One Solution for Multiple Sensors

Eliminate compatibility issues and reduce system complexity. A single amplifier supports a wide range of force and torque sensors, minimizing spare parts and simplifying commissioning.

Built‑In Intelligence Saves Time

Torque/speed and torque/rotational angle measurements are evaluated directly by the unit. Mechanical power is calculated automatically and displayed in real time—no external software or post‑processing required.

Capture What Matters Most

Integrated peak detection and extreme‑value monitoring ensure critical load conditions are never missed, helping protect equipment and improve product quality.

Proven Performance, Anywhere You Need It

Designed for both high‑volume production environments and precise test and laboratory applications, the amplifier delivers consistent, dependable results wherever accuracy matters.

Torque is measured directly using high‑accuracy strain gauge technology, delivering reliable and repeatable results across the entire measuring range. Measured values are transmitted digitally and contactless from rotor to stator, eliminating wear, minimizing maintenance, and ensuring long‑term signal stability—even in continuous operation.

Intelligent Measurement Built In

The integrated measurement amplifier evaluates:

• Torque / speed
• Torque / rotational angle

Mechanical power is calculated automatically by the unit and displayed in real time, providing immediate insight without the need for external calculation or additional software.

Wide Measuring Range with Dual Calibration

• Rated torque range: 100 Nm to 20,000 Nm
• Second, independently calibrated measuring range: 1:5 or 1:10

This dual‑range concept delivers high resolution for low‑torque measurements while maintaining full rated capacity—maximizing accuracy and flexibility without changing hardware.

Flexible Outputs & Easy System Integration

Both analog and digital output signals are available, enabling seamless integration into:

• Test benches and data acquisition systems
• PLCs and automation systems
• Production monitoring and quality control environments

Integrated digital inputs and outputs support efficient process control and automation.

Capture Critical Data with Confidence

Built‑in circuitry for:

• Extreme‑value and peak measurement
• Measurement curve recording and storage

ensures that critical load conditions are captured reliably—supporting quality assurance, traceability, and documentation requirements.

A key advantage of the KiTorq® System is its flexibility. Rotors and stators with the same speed rating are fully compatible and interchangeable, allowing users to easily configure, expand, or replace system components as required.

The modular design simplifies system integration, reduces spare-parts requirements, and provides a dependable solution for test benches, industrial drives, and research applications.

Key Features

• Modular torque measurement system
• Accurate torque measurement for rotating applications
• Type 455x Rotor for torque measurement
• Type 454x Stator for signal processing and evaluation
• Interchangeable rotors and stators within the same speed class
• Flexible and scalable system design
• Simplifies spare-parts management
• Suitable for test bench and industrial drive applications

Choose S.I. Instruments for precision you can trust, compliance you can rely on, and service that delivers confidence.

Model: Type 2160A
Supplier: Kistler Staiger Mohilo

The Kistler NCFB Joining Module Type 2160A is an economical electromechanical joining solution designed for force-displacement monitored assembly and joining processes up to 50 kN. Equipped with an integrated piezoelectric force sensor, it delivers reliable process monitoring and quality verification while maintaining a low total cost of ownership.

Available in two sizes, the NCFB enables manufacturers to implement standard joining applications quickly and cost effectively. It provides the essential functionality needed for quality-controlled production environments without the complexity and investment associated with advanced servo press systems.

Whether performing bearing installation, component assembly, connector insertion, or press-fit operations, the Type 2160A offers dependable performance, repeatability, and process transparency.

Key Features

Integrated Piezoelectric Force Sensor

The built-in force sensor continuously measures joining force during the assembly process, enabling real-time quality verification and process monitoring.

Force-Displacement Monitoring

Verify every assembly cycle using force-displacement analysis to ensure correct component installation and identify assembly defects as they occur.

Cost-Effective Electromechanical Solution

The NCFB is specifically designed to provide a practical and affordable joining solution for manufacturers seeking quality assurance without the investment of a full servo press system.

Available in Two Sizes

Multiple size options allow the joining module to be matched to a wide range of force and application requirements.

Compact Design

Its compact footprint makes integration into automated assembly systems, workstations, and manufacturing cells straightforward and cost-effective.

Technical Specifications

Benefits for Manufacturing and Quality Engineers

Reliable Process Validation

Ensure every assembly operation meets predefined process requirements and quality standards.

Improved Product Quality

Detect assembly defects during production rather than after final inspection.

Reduced Manufacturing Costs

Gain the benefits of force-monitored assembly at a lower investment cost than advanced servo press systems.

Reduced Scrap and Rework

Identify process deviations early, minimizing wasted materials and rework requirements.

Consistent Production Performance

Integrated force measurement helps maintain repeatable assembly quality across every production cycle.

Simplified Automation Integration

The compact module design allows rapid installation into existing manufacturing equipment and automated assembly cells.

Typical Applications

Automotive Manufacturing

• Bearing insertion
• Bushing installation
• Press-fit assembly
• Mechanical component joining

Electronics Manufacturing

• Connector insertion
• Housing assembly
• Switch and relay assembly
• Small component joining

General Industrial Assembly

• Press-fitting operations
• Mechanical assembly
• Component insertion
• Automated joining applications

Consumer Products and Appliances

• Housing assembly
• Motor component assembly
• Plastic and metal component insertion

Industry Applications

Industries Best Suited for the NCFB Type 2160A

The NCFB is ideal for manufacturers seeking reliable force-displacement monitoring for standardized joining tasks.

Typical Users

• Automotive component suppliers
• Appliance manufacturers
• Consumer goods manufacturers
• Electronics assemblers
• Contract manufacturers
• General industrial manufacturers
• Packaging equipment manufacturers

Why They Choose the NCFB

• Cost-effective investment
• Simple implementation
• Reliable process monitoring
• Dedicated production lines
• Lower operating costs
• Consistent assembly quality

Industries Best Suited for Servo Press Systems

Servo press systems such as the Kistler NCF-H are designed for manufacturers requiring greater flexibility, advanced motion control, and comprehensive process traceability.

Typical Users

• Automotive OEMs
• Tier 1 automotive suppliers
• EV battery manufacturers
• Medical device manufacturers
• Aerospace manufacturers
• Precision engineering companies
• High-end electronics manufacturers
• Automation machine builders

Why They Choose Servo Press Systems

• Advanced programmable motion profiles
• Multiple product variants on one line
• Enhanced traceability
• Industry 4.0 readiness
• Complex assembly requirements
• High-precision manufacturing

NCFB Type 2160A vs Servo Press Systems

While both technologies provide force-monitored joining capabilities, they are designed for different manufacturing requirements.

When to Choose the NCFB Type 2160A

Choose the Type 2160A if your requirements include:

✅ Cost-effective force-monitored joining
✅ Standard assembly operations
✅ Dedicated production lines
✅ Reliable quality verification
✅ Easy integration into automation systems
✅ Reduced capital expenditure

When to Choose a Servo Press System

A servo press solution may be the better option when you require:

✅ Complex motion profiles
✅ Advanced process control
✅ Multiple product variants
✅ High-value precision assemblies
✅ Enhanced traceability and analytics
✅ Smart factory and Industry 4.0 integration

Why Choose the Kistler NCFB Type 2160A?

The Kistler NCFB Type 2160A provides manufacturers with an economical path to force-monitored assembly. Combining integrated force sensing, force-displacement analysis, and reliable electromechanical performance, it delivers the quality assurance capabilities modern production environments demand while maintaining a highly attractive cost-performance ratio.

Key Advantages

• Joining forces up to 50 kN
• Integrated piezoelectric force measurement
• Force-displacement process monitoring
• Compact machine integration
• Reduced scrap and rework
• Improved assembly quality
• Cost-effective implementation
• Suitable for automated production environments

The Kistler NCF-H Servo Press System (Type 2151B) is a high-performance solution for precision joining and press-fit applications requiring forces up to 60 kN. Equipped with an integrated piezoelectric force sensor, the NCF-H provides accurate force measurement and real-time process monitoring to ensure consistent assembly quality and complete production traceability.

Its innovative hollow-shaft motor design delivers a compact footprint while maintaining generous stroke lengths of 200 mm (Size I) and 400 mm (Size II). The system can be mounted in virtually any orientation, including horizontal, vertical, angled, or inverted positions, providing exceptional flexibility for machine builders and automated manufacturing environments.

Capable of monitoring both push and pull operations, the NCF-H supports a wide range of joining and assembly applications while delivering the process data required for modern quality control and continuous improvement initiatives.

Key Features

Integrated Piezoelectric Force Sensor

The built-in force sensor continuously measures joining force throughout the process, enabling real-time quality monitoring and process validation.

Dual Measuring Range Technology

The NCF-H features a unique dual measuring range, allowing a single press to accurately perform both low-force and high-force applications.

Unlike conventional systems that sacrifice low-force accuracy when configured for higher loads, the NCF-H can switch between measurement ranges via PLC control. This allows manufacturers to use one press for multiple assembly operations while maintaining exceptional measurement accuracy across the entire force spectrum.

Benefits include:

• Increased measurement accuracy
• Greater process flexibility
• Reduced equipment requirements
• Support for mixed-product manufacturing
• Improved quality control at both low and high forces

Bidirectional Force Monitoring

Monitor and verify joining operations during both pressing and pulling movements, expanding application flexibility and process visibility.

Compact Hollow-Shaft Design

The hollow-shaft servo motor provides a compact overall footprint while maintaining high performance and long stroke capability.

Flexible Mounting Options

The NCF-H can be mounted:

• Horizontally
• Vertically
• At any angle
• Upside down
• Via wall or flange mounting

Technical Specifications

Benefits for Quality Engineers

100% Process Verification

Validate every assembly operation against predefined force and displacement criteria to ensure product quality and process consistency.

Early Defect Detection

Immediately identify:

• Missing components
• Incorrect parts
• Misalignment
• Incomplete insertion
• Damaged assemblies

before they proceed to downstream manufacturing stages.

Full Production Traceability

Capture force-displacement signatures and process data for every cycle, supporting quality documentation, compliance requirements, and customer audits.

Enhanced Statistical Process Control

Generate reliable process data for:

• SPC programs
• Cp/Cpk analysis
• Trend monitoring
• Continuous improvement initiatives

Reduced Scrap and Rework

Detect process deviations during assembly rather than after production, helping lower manufacturing costs and improve throughput.

Faster Root Cause Analysis

Historical force-displacement data provides engineers with valuable insight when diagnosing quality issues and implementing corrective actions.

Reduced Warranty Risk

By validating every joining operation, manufacturers can significantly reduce the risk of defective products reaching customers.

Typical Applications

Automotive Manufacturing

• Bearing insertion
• Seal installation
• Gear and transmission assembly
• Electric vehicle component assembly
• Motor and battery assembly

Electronics Manufacturing

• Connector insertion
• Switch assembly
• Small motor assembly
• Housing assembly

Medical Device Manufacturing

• Precision device assembly
• Injector and syringe assembly
• Regulated production processes

Aerospace and Precision Engineering

• Bushing installation
• Mechanical subassembly joining
• Actuator assembly
• Critical fit applications

Why Choose the Kistler NCF-H?

The Kistler NCF-H combines precision force measurement, advanced process monitoring, flexible mounting options, and dual-range measurement capability in one compact servo press solution.

Manufacturers benefit from:

• Superior assembly quality
• Increased production flexibility
• Reduced scrap and rework
• Complete process traceability
• Accurate force monitoring across multiple applications
• Improved compliance with quality standards

Whether for automotive, electronics, medical, or precision manufacturing applications, the NCF-H provides the performance and reliability required for today’s quality-driven production environments.

The Kistler maXYmos NC 5847A is an advanced process monitoring and control system designed specifically for electromechanical NC (Numeric Control) joining systems. Building on the proven functionality and user-friendly operation of the maXYmos product family, the maXYmos NC not only monitors joining processes but also actively controls them.

With a consistent operating philosophy across the entire maXYmos range, users benefit from intuitive configuration, simplified setup, and rapid commissioning. This reduces implementation time while enabling precise control and verification of force-displacement assembly and joining operations.

The maXYmos NC is ideal for manufacturers seeking a complete solution that combines process monitoring, quality assurance, and active joining system control within a single platform.

Key Features

Active Control of NC Joining Systems

Unlike traditional monitoring systems that only evaluate process results, the maXYmos NC actively controls the joining process in real time, ensuring consistent and repeatable assembly outcomes.

Intuitive User Interface

The consistent maXYmos operating concept minimizes training requirements and allows operators and engineers to quickly configure, manage, and optimize production processes.

Rapid Commissioning

Simplified setup procedures enable faster deployment of NC joining systems and minimize production downtime during installation and changeovers.

Process Monitoring and Verification

Monitor force-displacement curves and other process characteristics throughout the entire joining operation to validate product quality and process performance.

Quality Assurance Integration

Supports zero-defect manufacturing strategies by combining process control with real-time quality evaluation.

Technical Specifications

Benefits for Manufacturing and Quality Engineers

Monitor and Control in One System

Combines process evaluation and active machine control, reducing system complexity and improving manufacturing efficiency.

Faster System Implementation

The intuitive operating philosophy shortens commissioning time and reduces engineering effort.

Improved Process Consistency

Active control helps maintain process stability and repeatable joining performance.

Enhanced Product Quality

Monitor and control critical joining parameters to ensure every assembly operation meets specifications.

Reduced Scrap and Rework

Real-time process management helps prevent defects before they occur, reducing waste and production costs.

Simplified Operator Training

A consistent user experience across the maXYmos family enables quicker adoption and easier operation.

Typical Applications

Electromechanical Joining Systems

• Force-displacement controlled assembly
• Press-fit operations
• Bearing insertion
• Component assembly

Automotive Manufacturing

• Engine and transmission assemblies
• EV component assembly
• Safety-critical joining applications

Medical Device Manufacturing

• Precision assembly processes
• Quality-critical production environments

Electronics Manufacturing

• Connector insertion
• Housing assembly
• Precision component installation

Automated Production Lines

• Smart assembly stations
• Integrated quality assurance systems
• High-volume manufacturing environments

Why Active Control Matters

Traditional process monitoring systems evaluate results after an operation has been completed. The maXYmos NC goes a step further by actively controlling the joining system during the process.

Benefits of Active Control

✅ Improved process stability
✅ Greater assembly consistency
✅ Faster production optimization
✅ Reduced operator intervention
✅ Enhanced product quality
✅ Better repeatability between production cycles

This makes the maXYmos NC particularly valuable for manufacturers where assembly quality, process repeatability, and production efficiency are critical.

maXYmos Product Family Comparison

Which maXYmos System Is Right for You?

Choose maXYmos BL (5867A) if:

• You require affordable XY curve monitoring.
• Standard assembly and joining operations are your primary focus.
• Basic process verification is sufficient.

Choose maXYmos TL (5877A) if:

• You need advanced quality assurance and traceability.
• Your manufacturing process is quality-critical.
• Comprehensive process evaluation is required.

Choose maXYmos NC (5847A) if:

• You operate electromechanical NC joining systems.
• You need both monitoring and active process control.
• Process consistency and automation are top priorities.
• You want to simplify commissioning and machine operation.

Why Choose the Kistler maXYmos NC?

The Kistler maXYmos NC 5847A bridges the gap between process monitoring and process control. By integrating active control capabilities with the proven maXYmos monitoring platform, manufacturers gain a powerful solution that improves quality, increases productivity, and simplifies the operation of modern NC joining systems.

Key Advantages

• Active control of NC joining systems
• Real-time process monitoring
• Improved assembly consistency
• Faster commissioning and setup
• Enhanced quality assurance
• Reduced scrap and rework
• Intuitive user interface
• Seamless integration into automated production environments

The Kistler maXYmos TL (Top Level) 5877A is a process monitoring and quality assurance system designed to capture, analyze, and evaluate XY measurement curves between two measured variables. By monitoring the relationship between these variables in real time, the system enables manufacturers to verify product quality throughout the production process.

Rather than evaluating a single measurement value, maXYmos TL analyzes the complete curve generated during an operation. This provides a significantly higher level of process visibility, allowing manufacturers to identify defects, process deviations, and assembly errors before products leave the production line.

The resulting measurement curves provide reliable quality assessment for individual manufacturing steps, complete assemblies, and finished products, supporting modern quality management and traceability requirements.

Key Features

Advanced XY Curve Analysis

Capture and evaluate the relationship between two measured variables such as:

• Force vs. Displacement
• Force vs. Time
• Pressure vs. Time
• Torque vs. Angle
• Torque vs. Time

The system continuously analyzes measurement curves against predefined quality criteria.

Real-Time Process Monitoring

Monitor production processes during operation and immediately identify deviations from target process signatures.

Comprehensive Quality Evaluation

Evaluate entire manufacturing operations based on complete process profiles rather than isolated measurement points.

Pass/Fail Decision Making

Automatically assess whether a process meets specified quality requirements, helping to prevent defective products from progressing through production.

Production Traceability

Store process data and measurement curves to support quality documentation, audits, and continuous improvement initiatives.

Technical Specifications

How XY Curve Monitoring Works

Traditional quality inspection often checks only final dimensions or individual measurement values. However, many defects occur during assembly and may not be detected through conventional inspection methods.

The maXYmos TL evaluates the entire process signature by comparing measured XY curves against predefined acceptable profiles.

Example: Bearing Press-Fit Assembly

Benefits for Quality Engineers

100% Process Verification

Inspect every production cycle instead of relying on sample-based inspections.

Improved Defect Detection

Identify process abnormalities that may not be visible through dimensional inspection alone.

Full Traceability

Maintain historical process records and curve data for audits, customer requirements, and regulatory compliance.

Faster Root Cause Analysis

Use stored process signatures to compare good and failed parts, helping engineers identify the source of quality issues.

Reduced Scrap and Rework

Detect production problems early before defective products move to subsequent manufacturing stages.

Enhanced Statistical Process Control

Generate reliable quality data to support:

• SPC programs
• Process capability studies
• Trend analysis
• Continuous improvement projects

Typical Applications

Automotive Manufacturing

• Bearing insertion
• Seal assembly
• Press-fit monitoring
• Transmission assembly
• Electric vehicle component assembly

Medical Device Manufacturing

• Precision assembly operations
• Device validation processes
• Regulated manufacturing applications

Electronics Manufacturing

• Connector insertion
• Housing assembly
• Component joining
• Relay and switch production

Aerospace Manufacturing

• Critical assembly verification
• Mechanical joining processes
• Safety-critical component production

General Industrial Manufacturing

• Press-fitting
• Joining operations
• Assembly verification
• End-of-line quality monitoring

Industries That Use maXYmos TL

Automotive and EV Manufacturing

Monitor critical assembly processes where component fit and assembly quality directly impact product performance and safety.

Medical Device Manufacturing

Support regulatory compliance and process validation through detailed assembly verification and traceability.

Electronics Manufacturing

Ensure accurate and repeatable assembly of connectors, housings, switches, and precision electronic components.

Aerospace and Precision Engineering

Verify complex assembly processes where failure is not an option and complete process documentation is required.

Industrial Automation

Integrate curve monitoring into automated production systems to enhance process control and product quality.

Why Choose the Kistler maXYmos TL?

The Kistler maXYmos TL 5877A transforms quality control from simple measurement checking into comprehensive process evaluation. By analyzing complete XY measurement curves, manufacturers gain deeper insight into production performance, improved defect detection, and full process traceability.

Key Advantages

• Real-time XY curve analysis
• Automated quality assessment
• Enhanced defect detection
• 100% production monitoring
• Full process traceability
• Faster root cause analysis
• Reduced scrap and rework
• Suitable for automated manufacturing environments
• Improved product quality and consistency

Ideal Companion to Servo Press and Joining Systems

The maXYmos TL is often deployed alongside force-monitored assembly equipment such as:

• Kistler NCF-H Servo Press Systems
• Kistler NCFB Joining Modules
• Press-fit stations
• Automated assembly cells
• Force-displacement monitoring applications

Together, these systems provide complete process control, from force measurement during assembly to advanced curve analysis and quality validation.

Cost-Effective XY Curve Monitoring for Assembly and Joining Processes

The Kistler maXYmos BL (Basic Level) 5867A is an entry-level process monitoring system designed to capture, display, monitor, and evaluate XY curves generated by two related measurement variables. By analyzing the relationship between these variables in real time, manufacturers can verify process quality, detect deviations, and improve production consistency.

Ideal for joining, press-fitting, assembly, swiveling, and rotational processes, the maXYmos BL provides a practical and cost-effective solution for implementing process monitoring without the complexity of advanced quality analysis systems.

Compatible with piezoelectric, strain-gauge, and potentiometric sensors, the maXYmos BL offers the flexibility to monitor a broad range of manufacturing applications while delivering reliable quality verification and process transparency.

Key Features

XY Curve Monitoring and Evaluation

Monitor and evaluate the relationship between two measured variables to verify manufacturing process performance and product quality.

Wide Sensor Compatibility

Supports a variety of sensor technologies, including:

• Piezoelectric sensors
• Strain-gauge sensors
• Potentiometric sensors

This enables integration into a wide range of existing manufacturing environments.

Real-Time Process Monitoring

Visualize and analyze process curves as they are generated, providing immediate feedback on production performance.

Cost-Effective Quality Assurance

Provides essential process monitoring functionality at an economical investment level, making it ideal for standard production and assembly applications.

Flexible Application Support

Monitor numerous process relationships, including:

• Force vs. Displacement
• Torque vs. Angle
• Pressure vs. Time
• Force vs. Time
• Torque vs. Time

Technical Specifications

Benefits for Quality Engineers

Verify Every Production Cycle

Monitor critical production processes in real time to ensure consistent product quality.

Detect Process Deviations Early

Identify abnormal process behaviour before defects reach downstream manufacturing stages.

Improve Process Consistency

Use process curves to verify repeatable performance across all production cycles.

Reduce Scrap and Rework

Identify issues sooner, minimizing material waste and reducing production costs.

Simplify Root Cause Analysis

Historical process curves provide valuable insight when investigating quality concerns and production anomalies.

Support Continuous Improvement

Generate valuable process data for:

• Trend analysis
• Process optimization
• Capability studies
• Quality improvement initiatives

Typical Applications

Press-Fit Assembly

Monitor force-displacement relationships during bearing insertion, component assembly, and press-fit operations.

Rotational and Swiveling Processes

Analyze torque-angle and torque-time curves to verify mechanical performance.

Assembly and Joining Operations

Monitor critical assembly steps where process consistency directly impacts product quality.

Automated Manufacturing

Integrate process monitoring into automated production cells and assembly systems.

Detect Process Deviations Before They Become Defects

Example: Press-Fit Assembly

The maXYmos BL can verify:

✅ Correct force-displacement profile
✅ Proper insertion depth
✅ Consistent assembly behaviour
✅ Stable process performance

The same process analysis can also detect production issues such as:

• Missing components
• Incorrect parts
• Misalignment
• Damaged components
• Incomplete assembly

By identifying process deviations immediately, manufacturers can improve quality, reduce rework, and prevent defective products from reaching customers.

Typical Industries

Automotive Manufacturing

• Press-fit assembly
• Component insertion
• Mechanical assembly monitoring
• Automotive component production

Electronics Manufacturing

• Connector insertion
• Housing assembly
• Precision component installation

Medical Device Manufacturing

• Assembly verification
• Production quality monitoring
• Process validation

General Industrial Manufacturing

• Joining processes
• Quality assurance
• Production monitoring

Automation and Machine Building

• Automated assembly systems
• Manufacturing equipment integration
• Process verification solutions

maXYmos BL vs maXYmos TL

Which Process Monitoring Solution Is Right for Your Application?

Both the maXYmos BL (5867A) and maXYmos TL (5877A) monitor and evaluate XY curves to verify manufacturing processes and improve product quality. The primary difference lies in the depth of process analysis, traceability, and application complexity they support.

Feature Comparison

Typical Industry Fit

When to Choose maXYmos BL

Choose the maXYmos BL if you need:

• Cost-effective process monitoring
• Standard assembly and joining applications
• Reliable XY curve evaluation
• Simple implementation and operation
• Essential process verification capabilities

When to Choose maXYmos TL

Choose the maXYmos TL if you need:

• Advanced process analysis
• Enhanced traceability
• Comprehensive process validation
• Support for quality-critical manufacturing
• Greater insight into production performance
• More sophisticated quality assurance capabilities

Why Choose the Kistler maXYmos BL?

The Kistler maXYmos BL 5867A provides manufacturers with an affordable, flexible, and effective solution for real-time process monitoring. By evaluating the relationship between two measured variables, it helps improve quality, reduce waste, and increase confidence in production performance.

Key Advantages

• Cost-effective process monitoring
• Real-time XY curve analysis
• Broad sensor compatibility
• Easy integration into manufacturing systems
• Improved product quality
• Reduced scrap and rework
• Faster detection of process deviations
• Suitable for a wide range of assembly and joining applications