Joining technology for commercial vehicles – solutions for on-road, off-road and intralogistics

Commercial vehicle manufacturing is undergoing a transformation. Electrified powertrains, lightweight construction concepts, increasing load requirements and high quality standards are fundamentally changing design and production. Manufacturers of trucks, off-highway machinery and intralogistics systems face the challenge of integrating robust and cost-effective joining solutions into stable series production processes.

Requirements vary considerably depending on the application – yet all segments share the need for durable, reproducible and cost-effective joining technology, as well as precise and process-monitored joining and pressing applications.

Typical challenges include:

• joining high-strength and coated steels

• material mix of steel and aluminium

• processing of large and complex components in pressing applications

• thick sheet metal and high forces

• integration of battery housings and structural components

• increasing demands on energy efficiency

• complete process monitoring and documentation

Mechanical joining processes enable stable joints without thermal effects on the material. In combination with force-controlled press systems, this results in controlled and reproducible processes for series and special applications.

On-Road – Assembly solutions for trucks, buses and trailers

The manufacturing of trucks and buses is characterised by high production volumes, modular platform concepts and increasing electrification. Structural and frame components, cross members and battery housings require durable joints whilst maintaining short cycle times.

TOX^® develops energy-efficient joining solutions for high-strength steels and aluminium-steel joints. Force-controlled press systems with integrated process monitoring ensure reproducible quality in series production.

Examples from the manufacturing of lorries and buses illustrate how robust hinge solutions support high production volumes, short cycle times and reliable component quality.

Construction machinery, agricultural vehicles and mining equipment place particularly high demands on joining technology and system stability. Thick sheet metal, high static and dynamic loads, and harsh operating conditions call for robust processes.

TOX^® combines specially designed clinching tools with high-performance specialised presses that deliver consistent results even under high forces and with complex geometries. Furthermore, the press systems enable the precise insertion of components such as chains, bearings or bolts. This results in durable joints for demanding heavy-duty applications.

Typical applications from the off-road industry demonstrate how robust joining technologies enable reliable and durable structural joints, even under extreme loads.

Electric industrial trucks, automated warehouse systems, and AGV and AMR systems require flexible and cost-effective joining technology. A wide range of variants, compact assemblies and high repeatability place particular demands on assembly processes.

TOX^® develops scalable joining systems and press solutions that can be seamlessly integrated into automated production lines. Process monitoring and reproducible parameters ensure consistent quality – even with high production volumes.

Practical applications from intralogistics manufacturing demonstrate solutions for compact assemblies, modular vehicle concepts and a wide range of variants.

As an engineering partner, TOX^® supports projects from the initial analysis right through to series production integration:

1. Assessment of material, geometry and load requirements

2. Feasibility analysis and testing

3. Design of tooling and press systems

4. Integration into existing or new production lines

5. Validation and process monitoring

Our aim is not merely to join and press individual components, but to develop a robust, cost-effective and scalable overall process.