Process Monitoring

Systems
maXYmos XY Monitors for 100% Quality
in Production, Assembly and Product Testing

www.kistler.com
www.kistler.com

Content

Kistler Your Partner for Process

Efficiency and Cost Effectiveness
The Kistler Group is one of the
world's leading manufacturers of
sensors and systems to measure
pressure, force, torque and acceleration. Thanks to systems from Kistler,
measurement signals can be captured
and analyzed so companies benefit from increased process efficiency
and enhanced business success
over the long term.

www.kistler.com

www.kistler.com

Focus on Product Quality and Process Reliability

Plant Integration

Evaluation Objects

Product Overview: Monitoring Systems

maXYmos BL
maXYmos TL
maXYmos NC

9
10
11
12

Sequence Control (Sequencer Mode)

13

Measuring Chains

14

Solution Packages for Manually Operated and

Pneumatic Presses

16

Service: Customized Solutions from A to Z

18

Kistler At Our Customers' Service Across the Globe

19

The maXYmos process monitoring system offers maximum control of production, assembly and product testing.

Focusing on Product Quality

and Process Reliability
Quality is increasingly ranked as the critical cost factor in the industrial production sector, where processes have to run without
errors. Kistler's process monitoring systems use the profile to
monitor and evaluate the quality of a product or manufacturing
step. As well as meeting the highest standards for quality, safety
and reliability, these systems provide the essential basis for
business success.
The global market environment for industrial production is extremely challenging and this applies to every sector, from automobile manufacture and medical technology to electrical engineering. Requirements for product quality and process reliability
are already high, but they will become even more demanding as
time goes on. Now, the maXYmos family gives users a simple system that can quickly and accurately accomplish a variety of product testing tasks. maXYmos can be used in production plants, and
it is the ideal solution for end-to-end process monitoring, quality
assurance and documentation in joining, assembly, forming and
testing processes.

Benefits at a Glance:
In-process monitoring of joining and
assembly processes
Early detection of quality deviations
in the production process
Minimized outlay on quality
assurance
Faster feedback thanks to
transparency in the production
process
Traceable process results
No additional testing routines

www.kistler.com

Process Monitoring Systems for Every Application

maXYmos BL (Basic Level) is suitable for standard assembly and
product testing applications. maXYmos TL (Top Level) offers a
variety of interfaces, making it the ideal platform for capturing
and evaluating a diverse range of measurands. maXYmos NC
controls, monitors, evaluates and documents the XY profiles for
joining and press-fit processes in conjunction with NC Joining
Modules and the IndraDrive servo amplifier that is included in the
system.
Higher Quality Lower Costs
Convincing benefits across the board: with Kistler's XY monitors
and process monitoring systems, optimal cycle times and maximum repeat accuracy can also be achieved for multi-stage processes. Downtime is minimized and machine availability is increased resulting in a boost in productivity for the entire
manufacturing process. In short: Kistler provides the basis for
maximum control of the entire production chain paving the
way for increased quality and reduced costs in production.

www.kistler.com

Increased Process Efficiency

with Kistler Now Online!
View our animation to experience convincing, first-class Kistler solutions
the sure way to optimize process efficiency:
www.kistler.com/maXYmos

9211B

NO-PASS

START

RESET

READY

2869B + Monitor

OK

2869B

NOK

maXYmos uses defined evaluation objects (EOs) to analyze quality-relevant sections of the measured curves that are captured by
the measuring functions. To do this, the maXYmos monitoring
system verifies whether the curves pass through the evaluation
objects in the predefined manner. If so, maXYmos generates an
"OK" result; otherwise, the result is "Not OK" (NOK).

Benefits at a Glance:
Simple integration into existing
plants and processes
Uniform intuitive operating concept
High-performance evaluation
objects
Extensive diagnostic possibilities,
so causes of NOK are tracked down
quickly
Standard interfaces
Identical signal and data formats

Interfaces
For the Y channel, a connection for strain gage sensors and sensors with a 10 V output is provided, as well as the input for piezo sensors. For the X channel, inputs are installed for analog
sensors (potentiometric, 10 V, LVDT, inductive) and digital sensors (incremental, SSI). This means that the connected sensors
can be defined flexibly depending on the requirements set by the
measuring assignment.

1200A49

1457A1

1995A

Display Module (DIM)

Measuring and Evaluation

Modules (MEM)

Integration of maXYmos devices into a fieldbus environment enables communication with the machine control. This makes it possible to optimize coordination of the measurement to the production cycle. Also, individually definable measurements can be
transmitted via the fieldbus it is even possible to parameterize
the maXYmos monitoring system via the fieldbus.

Server

PLC

SERCOS III

Profiles of this sort can be generated for many applications: examples include press-fitting of ball bearings, rotation and swiveling of seat backrests, riveting and caulking of housing components, or tactile processes on rotary switches and also for
testing springs and measuring haptic behavior, e.g. in switch
tests.

Laptop

Integration into the plant infrastructure is simple because numerous interfaces are available. The maXYmos family supports a variety of data protocols, not only to control
the measuring cycle but also to transmit the measurement data obtained and for maintenance purposes.

Transparent Production Processes

Guarantee Quality
The maXYmos process monitoring system can use a profile to
monitor and assess the quality of a product or a production
step. To achieve this, the system interrelates all the measurands: those captured via the Y channel with force, torque or
pressure sensors, for instance, and those acquired via the X
channel with displacement or rotation angle sensors.

1708

USB

Dig IO (24V) or fieldbus

Kistler's XY monitors track and evaluate XY profiles where two measurands must be in a specified relation to one another.

2205

Ethernet

9247A

Cycle
control

ZERO-X

Channel-X

Channel-Y

6157B

Cascadability: up to eight pairs of XY channels. The MEMs can be accommodated

in the control cabinet. The DIM provides central visualization and can be connected
directly via a cable (cable extender > distance of 5m).

www.kistler.com

www.kistler.com

Extract: Evaluation Objects (EOs) for maXYmos

Product Overview: maXYmos BL/TL/NC

Type

5867B...

5877A...

5847A...

Name

maXYmos BL

maXYmos TL

maXYmos NC

Application

Process monitoring

Process monitoring

Joining with electromechanical

systems

Number of measurement channels per basic unit

1XY

1XY

1XY

XY Monitors

NOK

OK

NOK

OK

NOK
OK

The evaluation criterion is the speed

between the entry and exit points in
a special box.

Type SPEED

Evaluates the X-hysteresis between

forward and reverse curves
on a horizontal line.

NOK

Type ENVELOPE CURVE

OK

NOK
Expandable up to (maximum measurement channels)

Type AVERAGE
OK

NOK

NOK

Type GET-REF

The area under the curve is

determined and evaluated.

Evaluates the average of all

Y values in the box range.

Type TUNNEL BOX-X

Box detects significant curve features and their XY coordinates in

the expectancy range. These can be
used as reference points for other
EOs or as input for the CALC object.

A defined gradient change is expected within the expectancy range

(box) and can be used as a further
switching condition in the sequence.

The measured curve must not

violate the upper and lower line of
the envelope curve band.
Evaluation object can be "learned"
quickly with trend tracking.

Type NO-PASS

OK

X1

X2

NOK

Type BEND
OK

NOK

Type INTEGRAL
OK

NOK

Type HYSTERESIS-X
OK

NOK

OK

y = f(x), y = f(t),
y = f(x, t), x = f(t)

Storage depth per measured curve

8000* XY

8000* XY

8000* XY

Sampler rate (XY value pairs/second)

5000

20000

10000

Number of parameter sets per XY channel

16

128

128

Diagnosis storage for measured curves

360 curves

500 curves

500 curves

Potentiometer
Power 10 V
Monitor output

Object references two selectable

process values and performs calculations and evaluations with them,
e.g. to calculate the X-difference
between two ripples.

Type CALC
OK
OK

Type BREAK

Evaluates gradient dX/dY

between two horizontal
lines.

Type GRADIENT-X

If the curve path is within the defined range, the maximum force
offset between forward and reverse
curves is determined and verified.

OK

Incremental right angle (A, B, Z)

SSI

Inductive half bridge

NOK

Supplies "NOK" and online signal

in case of sudden gradient change
within an expectancy range
(box), e.g. tool breakage and
stops the sequence.

Incremental Sin-Cos (A, B, Z)

LVTD

NOK

NOK

Piezo
Strain gage
Power 10 V
Monitor output
UNI-BOX (window)
ENVELOPE (envelope curves)
LINE (X+Y)

OK

NO-PASS (line with online signal)

BREAK

NOK

Type DELTA-Y
OK

NOK

Y Y

Y Y

X X

Type DIG-IN
OK

y = f(x), y = f(t),
y = f(x, t), x = f(t)

NOK

X X

If the curve path is within the

defined range, testing determines
whether a digital signal is present
(switch test).

8XY

y = f(x), y = f(t),
y = f(x, t), x = f(t)

Type TIME

Y2

Y1

OK

The evaluation criterion is the time

between the entry and exit points in
a special box.

8XY

Measurement curve detection functions

Sensor
Channel X

Entry and exit as specified. Violation

of the closed sides supplies a realtime signal and stops the sequence.

OK

Type LINE-X

Sensor
Channel Y

The line must not be crossed.

Otherwise: "NOK" and "NOPASS" real-time signal appears.

The line must be crossed once.

An X-value at the point of intersection is monitored.

Type UNI-BOX

Motion elements for

evaluating curve progression

Entry and exit as specified. No violation of "closed" sides permitted.

Each side can be defined as an entry
or exit.

HYSTERESIS (X+Y)
SPEED
AVERAGE (average value BOX)
GRADIENT (X+Y)
TIME
GET-REF (finds reference point)
CALC (calculates and evaluates)
INTEGRAL
TUNNEL BOX (X+Y)

NOK

BEND
DIG IN
Standard
According to choice

www.kistler.com

www.kistler.com

Monitoring Devices
maXYmos BL

maXYmos TL
Technical Data

Type

Technical Data

Type

1X/Y

Number of measuring channels

Bit

24

Resolution per channel

Bit

24

Sampler rate X/Y max.

kHz

Sampler rate X/Y max.

kHz

20

Accuracy class

0,3

Accuracy class

0,3

Sensors that can be connected

Channel-X
Channel-Y

Potentiometer, transmitter 10 V
Piezo, strain gage, transmitter 10 V

Sensors that can be connected

Channel-X

Via menu choice: potentiometer, transmitter 10 V,

incremental, SSI, LVDT, inductive
Via menu choice: piezo, strain gage, transmitter 10 V

Measuring functions

DIM

Y(X), Y(t), Y(X,t), X(t)

Curve evaluation using

Evaluation Objects (EOs)

Type

Evaluation results via

DIG outputs
Fieldbus
Optical

OK, NOK
OK, NOK, process values
Curve, process values, traffic light

Data transfer via

Interface

Ethernet TCP/IP, USB, fieldbus: Profibus DP, ProfiNet,

EtherCAT, EtherNet IP, CC-LINK

Visualization
Data export via

CSV

Housing

Front panel or desktop/wall mounting

Data sheet: see www.kistler.com

5867B (000-863)

Channel-Y
Measuring functions

UNI-BOX, ENVELOPE, LINE (X+Y), NO-PASS

Via VNC or integrated display

Ethernet
(TCP/IP)

1X/Y ... 8X/Y

Y(X), Y(t), Y(X,t), X(t)

Curve evaluation using

Evaluation Objects (EOs)

Type

UNI-BOX, ENVELOPE, LINE (X+Y), NO-PASS, BREAK

HYSTERESIS, SPEED, AVERAGE, GRADIENT, TIME,
GET-REF, CALC, INTEGRAL, TUNNEL BOX (X+Y), BEND,
DIG IN

Evaluation results via

DIG outputs
Fieldbus
Optical

OK, NOK
OK, NOK, process values
Curve, process values, trend display, traffic light

Data transfer via

Interface

Ethernet TCP/IP, USB, fieldbus: Profibus DP, EtherNet/IP,

ProfiNet, EtherCat, CC-LINK

MEM

Visualization

Type 5877A...

Data export via

via VNC or DIM

USB
Ethernet
(TCP/IP)

Front panel or desktop/wall mounting (Combination of

MEM/DIM) accommodated in MEM switch cabinet
5877A (000-973)

Connector Set for Strain Gage

Version
(1 set included in scope of delivery)

Type

5867AZ010

Data sheet: see www.kistler.com

Connector Set for Piezo Version

(1 set included in scope of delivery)

Type

5867AZ011

Accessories

Windows Software Basic Version

Type

2830A1

Power supply, 240VAC/24VDC

Type

5779A3

maXYmos BL Sequencer Mode

License

Type

2832A1

www.kistler.com

www.kistler.com

CSV, XML, PDF, Q-Das, Q-DA9, IPM

Housing
Accessories

10

5877A...

Resolution per channel

Number of measuring channels

Type 5867B...

5867B...

Display Module (DIM)

Completes an existing Measuring
and Evaluation Module (MEM) by
adding a touchscreen

Type

5877AZ000

Measuring Module (MEM)

Extends an existing maXYmos TL
system with an additional XY
channel pair

Type

5877AK00

Basic Connector Set

(1 set included in scope of delivery)

Type

5877AZ010

Standard Rail Clip

to mount the measuring module
(MEM) on a DIN rail

Type

5877AZ...

Windows Software Basic Version

Type

2830A1

Power supply, 240 VAC/24 VDC

Type

5779A3

DIM Cable Extender

Type

1200A163

11

maXYmos NC to Monitor and Control NC Joining Modules

Technical Data

DIM

Type

Number of measuring channels

1X/Y

Resolution per channel

Bit

24

Sampler rate X/Y max.

kHz

10

Accuracy class

0,3

Sensors that can be

connected

Channel-X

Servo, SSI, incremental, potentiometer, process signal, 10 V,

inductive
Piezo, strain gage, transmitter 10 V

Channel-Y
Measuring functions

Y(X), Y(t), Y(X,t), X(t)

Curve evaluation using

Evaluation Objects (EOs)

Type

UNI-BOX, ENVELOPE, LINE (X+Y), NO-PASS, BREAK,

HYSTERESIS, SPEED, AVERAGE, GRADIENT, TIME,
GET-REF, CALC, INTEGRAL, TUNNEL BOX (X+Y), BEND, DIG IN

Evaluation results via

DIG outputs
Fieldbus
Optical

OK, NOK
OK, NOK, process values
Curve, process values, trend display, traffic light

Visualisation

MEM
Type 5847A...

5847A...

via VNC or DIM

Data export via

USB
Ethernet
(TCP/IP)

CSV, XML, PDF

Data transfer via

Interface

PROFIBUS DP, PROFINET, EtherCat, EtherNet/IP,

2-port Ethernet switch

Special features

Integrated sequence control to maximize flexibility; real-time

process control with SERCOS III so cycle times are shorter;
high-performance control and evaluation functions (EOs with
partially live evaluation); uniform operating philosophy.
Everything is on board (e.g. PROFIBUS, PROFINET, EtherCAT,
EtherNet/IP); minimal spare parts inventory (one type only)

Data sheet: see www.kistler.com

5847A (003-126)

DIM Cable Extender, actively extends cables between maXYmos MEM and display DIM, range: up to 100 m
Technical Data

Type

1200A163

Power supply

VDC

18 ... 30

24

mm

19716326,5

Power consumption:
DIM Cable Extender only
Total (plugged into
maXYmos DIM)
Dimensions
with mounting plate

Simple Control
of Complex Processes
Sequencer mode makes it possible to program sequence
controls for targeted control of the production process.
An independent program can be created for each sequence
of measurements for instance, special processrelevant conditions can be interrogated and/or outputted
via the freely programmable digital inputs and outputs.

Special features

Screen content data transmission; touch and USB via one Ethernet
cable for distances >5 m; multiple measuring modules can be
selected on one display; mixed operating mode (maXYmos TL/NC)
is possible

Accessories (included in delivery scope)

Supply voltage connector with terminal housing Type 55145411

Data sheet: see www.kistler.com

1200A163 (003-221)

Sequencer mode was developed so that multiple testing

sequences can be programmed and evaluated in one
device. In other words, multiple testing tasks can be accomplished with a single device. This not only allows separation
of the end results into good and bad; it also allows a precise
specification of whether the desired quality was achieved
in each step of the sequence chain.
Thanks to integrated sequence control, complex test processes
can also be mapped with no need to rely on costly external PLC
programming. The programs can be set up quickly and easily
via the intuitive user interface on the touch display and no programming know-how is required.
Now, maXYmos users can also measure multi-stage production
processes (i.e. those with consecutive staggered steps) in

12

www.kistler.com

every application: this has been made possible by equipping

the maXYmos TL (Top-Level System) and the maXYmos BL
(Basic-Level System) with a sequencer mode, in the same way
as the maXYmos NC (Numeric Control).

www.kistler.com

An independent sequence can be defined for each of the programs

(up to 128 in number).

13

Measuring Chains
In order to integrate sensor technology into a given application,
it is beneficial to clarify the following points in advance. This
will provide the basis for selecting the relevant components to
generate the measuring chain:
Type of signal: charge for piezoelectric sensors, voltage,
frequency, PLC integration (fieldbus, TCP/IP)
Pin allocation for sensor and evaluation unit (see data sheet)

Measure

Amplify

Monitor & Control

High-insulation cable (typical insulation value: >1E12 Ohm) is

a particularly important element of piezoelectric measuring
technology, and it should be selected according to the ambient
conditions.
y = f(t)
Type 9333A
Type 5877A

When installing the cables, make sure that the maximum

permitted cable length is not exceeded. It is advisable to use
original Kistler cables only.

Measure

Connect

Connect

Amplify

6157B

9247A

6157B

9211B
9247A

9211B

2205

2205

1708
1708

6157B

9247A

6157B

9211B
9247A

9211B

2205

2205

1708
1708

Type 4503B

Monitor & Control

2869B + Monitor
6157B

Type 5877A
2869B + Monitor

9247A

6157B

2869B
9211B

2869B
9247A

9211B

Laptop
Laptop
2205

2205

1708
1708

1200A491200A49

6157B

9247A

6157B

9211B

9247A

9211B

2205

17081708

2205

6157B
2869B
+ Monitor

9247A

2869B +6157B
Monitor

9211B
2869B 9247A

9211B
2869B

2205

1457A1
2205

1995A

1457A1
1708
1708
Laptop
Laptop

1995A

1200A491200A49

Type 4501A

2869B + Monitor 2869B

Type 9232A

Laptop Laptop

2869B

1200A49

1200A49

1457A1

1457A1

1995A

1995A

Typ 2151B

2869B + Monitor

Type 2118A

www.kistler.com

2869B + Monitor 2869B

2869B + Monitor 2869B

Type 4577A

Type 2118A

14

1457A1

1995A

1995A

Type 5847A
2869B + Monitor

2869B + Monitor

1457A1

Type 5867B

www.kistler.com

2869B

2869B

LaptopLaptop

1200A49

1200A49

1457A1

LaptopLaptop
1457A1

1200A49
1995A

1200A49
1995A

1457A1

1457A1

1995A

1995A 5877A
Type

PLC

15

Accessories
Displacement Sensors

Type 2112A...
Potentiometric displacement sensor

Technical Data

Model

TRS25

TRS50

TRS75

TRS100

Measuring range

mm

25

50

75

100

Repeat accuracy

mm

0,002

0,002

0,002

0,002

Maximum permitted
supply voltage

42

42

42

42

Actuation force
(horizontal)

Temperature range

30 ... 100

Oscillations

Hz

5 ... 2 000

Shock

g/ms

50/11

Degree of protection
(EN 60529)

IP

40

General Technical Data

Type 2118A...
Potentiometric displacement sensor

Solution Packages for

Manually Operated Presses
Thanks to solution packages from Kistler, quality control
using force-displacement monitoring can now be integrated
for manually or pneumatically operated presses.
Compression connectors are often manufactured on manually
operated presses. The only option for post-production control of
the joint in this particular case is destructive testing. In this
situation, it pays off to integrate quality control directly into the
process. This solution allows immediate detection and separation of rejects so that zero-defect manufacture of the end products is guaranteed.
The force-displacement monitoring system can be used or retrofitted wherever manual knuckle-joint presses or pneumatically
powered presses are in operation. For this purpose, the piezoelectric sensor is clamped directly between the press ram and the
die. Evaluation of the resultant force-displacement curve then provides the basis for good/bad assessment, making it is a key factor
in achieving zero-defect production.

16

Electrical connection

5-pole round connector, IEC 130-9

Data sheet: see www.kistler.com

2112A (000-868)

Technical Data

Model

TR10

TR25

TR50

TR75

TR100

Measuring range

mm

10

25

50

75

100

Repeat accuracy

mm

0,002

0,002

0,002

0,002

0,002

Maximum permitted
supply voltage

24

42

42

42

42

Actuation force
(horizontal)

Oscillations

Hz

5 ... 2 000

Shock

g/ms

50/11

Degree of protection
(EN 60529)

IP

40

General Technical Data

The ready-packaged solution

also available as a retrofit for existing
manual presses, Type 9819A...
This package includes the new Press
Force Sensor and the maXYmos BL XY
monitor for process recording and
monitoring. Also included: mounting
pin for the force sensor, displacement sensor, cable and attachment fittings.
Press Force Sensor, Type 9340A...
Measuring range 10 ... 60 kN
Calibrated for 1%, 10%, 100%
Ready to measure no on-site
calibration
Fits tool adapter 10 or 12 mm

www.kistler.com

Electrical connection

3-wire, shielded cable with tension relief, length: 2 m

Data sheet: see www.kistler.com

2118A (000-875)

Technical Data

Model

DK10

DK25

DK50

DK100

Repeat accuracy

mm

10

25

50

100

Repeat accuracy (for 20)

Shock

< 4,9

< 4,9

< 6,2

< 9,3

Vibration resistance
(10 ... 2 000 Hz)

m/s2

150

Temperature range

0 ... 50

Power supply

VDC

+5 ( 5%)

Degree of protection
(sensor body)

IP

64

General Technical Data

Type 2122B...
Incremental displacement sensor

www.kistler.com

Lifetime

Minimum of 5 million strokes without shock

Data sheet: see www.kistler.com

2122B (003-235)

17

Kistler At Our Customers'

Service Across the Globe
With over 1400 employees, the Kistler Group leads the global
market for dynamic measuring technology. 31 group companies
and over 30 distributors ensure close contact with customers,
individual application support and short delivery times.

Data Sheets and Documents

Use our search engine to
download data sheets,
brochures or CAD data.

From professional advice on installation to speedy deliveries of spare parts: Kistler's comprehensive range of services and training is at your disposal across the globe.

Service: Customized
Solutions from A to Z
Kistler offers sales and service wherever automated
manufacturing processes take place.
In addition to sensors and systems, Kistler offers a host of
services ranging from professional advice on installation to
speedy deliveries of spare parts worldwide. For an overview
of the services we offer, visit www.kistler.com. For detailed information on our training courses, please contact our local distri
bution partners (see page 19).

18

Kistler Services at a Glance

Advice
Support with system commissioning
Process optimization
Periodic sensor calibration
Education and training events
Development services
On-site calibration of maXYmos
equipment

Your Contacts
No matter whether you come to us for
advice or support with an installation on
our website, you will find the contact
details for your personal partner anywhere
in the world.

Education and Training Events

Education and training courses when
our sensors and measuring systems are
explained by experienced Kistler experts
are the most efficient way for you to
acquire the expertise you need.

www.kistler.com

www.kistler.com

19

2016, Kistler Group

960-338e-10.16

Kistler Group
Eulachstrasse 22
8408 Winterthur
Switzerland
Tel. +41 52 224 11 11
Kistler Group includes the Kistler Holding AG and
all its subsidiaries in Europe, Asia, Americas and Australia.
Find your local contact on
www.kistler.com