Controlled Joining Process Why Modern Joining Requires Servo Presses

Related Vendors

Delta Electronics Netherlands BV

FAULHABER Drive Systems

Wuxi InfiMotion Technology Co., Ltd.

Where classic pneumatic or hydraulic presses reach their limits—for example, due to traceability—electric servo presses take over the tasks. They score with easy monitoring and documentation as well as quick switching between different control modes.

The shift to electromobility, the miniaturization of electronic components, and increasing demands for traceability in production processes pose new challenges for many manufacturers. This is especially true when joining sensitive components: whether it's pressing connectors, crimping cables, or positioning cell connectors in battery modules. In these cases, traditional pneumatic or hydraulic presses reach their limits. But how can these processes be made more efficient, flexible, and secure in the future without compromising on quality or documentation?

To complete the picture, a glance at the services of an electronics supplier is enough. For example, if they are planning the setup of a line for assembling power electronics modules, the customer requirements – especially within the automotive industry – are clear: Every joining process must be precisely documented, every pressing operation traceable, and every component change possible without significant setup effort. However, this is hardly achievable with conventional press technology – the demands in this area are simply too high. The solution lies in electric servo presses, which are increasingly becoming a strategic tool in industrial production.

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New Requirements for Joining Technology

Electric servo presses operate quietly, energy-efficiently, and with high repeatability. Thanks to integrated sensors and intelligent drive control, force and displacement can be precisely controlled, monitored, and documented. Unlike pneumatic systems, there is no energy loss from compressed air, and compared to hydraulic systems, they require significantly less maintenance and are cleaner. Modern servo presses can switch between different control modes, such as force, displacement, or combined controls, allowing them to adapt flexibly to various components and processes. This not only enables greater process stability but also faster transitions to new product variants.

The areas of application are diverse. In addition to the automotive industry, servo presses are also used in medical technology or battery production. In medical technology, for example, small plastic parts must be joined with controlled force without causing material deformation. A typical application field is also cell contacting in battery manufacturing, where joints are made with precisely defined force without damaging the sensitive cell material. Electric servo presses enable this process with high reproducibility while simultaneously documenting each pressing operation for quality assurance. Their precision in electric joining technology also shines in the production of connectors or during crimping processes in cable assembly.

Modular System Approach for Electric Joining Technology

The advantages of electric servo presses unfold particularly when they are embedded in a superior control system. Modern press systems rely on open interfaces, modular expandability, and real-time capability. Only in combination with intelligent drive and control technology can the full potential of the technology be realized.

As a solution provider for such requirements, Delta Electronics offers a comprehensive system of hardware and software. The electric servo press AM-ESP S serves as the centerpiece. Compared to conventional pneumatic or hydraulic presses, it offers precise force-displacement control through a backlash-free ball screw drive and an integrated servo motor. Depending on the model, pressing forces ranging from 1,100 to 11,000 Pounds can be achieved. Multiple control modes allow regulation based on position, force, or a combination of both parameters depending on the application. The integrated sensors capture force and displacement data in real-time, while the DIA Servopress software platform handles the visualization, storage, and analysis of the data. Operation is intuitive via a PC interface or can be managed through a central machine control system.

Alternatively, the servo press can also be operated as an autonomous module – for instance, in semi-automated production cells where a central control system is not required. This makes it equally suitable for use in traditionally networked lines as well as for pragmatic automation solutions on a smaller scale.

Networked Control and Automated Joining

Electric servo presses like the AM-ESP S are often operated as standalone units in practice. They feature integrated sensors, their own drive, and an associated software interface, enabling operation and the recording of process data without additional control components. For many applications, complex integration into manufacturing lines is therefore not necessary.

Against the backdrop of the increasing shortage of skilled workers, the question arises as to how such autonomous systems can be integrated into semi-automated work environments in the future. One possible scenario is the combination with a collaborative robot, such as from Delta's D-Bot series. In this setup, the robot takes over the insertion or positioning of components, while the servo press performs the actual joining process with the predefined parameters. Both systems operate independently, with communication possible through simple digital signals.

Such a setup could also be integrated into existing production cells – without major technical modifications and without a central line control. This would make a semi-automated solution conceivable that, on the one hand, builds on already existing components and, on the other hand, enables stable process control with minimal personnel involvement. For certain applications with medium throughput and high repeatability, this could be a pragmatic response to current production requirements.

Future-Proof Platform

With their combination of mechanical precision, flexible control, and integrated data acquisition, electric servo presses today represent far more than just a replacement for conventional systems. They open up new possibilities for production that must adapt to increasing demands for quality, traceability, and energy efficiency.

Whether as a standalone solution or embedded in complex lines, the technology can be scaled, modularly expanded, and seamlessly integrated into existing production environments with modern interfaces. For machine builders, the standardized platform concept offers short planning and commissioning times as well as the option for integration into networked manufacturing architectures.

Those who want to remain competitive in the future need more than just force in the process: control, transparency, and integration capabilities are becoming central factors of industrial competitiveness. Servo presses make an important contribution to this – serving as a bridge between traditional production and the digital factory.

*Holger Friedrich is Sr. Group Key Account Manager at Delta Electronics EMEA