integrated sensors, FRL (Filter-Regulator-Lubricator), and two-hand pneumatic safety controls, meaning all you need to do is add tooling. Start working faster without the hassle of additional setup.
Exclusive North American Distributor
As the exclusive distributor for Mader and Burster in North America, A-Tech offers factory-direct pricing, giving you an edge on costs while providing superior performance.
Customizable for Your Unique Needs
We understand that no two assembly lines are the same. That’s why we offer full customization, including:
- Dual Force Ranges for handling high and low force assemblies.
- Speed Control with flow controllers to optimize cycle times.
- Safety Features like light curtains and side shrouds for enhanced operator protection.
- Integrated Automation options, including PLC for automatic program selection and tooling recognition.
- Barcode Scanning for part tracking and serialization.
Technical Specifications
Feature Specification
Max Force Up to 60 kN
Max Stroke Up to 120 mm
Operating Pressure 6 bar
Monitoring System Burster Digiforce Monitoring
Safety Two-hand pneumatic controls
Options Light Curtains, Dual Force Output, Barcode Scanners, PLC for added Automation, Smart Cameras for Visual Inspection
Industries We Serve
Our pneumatic press solutions are trusted by leading manufacturers in automotive, aerospace, electronics, and medical industries, where precision and reliability are critical. Whether you're assembling intricate components or larger assemblies, our press systems are designed to handle it all with accuracy and repeatability.
Tailored Solutions to Meet Your Requirements
A-Tech offers fully customizable press solutions. Whether you need dual force ranges, integrated safety systems, or automation options, we can design a system that fits seamlessly into your assembly line.
Customization Examples:
- Dual force ranges for diverse assembly needs
- Speed control for optimized performance
- Light curtain and side shroud for operator safety
- Optional PLC for program and tooling recognition
- Barcode scanner integration for part tracking
Direct Acting Pneumatic Presses
Direct-acting (DA) pneumatic presses are designed to provide consistent force throughout the entire stroke length, making them a reliable solution for precision assembly tasks.
At A-Tech, we offer DA pneumatic presses with a modular design, allowing customization based on the specific requirements of your assembly line. Standard stroke lengths range from 40 mm to 120 mm, with the option to request custom lengths for more specialized applications. This modularity ensures that you have the right press for any job, whether you're working with sheet metal, printed circuit boards, or larger components requiring more vertical space.
In addition to their versatility, DA pneumatic presses feature precision stroke adjustment, allowing operators to make fine adjustments with an accuracy of up to 0.01 mm. The robust construction, featuring anti-twist rams and double-acting cylinders, ensures reliable performance over time with minimal maintenance required.
Advanced Monitoring Features
DIGIFORCE - Universal Press Monitoring Solutions:
Our Pneumatic Assembly Press features a Burster DIGIFORCE monitoring system, designed to capture and analyze operational signatures with precision. By defining pass/fail criteria and delivering real-time feedback through the system, this technology ensures that no aspect of your operation’s quality control is left to chance, even in highly automated manufacturing environments.
Advanced Evaluation Techniques with DIGIFORCE
Once the system gathers data, the DIGIFORCE unit immediately enters the evaluation phase, analyzing each measurement curve to ensure every press operation meets your strict quality standards. The system automatically categorizes parts as GOOD (Pass) or BAD (Fail), delivering results directly on the integrated display. This real-time feedback allows for quick adjustments to maintain efficiency and consistent high-quality output.
Because no two press operations are exactly alike, the DIGIFORCE® system provides flexibility by adapting to minor variations, ensuring each part meets the required specifications. This minimizes unnecessary rejections and maximizes overall productivity.
Evaluation Tools in DIGIFORCE
Traditional Windows
Traditional windows are used to ensure that the measurement curve passes through specific predefined entry and exit points in a rectangular orientation. Operators can configure these windows to allow one or multiple entries and exits. Additionally, these windows can operate in "Online" mode, meaning that any deviation from the predefined path will trigger an instant update to the PLC, ensuring real-time quality adjustments.
Trapezoidal Windows
Trapezoidal windows are available in two types: "Trapezoid X" and "Trapezoid Y." These windows evaluate sloped portions of the measurement curve by limiting either X or Y values, making them ideal for processes where force changes progressively, such as bending or forming operations. Trapezoidal windows provide flexible, dynamic control for more complex tasks.
Dynamic Thresholds
Thresholds act as checkpoints during evaluation, establishing minimum and maximum bounds that the measurement curve must pass through. This ensures that the force applied during each press cycle meets the precise requirements, preventing both under-pressing and over-pressing. These thresholds are essential for maintaining both part durability and operational quality.
Tolerance Envelopes
Envelopes allow operators to generate a tolerance band around the measurement curve based on sampled data. These envelopes help define acceptable deviation ranges for both tight and loose fits, providing a flexible tool for high-precision applications. The envelope can be adjusted along the X and Y axes as needed, ensuring consistent product quality within the specified tolerances.
Automated Data Collection and Reporting
Automated Data Collection
The DIGIFORCE system offers advanced data collection capabilities. Its software not only configures sensor calibration and triggering but also captures detailed measurement curves, providing a full display of operational data. This data is stored with part tracking and timestamps, allowing operators to easily manage and retrieve information. The system also supports program backups, ensuring all evaluation results and statistics are accessible for review and continuous improvement.
Simple Report Generation
With its intuitive data review wizard, the DIGIFORCE software simplifies historical data searches by filtering results based on station, part number, serial number, date, time, and OK/NOK status. This capability allows for efficient report generation, with outputs available in both Excel and PDF formats. Whether for routine quality control or in-depth process optimization, generating detailed reports is quick and hassle-free.
Frequently Asked Questions
Do I need a PLC for this system?
No, our pneumatic press systems feature a fully pneumatic two-hand start bar that eliminates the need for a PLC.
What force range do your presses cover?
Our presses handle forces up to 60 kN, with strokes up to 120 mm.
Can the system be customized to my specific needs?
Yes, we offer full customization including custom frames, force ranges, speed controls, safety features, and automation options.