Henrob self-pierce riveting
Customers in 180 countries 34000 employees in 90 countries Atlas Copco Established in 1873 Stockholm, Sweden in figures Turnover of nearly 86 B SEK / 9 B EURO A decentralized group with 4 business areas 2
3 Part of the Atlas Copco group since 2014 Vacuum Power Compressor Technique Technique Technique SCA adhesive Henrob self-pierce K-Flow flow drill Tightening dispensing riveting fastening 3
#1 Global joining partner Hybrid Battery joining assembly Self-pierce Sound riveting dampening Sealing & Quality Flow drill adhesive Inspection fastening dispensing 4
Customer challenges Increased need for innovative joining Global market drivers Trends Customer challenges Our solution Lowering of Increasing usage Combining many Innovative joining emissions of lightweight materials different materials technologies in to a strong and tailored to Improving car bodies light car body customer needs energy efficiency Electric vehicles Environmental legislation 5
Henrob self-pierce riveting Rivets and riveting systems for applications in cutting edge industries 6
SCA dispensing Increased productivity in demanding environments 7
K-Flow fastening Reliable and reversible joint with one-sided access 8
Quiss vision system Quality inspection of dispensing applications 9
Competence in our customers’ processes Partnership with the automotive industry Simultaneous engineering Body shop Paint shop Powertrain Final assembly Quality assurance Service 10
Global presence 11
Henrob self-pierce riveting
Manufacturing facilities New Hudson, MI, USA and Deeside, UK Over 8,500 In-house Rivet production systems in plant production: capability: operation globally 10 billion / year Tooling assembly Cold forging 44,000m 2 of Over 600 Heat treatment manufacturing employees Plating space 13
Industry segments and applications Solar panels Motor vehicle Steel frame housing Recreational HVAC ducting Heavy truck
What is self-pierce riveting? Self-pierce riveting (SPR) is a method of joining two or more pieces of material using a rivet without the need for a pre-drilled hole. The basic self-pierce riveting process involves driving a rivet at high force through the material layers to be joined, into a die which causes the tail of the rivet to flare out and form a joint. Rivet Starting Material Rivet insertion Insertion penetration condition clamped complete 15
Advantages of SPR No Ability to Fast cycle pre-drilling use with times required coated or painted surfaces High strength with a visibly checkable No Low energy joint debris or demands filings SPR Plastics Operator and No Joins Aluminum environment heat Joins multiple multiple friendly similar or material different stacks material No High combinations No excessive Compatible strength sparks No noise with steel fumes adhesives (HSS) and lubricants Composites 16
Components of a reliable SPR joint Rivet length · Longer rivets required to pierce multiple layers · Determined by thickness of material to be joined Rivet geometry · Body style · Wall thickness · Tip geometry · Determined by material type being joined Rivet diameter · ø3mm for thin material · ø5mm for structural · Determined by application Rivet hardness · Influences rivet flare · Determined by hardness of material being joined Rivet head style · Determined by application · Flush heads for mating panels · Thicker heads for UHSS Die volume · Determined by material ductility · Increases with rivet size · Influences rivet performance Die geometry · Influences rivet flare · Determined by material type 17
Leading the way in rivet designs C, J, and K-Rivets T-Rivets • • Used in the widest range Designed for low-ductility of applications thick Al joints • Enables smaller die volumes A-Rivets Self-piercing studs • Designed for low-ductility • High impact resistance thin Al joints • High torque • Enables smaller die volumes • Low electrical impedance PG-Rivet BG-Rivet • • Piercing 1100MPa steel Ideal for castings • <1.5mm thick Optimized for mixed • HSS to HSS materials • HSS / UHSS to Aluminum 18
Joining capabilities Thin joints Hood, fender & closures Composites Sunroof Aluminum joining Floors, dash & cowl panels, body sides, High strength steel pillars Shock towers, pillars Thick joints & rails Body sides, Al pillars, rocker panels 19
Rivet manufacturing Cold forging All steps of rivet manufacture in-house Wire stock Heat treat Wire stock Packaging Packaging Plating Visual inspection / sorting 20
SPR joint development Adhesive application (optional) Customer materials Create test coupons Wire stock Facilities to test large (full BIW) or small scale projects Corrosion testing Joint analysis Tensile testing 21
Joint development Testing conducted on customer supplied material offers the opportunity to trial and validate riveting parameters. Rivets and dies chosen to join a specific material combination can be assessed for suitability: Ensure the rivet correctly flares and engages in the materials Determine how strong the joint will be Simulate production variation to establish joint design robustness Joint Joint Joint attributes strength repeatability Visual inspection & Tensile testing Head height range cross sectional testing analysis 22
Joint development evaluation Joint attributes: Visual inspection of head height & button appearance Head height Head height is a simple measurement which can be useful as a non-destructive indicator of whether a joint is performing as expected Determine process parameters to operate nominally at 0.00mm Button appearance Visual inspection of the rivet button can indicate any potential issues and whether further joint analysis should be conducted 23
Joint development evaluation Joint attributes: Cross-section analysis Joint symmetry Head flushness (HH) HH • Indication of joint • Flush with top sheet • stability Sealed under-head • Robust joint • No crevice points performance dY t min Interlock (IntX & dY) • Minimum bottom layer IntX • thickness Engagement of rivet legs • Corrosion protection into bottom sheet t min • • Bottom sheet Indicator of strength • completely Legs flare evenly without encapsulates rivet buckling 24
Joint development evaluation Joint strength: Tensile testing Lap shear test Cross-tension peel test Coach peel test Lap shear joints rotate during testing, Peel load is distributed all around the Peel load is concentrated in one area of applying a combination of shear and rivet head the rivet head. Also referred to as a “T peel loading peel” 25
Joint development evaluation Joint repeatability: Head height range testing Changes in parameters such as material thickness and composition can result in a variation of head height (HH). Our Fixed Energy process allows us to use HH as an indicator of the joint integrity. A simple gauge check is then a robust non-destructive test method of joint performance. HH HH HH IntX IntX dY dY t min t min Repeatability testing in the lab validates a range of head heights for use on the production line 26
System manufacturing Design Machining Lean manufacturing Tool build System test 27
Upset die manufacturing In-house manufacturing of more than 144 die types We manufacture upset dies in-house to be able to offer comprehensive solutions for your SPR needs. A two-step operation with robotic loading and unloading finishes with rigid quality inspection. Optional poka-yoke posts are available for your lean manufacturing processes to prevent using an incorrect die. 13 February 2019 28
Self-piercing rivet systems Largest range of application specific systems Manual Servo Electric RivLite • Inertia system • Fixed or manual • Battery powered • Multi axis hangers hydraulic pump • Tape feed • Fixed range • Limited size range • Tape feed • 2-5 sec cycle time • 5 sec cycle time • Rivet setting and removal Hydraulic Auto Servo Electric • • Hydraulic actuation Inertia system • • Fixed or suspended Fixed or robot-mount • • Manual or auto applications 85mm - 780mm size • • Tape or loose feed (2-4 Double Acting or Pre-clamp • rivets) Tape or loose feed • • 2 sec cycle time 1 sec cycle time 29
Rivet feeding Loose feed Application-specific feed systems • Magazine in robot tools • Direct blow to pedestals • T-tube feed for consistency • RFID poka-yoke containers available • Magazine ideal for high actuation robot- mounted systems Tape feed • Pneumatic feed system • Sprocket holes in tape • Poka-yoke spools available • Trigger, sensor and anti- pullback make it ideal for low or high actuation automated systems 30
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