THE ORBITFORM JOURNAL VOL. 2
Transcription
THE ORBITFORM JOURNAL VOL. 2
MADE IN THE USA IT ALL STARTS WITH THE CUSTOMER’S PART THE ORBITFORM JOURNAL VOL. 2 ASSEMBLY EQUIPMENT SOLUTIONS FOR MANUFACTURING SINCE 1984 RIVETING 4 6 FORMING 11 12 PROJECTION WELDING 14 16 CONVEYORS 17 18 ORBITFORM’S SOLUTIONS LAB IT ALL STARTS WITH THE CUSTOMER’S PART PERMANENT PART ASSEMBLY CONSIDERATIONS & APPLICATIONS ORBITFORM’S IMPACT RIVETING CASE STUDY ORBITFORM’S NEW SPIN ON ROLLER FORMING ORBITFORM’S NEW PRODUCTS THREE NEW WAYS TO HOLD THINGS TOGETHER ORBITFORM FOR MEDICAL DEVICES ASSEMBLY EQUIPMENT FOR MEDICAL EFFICIENT PART TRANSFER WITH ORBITFORM PALLETIZED CONVEYOR LINE HOW TO USE PROCESS MONITORING WITH ORBITAL FORMING TO REDUCE SCRAP & IMPROVE QUALITY SYSTEMS Orbitform Journal Volume 2, © 2014, Orbitform LLC www.orbitform.com All materials are owned by Orbitform unless otherwise noted. Nothing from this journal may be reproduced without permission from Orbitform LLC. Editor: John Price Graphic Designer: David Olson 2 Riveting, Forming, Welding, Projection Conveyors, Systems Orbitform designs and builds assembly equipment solutions for manufacturing including: Orbital, Spiral, and Impact riveting, Roller forming, Hot Upset forming and riveting, Projection and Resistance welding, and Palletized and Low Backline Pressure conveying systems. Orbitform’s services include Assembly Analysis, Tooling Development, and low-volume production runs. Since 1984, Orbitform has delivered over 7,000 assembly machines and custom assembly systems to a wide range of customers and industries around the world. Orbitform also manufactures a standard line of Powerheads and assembly system components for machine integrators. All Orbitform systems, machine components, spare parts and tooling are made in the USA within our one‑hundred-twentythousand square-foot manufacturing facility located in Jackson, Michigan. What sets us apart from our competitors is our unbiased approach. With Orbitform, you’re not restricted to a single product line or assembly process. It all starts with the customer’s part in our state-of-the-art Assembly Solutions Lab, where we assemble your sample parts to define, verify and optimize the assembly process that best meets your quality, strength and aesthetic requirements. We can offer a wide range of solutions, to provide you the product, process or service that’s right for your application. Our in-house engineers, technicians and machinists represent over 550 years of combined experience, and unlike our competitors, our Engineering, Manufacturing, Machine Build, Service department, Spare Parts and Tooling are all under one roof. So, whether you need a Powerhead, bench machine, multi-process workstation, multi-station work cell, or fully automated assembly system, Orbitform is your one-stop shop. Increase throughput, improve quality, reduce scrap and maximize profits. Orbitform… solutions delivered. IT ALL STARTS WITH THE CUSTOMER’S PART 3 The Orbitform Journal Volume 2 www.orbitform.com 800-957-4838 ORBITFORM SOLUTIONS LAB IT ALL STARTS WITH THE CUSTOMER’S PART At Orbitform it all starts with the customer’s part in our Assembly Solutions Lab. Our application engineers know the best way to optimize an assembly process is by assembling your sample parts. Product engineers receive invaluable feedback, suggestions for part features, and a more efficient and cost effective process. What sets us apart is our unbiased approach as you’re not restricted to a single product line. Orbitform offers a range of assembly processes including: Orbital, Spiral, Impact, Hot Upset, Roller Forming, Pressing, and Projection and Resistance welding. When spot-welding failed, an automotive parts supplier contacted Orbitform to attach a hardened steel gear to a metal stamping. Orbitform engineers suggested adding an extrusion and orbitally forming the extruded lip over the gear, eliminating the need for a costly fastener. Peen Shoulder Threaded Fastener 4 Extrusion Peen Gear In another example, a round threaded steel fastener needed to be secured into a hex hole through a 1/8” wall aluminum stamping. The fastener also needed to hold torque while a nut was applied. Projection welding was not an option with dissimilar metals. Orbitform engineers developed a cold headed, shouldered fastener and hollow peen to orbitally ring‑stake the fastener’s shoulder, locking it into place. ASSEMBLY SOLUTIONS FOR MANUFACTURING SINCE 1984 Riveting, Forming, Welding, Projection Conveyors, Systems An electrical sensor manufacture was multi-point crimping a metal cap over a heat sensor. Stress risers at the crimp points allowed moisture inside, damaging components. Orbitform engineers’ Roller Formed the cap for a tighter seal with 360 degrees of retention. An equipment manufacture was welding a hardened steel rod into a hex hole to prevent rotation, but welding annealed the rod and vibration caused some joints to fail. Orbital forming did not flow enough material to prevent rotation, so application engineers applied Hot Upset, creating a high torque joint with 99% hole-fill at a lower temperature than welding. What can Orbitform’s Assembly Solutions Lab do for you? Send us your sample parts and let us find the assembly process that best meets your needs… IT ALL STARTS WITH THE CUSTOMER’S PART 5 The Orbitform Journal Volume 2 www.orbitform.com 800-957-4838 PERMANENT PART ASSEMBLY CONSIDERATIONS & APPLICATIONS SEMI TUBULAR RIVET IMPACT FORMED SOLID RIVET IMPACT FORMED SOLID RIVET ORBITAL FORMED SOLID RIVET HOT UPSET FORMED TENON ORBITAL FORMED BOLT & NUT ORBITAL FORMED HEAD PERMANENT JOINT APPLICATIONS This article examines basic applications and considerations for common fastening and joining techniques used in permanent part assembly. There are many reasons products should not be taken apart: •Personal Safety ‑ the product is inherently unsafe to repair. •Operational Safety – high product liability if the product fails during operation. •Extreme operating forces – high shock, vibration, Push‑Pull, and Shear. •Regulatory requirements ‑ part must be new, not repaired, required by law. •Warranty / Product integrity ‑ part must be new and not repaired. •Modular assemblies – permanently assembled components. •Security/Tamper‑proof/Vandalism – you don’t want anybody messin’ with it. Industries familiar with these concerns include: Automotive, Medical, Aerospace, Aviation, Electrical, Power Distribution, Safety, Military, and basically any products where lives are on the line and product liability is high, for example: Airbag Canisters, Mountain Climbing Gear, and Fire Extinguishers. BOLT & NUT SCREW If your product doesn’t need to be taken apart, and you’re using a non‑permanent fastening method such as retaining rings, threaded fasteners, posts and cotter pins, etc., you may want to consider permanent assembly for some of the following reasons: •Reduce the cost of fastening hardware: retaining rings, threaded fasteners, nuts, washers, and cotter pins •Reducing the costs of machining operations: machining grooves and threads, drilling and tapping holes •Reducing the costs of assembly operations and cycle time: forming a rivet or post vs. installing a retaining ring, cotter pin, or driving a screw / nut •Superior retention ‑ compared to cotter pins, retaining rings, and Loctite® •Improved aesthetics ‑ Formed head versus bolt head, nut, screw head, cotter pin, or retaining ring. We recognize every application is different, and there is no “one size fits all” solution for permanent part assembly. On the next page is a matrix of fasteners & fastening processes, along with a few common joint requirements and costing considerations. COTTER PIN RETAINING RING NON-PERMANENT JOINT APPLICATIONS 6 ASSEMBLY SOLUTIONS FOR MANUFACTURING SINCE 1984 STUD & NUT Riveting, Forming, Welding, Projection Conveyors, Systems JOINT CHARACTERISTIC PERMANENT OVERALL COST ASSEMBLY LABOR COST EQUIPMENT COST MACHINING COST FASTENER COST AESTHETICS HOLE FILL SHOCK VIBRATION RESISTANT LOW PROFILE COMPRESSION (CLAMP LOAD) ARTICULATING FASTENER / PROCESS COSTING TENON ORBITAL/SPIRAL TENON HOT UPSET SOLID RIVET IMPACT SEMI-TUBULAR RIVET IMPACT RIVET ORBITAL/SPIRAL RIVET HOT UPSET BOLT/NUT FORMED NON-PERMANENT BOLT/NUT STUD/NUT SCREW RETAINING RING COTTER PIN KEY: POOR The matrix rates generic process effectiveness for each joint requirement. All fastening processes were compared based on non‑manual, using minimally‑automated methods and typical application requirements. For the rating, we examined the lowest cost and least number of machining steps to achieve the requirement in the simplest way possible. For example, a low profile joint may be achieved with a counter sink or counter bore, at the cost of extra machining, just as aesthetics is greatly determined by the type of fastener, coating and/or finish, which greatly impacts the fastener’s cost. A retaining ring or cotter pin is a more expensive fastener, compared to a rivet, especially if that cost includes a mating pin with FAIR GOOD BEST groove or through‑hole, resulting in lower machining costs because only a through‑hole for the pin is needed. Overall cost considerations include: fastener, machining, equipment/utilities, and assembly costs, based on the best overall value. All cost estimates are relative to each other across processes. For example, a tenon has no fastener, and therefore, no fastener cost relative to a rivet or bolt, but a machined tenon has a greater machining cost than a thru‑hole for a rivet or bolt. A tenon formed as part of a casting would result in a different costing analysis. IT ALL STARTS WITH THE CUSTOMER’S PART 7 The Orbitform Journal Volume 2 www.orbitform.com head and the part, the final joint will allow the rivet to float and will not provide any compressive loading. If the manufactured rivet head is supported (fig. 1.2), eliminating the gap between the part and the rivet, the joint will exhibit compressive loading. To improve clamp loading options include: a pressure pad to pre‑clamp the part, increasing the advance rate of the Powerhead, and/or using an orbital head with a reduced attack angle to increase downward force. ORBITAL‑RIVETING & FORMING Orbital riveting and forming is a cold forming process using a peen tool held at a fixed angle to create a sweeping line of pressure around the part, progressively forming the material with each rotation. This process (fig. 1.1) reduces the amount of forming force required by approximately 80% of a standard press. The orbital process can form mild steel solid rivets from less than 1/16” up to 1‑1/2” in diameter. The orbital forming process creates a low profile, aesthetically appealing finish, and allows for joint articulation as seen in multi‑tool pliers, automotive door hinges, casters, etc. Spiral riveting and forming, also known as Radial, is similar to the Orbital process, but the material is displaced from the center outward in a rosette or rose curve pattern; this creates less side force than the orbital process, which can cause parts to wobble during forming. This is especially true when forming small diameter rivets, and/or long rivets that are not held rigid by the part SPIRAL FORMING DIAGRAM or part fixture during assembly. The Spiral process is not recommended for semi‑tubular and/or hollow rivets because the peen loses contact with the part being formed. 800-957-4838 FIGURE 1.1 ORBITAL FORMING DIAGRAM head’s planetary gear, thrust plate, and pressure cup significantly increases overall cost of ownership. H o w e v e r, f o r l o n g , t h i n , a n d unsupported rivets, Spiral/Radial may be the better option. In general, Orbital has a longer reach than spiral, which can be further extended using a special 3 or 4 degree long‑reach orbital head, or an orbital head extension. To form around obstructions, options include: a c‑frame orbital head with an anti‑rotate device, an offset orbital head, and/or a modified peen with anti‑rotate device. In addition, orbital heads can be configured to form multiple rivets simultaneously, using multi‑spindle or multi‑point tooling heads. Clamp loading will vary based on forming a tenon or rivet, the type of material, tooling, and fixturing used. For example, If the part is supported (fig. 1.3), allowing a gap between the manufactured rivet Both Orbital and Spiral processes are recommended for low profile joints requiring articulation, because they form the rivet head without completely collapsing the shank. Clamp load can be adjusted to maintain some rotational torque/ friction, as required in applications such as surgical scissors. Retaining rings and cotter pins allow articulation, but do not provide compressive loading characteristics, and therefore allow vibration between the fastener and the parts. If the joint requires superior clamp loading and torque control, one fastening option is to use a bolt and nut, and then orbitally form the bolt against the face of the nut, locking the nut in place. Another option is to orbitally ring‑stake the nut into the bolt’s threads to permanently lock them together. This additional operation adds to the production cost and reduces throughput. As a permanent solution, this is only recommended when extreme clamp loading and precise torque control is needed. As a rule of thumb, 90% of all Radial/Spiral riveting can be done with the Orbital process, with lower maintenance costs as compared to the Spiral/Radial process. The complexity of the Spiral tooling FIGURE 1.2 8 ASSEMBLY SOLUTIONS FOR MANUFACTURING SINCE 1984 FIGURE 1.3 Riveting, Forming, Welding, Projection Conveyors, Systems of material until the bottom layer is displaced into a pocket in the anvil, creating a button shape similar to clinching. This process eliminates the cost of machining a hole, but with the absence of a hole, some applications may require external fixturing to align the parts. HOT UPSET FORMING & RIVETING The Hot Upset forming and riveting process uses heat and pressure to form the fastener. Similar to electro‑forging, the heated material becomes malleable and collapses under pressure applied by the Powerhead. With this process it is possible to form a round fastener into a square hole, creating a high‑torque joint. Unlike welding, in most cases the base material does not bond with the fastener, but depending upon the material bonding may occur. In addition, this process may change the microstructure of the material being formed, altering its metallic properties. Testing the rivet or formed material is recommended. As a rule of thumb, Hot Upset is best suited for hardened materials that cannot be formed by other methods. This unique process provides greater hole‑fill, over 98% percent, increases push‑out force, and creates an overall tighter joint due to molecular contraction during cooling. This process is not HOT UPSET JOINT DIAGRAM recommended for joints that require articulation; it may also affect surface coating aesthetics. Example applications include automotive striker‑wires, ball studs, and joints with high torque and high shock or vibration requirements, such as military weaponry. slower than orbital or impact riveting. In addition, hot parts require special handling considerations. Direct current (DC) powered systems are more efficient and precise than their AC counterparts, but come at a higher initial cost. Cost of ownership includes power consumption and tooling electrodes. Hot Upset systems also require a chiller to maintain optimal tooling temperature. Standard Impact Riveting machines have a much quicker cycle time than standard Orbital, Spiral and Hot Upset machines, and provide higher production throughput, commonly used for high volume commodity products such as HVAC duct work, brake pads, and circuit breakers. In addition, impact machines include automatic rivet feeding systems, eliminating manual rivet handling, making the process ideal for installing multiple rivets in a single part assembly. In most cases the IMPACT RIVETING ‑ SOLID & SEMI TUBULAR RIVETS Impact Riveting is a cold forming assembly process using pneumatic, electro‑mechanical, hydra‑pneumatic, or hydraulic force to install a rivet. Joint characteristics can vary greatly depending on the rivet type, material and geometry. Some common rivet types include solid, semi‑tubular, and self‑piercing. The forming sequence is unique to each type of rivet. The shank on a solid rivet must swell to fill the hole before the head collapses. On a semi‑tubular rivet, the hollow tenon curls over on impact, drawing the parts together with minimal shank swell. Self‑piercing rivets (fig. 1.4), used to join sheet metal and other thin materials, pierce the upper layers FIGURE 1.4: SELF-PIERCING RIVET operator handles the part, so there is no cost for part fixturing. High capacity impact machines can install solid rivets up to 5/8” inches in diameter, providing a robust, low‑profile, solution for permanent a s s e m b l y. Ty p i c a l p e r i s h a b l e tooling includes: Jaws, Drivers, and Rollsets. For high volume assembly of brittle materials like clutch assemblies, circuit boards and plastics, riveting machines can be configured with load‑deflecting components. Hot Upset typically has a 3‑4 second cycle time, which is generally THE IMPACT RIVETING PROCESS IT ALL STARTS WITH THE CUSTOMER’S PART 9 The Orbitform Journal Volume 2 To consolidate equipment and reduce the work area footprint, a single machine can be configured to install up to four rivets simultaneously; other options for multi‑riveting include dual head and multi‑head machines. Using an offset driver accessory, riveting heads can be positioned as close as 1/16” of an inch between rivet heads. ROLLER FORMING––ASSEMBLING CYLINDRICAL PARTS Another permanent fastening method, specifically designed for assembling large diameter parts, is Roller Forming. Roller Forming is a non‑impact process using a spinning Roller‑head with two or more rollers to apply a symmetrical force to the part. Roller forming is used for flaring, forming a lip, crimping, or forming a groove in cylindrical parts too large for other processes. Assembly applications include: water pumps, bearings, ball joints, air bag canisters, electrical sensors, fuses, solenoids, and parts where a groove or lip is needed, such as sealing the end of a tube. www.orbitform.com cycle times range from 3‑5 seconds depending on the application. Articulating Roller‑heads are used for navigating around part obstructions and applying horizontal pressure needed for crimping or grooving applications. Pneumatically actuated Articulating Roller‑heads can deliver a horizontal force up to 5,000 lbs. @ 100 psi. Typical cycle times for an Articulating Roller‑head range from 4‑10 seconds depending on the application. Roller Forming’s non‑impact symmetrical loading and precision control allows this process to form a retaining lip over glass or other brittle materials. Roller Forming can also replace multi‑point crimping with a full 360 degrees of contact retention. If a torque resistant interface is required, rough or knurled mating component surfaces are needed 800-957-4838 to grip against the formed lip or groove. This process can, in some cases, replace welding to provide a strong joint with an aesthetically appealing finish, reducing production time and assembly cost. Sealing characteristics depend on the part’s design and usually requires the addition of a gasket or O‑ring; customer testing is highly recommended. If your product doesn’t need to be taken apart for shipping, maintenance or repair, permanent part assembly can be a cost effective solution to other fastening methods, in addition to increasing production throughput, and reducing fastener, machining, and overall assembly costs; you also get the many inherent benefits of permanently assembling your product. As a general rule, 90% of all Roller Forming applications are between 3/8” and 6” inches in diameter. Wall thickness can vary from 1/32” to over 1/4” of an inch depending on the type of material. The Roller‑head RPM and advance rate are controlled by a Powerhead configured with an integrated Load Cell and LVDT for process monitoring and control. For part clamping, a Thru‑Spindle Pressure Pad option is available. For static Roller‑heads, typical ROLLER FORMING A LIP 10 ASSEMBLY SOLUTIONS FOR MANUFACTURING SINCE 1984 Riveting, Forming, Welding, Projection Conveyors, Systems IMPACT RIVETING SOLUTIONS CASE STUDY A home improvement manufacturer needed to fasten several metal brackets to an attic door assembly. They also needed to use two different lengths of semi-tubular rivets, 3.25” and 2.50” inches in length both with oversized 9/16” diameter heads, posing a number of challenges. Fortunately, Orbitform’s Milford 423 is specifically designed to set long rivets. What made this application unique is the 423 was designed with a changeover kit to handle both rivet lengths. Because longer rivets do not feed correctly in a standard rotary hopper, the 423 comes standard with a vibratory feeder bowl. In this application the bowl diameter was increased from 14” to 18” inches to allow the 3.25” rivets to spread out to lower the spring loaded plunger on the Rollset. Once the parts were in place releasing the pedal allowed the pin to spring back and align the holes. For impact riveting applications ask about Orbitform’s Milford line of impact riveters. Orbitform... solutions delivered. EXTRA LONG ROLLSET & SAFTEY PROBE VIBRATORY BOWL ACCOMMODATES LONG RIVETS for auto feeding. As with all impact riveting applications, tooling is unique to the application. Orbitform engineers designed a custom tooling package specific to the attic door assembly including: Jaws, Drivers, and Rollsets. Because long rivets can dangle unpredictably, the 423’s Jaws are engineered to open and then close, securing and aligning the rivet during the advance phase of the cycle. IMPACT RIVETER WITH VIBRATORY FEEDER BOWL Another consideration was loading and unloading the assembly. To align the holes in the door and brackets, the Rollset Plunger needed an intrusive 3” inch stick out. An available option on the Milford line is a manually operated foot pedal IT ALL STARTS WITH THE CUSTOMER’S PART 11 The Orbitform Journal Volume 2 www.orbitform.com 800-957-4838 ORBITFORM’S NEW SPIN ON ROLLER FORMING If you are struggling to permanently assemble tubular or large diameter parts, Orbitform’s Roller Forming process may be the solution. Roller Forming is a non‑impact process using a spinning Roller‑head with two or more rollers to apply a symmetrical force to the part. Roller forming is used for flaring, forming a lip, crimping, or forming a groove in cylindrical parts too large for other processes. Assembly applications include: water pumps, bearings, ball joints, air bag canisters, electrical sensors, fuses, solenoids, and parts where a groove or lip is needed, such as sealing the end of a tube. An automotive part supplier wanted to reduce the cost and weight of their water pump by converting its cast iron housing to cast aluminum. Originally the bearing was press‑fit into the housing. The result was lighter, but thermal expansion was greater. Repeated heating ROLLER FORMED AUTOMOTIVE PART 12 and cooling caused the bearing to walk‑out. The customer tried adhesives to retain the bearing, which added expense and an additional process that was messy. Orbitform’s Applications Engineers worked with the customer to design a retaining feature that could be formed using Orbitform’s Roller Forming process to permanently retain the bearing. A custom static two‑roller tooling head was developed and tested using Orbitform’s standard Powerhead. For this application our engineers determined a rotational speed of 400 rpm was optimal when combined with the downward force of the Powerhead. The customer verified the result using a push‑out test, which caused the cast aluminum housing to fail without pushing the bearing past the formed retaining lip. A custom designed fixture held t h e h o u s i n g a s s e m b l y, a n d a Thru‑Spindle Pressure Pad held the bearing in place. Process monitoring included bearing presence confirmation, a load cell to monitor force, and LVDT to monitor the Powerhead’s stroke position. Three interchangeable Roller‑heads allowed the customer to use the same machine for three different water‑pump assemblies. Safety equipment included a light curtain, guarding and Opto‑Touch activation buttons. As a general rule, 90% of Roller Forming applications are between 3/8” and 6” inches in diameter. Wall thickness can vary from 1/32” to over 1/4” of an inch depending on the type of material. The Roller‑head RPM and advance rate are controlled by Orbitform’s standard Powerhead to precisely form the material. The Powerhead can also be configured with an integrated Load Cell and LVDT for process monitoring and control, along with a Thru‑Spindle Pressure Pad for part clamping during the forming process. For static Roller‑heads, typical cycle times range from 3‑5 seconds depending on the application. Roller Forming’s non‑impact symmetrical loading and precision control allows this process to form a retaining lip over glass and other brittle materials. This process can, in some cases, replace welding to provide a strong joint with an aesthetically appealing finish. Sealing characteristics depend on the part’s design and usually requires the addition of a gasket or O‑ring; customer testing is highly ASSEMBLY SOLUTIONS FOR MANUFACTURING SINCE 1984 Riveting, Forming, Welding, Projection Conveyors, Systems LIP GROOVE ROLLER FORMING DIAGRAM ROLLERFORMING A GROOVE recommended. Roller Forming can replace multi‑point crimping with a full 360 degrees of contact retention. If a torque resistant interface is required, rough or knurled mating component surfaces are needed to grip against the formed lip or groove. MADE IN THE USA Orbitform is the only company that offers pneumatically actuated Articulating Roller‑heads for navigating around part obstructions and applying horizontal pressure needed for crimping or grooving applications. Orbitform designs and builds assembly equipment solutions for manufacturing, including Riveting, Forming, Welding, C o n v e y o r s , and Custom Engineered Assembly S y s t e m s . O r b i t f o r m manufactures its own line of standard assembly products, all made in the USA since 1984. Services include Assembly Analysis, Tooling Development, and lowvolume production runs. Orbitform’s Articulating Roller‑heads can deliver a horizontal force up to 5,000 lbs. @ 100 psi. To fine tune the forming process or accommodate multiple parts with different diameters, Articulating Roller‑heads offer an infinitely adjustable horizontal stroke within a 3mm to 25mm range. Typical cycle times for an Articulating Roller‑head range from 4‑10 seconds depending on the application. As a replacement for welding or crimping, Roller Forming can reduce production time and assembly costs, while improving consistency, strength, and aesthetic appeal. Send us your sample parts and let Orbitform’s Application Engineers see if Roller Forming is right for you. • • • • Modular Assembly Components Custom Engineered Systmes Service Parts & Tooling Assembly Solutions Lab 1600 Executive Dr, Jackson, MI www.orbitform.com | (517) 787-9447 IT ALL STARTS WITH THE CUSTOMER’S PART ASSEMBLY SOLUTIONS FOR MANUFACTURING SINCE 1984 13 The Orbitform Journal Volume 2 www.orbitform.com 800-957-4838 ORBITFORM’S NEW PRODUCTS: 3 NEW WAYS TO HOLD THINGS TOGETHER Orbitform was proud to debut three new products this year, all aimed at meeting our customers’ needs. We introduced the new 840 Powerhead, the new Servo Powerhead, and the Standard Hot Upset machine system. THE M-840 POWERHEAD THE SERVO POWERHEAD The new Orbitform 840 Powerhead extends pneumatic capability into hydraulic level forces by providing up to 12,700 lbs of forming force, making it one of the most powerful pneumatic orbital forming systems on the market today. The 840 is offered in standard bench and pedestal machine configurations. Orbitform’s new Servo Driven Powerhead offers precision control, variable advance and retract rates, and a range of forming forces for the most delicate to the most technically demanding assembly applications. This innovative powerhead provides the control you need with the speed you want. Features & Options Include: Features & Options Include: Features & Options Include: • Cost Effective Solution for High Forming Forces • Reduce cycle time, variable advance and retract up to 4” per second. • Form Hardened Rivets • Forming Force of up to 12,700 lbs. @ 100psi • Process Monitoring and Control • Not impacted by atmospheric conditions or drops in line pressure • No Exhaust, clean-room compliant - perfect for medical and electronic applications • Precision programmed dwell in both position and time HOT UPSET RIVETING MACHINE The Hot Upset forming and riveting process uses heat and pressure to form the fastener. The material being formed becomes malleable and collapses under pressure applied by the Powerhead. Using this process, fasteners have increased hole fill, allowing the creation of very high torque joints. THE NEW 840 POWERHEAD 14 THE HOT UPSET RIVETING MACHINE • Create High Torque and High Push/Pull Force Joints • Increased Hole Fill • Resistant to Vibrational Fatigue THE ORBITFORM ADVANTAGE Orbitform designs and builds assembly equipment solutions for manufacturing, including Riveting, Forming, Welding, Conveyors, and Custom Engineered Assembly Systems. Orbitform manufactures its own line of standard assembly products, all made in the USA since 1984. Services include Assembly Analysis, Tooling Development, and Low-Volume Production Runs. Since 1984, Orbitform has delivered over 7,000 assembly machines and custom assembly ASSEMBLY SOLUTIONS FOR MANUFACTURING SINCE 1984 Riveting, Forming, Welding, Projection Conveyors, Systems systems to a wide range of customers and industries around the world. Orbitform also manufactures a standard line of Powerheads and assembly system components for machine integrators. All Orbitform systems, machine components, spare parts and tooling are made in the USA within our one-hundredtwenty-thousand square-foot manufacturing facility located in Jackson, Michigan. MADE IN USA IT ALL STARTS WITH THE CUSTOMER’S PART IMPACT RIVETING ORBITAL RIVETING Orbitform...Solutions Delivered. HOT UPSET RIVETING TOOLING ROLLER FORMING SYSTEMS ASSEMBLY SOLUTIONS FOR MANUFACTURING SINCE 1984 THE NEW SERVO POWERHEAD LBP CONVEYORS PROJECTION WELDING MODULAR COMPONENTS MADE IN THE USA PALLETIZED CONVEYORS SOLUTIONS DELIVERED 1600 EXECUTIVE DR, JACKSON, MI | WWW.ORBITFORM.COM | (517) 787-9447 IT ALL STARTS WITH THE CUSTOMER’S PART 15 The Orbitform Journal Volume 2 www.orbitform.com 800-957-4838 ORBITFORM FOR MEDICAL ASSEMBLY EQUIPMENT FOR MEDICAL DEVICES Orbitform has extensive experience with the permanent assembly of medical devices. Forming rivets as small as .048” in diameter on the most delicate Laparoscopic instruments all the way to a 5/8” inch rivet on the most durable gurney wheel, Orbitform has you covered. With Orbitform you’re not restricted to a single product line; we offer: Orbital, Spiral and impact riveting, Roller forming, and Hot Upset forming and riveting. Orbitform application engineers know how to fixture parts to allow articulation and articulation with torque like surgical scissors, and high volume production techniques like simultaneously forming multiple rivets for increased throughput. If you are using screws in your medical instruments, orbitally staking can lock threaded fasteners into place permanently. Our controls engineers understand the rigorous standards in the medical industry and know process monitoring including: rivet detection, measuring rivet height, stack up height, force applied, dwell time, forming to a height, and forming to a force to assure every rivet is formed correctly and within your spec. Ta k e y o u r m e d i c a l d e v i c e production to the next level. Orbitform designs and manufactures powerheads, bench machines, pedestal machines, work cells, all the way up to fully automated assembly systems. Orbitform… Solutions delivered. .048” SEMI-TUBULAR RIVET ARTICULATING JOINTS WITH PRECISION TORQUE Photo Courtesy of Top Shelf Manufacturing IMPACT RIVETS ON AN ORTHOPEDIC BRACE OUR SYSTEMS ASSEMBLE: • Orthopedic Braces • Defibrillator Pads • Laparoscopic Scissors • Biopsy Forceps • Knee Implants • Spinal Implants MULTI=FORM FOR HIGHER THROUGHPUT • Face Shields • Protective Gear • Sterilization Racks • Gurney Wheels • Catheters • Insulin Monitor Contacts ARTICULATING JOINTS 16 ASSEMBLY SOLUTIONS FOR MANUFACTURING SINCE 1984 Riveting, Forming, Welding, Projection Conveyors, Systems EFFICIENT PART TRANSFER WITH ORBITFORM PALLETIZED CONVEYOR LINE An automotive part supplier needed an efficient and economical way to transfer parts from multiple machining centers through a single part washer to an assembly cell. Challenges included: navigating physical obstructions on their factory floor, the interface between part washer and the Orbitform conveyor, and assuring 4 different parts arrive together as a kit at the assembly cell. Orbitform engineers examined both our Low Backline Pressure (LBP) and Palletized conveyor lines. Orbitform’s LBP conveyor allows parts to ride directly on the conveyor’s roller chain and allows parts to buffer with minimal contact force. Part washing was critical to the assembly and removing the metal chips and coolant from the deep part features required each part to be precisely oriented. To accomplish this Orbitform engineers selected our Palletized conveyor to carry custom fixtures designed to orient each part for the 40 foot ride through the Part washer. FORM PARTS ON THE CONVEYOR LINE Orbitform engineers worked closely with the customer as well as the part washer manufacture to find the optimal part transfer solution, including development of a pallet train capable of carrying all 4 parts, while still being able to navigate the turns in the 150 foot long conveyor. Because pallets move on the conveyor asynchronously, they can buffer in queue prior to part washing. Traffic controls release pallets as the part washer is ready to receive them. By eliminating bulk transfer and automating their production using Orbitform’s Palletized Conveyor, part are metered at a rate the machines and operators can handle increasing both machine and operator efficiency. Solution Delivered. LOOPS TO FIT EXISTING PLANT CONFIGURATIONS CONVEYORS FOR AUTOMATION PICK & PLACE INTEGRATION WITH ROBOTIC ARM IT ALL STARTS WITH THE CUSTOMER’S PART 17 The Orbitform Journal Volume 2 www.orbitform.com 800-957-4838 HOW TO USE PROCESS INTELLIGENCE WITH ORBITAL FORMING TO REDUCE SCRAP & IMPROVE QUALITY Manufacturers are always looking for ways to improve quality and reduce scrap to increase their bottom line. One way to do this is by adding process intelligence to your Orbital assembly system. The physical part and or part specification always dictates what type and what configuration is needed. In example 1, even though the hard-stop is the same on both forms the rivet heads deform differently because of variations in rivet length and part stack up. Part testing is required to determine if both these rivets are formed within the customer’s specifications. If both of these rivets are acceptable, forming to a hard-stop may be the best solution. If the rivet form is outside the customer’s spec, then some type of process intelligence may be required. Factors that can affect the type and configuration of Process Intelligences include: • Part Geometry and rivet access • Variations in Parts, Stack-Up, and rivet length. • Form Spec: Shear, Push/Pull, Torque, etc. • Material: non-Ferris, mild steel, Stainless, etc. 18 Hard Stop Hard Stop Rivet Rivet Stick-Up Stick-Up Stack Stack UpUp Forming to a hard-stop is generally the fastest most repeatable orbital riveting configuration, but variations in part thickness and rivet length will affect the final form. Many times our application engineers form coupons in our Assembly Solutions Lab to determine if a good part can be made at the upper and lower limits of variation. Short Rivet / Long Stackup Short Rivet / Long Stackup Long Rivet / Short Stackup Long Rivet / Short Stackup EXAMPLE 1 INITIAL INITIAL HEIGHT HEIGHT FINAL HEIGHT FINAL HEIGHT STACK UP STACK UP HEIGHT HEIGHT FIGURE 1 • Fixturing: The part must be stable measurement and process control. • Head Form shape: A reliable datum surface PRE-FORM MEASUREMENT: • C y c l e Ti m e : M a y i n c r e a s e cycle‑time Process Intelligence can occur before, during,and after the forming process. The stages are: Pre-Form Measurement, Process Control and Process Monitoring. They can also be combined, for example pre-form Pre-Form measurement occurs prior to forming to verify the part is good to form. Forming a short rivet, oversized part or not detecting a missing component could send an expensive assembly to the rework shop or scrap heap. But this Pokayoke approach comes at the cost of increased cycle time. The question ASSEMBLY SOLUTIONS FOR MANUFACTURING SINCE 1984 Riveting, Forming, Welding, Projection Conveyors, Systems is, “To scrap or not to scrap?” For high volume inexpensive parts it may make financial sense to form and then scrap assemblies out of spec. Scrapping complex assemblies or components made from expensive materials such as titanium can be costly and well worth the increased cycle time required to measure. Typical Pre-Form Measurements: (Figure 1) • Rivet Height • Part Stack Up • Rivet Stick Out (calculated) Measurements that are out of spec set a machine fault and stop the forming process allowing good parts to be salvaged before they’re permanently assembled. Pre-form measurements can also help isolate production problems upstream, for example a bad batch of rivets or out of spec parts, as well as detecting problems with the assembly equipment such as a broken peen. PROCESS CONTROL: Process Control occurs during the forming process to control the force and/or distance. Cycle-time may need to increase as higher forming speeds can affect the ability to accurately hit target parameters Typical Process Control Measurements: • Form to a Force • Form to a distance • Form to a distance offset from a surface In forming to a distance offset, a height sensing pressure pad is required to establish a surface location. Forming to a force requires a load cell and electronic air regulator. Process control is the more costly of the three process intelligence stages, but for assembling expensive components, the extra cost can easily be justified. PROCESS MONITORING: Process monitoring reports the maximum value of the forming parameters after completion of the forming process. Parts formed out of spec trigger a machine fault alerting the operator. Cycle-time is not effected as passive monitoring happens during forming. Process monitoring is a good fit when quality control is needed and forming and scrapping out of spec parts makes financial sense. Typical Process Monitoring: • Final Form Height • Peak Force • Form Collapse • Touch Point (Rivet Contact) Depending on the configuration adding Process intelligence to an assembly system requires additional hardware such as a load cell, LVDT, electronic air regulator, clutch brake, and/or height sensing pressure pad. But the increased machine cost and potential increase in cycle time may be well worth the expense for components or sub-assemblies that are too costly to scrap or require a high level of quality control as in medical and aerospace applications. To improve quality, reduce scrap and increase your bottom line, process intelligence can be a cost effective solution. IT ALL STARTS WITH THE CUSTOMER’S PART 19 IT ALL STARTS WITH THE CUSTOMER’S PART RIVETING FORMING CONVEYORS SYSTEMS ASSEMBLY EQUIPMENT SOLUTIONS Orbitform designs and builds assembly equipment, including Riveting, Forming, Welding, Conveyors, and Custom Assembly Systems. Orbitform manufactures its own line of assembly components, made in the USA since 1984. Services include Assembly Analysis, Tooling Development, and low-volume production runs. MADE IN THE USA TOOLING (800) 957-4838 www.orbitform.com VOLUME 2 1600 Executive Dr Jackson, MI 49203 PROJECTION WELDING POWERHEADS & ASSEMBLY COMPONENTS
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On the next page is a matrix of fasteners & fastening
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