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