FAQs about the TOX^® Software

The TOX^® Software is the central software for operating, commissioning and analyzing TOX^® products. It establishes the connection to the joining module, enables movements and process executions, and displays relevant process and quality data. While it is not strictly required after commissioning, it is recommended.

It is used to connect, operate, parameterize and analyze a joining module. This includes homing, manual movements, execution of prepared programs, viewing and exporting curves and measured values, as well as the use of customizable dashboards.

The TOX^® Software covers the key functions for operation and analysis: connection to the joining module, user management, homing and operation, program execution, and visualization via dashboards. This makes it suitable for commissioning, ongoing operation and analysis.

For the connection, the Engineering Port RJ45 port must be used, as it is intended for Ethernet communication between the drive controller and the TOX^® Software. In addition, the network adapter used on the computer must be configured accordingly. Once the connection is established, the software displays, among other things, the position display, live force value and active connection status.

A correct IPv4 configuration of the network adapter is required. The IP address must not be assigned via DHCP, but must be set statically. The PC must be within the range 192.168.50.xxx; the last number must not be 100. By default, the TOX^® ControlSystem or TOX^® PowerModule is set to 192.168.50.100.

If multiple joining modules are present in the network, the software can manage communication with several systems in parallel. The dashboard can display widgets of all joining modules simultaneously, and parameterization can be performed selectively. Parameters can also be duplicated to connected joining modules.

The software works with the user levels tox1 to tox4. tox4 is the highest released authorization level with full access. Higher permissions are always required when changes to software settings, HMI functions or processes are to be made. The exact permissions of each user level are stored in User Management. Additionally, custom users and user groups with individual access rights can be created. This ensures traceability of which user made which changes.

The resolver must be referenced before the first movement so that the system knows the correct position. Only then can movements and programs be executed reliably. For manual homing using the TOX^® software, the Manual and Internal operating modes must be active. Without an active connection to the joining module, no movement is possible.

The dashboard is the customizable operation and visualization layer of the TOX^® Software. It can be built using widgets such as curves, tables, status indicators or links and is particularly suitable as an HMI interface. Important: the dashboard initially starts empty, and process data only becomes visible after cycles have been executed.

Data and settings are backed up using the backup function of the TOX^® Software. A manual backup can be created at any time. In addition, the software also supports automatic backups as long as an active connection to the system exists.

A backup is used to save the current state of configurations and settings so that it can be restored if needed. This is particularly relevant before making changes, to secure existing configurations or to preserve a known system state.

Backed-up data is restored using the restore function. It is possible to select whether only specific areas, such as HMI settings, or the complete system configuration should be restored. A restore directly from a ZIP file is also possible.

The TOX^® Software offers several options for process monitoring. These include threshold monitoring, envelope monitoring and window monitoring. These methods differ in their level of detail, but all pursue the goal of detecting process deviations early and evaluating process quality.

Threshold monitoring is a very simple and quickly managed method of monitoring upper and lower limits. Within a process step, maximum and minimum permissible force, distance and time can be monitored simultaneously.

Envelope monitoring checks whether the process curve remains within a defined envelope. The envelope is learned from definable average values of the force-displacement curve. This method is particularly suitable when not only individual limit values but the entire curve progression needs to be evaluated.

Window monitoring checks specific areas within the process curve. For this purpose, windows are defined that can be adjusted in position, size and evaluation logic. This allows individual critical curve sections to be monitored very precisely.

Active errors are clearly displayed in the TOX^® Software. They can be reset directly in the user interface via a reset function or externally via the PLC. After the reset, the error status is updated accordingly.

For error diagnosis, the software provides a diagnostic log with active and acknowledged messages. Detailed information including description, notes and process reference can be displayed for each message. In addition, Final Values help to quickly identify the affected process step and the corresponding measured value.

Processes can not only be restored from a backup but also transferred from an offline status. For this purpose, the backup file contains an EDPM file that can be used as an offline adapter. Processes and parameters can be compared, copied and selectively transferred to other system states via the Device Explorer.

The TOX^® Software primarily provides process curves, final values and status information for analysis. This allows both the progression of a cycle and its result and quality evaluation to be traced.

Chart data are the recorded measurement data of a cycle. They contain the complete progression of the process data and are mainly used when curves need to be analyzed or exported.

Final values are important result values of a process. They show measured values, status messages and the reference to individual process steps. This allows results to be evaluated quickly and errors to be assigned more easily.

Process data can be evaluated via the archive, chart views and a final values list. This allows curves to be viewed, final values to be compared and status messages to be analyzed. The software therefore supports both a quick overview and targeted detailed analysis.

The archive is the central tool for traceability and analysis of process data. It displays production days, data records, OK/NOK status, process curves and Final Values, making past cycles traceable.

In the archive, multiple data records can be selected simultaneously and their curves can be overlaid directly. This allows process progressions to be compared visually and trends to be identified quickly. Additionally, individual curve sections can be zoomed into.

Data records can be filtered in the archive according to various criteria, for example by OK/NOK status, program names, numbers, serial numbers or time ranges. Multiple filters can be combined to narrow down specific data records precisely.

The Final Values List shows which measured value was generated in which process step and whether the result was within the defined limits. This directly supports quality evaluation and helps to quickly identify the affected process step in the event of an error.

Analysis views can be configured individually using adjustable columns, information that can be shown or hidden, and saved favorite views. This allows tables and evaluations to be tailored to the respective application and reused in the same form.

Process and quality data can be output via defined export functions. It is possible to define which data type is exported, in which format the output is created and how the file and folder structure is organized. This allows the data to be prepared specifically for further analysis or external systems.

Processes are created, adjusted and managed in the “Editing” area. Existing programs are available as a basis and can be copied, extended and modified. After saving, the changes are transferred to the system.

A process consists of several consecutive process steps. These typically include initialization, start of data acquisition as well as movement or pressing steps with defined target values and monitoring. Motion parameters can also be transferred to the system via a PLC.

Data acquisition ensures that the process progression is available as a curve and as a basis of measured values for analysis, monitoring and archiving. For this purpose, a corresponding chart or data acquisition step is used within the process. The sampling rate is adjustable, and up to 5,000 chart points per channel and cycle can be recorded.

In a process step, parameters such as target position or target force, speed, limit values, position and time monitoring as well as holding times can be defined. In addition, advanced functions such as smooth transitions between steps or stop events are available.

After saving, a process can be tested directly, either via the controller or in manual operation of the TOX^® Software. The curve progression and behavior can then be evaluated and the process can be further adjusted in a targeted manner.

External signals can be integrated into the process as digital inputs or outputs. Inputs are used, for example, as start or release conditions, while outputs can be used to control external components such as signal lights or actuators.

External sensors (e.g. position sensors, force sensors, pressure sensors) are configured via the measurement channels. This defines which signal source is used, how the signal is scaled and which unit is applied. After configuration, the sensor signals can be recorded within the process and displayed together with internal measured values.

A joining module can be started via the TOX^® Software, via digital input signals or via a PLC. In the start options, it is defined whether control is internal or external and who specifies process selection, operating mode and start signal.

PLC data sets are predefined parameter sets with which target values and motion data are not defined directly in the TOX^® Software but via the PLC. This allows the controller to transfer central process parameters to the system.

PLC data sets are used when process parameters such as target position, target force or speeds need to be defined flexibly by a higher-level PLC. This is particularly useful when different product variants or parameter changes are managed centrally via the controller.

The TOX^® Software is updated differently depending on the system. On a Windows PC, the update is carried out using the provided installation file. On a TOX^® UDI screen, the update is started directly via the software interface using a USB stick.

A backup secures the current state of settings and configurations. This allows returning to a known state in case of issues after the update. This is particularly important because new parameters or changed requirements may occur after software or firmware updates.

The installed version is displayed in the information area of the software after the update. There it can be directly verified which version is currently installed on the system.

The Press Screen is used to operate the system directly during operation. This includes manual movements, homing, the selection of processes in automatic mode as well as the operation of integrated station functions.

The Press Screen provides functions such as homing, jog operation, return to the home position, process selection and process start. Depending on the system, additional integrated components such as a safety door or a sliding table can also be operated directly.

Virtual beacons are visual displays within the TOX^® Software. They show important states such as process readiness, running cycle or error conditions.

Virtual beacons are used to make operating and error states quickly and clearly visible. The logic and visualization of these indicators can be adapted to the respective application.

The TOX^® Software supports barcode scanner functions for assigning part information and for process selection via scan. This requires that the corresponding license functions are activated.

Barcode scanners are used, for example, to assign serial numbers or component information to a press cycle or to automatically select the appropriate process.