Adding a high-precision load cell to a Coretec servo press dramatically improves the performance of the CORETEC WPS “Work Explorer” feature.
Coretec tools (for example the GS and MS servo press series) are highly sophisticated measuring instruments.
They don't just push, they analyze:
Work Explorer Function:
Coretec controllers feature a Work Explorer mode. This allows the punch to move at a specific search speed until it detects a minimal change in force (contact). It then records the exact position, effectively acting as a contact probe.
High sampling rate:
Coretec is known for its ultra-high-speed data processing (over 1000 samples/sec), which is essential when using the servo press as a probe to ensure the trigger point is accurately detected.
Improved features:
1. High sensitivity to contact (trigger point). The standard load cell integrated into a servo press is sized for the maximum capacity of the machine (for example, 5 kN). For this reason, it does not have the resolution necessary to detect very small contacts.
Advantage: An external sensor can be specifically sized for the probing phase (for example, to detect a 0.5 N contact on a 5 kN machine). This ensures that the servo press stops when it touches the surface without deforming the part, providing a much more precise zero-point measurement.
2. Eliminate internal friction (noise). Internal sensors must account for the friction of the ball screw, motor bearings, and seals. This mechanical noise can mask the actual force at the tool tip.
Advantage: An external sensor mounted directly on the tool measures only the force applied to the workpiece. This clean signal allows the Coretec Work Explorer function to activate with much greater repeatability, as it is unaffected by heat, wear, or the internal mechanics of the servo press.
3. Micron-level dimensional accuracy. When using a servo press as a probe, you often try to calculate a relative dimension (for example, measuring the height of a component to determine how much shim to insert).
Advantage: Since the calculation is Force + Displacement, any error in the force detection results in an error in the recorded position. A more accurate sensor reduces this uncertainty, allowing for tighter assembly tolerances that are impossible to achieve with a standard internal sensor.
4. Direct traceability. In various industries, such as medical device manufacturing and the aerospace industry, servo presses are often considered measuring instruments.
Advantage: It is significantly easier to calibrate and certify a high-precision external load cell to international standards than to calibrate the entire internal drive system of a servo press.
Coretec with external sensors:
The WPS controller is designed with high-speed analog inputs to specifically handle this external sensor, making it very easy to implement a high-precision secondary force feedback loop.
Digital monitoring improves motor reliability in a cement manufacturing plant
WEG and Nuova Ites implement WEGSCAN solution to improve efficiency Nuova Ites Srl, a leading European company specializing in the repair and overhaul of rotating electrical machinery, recently partnered with industrial equipment manufacturer WEG to improve operational monitoring of one of the key industrial motors at a cement plant. As part of its ongoing commitment to reliability and performance, Nuova Ites installed the WEGSCAN electric motor monitoring system, a cutting-edge solution developed by WEG to monitor motor performance and identify potential issues before they impact operations. Nuova Ites, a specialist in the repair and overhaul of rotating electrical machinery across Europe, with over 800 wind turbines fully serviced in collaboration with leading operators such as Vestas, Enel, and ERG Renew, identified the need for continuous motor monitoring in a high-load application. In this case, a 132 kW, 2-pole WEG special series motor was coupled to an Atlas Copco compressor, forming a critical component of the customer's production process. Performance and reliability in this mixed-equipment configuration were crucial, but visibility into the motor's condition was limited. To address this issue, WEG supplied and installed a complete monitoring solution consisting of the Cassia X2000 Gateway and the WEGSCAN 100 unit. Following a WEG technical visit to the Nuova Ites workshop in late 2025, the equipment was ordered and delivered in early January 2026. The system was configured on-site to meet the specific application requirements and integrated into the monitoring processes of both Nuova Ites and the cement plant. The WEGSCAN system is designed to support real-time monitoring of multiple operating parameters, including vibration signatures, temperature trends, and other mechanical and electrical health indicators. Its dual-access capability allows engineers to view data from a standard PC interface or smartphone, facilitating remote condition monitoring and immediate performance visibility. Supporting the monitoring infrastructure is the Cassia X2000 Gateway, which serves as the system's communications hub. The gateway enables reliable wireless connectivity between the WEGSCAN device and the wider network, ensuring that operating data from the engine can be transmitted and accessed in real time. Designed for demanding conditions, the gateway operates over a wide temperature range of −40 to 65°C, ensuring stable communication between sensors and monitoring systems in harsh operating environments. By acquiring continuous operational data, Nuova Ites is now able to identify early signs of abnormal behavior and proactively plan maintenance, helping to reduce unplanned downtime, optimize service interventions, and improve overall energy efficiency. This level of insight is particularly valuable in environments where the costs of downtime and reactive repairs are high. "For Nuova Ites, the monitoring system has become an essential tool in its service portfolio, helping to integrate condition-based maintenance into the standard workflow and offering customers greater reliability and full lifecycle support," said Fabrizio Arosio, Head of Drive and Automation Systems at WEG Italia. “With the ability to more closely monitor critical engines, the company is better equipped to anticipate problems, optimize maintenance planning, and provide data-driven insights that add measurable value to asset performance and business continuity.” Digital monitoring technologies like WEGSCAN also help make industrial operations more sustainable. By providing continuous information on engine performance under real-world operating conditions, operators can keep equipment closer to its optimum efficiency point. In energy-intensive industries like cement production, improving the efficiency and lifespan of critical rotating equipment plays an important role in reducing overall resource consumption and supporting more sustainable plant operations.
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