OVERVIEW
WHY ORBITFORM?
Assembly Equipment Solutions for Manufacturing Since 1984
ISO
9001 : 2008 CERTIFIED
2
MADE IN USA
RIVETING FORMING WELDING CONVEYORS
Orbitform designs and builds assembly equipment solutions for manufacturing, including Riveting, Forming, Welding, Conveyors, and Custom-Engineered Assembly Systems. Orbitform also 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.
SYSTEMS
• We support competitor equipment with service parts and tooling.
SERVICES
• You have Orbitform equipment
CONTENTS
• You design or manufacture products requiring assembly
Assembly Equipment
It all starts with the customer’s part
RIVETING Orbital Riveting & Forming
WELDING Fixed Tool Resistance Welding
Bench Machines Pedestal Machines Tooling Tool Holders / Orbital Heads
Powerheads
Spiral Riveting & Forming
Powerheads
Bench Machine Configurations Tool Holders / Spiral Heads
Impact Riveting Pnematic Heads
Projection Welding
CONVEYORS Palletized Conveyors
Low Backline Pressure (LBP) Conveyors
SYSTEMS Custom Engineered Assembly Systems
Bench Machine Configurations Pedestal Machine Configurations Tooling Dual / Multi-riveting
SERVICES Solutions Lab
Tooling Development Small Volume Production
Process Monitoring & Control
FORMING Hot Upset Forming & Riveting
Assembly Analysis
Parts & Tooling
Custom Machine Configurations Process Monitoring
Roller Forming
Roller Head Configurations Tooling Process Monitoring
Options & Accessories
SOLUTIONS SINCE 1984
3
ORBITAL RIVETING & FORMING
PRESSURE AND ROTATION FROM POWERHEAD 3-6
STROKE ADVANCE
What is Orbital Riveting & Forming? Orbital Riveting and Forming is a quiet, non-impact cold forming process using an angular contact peen tool combined with pressure to form the material. The orbital process creates a low profile, aesthetically appealing head forming and finish, and can allow for joint articulation as seen in multi-tool pliers, automotive door hinges, and casters. In the Orbital process. a Peen tool is held at a fixed angle, creating a sweeping line of pressure around the part, progressively moving material with each rotation. This process reduces the amount of forming force required by approximately 75% 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.
PEEN WORKPIECE
PROCESS DIAGRAM
• Smooth, non-impact • Precision Control • Articulating Joints • Aesthetic Appeal • Single & Multi-point • 75% Less force than using a press
4
Assembly Equipment
Modular Powerhead
Bench Top Orbital Forming Machine
Orbital Forming with an X-Y Position System
SOLUTIONS SINCE 1984
RIVETING
It all starts with the customer’s part
Orbital Forming Workcell
Example of a Formed Joint
5
RIVETING
ORBITAL POWERHEADS The Industry Standard Orbitform Powerheads are available in a wide range of sizes for custom applications. They are efficient at any angle and can be easily integrated with other assembly equipment. All Powerheads are available in single, multi-spindle, or multi-point configurations and include a standard orbital head and peen. Most Orbitform powerheads come complete with pre-wired, built-in, internal limit switches. Motors are pre-wired for convenience.
MODULAR POWERHEADS PNEUMATIC
Head Forming Capacity in Mild Steel
M-125
(3.17 mm)
Lubed for Life
M-240
(6 mm)
Designed for rugged low-maintenance use, Orbitform Powerheads come with hassle-free lifetime bearing and seal lubrication. Without preventive maintenance the life expectancy of a competitor’s Powerhead is often greatly reduced. With Orbitform’s orbital powerheads the components can last for years. Orbitform’s main drive spindle incorporates a set of angular contact bearings as opposed to a single row of thrust bearings. With this arrangement the comparable thrust capacity is significantly greater, by as much as 40 percent.
M-310
NOTE: Motors and limit switches are CE marked and compliant with European safety regulations 6
.236 .312
(7.92 mm)
.312
.06-1.5
(38.1 mm)
.06-1.75
(44.45 mm)
.06-2.0
(50.8 mm
.06-2.5
M-320
(7.92 mm)
M-500
(12.7 mm)
M-503
(12.7 mm)
M-506
(12.7 mm)
M-750
(19.05 mm)
(63.5 mm
MODULAR POWERHEADS HYDRAULIC
Head Forming Capacity in Mild Steel
Stroke
M-1000 AVAILABLE OPTIONS: 220-240V 50 Hz single phase motor or 380440V 50 Hz three phase motor.
.125
Stroke
.500 .500 .500 .750
1
(25.4 mm)
1
M-1006
(25.4 mm)
M-1500
(38.10 mm)
1.5
Assembly Equipment
(63.5 mm
.06-2.5
(63.5 mm
.75-3.0
(76.2 mm
3.5-6.0
(152.4 mm)
.06-2.5
.06-2.5
(63.5 mm
4.0-6.0
(152.4 mm)
.06-3.0
(76.2 mm
NEAR RIGHT: Orbitform Modular Powerhead FAR RIGHT: Orbitform bench machine with an interchangeable spiral powerhead Stroke
.06-1.5
Maximum Downward Force
Weight
590 lbs.
80 lbs.
(38.1 mm)
@ 100 psi
A
1.5
B
3.0
mm)
(38.1 mm)
)
(44.45 mm)
.06-1.75 1460 lbs. @ 100 psi
100 lbs.
(44.45 mm) (95.2 mm)
.06-2.0
2120 lbs.
120 lbs.
(44.45 mm) (133.4 mm)
.06-2.5
2120 lbs.
120 lbs.
(63.5 mm)
.06-2.5
4400 lbs.
240 lbs.
(63.5 mm)
.75-3.0
4400 lbs.
240 lbs.
(63.5 mm)
mm)
mm)
(50.8 mm) (63.5 mm)
@ 100 psi
@ 100 psi
@ 100 psi
(76.2 mm)
1.75
3.75
1.75
5.25
2.5
2.5
5.25
(133.4 mm)
8.0
C
4.0
(101.6 mm)
5.5
(139.7 mm)
7.0
(177.8 mm)
7.0
(177.8 mm)
9.5
D
5.0
(127 mm)
6.5
(165.1 mm)
8.75
(222.3 mm)
8.75
(222.3 mm)
12.75
E
21.0
(533.4 mm)
23.0
(584.2 mm)
28.38
(720.8 mm)
28.38
(720.8 mm)
31.38
mm)
(63.5 mm)
mm)
(76.2 mm)
mm)
3.5-6.0
4400 lbs.
(152.4 mm)
@ 100 psi
375 lbs.
(63.5 mm)
.06-2.5
7510 lbs.
350 lbs.
(63.5 mm)
(203.2 mm)
(241.3 mm)
(323.8 mm)
(952.5 mm)
Maximum Downward Force
Weight
A
B
C
D
E
mm)
(63.5 mm)
rming y in eel
Stroke
mm)
(63.5 mm)
mm)
mm)
RIVETING
rming y in eel
It all starts with the customer’s part
@ 100 psi
@ 100 psi
.06-2.5
18,000 lbs.
350 lbs.
4.0-6.0
18,000 lbs.
450 lbs.
(152.4 mm)
@ 1000 psi @ 1000 psi
38,500 lbs. 625 lbs. (76.2 mm) @ 1000 psi .06-3.0
2.5 2.5 2.5
2.5
(63.5 mm)
6.0
(152.4 mm)
3.0
(76.2 mm)
(203.2 mm)
8.0
(203.2 mm)
8.0
(203.2 mm)
8.0
8.0
(203.2 mm)
8.0
(203.2 mm)
8.0
(203.2 mm)
(241.3 mm)
9.5
(241.3 mm)
9.5
(241.3 mm)
9.5
9.5
(323.8 mm)
12.75
(323.8 mm)
12.75
(323.8 mm)
12.75
12.75
(797 mm)
31.38
(797 mm)
37.5
(952.5 mm)
37.5
37.5
(241.3 mm)
(323.8 mm)
(952.5 mm)
9.5
12.75
43.26
(241.3 mm)
(323.8 mm)
12.0
14.0
(304.8 mm) (355.6 mm)
SOLUTIONS SINCE 1984
F
4.0
G
Air Consumption Displacement
SCFM @ 100 PSI*
6.19
16 cubic in.
.72
5.5
5.75
46 cubic in.
2.07
7.5
6.5
62 cubic in.
2.80
7.5
6.5
62 cubic in.
2.80
7.5
5.19
208 cubic in.
9.39
7.5
5.19
208 cubic in.
9.39
7.5
6.25
370 cubic in.
16.88
7.5
6.25
364 cubic in.
16.43
F
G
9.0
9.25
8.5
7.5
(101.6 mm)
(157.2 mm)
(139.7 mm) (146.0 mm)
(190.5 mm) (165.1 mm)
(190.5 mm) (165.1 mm)
(190.5 mm) (131.8 mm)
(190.5 mm) (131.8 mm)
(190.5 mm) (158.8 mm)
(190.5 mm) (158.8 mm)
(228.6 mm) (234.9 mm)
(1098.8 mm)
(215.9 mm) (190.5 mm)
49.88
10.12
(1266.95 mm) (257 mm)
14.5
(368.3 mm)
7
BENCH MACHINES Flexible Assembly Solutions
Orbitform bench machines are designed for tabletop use across multiple industries and applications. The Flexible design allows components to be added to support many applications. All bench machines are pneumatic. Force is caculated based on 100 psi line pressure. For a list of options and accessories, see page 14 Rivet Diameter
A Stroke (min/max)
Maximum Downward Force
Complete Workstations Include:
B-125
.125
.06-1.5
(38.1 mm)
590 lbs.
@ 100 psi
• Powerhead Assembly
B-240
.236
.06-1.75
1460 lbs. 25
• Cast column and base with
B-310
.312
.06-1.75
2120 lbs. 58
B-500
.500
(12.7 mm)
.06-2.5
4400 lbs. 100
(63.5 mm) @ 100 psi
B-503
.500
(12.7 mm)
.75-3.0
4400 lbs. 100
(73.5 mm) @ 100 psi
B-506
.500
(1.27 mm)
3.5-6.0
4400 lbs. 120
(152.4 mm) @ 100 psi
B-750
.750
.06-2.5
7510 lbs. 110
BENCH MACHINES
vertical adjustment • Availible with & without controls • Dual palm buttons
8
(3.17 mm) (6 mm) (7.92 mm)
(19.5 mm)
We
150
(44.45 mm) @ 100 psi (44.45 mm) @ 100 psi
(63.5 mm) @ 100 psi
Assembly Equipment
F
J
K
A
OPOSITE PAGE: Bench Machine on Machine Base with Guarding and Controls E max
H
C
D
um ard
bs.
psi
Weight
150 lbs.
lbs. 250 lbs. psi
lbs. 580 lbs. psi
0 lbs. 1000 lbs. psi
0 lbs. 1000 lbs. psi
0 lbs. 1200 lbs. psi
lbs. 1100 lbs. psi
B
3.5
(88.9 mm)
4.50
(10.16 mm)
5.25
(133.35 mm)
8.0
(203.2 mm)
8.0
(203.2 mm)
8.0
(203.2 mm)
8.0
(203.2 mm)
LEFT: Measurements Chart RIGHT: Orbitform B-500 Bench Machine
G
B
RIVETING
It all starts with the customer’s part
C
7.0
(44.45 mm)
8.75
(222.3 mm)
11.25
D
13.0
(330.2 mm)
E
30.5
16.0 16.0
(406.4 mm)
16.0
(406.4 mm)
16.0
(406.4 mm)
11.0
(762 mm)
(279.4 mm)
14.75
35.75
19.25
19.0
41.62
G
2.0
(50.8 mm)
4.0
(374.65mm) (908.05 mm) (488.95mm) (10.16 mm)
(285.75 mm) (482.6 mm) (1057.1 mm)
(406.4 mm)
F
28.0
(711.2 mm)
28.0
(711.2 mm)
28.0
(711.2 mm)
28.0
(711.2 mm)
49.38
(1254.2 mm)
49.38
(1254.2 mm)
61.0
(1549.4 mm)
57.25
(1454.1 mm)
SOLUTIONS SINCE 1984
18.0
(457.2 mm)
27.0
(685.8 mm)
27.0
(685.8 mm)
27.0
(685.8 mm)
27.0
(685.8 mm)
5.38
H
8.0
(203.2 mm)
J
4.5
(114.3 mm)
12.75
6.0
13.25
7.5
(323.85 mm) (152.4 mm)
(136.65 mm) (336.55 mm) (190.5 mm)
6.0
(152.4 mm)
6.0
(152.4 mm)
6.0
(152.4 mm)
6.0
(152.4 mm)
18.0
(457.2 mm)
18.0
(457.2 mm)
18.0
(457.2 mm)
17.0
(431.8 mm)
10.0
(254 mm)
10.0
(254 mm)
10.0
(254 mm)
10.0
(254 mm)
K
11.0
(279.4 mm)
13.25
(336.5 mm)
15.5
(393.7 mm)
18.0
(457.2 mm)
18.0
(457.2 mm)
18.0
(457.2 mm)
18.0
(457.2 mm)
9
PEDESTAL MACHINES
For standard parts that require loading clearance, Orbitform’s pedestal machines are the answer. Fabricated steel frames provide stability during the forming process. These stand alone machines, with built-in heightadjustable work surface, provides comfortable work-positioning and unrestricted access. Orbitform pedestal machines are availible in both pneumatic and hydraulic. Features include: • Fixed powerheads with adjustable work surface • Heavy duty steel frame • Same controls and features as bench machines
PEDESTAL MACHINES PNEUMATIC
P-500 P-506 P-750
Stroke
.500
.06-2.5
(12.7 mm)
.500
(12.7 mm)
.750
(19.05 mm)
(63.5 mm)
3.5-6.0
(152.4 mm)
.06-2.5
(63.5 mm)
Maximum Downward Force
Weigh
4400 lbs. 850 lb
@ 100 psi
4400 lbs. 1050 l
@ 100 psi
7510 lbs.
@ 100 psi
950 lb
PEDESTAL MACHINES HYDRAULIC
Head Forming Capacity in Mild Steel
Stroke
P-1000
1
.06-2.5 18,000 lbs. 1150 lb
P-1006 P-1500 10
Rivet Diameter
(25.4 mm)
1
(25.4 mm)
1.5
(38.1 mm)
(63.5 mm)
Maximum Downward Force
Weigh
@ 1000 psi
4.0-6.0 18,000 lbs. 1150 lb
(152.4 mm)
@ 1000 psi
.06-3.0 38,500 lbs. 1500 l
(76.2 mm)
@ 1000 psi
Assembly Equipment
ABOVE: Standard Pedestal Machine RIGHT: P-1000 Standard Pedestal Machine with Custom Part Fixture, Light Curtain, and Guarding Accessories Weight
bs. 850 lbs.
bs. 1050 lbs.
bs.
m d
RIVETING
m d
It all starts with the customer’s part
950 lbs. Weight
bs. 1150 lbs.
si
bs. 1150 lbs.
A
2.5
(63.5 mm)
2.5
(63.5 mm)
2.5
(63.5 mm) A
2.5
(63.5 mm)
2.5
si
(63.5 mm)
si
(76.2 mm)
bs. 1500 lbs.
3.0
B
9.0
(28.6 mm)
9.0
(28.6 mm)
9.0
(28.6 mm) B
9.0
(28.6 mm)
9.0
(28.6 mm)
9.0
(28.6 mm)
C
D
E
F
G
H
J
K
12.0
33.0
86.0
36.0
48.0
48.5
14.0
25.0
12.0
33.0
92.0
36.0
48.0
48.5
14.0
25.0
12.0
33.0
87.0
36.0
48.0
48.5
14.0
25.0
C
D
E
F
G
H
J
K
12.0
52.0
86.0
36.0
48.0
48.5
14.0
25.0
12.0
52.0
92.0
36.0
48.0
48.5
14.0
25.0
12.0
64.0
104.0
36.0
48.0
48.5
21.0
32.0
(304.8 mm) (838.2 mm) (304.8 mm) (838.2 mm) (304.8 mm) (838.2 mm)
(2184.4 mm) (914.4 mm) (1219.2 mm) (1231.9 mm) (355.6 mm) (635 mm) (2336.8 mm) (914.4 mm) (1219.2 mm) (1231.9 mm) (355.6 mm) (635 mm) (2209.8 mm) (914.4 mm) (1219.2 mm) (1231.9 mm) (355.6 mm) (635 mm)
(304.8 mm) (1320.8 mm) (2184.4 mm) (914.4 mm) (1219.2 mm) (1231.9 mm) (355.6 mm) (635 mm) (304.8 mm) (1320.8 mm) (2336.8 mm) (914.4 mm) (1219.2 mm) (1231.9 mm) (355.6 mm) (635 mm) (304.8 mm) (1625.6 mm) (2641.6 mm
SOLUTIONS SINCE 1984
L
36.0
(914.4 mm)
36.0
(914.4 mm)
36.0
(914.4 mm) L
36.0
(914.4 mm)
36.0
(914.4 mm)
46.0
(914.4 mm) (1219.2 mm) (1231.9 mm) (533.4 mm) (812.8 mm) (1168.4 mm)
11
ORBITAL TOOLING Orbitform has the engineering and manufacturing resources to offer replacement parts, and riveting and forming tools. We offer quick turnaround and blanket orders - to help meet your needs.
FLAT PEEN
CONICAL PEEN
CAPTURED FLAT PEEN
CROWN PEEN
CONICAL FORM
FLAT FORMC
APTURED FORM
CROWN FORM
FLARE PEEN
EYELET PEEN
RING STAKE PEEN
CRIMPING PEEN
FLARE FORM
EYELET FORM
RING STAKE FORM
CRIMPING
ABOVE: Orbital forming tools (peens) can be designed to satisfy your specific application needs. For information on orbital applications, spare parts or anything related to forming, fastening, joining, and assembly, please call 1-800-957-4838 or e-mail sales@orbitform.com 12
Assembly Equipment
RIVETING
It all starts with the customer’s part
TOOL HOLDERS HS/ GS Series SINGLE POINT ORBITAL HEAD DIMENSIONS
HS-250 HS-310 HS-500 HS-750 HS-1000-4 HS-1000-6 HL-225 HL-250 HL-310 HL-500 HL-600 HL-700 HL-750 HL-900
Peen Diameter
.312
(7.92 mm)
.312
(7.92 mm)
.50
(12.7 mm)
.75
(19.05 mm)
1.0
(25.4 mm)
1.0
(25.4 mm)
.312
(7.92 mm)
.312
(7.92 mm)
.312
(7.92 mm)
.50
(12.7 mm)
.625
(15.87 mm)
.75
(19.05 mm)
.75
(19.05 mm)
1.0
(25.4 mm)
Capacity
.180
(4.57 mm)
.312
(7.92 mm)
.50
(12.7 mm)
Peen Length
A
B
2.187
1.75
4.0
(55.55 mm) (44.45 mm) (101.6 mm)
1.625
(41.27 mm)
2.25
(57.15 mm)
.75
3.0
1.0
5.0
(19.05 mm) (76.2 mm) (25.4 mm)
1.0
(25.4 mm)
.180
(4.57 mm)
.180
(4.57 mm)
.312
(7.92 mm)
.50
(12.7 mm)
.625
(15.87 mm)
(127 mm)
5.0
(127 mm)
2.187
2.0
(50.8 mm)
3.5 3.5
(88.9 mm)
1.43
(36.32 mm)
1.38
(35.05 mm)
2.75
5.0
3.62
6.0
2.0
4.5
8.0
3.0
8.0
2.88
4.625
1.5
(69.85 mm) (635 mm)
1.50
(127 mm)
(91.95 mm) (152.4 mm) (50.8 mm) (114.3 mm)
5.0
(127 mm)
1.5
(55.55 mm) (38.1 mm) (88.9 mm)
4.0
(101.6 mm)
C
1.75
(203.2 mm) (76.2 mm) (203.2 mm) (73.15 mm) (117.47 mm) (38.1 mm)
6.5
(44.45 mm) (165.1 mm)
2.0
(50.8 mm)
5.5
(139.7 mm)
3.0
(76.2 mm)
2.0
(50.8 mm)
3.875
2.75
7.5
2.88
4.25
3.25
8.5
3.0
3.62
9.0
3.5
3.62
9.0
3.4
3.6
9.0
4.25
(98.42 mm) (69.85 mm) (190.5 mm) (73.15 mm) (107.95 mm) (82.55 mm) (215.9 mm) (76.2 mm)
.75
5.0
.75
5.0
.75
3.375
(19.05 mm) (127 mm) (19.05 mm) (127 mm) (19.05 mm) (85.72 mm)
(91.95 mm) (228.6 mm) (88.9 mm) (91.95 mm) (228.6 mm) (86.36 mm)
D
.312
(7.92 mm)
.312
(7.92 mm)
.50
(12.7 mm)
.88
(22.35 mm)
.62
(15.75 mm)
.75
1.25
1.0
2.0
1.0
(25.4 mm)
.312
(7.92 mm)
.312
(7.92 mm)
.312
(7.92 mm)
.50
(12.7 mm)
B
.88
(22.35 mm)
(19.05 mm) (31.75 mm) (25.4 mm)
A
E
(50.8 mm)
C
E
D
2.0
(50.8 mm)
HL/GL Series
.75
(19.05 mm)
A
1.75
(44.45 mm)
1.25
(31.75 mm)
1.38
(35.05 mm)
.625
1.38
.75
2.0
.75
2.0
B
(15.87 mm) (35.05 mm) (19.05 mm) (50.8 mm) (19.05 mm) (50.8 mm)
1.0
(91.44 mm) (228.6 mm) (107.95 mm) (25.4 mm)
1.53
E
(38.86 mm)
C D
Orbitform’s Gold Series orbital heads provide: • Top efficiency and forming capacity (18 times over std. heads) • Ability to handle short/long cycles, hard materials and multiple shifts • Maximum punch in a small envelope i.e., multi-spindles/close centers • Maximum forming power using minimal energy.
SOLUTIONS SINCE 1984
13
OPTIONS & ACCSSORIES
Orbitform’s modular powerheads can be ordered with a wide variety of accessories for machine builders. Please inqure for further information.
C-Frame Columns
Straight Columns
14
Assembly Equipment
Linear Displacement Transducer (LDT) on a M-310 Powerhead
Offset Motor Mount with Thru-Spindle Pressure Pad
SOLUTIONS SINCE 1984
RIVETING
It all starts with the customer’s part
Programmable Height-Sensing Pressure Pad Assembly
Quick Changeover Slides for Part Positioning
15
MULTI FORM
Multiple Options for Automation
Oribitform multi-spindle, multi-point and parallel plate eccentric drive forming heads are used throughout manufacturing and assembly operations. The advantages are cost and cycle time reduction for volume production. Multi-Spindle Forming Heads Center distances for multi-spindle applications typically range from 1.7 inch (43.2 mm) to 12 inch (304.8 mm). Minimum center distances are dependent on rivet size and corresponding orbital head.
Multi-Spindle Bench Machine
Multi-spindle orbital forming is not restricted to a single plane since separate spindles and orbital heads are used for each rivet. These heads can be designed for different heights in relationship to one another. Multi-Point Forming Heads Multi-point forming heads are eccentric driven with integral, fixed center forming peens used in close center applications. Orbital motion is generated by the eccentric action of the head. Center distances for multi-point applications can range from .188 inches (4.7 mm) to 3.0 inches (76.2 mm).
Multi-spindal Orbital Heads
16
Assembly Equipment
PROCESS MONITORING
Typical Orbitform Features Process Monitoring • Force Monitoring • Form Height • Form Collapse • Part Presence
Process Control • Form to Force Control • Morn to Height • Form to Distance • Form to Collapse Position Control • Variable Ramp Rate Control
SOLUTIONS SINCE 1984
17
RIVETING
It all starts with the customer’s part
SPIRAL RIVETING & FORMING What is Spiral Riveting & Forming? In Spiral Forming, also known as Radial Forming, the material is displaced from the center outward, described as an eleven petal Rose Curve, or rosette pattern, defined by [r = cos (11*Ɵ)]. This motion creates less side force than orbital, which can cause parts to wobble during forming. This is especially true when forming smaller diameter rivets, and/or long rivets that are not held rigid by the part or part fixture. The Spiral process is not recommended for tubular rivets or parts, because the peen looses contact during the forming process. As a rule of thumb, 80% of all Spiral/Radial riveting can be done with the Orbital process at a lower maintenance cost. The complexity of the Spiral tooling head’s planetary gear, thrust plate, and pressure cup significantly increases the overall cost of ownership. However, for long, thin, and unsupported rivets, Spiral/Radial is typically a better option.
18
PROCESS DIAGRAM
JOINT DIAGRAM
• Long, unsupported, small diameter rivets • Forming non-round fasteners (hex, square, star, D-type) • Die cast materials (aluminum, zinc, magnesium) • Non-ferrous, thermoplastics, and precious metals • Brittle materials
Assembly Equipment
Bench Top Spiral Forming Machine
Small Diameter Rivets
SOLUTIONS SINCE 1984
RIVETING
It all starts with the customer’s part
Bench Top Spiral Forming Machine
Ideal for Low Force Delicate Parts
19
SPIRAL BENCH MACHINE CONFIGURATIONS Spiral forming on an Orbitform bench machine uses the same technology as a regular orbital machine, including process monitoring and process control. The motion is beneficial to a range of applications, and when swapped out on an orbital powerhead, utilizes the best of both orbital and spiral environments. Using the Spiral form machine is straight forward and intuitive. The fundamentals are the same as using an orbital machine only the motion is different. Spiral Forming is especially beneficial for delicate applications. Used on a standard bench machine, the unique motion is an alternative to the orbital motion with results that meet specific application needs.
20
Assembly Equipment
RIVETING
It all starts with the customer’s part LEFT: Benchtop Spiral forming machine Below: Measurement diagrams Right: Spiralforming process diagram
K F
J
A
E max
H G B
C
D
SOLUTIONS SINCE 1984
21
SPIRAL TOOLING Orbitform’s Spiral form cartridges and machines are now available for your unique applications. Well suited for the fastening and assembly of delicate materials, this process has certain benefits over other types of riveting and forming.
CONICAL PEEN
FLAT PEEN
CONICAL FORM
FLAT FORM
CAPTURED FLAT PEEN
CAPTURED FORM
CROWN PEEN
CROWN FORM
PROCESS MONITORING Typical Orbitform Features Process Monitoring • Force Monitoring • Form Height • Form Collapse • Part Presence
22
Process Control • Form to Force Control • Morn to Height • Form to Distance • Form to Collapse Position Control • Variable Ramp Rate Control
Assembly Equipment
RIVETING
It all starts with the customer’s part
TOOL HOLDERS The newest development at Orbitform, Spiral form is a forming process using a “spiralgraph” type motion. Especially beneficial for delicate applications, many Orbitform powerheads can be converted to Spiral form.
S ING L E P O INT O R B I T A L HE A D DIME NS IO NS
P een D i a me ter
C ap ac i ty
HS -250
. 31 2
. 1 80
(4. 57 mm)
(55. 55 mm)
HS - 310
. 31 2
( 7 . 92 mm)
. 31 2
HS - 500
( 1 2. 7 mm)
HS - 75 0
( 1 9. 05 mm)
HS -1000 - 4
( 25. 4 mm)
HS-1000-6
( 25. 4 mm)
( 7. 92 mm)
. 50 .7 5
1 .0 1 .0
( 7 . 92 mm)
. 50
( 1 2. 7 mm)
.7 5
( 1 9. 05 mm)
1 .0
( 25. 4 mm)
1 .0
( 25. 4 mm)
P een L en g th
A
2. 1 87
1 .7 5
(44. 45 mm)
( 1 01 . 6 mm)
1 . 625
2. 0
(41 . 27 mm)
2. 25
(57 . 1 5 mm)
3. 0
(7 6. 2 mm)
5. 0
(1 27 mm)
5. 0
(1 27 mm)
( 50. 8 mm)
2. 7 5
(69. 85 mm)
3. 62
(91 . 95 mm)
4. 5
( 1 1 4 . 3 mm)
5. 0
(1 27 mm)
B
C
4. 0
1 . 43
(36. 32 mm)
( 7 . 92 mm)
( 22. 35 mm)
4. 0
1 . 38
. 31 2
. 62
5. 0
1 . 50
( 1 01 . 6 mm)
( 635 mm)
6. 0
( 1 52. 4 mm)
8. 0
( 203. 2 mm)
8. 0
( 203. 2 mm)
(35. 05 mm)
(1 27 mm)
2. 0
(50. 8 mm)
3. 0
D . 31 2
( 7 . 92 mm)
. 50
( 1 2. 7 mm)
.7 5
( 1 9. 05 mm)
1 .0
(7 6. 2 mm)
( 25. 4 mm)
2. 88
1 .0
(7 3. 1 5 mm)
(25. 4 mm)
E . 88
. 31 2
( 7 . 92 mm)
HL-500
( 1 2. 7 mm)
. 1 80
(4. 57 mm)
3. 5
(88. 9 mm)
1 .7 5
(44. 45 mm)
6. 5
( 1 65. 1 mm)
3. 0
( 7 6. 2 mm)
. 31 2
( 7 . 92 mm)
. 88
( 22. 35 mm)
1 . 25
( 31 . 7 5 mm)
. 50
( 1 2. 7 mm)
3. 87 5
(98. 42 mm)
2. 7 5
(69. 85 mm)
7 .5
( 1 90. 5 mm)
2. 88
(7 3. 1 5 mm)
SOLUTIONS SINCE 1984 HL-600
. 625
(1 5. 87 mm)
. 625
( 1 5. 87 mm)
4. 25
(1 07 . 95 mm)
3. 25
(82. 55 mm)
8. 5
(21 5. 9 mm)
3. 0
(7 6. 2 mm)
. 50
( 1 2. 7 mm)
. 625
( 1 5. 87 mm)
B
2. 0
( 50. 8 mm)
2. 0
(50. 8 mm)
1 .7 5
(44. 45 mm)
For information on orbital applications, spare parts or anything related to forming, fastening, . 31 2 . 31 2 3. 5 2. 0 5. 5 2. 0 . 31 2 1 . 25 joining,HL-310 and assembly, please ( 7 . 92 m m) ( 7 .call 92 mm) 1-800-957-4838 (88. 9 mm) (50. 8 mm) or (e-mail 1 39. 7 mm) sales@orbitform.com (50. 8 mm) ( 7 . 92 mm) ( 31 . 7 5 mm) . 50
A
( 1 5. 7 5 mm)
LEFT: Orbital forming. 31tools (peens) can2. 1be to satisfy your 2 . 1 80 87 designed 1 .5 4. 625 1 . 5 specific . 31 2 application .7 5 HL-225 ( 7 . 92 mm) (4. 57 mm) (55. 55 mm) (38. 1 mm) ( 1 1 7 . 4 7 mm) (38. 1 mm) ( 7 . 92 mm) (1 9. 05 mm) needs. HL-250
Standard HS
E
C D
1 . 38
(35. 05 mm)
1 . 38
( 35. 05 mm)
23
IMPACT RIVETING What is Impact Riveting?
JOINT DIAGRAM
Impact riveting is a cold forming assembly process in which a short soft metal rivet, having a head on one end, is used to join objects, such as heavy metal plates, by passing a shank through holes and forming a new head by flattening out the other end. It is a permanent process in which a rivet is automatically fed and inserted into one or more components, joining them with compressive distortion of the rivet end.
ROLLSET DIAGRAM
Impact riveting is inexpensive, quick and reliable. It is a rugged assembly method for joining similar or dissimilar materials. With automatic feed impact riveting, there must be clear access to the rivet location from both sides of the parts being assembled. Clearance from only one side will require either the use of blind fasteners (typically an increase in both fastener and installation costs) or redesign so that access from both sides is available. The force to insert the rivets is generated mechanically, pneumatically, or hydraulically. Orbitform impact riveters include all of these rivets.
24
• Solid Rivets
In solid impact riveting, a compressive axial load is applied to the end of the rivet shank. This causes the rivet shank to swell throughout its length as it shortens under the load. The rivet expands until the hole restricts further expansion, after which the rivet clinch forms.
Assembly Equipment
Modular Powerhead
Bench Machine
Pedestal Machine
RIVETING
It all starts with the customer’s part
Heavy Duty Machine
Solid Impact Process Diagram
• Self Piercing Rivets Self-pierce riveting allows the joining of two or three dissimilar materials, i.e. steel, aluminum, and plastic. It has lower cost than other types of riveting and spot welding. Used in many industries, from metal fabrication and construction to transportation and electronics, the self-piercing process makes high-quality joints.
SOLUTIONS SINCE 1984
• Semi-Tubular Rivets Semi-tubular riveting requires less force and allows longer rivets to be used without buckling the rivet shank. Semitubular rivets are inserted like solid rivets. The force is applied with a specially shaped tool, causing the rivet end to flare as it forms against the surface of the workpiece. 25
BENCH MACHINE CONFIGURATIONS Versatility, Quality, Durability Orbitform’s product line of impact riveters are engineered for a lifetime of hard work. Besides their dependability and rugged construction quality, they feature the industry’s most heavy duty clutches, drives, and cylinders. Hopper changeover is easy. All machines are available with an unlimited variety of tooling, anvils, anvil holders, and special fixturing per application. Orbitform supports our customers with factory trained sales engineers and applications specialists. We have the expertise to satisfy all of your riveting needs.
ABOVE: Impact riveting with safety features.
26
Assembly Equipment
BENCHTOP MODELS
63* 64*
Rivet Diameter (max. inches) Semi-Tubular
.125
(3.17 mm)
.156
(3.97 mm)
Rivet Length (max. inches)
.562
(14.28 mm)
.75
(19 mm)
Throat Depth (inches)
6.25
(158.75 mm)
6.25
(158.75 mm)
* Also offered as pneumatic, horizontal, offset, and fixed center models.
BENCHTOP PNEUMATIC
56 57 58
Rivet Diameter (max. inches) Semi-Tubular
.125
(3.17 mm)
.187
(4.75 mm)
.25
(6.35 mm)
Rivet Length (max. inches)
.562
(14.28 mm)
.75
(19 mm)
.75
(19 mm)
Throat Depth (inches)
9
(228.6 mm)
12
(304.8 mm)
12
(304.8 mm)
Stroke (inches)
Dimensions (W x L x H inches)
2
15.5 x 22 x 26
2
17.125 x 23.5 x 28.5
Stroke (inches)
Dimensions (W x L x H inches)
2
3.25 x 18.25 x 25.75
3
5 x 23.25 x 33.625
3
5 x 23.25 x 33.625
(50.8 mm)
(50.8 mm)
(50.8 mm)
(76.2 mm)
(76.2 mm)
(393.7 x 558.8 x 660.4 mm)
(434.97 x 596.9 x 723.9 mm)
(82.55 x 463.55 x 654.05 mm)
(127 x 590.55 x 854.07 mm)
(127 x 590.55 x 854.07 mm)
RIVETING
It all starts with the customer’s part
Weight (pounds)
220
(99.88 k)
235
(106.69 k)
Weight (pounds)
90
(40.86 k)
230
(104.42 k)
230
(104.42 k)
* Features loadcell as standard.
SOLUTIONS SINCE 1984
27
PEDESTAL CONFIGURATIONS
RIGHT: Pedestal Impact Machines 405 and 305, respectively BELOW: Impact riveting with safety features.
Safe and Easy-to-Use Orbitform products are designed for maximum operator protection and ergonomics including: safety ring guards, palm buttons, foot switches, and light curtains. Full powertrain guarding and enclosed flywheel, crankshaft, and connecting rod make for efficient and safe operation. All pedestal impact riveting products include: • Good work visibility for safe, efficient use • Convenient positioning of operating switches • Ergonomic operation and reduced noise levels for less operator fatigue
28
Larger Throat Depth: An Orbitform Advantage Orbitform impact riveters are designed for reliability and simplified maintenance under severe production requirements. Pedestal models have a standard throat depth of 12 inches with an optional 24 inch throat for extra clearance for applications with larger surface areas.
Assembly Equipment
MEDIUM CAPACITY PEDESTAL MODELS
Rivet Diameter (max. inches) Semi-Tubular
.125
255*
(3.17 mm)
256*
(3.96 mm)
305*
(4.76 mm)
305-24
(4.76 mm)
310
(4.76 mm)
310-24
(4.76 mm)
313
(4.76 mm)
313-24
(4.76 mm)
405*
(.35 mm)
410
(6.35 mm)
413
(6.35 mm)
423
(6.35 mm)
.156 .187 .187 .187 .187 .187 .187 .25 .25 .25 .25
Rivet Length (max. inches)
.562
(14.28 mm)
.75
(19 mm)
.75
(19 mm)
.75
(19 mm)
1
(25.4 mm)
1
(25.4 mm)
1.375
(34.92 mm)
1.375
(34.92 mm)
.75
(19 mm)
1
(25.4 mm)
1.375
(34.92 mm)
2.375
(60.32 mm)
Throat Depth (inches)
12
(304.8 mm)
12
(304.8 mm)
12
(304.8 mm)
24
(609.6 mm)
12
(304.8 mm)
24
(609.6 mm)
12
(304.8 mm)
24
(609.6 mm)
12
(304.8 mm)
12
(304.8 mm)
12
(304.8 mm)
12
(304.8 mm)
Stroke (inches)
2.5
(63.5 mm)
2.5
(63.5 mm)
3.5
(88.9 mm)
3.5
(88.9 mm)
3.5
(88.9 mm)
3.5
(88.9 mm)
3.5
(88.9 mm)
3.5
(88.8 mm)
3.5
(88.9 mm)
3.5
(88.9 mm)
3.5
(88.9 mm)
5.5
(139.7 mm)
Dimensions (W x L x H inches)
30 x 24 x 67
(762 x 609.6 x 1701.8 mm)
30 x 24 x 67
(762 x 609.6 x 1701.8 mm)
27 x 33 x 70.5
(685.8 x 838.2 x 1790.7 mm)
27 x 51 x 72
(685.8 x 1295.4 x 1828.8 mm)
27 x 33 x 72
(685.8 x 838.2 x 1828.8 mm)
27 x 51 x 72
(685.8 x 1295.4 x 1828.8 mm)
27 x 33 x 72
(685.8 x 838.2 x 1828.8 mm)
27 x 51 x 72
(685.8 x 1295.4 1828.8 mm)
27 x 33 x 72
(685.8 x 838.2 x 1828.8 mm)
27 x 33 x 72
(685.8 x 838.2 x 1828 mm)
27 x 33 x 72
(685.8 x 838.2 x 1828.8 mm)
26 x 39 x 78
(660.4 x 990.6 x 1981.2 mm)
RIVETING
It all starts with the customer’s part
Weight (pounds)
535
(249.7 k)
550
(249.7 k)
690
(314 k)
755
(342.77 k)
715
(324.61 k)
960
(435.84 k)
755
(342.77 k)
755
(342.77 k)
755
(342.77 k)
870
(394.9 k)
900
(408.6 k)
900
(408.6 k)
* Also offered as fixed center models.
SOLUTIONS SINCE 1984
29
HEAVY CAPACITY Flexible Production with Minimal Down Time
Orbitform’s heavy capacity riveting machines utilize high speed clutches for fast and accurate cycling. Quick rivet delivery with every machine sequence is assured by a robust rivet escapement. Parts supply bins and spill trays can be placed inches from the setting tools for increased productivity. Advantages of these machines include: • Quick retooling for different rivet sizes with quick-change raceways • Clutch maintenance and adjustment rarely needed • No hopper drive lubrication with enclosed cam clutch • Rated power availible throughout the full range of the machine stroke • No perishable drive train components • Adjustable rivet setting force • (Optional) forcea nd position monitoring integration. These machines are also availible as table-mounted units with the hydraulic power unit mounted beneath the table for conservation of floor space. 30
Assembly Equipment
RIVETING
It all starts with the customer’s part TOP LEFT: Model H-2000 BOTTOM LEFT: Model RVH-2000
HEAVY CAPACITY HYDRAULIC MODELS H-2001 H-2002 Double Drive Fixed Center H-4001 H-4002 Double Drive Fixed Center HEAVY CAPACITY PEDESTAL MODELS
510 513 R-2000 RS-2000
.312**
(7.93 mm)
.312**
(7.93 mm)
.25
(6.35 mm)
.25
(6.35mm)
(6.35 mm)
R-5000 Long Stroke
(4.78 mm)
RHV-2000
RIVET LENGTH (max. inches)
THROAT DEPTH (inches)
STROKE (inches)
FLOOR SPACE (inches)
.406
1.25
12
4
24 x 36
(10.3 mm)
(31.8 mm)
(304.8 mm)
.281
1.25
12
(7.1 mm)(2)
(31.8 mm)
(304.8 mm)
.625
1.25
12
(31.8 mm)
(304.8 mm)
.438
1.25
12
(31.8 mm)
(304.8 mm)
.25
.188
.188
(4.78 mm)
.375
(9.53 mm)
RCHV-2000 Underfeed***
(9.53 mm)
RHV-5000 Long Stroke
(7.95 mm)
.375 .313
1
(25.4 mm)
1.375
(32.92 mm)
.75
(19 mm)
.75
(19 mm)
.75
(19 mm)
2
(50.8 mm)
2
(50.8 mm)
.75
(19 mm)
.75
(9.53 mm)
2
(50.8 mm)
Throat Depth (inches)
12
(304.8 mm)
12
(304.8 mm)
8
(203.2 mm)
9 to 40
(228.6 to 1016 mm)
8
(203.2 mm)
8
(203.2 mm)
14-40
(6.35-18.14 mm)
8 to 12
(203.2 to 304.8 mm)
8
(203.2 mm)
8
(203.2 mm)
(610 x 915 mm)
(101.6 mm)
24 x 36 (610 x 915 mm)
4
(11.1 mm)(2) Rivet Length (max. inches)
(101.6 mm)
4
(15.9 mm)
Rivet Diameter (max. inches) Solid Rivets
RC-2000 Underfeed***
RS-5000
RIVET DIAMETER (max. inches)
(101.6 mm)
30 x 36 (762 x 915 mm)
4 Stroke (inches)
3.5
(88.9 mm)
3.5
(88.9 mm)
3
(76.2 mm)
3
(76.2 mm)
3
(76.2 mm)
5
(127 mm)
5
(127 mm)
3
(76.2 mm)
3
(76.2 mm)
5
(127 mm)
(101.6 mm)
30 x 36 (762 x 915 mm)
Dimensions (W x L x H inches)
28 x 32 x 78
(711.2 x 812.8 x 1981.2 mm)
28 x 32 x 78
(711.2 x 812.8 x 1981.2 mm)
22 x 29 x 62 (560 x 865 x 1575 mm)
varies 28 x 36 x 62
(712 x 915 x 1575 mm)
26 x 29 x 66
(660 x 740 x 1680 mm)
varies 24 x 34 x 66
(610 x 865 x 1676 mm)
24 x 34 x 74
(610 x 865 x 1880 mm)
24 x 34 x 66
(610 x 865 x 1680 mm)
Weight (pounds)
1040
(472.16 k)
1040
(472.16 k)
675
(306.45 k)
865-2400
(392-1090 k)
800
(363.2 k)
675
(306.45 k)
865-2400
(392-1090 k)
1000
(454 k)
1000
(454 k)
675
(306.45 k)
* Also offered as fixed center model **Semi-tubular rivets ***Underfeed system brings in rivets from below part
SOLUTIONS SINCE 1984
31
HYDRA-PNEUMATIC Riveter provides versatility and reliability - a technology update! Orbitform’s hydra-pneumatic (HP) riveter gives rivets a smooth ride. The HP is more controllable and adaptable than other impact riveting machines. Available with up to a 24 inch throat, the HP can autofeed and can quickly set solid rivets up to 7/16 inch diameter. Orbitform’s HP riveter features: • Twenty ton capacity • Lubed for life ram assembly (less maintenance) • Single/multiple tooling availible • Ease of alighment (upper/lower tooling) • Long stroke range • Ability to set rivets at multiple finished heights • Few moving parts and wear points • Quiet operation • Optional features for dynamic force and distance monitoring and control • Palm buttons, foot switches, or light curtains availible
HYDRA PNEUMATIC MODELS
HP800 HP1000 HP2000 32
Rivet Diameter (max. inches) Solid-Mild Steel
.281
(7.13 mm)
.343
(8.71 mm)
.437
(11.11 mm)
Rivet Length (max. inches)
1.5
(38.1 mm)
1.5
(38.1 mm)
1.5
(38.1 mm)
Throat Depth (inches)
18
(457.2 mm)
18
(457.2 mm)
18
(457.2 mm)
Stroke (inches)
Force at 100 PSI
4
15886
4
25950
4
38671
(101.6 mm)
(101.6 mm)
(101.6 mm)
Dimensions (W x L x H inches)
30 x 37 x 86
(762 x 939.8 x 2184.4 .mm)
33 x 44 x 90
(838.2 x 1117.6 x 2286 mm)
33 x 44 x 90
(838.2 x 1117.6 x 2286 mm)
Weight (pounds)
1100
(499.4 k)
2100
(954.5 k)
2100
(954.5 k)
Assembly Equipment
RIVETING
It all starts with the customer’s part
MULTI/DUAL RIVETING Multi-Purpose Machines Powerful multiple head, fixed center riveters are availible for the most demanding applications and production schedules. Durrable and dependable, these machines are built to last and will work for years to come. FIXED CENTER MODELS
63 FC 64 FC 255 FC 256 FC 305 FC 405 FC QR-2000 RR-2000 RR-5000 RRS-2000 RRS-5000 RRHV-2000 Double Drive RRHV-5000 QRHV-5000
Rivet Diameter (max. inches) Semi-Tubular
.093
(.22 mm)
.125
(3.17 mm)
.093
(.22 mm)
.125
(3.17 mm)
.14
(3.57 mm)
.187
(4.74 mm)
.250* (4)
(6.35 mm)
.156* (2)
(3.96 mm)
.125 (2)
(3.17 mm)
.156* (2)
(3.96 mm)
.125
(3.17 mm)
.250* (2)
(6.35 mm)
.187 (2)
(4.74 mm)
.125* (4)
(3.17 mm)
Rivet Length (max. inches)
.562
(14.28 mm)
.75
(19 mm)
.562
(14.28 mm)
.75
(19 mm)
.75
(19 mm)
.75
(19 mm)
.75
(19 mm)
.75
(19 mm)
2
50.8 mm)
.75
(19 mm)
2
50.8 mm)
.75
(19 mm)
2
(50.8 mm)
2
(50.8 mm)
Throat Depth (inches)
6.25
(158.75 mm)
6.25
(158.75 mm)
12
(304.8 mm)
12
(304.8 mm)
12
(304.8 mm)
12
(304.8 mm)
8
(203.2 mm)
8
(203.2 mm)
8
(203.2 mm)
9-40
(228.6-18.14 mm)
14-40
(6.35-18.14 mm)
8
(203.2 mm)
8
(203.2 mm)
8
(203.2 mm)
Stroke (inches)
2
(50.8 mm)
2
(50.8 mm)
2.5
(63.5 mm)
2.5
(63.4 mm)
3.5
(88.9 mm)
3.5
(88.9 mm)
3
(76.2 mm)
3
(76.2 mm)
5
(127 mm)
Dimensions (W x L x H inches)
23.75 x 23.5 x 26
(603.25 x 596.9 x 660.4 mm)
26.25 x 23.5 x 28.5
(673.1 x 596.9 x 723,9 mm)
30 x 24 x 67
(762 x 610 x 1701.8 mm)
30 x 24 x 67
(762 x 610 x 1701.8 mm)
27 x 33 x 70.5
(685.8 x 838.2 x 1790.7 mm)
27 x 33 x 72
(685.8 x 838.2 x 1828.8 mm)
22 x 34 x 62
(560 x 865 x 1575 mm
22 x 34 x 62
5
(127 mm)
5
(127 mm)
595
(270.13 k)
785
(356.39 k)
785
(356.39 k)
750
(340.5 k)
750
950
varies
3
600
(272.4 k)
24 x 34 x 60
(610 x 865 x 1676 mm)
5
(76.2 mm)
280
(127.12 k)
(340.5 k)
varies
(127 mm)
250
(113.5 k)
(560 x 865 x 1575 mm)
3
(76.2 mm)
Weight (pounds)
24 x 34 x 66
(610 x 865 x 1676 mm)
24 x 34 x 66
(610 x 865 x 1676 mm)
24 x 34 x 66
(610 x 865 x 1676 mm)
940-2475
(427-1123 k)
940-2475
(427-1123 k)
1100
(499.4 k)
1300
(590.2 k)
1500
(681 k)
*Solid rivet
SOLUTIONS SINCE 1984
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IMPACT TOOLING
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Impact parts and Tooling
IMPACT OPTIONS & ACCESSOREIS Impact Options and Accessories include the following: • • • • • • • •
Quick Change Raceway Narrow Anvil Arm Dual Palm Buttons Custom Part fixturing Benchtop or Pedestal Base Controls Package with Foot Switch Load Deflection Device Toggle Bar Maintenance Tool
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Assembly Equipment
PROCESS MONITORING
Orbitform’s Process Control method is distinctively different from Process Monitoring. In these systems, the same types of data is monitored, however now the data is immediately used to drive the operating sequence of the machinery. Common methods of process control include: • Form-to-Force • Form-to-Distance • Form-to-Form Height
The bottom line is results - results that help you ship excellent products to your customer on time, at lower cost, with the highest possible quality - so you can be in an excellent position for their next product launch. Orbitform can help you achieve these goals. Process Intelligence - The premiere Process Monitoring and Control solutions!
SOLUTIONS SINCE 1984
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RIVETING
It all starts with the customer’s part
HOT UPSET FORMING & RIVETING What is Hot Upset 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.
JOINT DIAGRAM
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 recommended for joints that require articulation; it may also affect surface coating aesthetics. Example applications include automotive strikerwires, ball studs, and joints with high torque and high shock or vibration requirements. Hot Upset typically has a 3-4 second cycle time, which is generally 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 counterpart, 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.
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Assembly Equipment
OPOSITE PAGE TOP: Hardened formed rivet. Note the increased hole fill. OPPOSITE PAGE BOTTOM: Hot Upset gun forming a tenon. ABOVE: Hot Upset pedestal machine TOP RIGHT: Orbitform weld heads unite with the hot upset process to create the industry standard in Hot Upset forming. BOTTOM RIGHT: Hot Upset head forming a tenon.
SOLUTIONS SINCE 1984
FORMING
It all starts with the customer’s part
• Forming with heat and pressure • Hardened Rivets • High Torque Joints • Increased Hole Fill • High Push/Pull Force Joints • Resistant to Vibrational Fatigue 37
ROLLER FORMING
LIP GROOVE
What is Roller Forming?
Orbitform’s Roller Forming process uses multiple rollers mounted on a rotating spindle to gently smooth and form material into a seamless, solid form. The rollers intersect the workpiece on an exact contact line, gradually moving material to the desired shape as the powerhead advances.
ROLLERFORMING DIAGRAM
Roller forming can displace large diameter and thin wall materials, often difficult with other fastening methods. The process is advantageous when used to roll or close a lip. Rollerforming can be used in applications where rollers articulate as well as rotate, allowing for access into grooves and other areas. Forming a curl or lip with Roller Forming takes less force than normally requiredi for straight crimping or pressing. Roller Forming replaces crimp tooling which can be problematic in appearance, process control and reliability. It is strong for critical automotive applications of steel and aluminum, and versatile for appearance sensitive plastic parts. 38
• Crimp and seal using multiple rollers • Cold form with precise control • Satisfy cosmetic requirements on assembled parts • form both inside and outside diameter simultaneously • Be used in work cells and automated assembly
Assembly Equipment
FORMING
It all starts with the customer’s part
TOP: Rollerforming a groove RIGHT: Benchtop Rollerforming Machine BELOW: Rollerforming a lip
Rollerfom Pedestal Machine
LEFT: A rollerforming platform with fixed rollers.
SOLUTIONS SINCE 1984
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FORMING
TOOLING & PROCESS MONITORING Oluptatur samusantio. Nem re la vel ipsum que nimolore conectum is consedit quiatus duciassum vel est, eserovide velit latem vid quaspis dolorent omniet dus, vel ipist, sitatum ant. Occus enda qui beribus andaectem laborum fuga. Vitio. Sed ut ad qui blanditati omnienest porecep udipsant arum fugiati odi sed ex etur atur ma voluptur sam quam fuga. Ihillat. Od eatat doluptat ut quid moloreiur rest rest, sus molorep elecaboriae natempo rporpos dolupta pratur, as am fugitatem vitio. Riant occullu ptatios sunditi beaquias ea aribus dolor am, con perorectist asped etur a doloreperem into quam eum eumquas ipid ut atur sum et velicim olupiendunt, odit quatquatur ati ommolo volore simus. Cus quatum que poribus andam, qui occume pelenis quaecus aperess imagnim isqui que im nonest, etur atur sunt quia eatio et dolores il ipsus cumquas sum net assum fugia illuptas rectia veles sum int ute voluptas magnimi, occuptat quo es dolorae vendissita num, volo
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Orbitform’s Process Monitoring Panel
Assembly Equipment
OPTIONS & ACCESSORIES There are several different availible options availible for rollerforming machines. They differ between roller configurations.
Offset Motor Mount with Thru-Spindle Pressure Pad
Fixed Roller Configurations • Force Monitoring Measures forming to force • Through Spindle Pressure Pad Articulating Rollers Load Cell - Only Fixed LVDT - Fixed Rollers
Linear Displacement Tranducer (LDT)
SOLUTIONS SINCE 1984
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FORMING
It all starts with the customer’s part
WELDING
FIXED TOOL RESISTANCE WELDING
Versatile Manufacturing Platform Orbitform’s resistance welders are available as a complete system or a base for custom integration. The M-Series comes in 32 and 48 inch standard widths with a 16 inch upper and lower platen depth. The M-Series can incorporate multiple guns for custom resistance, spot or projection welding. Designed to provide versatile automation, Orbitform’s pedestal welder can be used to weld various materials, including steel and stainless.
H- Frame Resistance Welder
COOLANT WELD AREA
A small footprint gives the unit ease of mobility, via forklift pockets, and accessibility for tooling changeover. Operator safety and efficiency is maximized with ergonomically designed light curtains/palm buttons and tooling/fixturing. Shipped assembled and ready for immediate installation and production, the M-Series is well suited as an alternative to manual welding.
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• High Volume • Thin Materials • Single and Multi-Gun Systems • X-Y Driven Fixtures Available • Automatic Part Removal Optional
Assembly Equipment
WELDING
It all starts with the customer’s part
PROJECTION WELDING
• Alternating or Direct Current Systems • Custom Part Fixturing • Uses Orbitform’s standard forging head
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eliminates Air/Oil Weld Cylinders
SOLUTIONS SINCE 1984
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CONVEYORS
PALLETIZED CONVEYOR SYSTEMS
BELOW: Custom loop with multiple stops and turn modules.
Get Your Parts Into the Loop Orbitform designs and builds material handling and assembly systems of all layouts and configurations. Mechanical and controls engineers analyze each aspect of motion to provide speed and efficiency. Orbitform’s customized systems are robust and reliable. When you partner with Orbitform you get a complete integration solution. Profit from our experience and integrate your manufacturing process! Heavy Duty Options Availible for harsh environments or systems that require heavy duty applications is the Orbitform Heavy-Duty Palletized Conveyor. It can handle parts of all sizes with ease. Features include the inustry’s heaviest extrusion with a capacity to 200 lbs/ft. Other options include a soft start variable frequency drive system and an integrated interface panel.
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• Modular Components • Precision Part Placement • Traffic Control • RFID Tracking
Assembly Equipment
CONVEYORS
It all starts with the customer’s part
Custom Palletized Loop
Standard Palletized Loop
PALLETIZED SOLUTIONS
MODULAR CONSTRUCTION
• Perform well in low and high load
• Rugged welded steel tube leg frames
applications • Designed for all environments • Minimizes part handling and cycle time
• adjustable leveling feet for fast setup and installation • Optional weldable leg attatchments for permanent installations
SOLUTIONS SINCE 1984
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CONVEYORS
LOW BACKLINE PRESSURE (LBP) Solutions to Conveying Needs Using Orbitform’s Low Backline Pressure conveyors, parts ride directly on a densely populated array of plastic rollers. The parts flow freely with very low friction and exert minimal force on adjacent parts. When accurate pick-up or drop-off is required by ancillary equipment, Orbitform can configure shuttleoff mechanisms for secure part positioning. Orbitform can also create buffering systems to accumulate a large number of parts prior to critical operation.
MINIMAL CONTACT FORCE MAKES LBP CONVEYOR SYSTEMS IDEAL FOR SMALL AND DELICATE PARTS
Orbitform’s innovative solutions mean enhanced productivity for OEM and end users. Our heritage in orbital forming, impact riveting, welding, and assembly systems gives us the experience to understand your total assembly and material handling process needs. • High Volume Production • Part Buffering • Minimal Contact Force • Low Friction Eliminates Static Charge
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Assembly Equipment
CONVEYORS
It all starts with the customer’s part
Wide Range of Configurations
Part Buffering System
SOLUTIONS SINCE 1984
Part Division
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SYSTEMS
CUSTOM ENGINEERED ASSEMBLY SYSTEMS Integration Experts Orbitform’s Custom-Engineered Assembly Systems include multiprocess dial machines, multi-station work cells, multi-operator work cells, up to highly automated assembly systems with integrated conveyors. We are experts at integrating our core Assembly and Conveyor products with third-party equipment such as automatic feeder systems, part washers, greasing systems, screwdrivers and nut-runners, gauging and inspection equipment, vision systems, robotic components, machining centers, and other automated equipment. Our unbiased approach assures you get the right assembly-system-solution to meet your most demanding manufacturing requirements. Our Machine Builders and Controls Engineers are experts in process automation, systems integration, and programmable control interfaces. Let Orbitform take your manufacturing into the future.
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• • • • •
Built in the USA Under One Roof Modular Designs Flexible System Process Monitoring Intelligence Custom Integration
Assembly Equipment
SYSTEMS
It all starts with the customer’s part
Orbitform’s innovative workflow designs can increase productivity and quality
SOLUTIONS SINCE 1984
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SERVICES
SOLUTIONS LAB Custom Solutions Orbitform’s world renowned Solutions Lab is unique to the industry and allows customers to recieve the individual service they deserve regardless of the size or scope of the project. From prototypes to short-run production, Orbitform’s expertise is here for your advantage. Have your sample parts analyzed to determine the best fastening method and the most efficient type of forming. Our services often result in specific product design imput for our customers. Orbitform’s custom application engineering includes: • Impact, orbital, and welding solutions • Fast personal response, quick part turnaround • Value driven proposals • Product design feedback/ guidance From saddles to satellites, let Orbitform’s skilled applciation team help you define and design your product and process.
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Assembly Equipment
SOLUTIONS SINCE 1984
SERVICES
It all starts with the customer’s part
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