TOX® supports the commercial vehicle industry as a technology and engineering partner – offering innovative joining technology, mechanical joining via clinching, high-performance press systems and custom-built special presses for demanding applications.
The commercial vehicle industry is facing profound changes. Electrified powertrains, lightweight construction concepts, increasing load requirements, and high quality standards are placing new demands on the manufacturing of trucks, off-road vehicles, and intralogistics systems. There is a need for robust, cost-effective, and reliable solutions for joining and pressing applications in series production.
TOX® supports manufacturers with innovative joining technology, high-performance press systems, and intelligent process monitoring for modern production environments. Our solutions help streamline manufacturing processes, ensure consistent quality, and sustainably increase the profitability of commercial vehicle production.
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
Assembly solutions for trucks, buses and trailers
Robust joining technology for heavy-duty applications
Precision joining technology for industrial trucks, AGVs, and AMRs
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.
Punching holes for fastening components
Pressing in engine mounts / pins / gearboxes
Pressing in wheel bolts / bearings
Inserting functional element into flap
Clinching the clamping strap
Clinching the carrier
Examples from the manufacturing of lorries and buses illustrate how robust hinge solutions support high production volumes, short cycle times and reliable component quality.
Precise, monitored joining processes with intelligent force/displacement control ensure the highest process quality and comprehensive, OEM-compliant documentation. Dynamic drive technology and high system availability enable short cycle times and boost productivity, whilst energy-efficient press drives and durable components reduce maintenance requirements and operating costs. Modular systems with open interfaces can also be flexibly integrated into existing or new production lines, and CE-compliant safety concepts ensure safe, ergonomic work processes with a high level of user comfort.
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.
Fit the battery casing
Press in wheel bolts
Align and measure pinion head bearings
Fit bushings onto shafts
Mount bearings on shafts / Press on gearbox bearings / Mount clutch shaft
Typical applications from the off-road industry demonstrate how robust joining technologies enable reliable and durable structural joints, even under extreme loads.
TOX® presses are designed for high cycle counts and continuous operation, ensuring robust, reliable long-term production with high system availability. Intelligent force/displacement monitoring ensures stable and precise joining processes, even with large tolerances, variable geometries and heavy components. Energy-efficient servo drives and hydro-pneumatic systems reduce maintenance requirements and operating costs, whilst modular system concepts enable flexible production of a wide variety of heavy-duty components. Open interfaces also facilitate easy integration into modern, networked production environments, and controlled motion sequences as well as CE-compliant safety concepts enhance safety and ergonomics when handling large components.
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.
Aligning the piston rod with the telescopic rod
Pressing in wheel bolts
Clinching the clamping strap
Assemble battery housing
Pressing fan wheels onto the motor shaft
Practical applications from intralogistics manufacturing demonstrate solutions for compact assemblies, modular vehicle concepts and a wide range of variants.
Servo presses and power packages enable highly precise, monitored joining processes with full documentation, thereby ensuring maximum operational reliability and consistent quality. Modular press systems with rapid set-up processes support the efficient production of vehicle designs with a wide range of variants, whilst energy-efficient servo drives and pneumo-hydraulic power units reduce energy consumption, maintenance requirements and operating costs. Open interfaces such as OPC UA, MQTT, Profinet, Ethernet/IP and EtherCAT also enable seamless integration into digital production and automation environments, whilst servo-controlled movements and CE-compliant machine designs ensure safe, ergonomic workplaces and high process stability.
Standard machines often reach their limits when it comes to complex commercial vehicle applications. Installation space, power requirements, cycle times and the level of automation call for bespoke solutions. In many applications, it is crucial that the press comes to the part—rather than the other way around—to ensure maximum flexibility when dealing with large components and a wide variety of variants.
TOX® develops customised special presses and hand presses that are precisely tailored to:
component geometries
required pressing forces
Line integration
automation requirements
process monitoring
are tailored – from individual workstations to fully automated production cells.
As an engineering partner, TOX® supports projects from the initial analysis right through to series production integration:
Assessment of material, geometry and load requirements
Feasibility analysis and testing
Design of tooling and press systems
Integration into existing or new production lines
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.
Modular systems for clinching, riveting and press-fitting – flexible combinations and ideal for automation
Electromechanical drives for maximum process control, energy efficiency and flexible integration
Pneumo-hydraulic drives for high pressing forces, heavy-duty applications and cost-effective mass production
Clinching straps
Pressing in wheel bolts
Fitting bushings and shafts
Connecting electrical components
Punching sheet metal
