Help Me Understand Toggle-Aire Press Shut Height and Stroke

Shut height is distance between the ram and the bolster plate when the ram is down or “doing work.” Stroke is the distance from shut height and full retract. On Toggle-Aire press Models 1030 & 1530 the stroke is specified as 2.5”, but this is a nominal dimension because stroke changes depending on the shut height adjustment and the linkage geometry. Therefore, we don’t focus on stroke what matters is shut height. We can provide customers with shorter strokes on Toggle-Aire presses, but nothing longer than the specified standard stroke. The Toggle-Aire Models 2530 &3530 have a standard stroke of 1.5”, but can be offered with 2” as option.

Force Monitoring Options: Closed Loop vs. Force Triggering

The closed loop FM-CL package will allow for data logging via the MS excel spreadsheet which can/will allow for record keeping data/QC if this is needed. This system also provides monitoring of the pressure in the system as well to always ensure the correct force is being applied to the part. If they do an outside form of inspection/QC then the FM package would be sufficient it will still provide them with data logging via the MS excel spreadsheet. Both provide an accurate measurement of force via a load cell. The FM package includes only a load cell that is calibrated to a given engineering unit and provides no compensation or monitoring to the pressure in the system, hence the non-closed loop. With the FT package this will provide a basic pressure monitoring system, which if mathematically extrapolated can provide you with a given force of the system. All the systems will provide an accurate force over a given pressure range. However, If they need a full feedback (IE: displays/readouts/data logging/force via a load cell) the FM-CL would be the best option. If they need to press to a given engineering unit with minimal feedback (IE: data logging/force via a load cell) the FM package would be suitable. Inversely if they need a price conscious system that provides the basic mathematical force with no feedback (IE: pressure monitoring only) then the FT package will suffice.

When do I need the ASH- Adjustable Hard Stop option?

The ASH (Adjustable Hard Stop) is an optional featured offered with our Direct-Aire press series. You may be able to perform your operations without this feature by simply placing stop blocks(block of steel) between the ram and bottom plate to stop the ram from entering too deep into your parts. Our ASH utilizes a common piston shaft with a ram protruding from the top with an adjustable collar for depth setting.

What is the FRL– Filter, Regulator Lubricator?

The FRL is an essential component to long trouble free operation of any pneumatically operated device. The FRL cleans the air and supplies lubrication to the internals of the valving and seals, as well as offering adjustability of pressure. This is offered as an option since facilities/ operation managers have a preference on how they maintain their air supply systems – dryers, condensers, FRL, etc.

Setting up your FRL? Click Here:FRL FAQ

What is the NR- Non Rotating Ram and what purpose does it serve?

In Direct Air Presses- just as your older units, the piston is free to rotate inside the cylinder unless there is a mechanism designed to stop possible rotation of the ram. In some applications it’s not a concern – such as having a simple flat on the ram that is used to press fit components – in such application the ram rotation has no impact on the operation – however, if an application was to punch a shape such as a square – you would not want rotation to occur as it would destroy the tooling and offer inferior quality parts.

What is the SV- Tooling Set-Up Valve and what purpose does it serve?

The Set-Up Valve is the small toggle switch feature located at the back of Direct-Aire presses – when flipped on, it activates and holds the ram to the down position. When flipped off – ram returns up. This feature is used for setting tooling to the proper depth more value ad

What are the ways that TOGGLE-AIRE® presses can be controlled?

1. BEM Impulse Mode.

In operation, this control method requires momentary actuation of the Synchro-Sig two hand unit to initiate the press cycle. Once the press has been activated the ram will descend until it reaches the bottom of the stroke where the linkage stops against a positive stop before the press will reverse. The ram will not return up until it reaches maximum strength and travel. The BEM Impulse mode of operation insures a very accurate stroke and helps guard against inattention of the operator, loss of air pressure, improper loading etc., and maintains the quality of the work being performed. Repeatability in this mode is plus or minus .001″

2. CSR-G2 (Constant Signal Required Mode, Version 2) CURRENT STANDARD CONFIGURATION

This method of control requires that the operator’s hands be held down on the SS-actuator for the full duration of the down stroke of the press. If one or both hands are removed before the press ram reaches bottom the ram will instantly reverse and return to the top of the stroke and await a new signal from the two hand unit. This method of operation is especially useful in applications requiring slow ram speeds or special loading considerations. As the standard configuration, operators are told to keep both hands on the controller until the press automatically cycles. Once the ram has bottomed, it will automatically reverse and retract, insuring a complete and accurate part, while maintaining a safe operation.

3. SAR Stall Activated Reverse.

In this method of control the press ram reverses automatically as soon as it stalls, regardless of its position relative to the bottom of the stroke. It is quite useful in coping with tolerance variations of parts to be assembled, die castings, etc., as the ram does not have to reach absolute bottom before it will retract. it is important to remember that this can be used only if you have established that the press will have enough power to do the job in question throughout the full range of your parts, that is, both ends of the tolerances. See the RAM FORCE tables for each model to determine how much power you will have at your disposal. The SAR Stall Activated Reverse Mode is also very useful in delicate jobs. By playing the air supply pressure against the depth setting of your tools you can, in effect, reverse the press when a desired maximum force has been developed and create a very delicate stroke which will not damage fragile parts, etc.

4. CSR (Constant Signal Required)

This standard method of control for our Direct-Aire presses means the ram stays down as long as the operator keeps their hands on the controller. Once removed it retracts.



Example Looking to punch 0.25″ diameter hole in 0.125″ thick aluminum sheet. Material Strength for aluminum estimated at 25,000psi (25ksi)

(0.25″ x 3.14) x (0.125″) x (25,000psi) = 2453 lbs ( 0.125″ thickness the force charts suggests the Model 1530 Toggle-Aire can provide 2500 to 3200 lbs force between 80 and 100psi.) However, depending on sharpness of tooling and ability of your compressor to maintain working pressure, you may decide to select the Model 2530 as it provides a larger working range. Being a toggle press, the press provides a reaction force up to the max capacity of the machine. So the Model 2530 would offer more flexibility, minimizes wear on the press components, and won’t damage your parts due to the nature of reaction forces.

You will then need to refer to press force charts (found with each press model), for press based on material thicknesss to determine correct model

Why a Pneumatic Press?

AIM Joraco TOGGLE-AIRE® presses use fully pneumatic circuitry. One connection to an air-line is all you need. No clutches or brakes, no pumps, fluids or messy leaks associated with hydraulic or mechanical presses. None of the hazards of electrical controls like shocks or sparks. And pneumatic valving systems are completely compatible with any other equipment you may be using. This flexibility plus their high power and quick response make them more suitable for today’s applications than older straight cylinder presses.

Why a Toggle Press?

AIM Joraco TOGGLE-AIRE® presses combine the mechanical advantages of levers and toggles. The ram force they generate builds as they reach the bottom of their stroke and effects a powerful shockless squeeze regardless of ram speed. Forces produced don’t rely on impact. With an AIM Joraco 3 Ton press this power is over 300% greater than with a straight cylinder press of comparable size yet only 58% of the air is needed. The stroke is also very precise with a ± .001″ repeatability. All this in a compact size, with the largest of our presses fitting on a 12″ x 18″ mounting area.