Orbitform’s Assembly Products & Services
Orbitform designs and builds assembly equipment for manufacturing. 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.
We Build Machines For:
- Orbital Riveting & Fastening
- Impact Riveting
- Roller Forming
- Hot Upset Forming & Riveting
- Projection & Resistance Welding
- Assembly Automation
- Conveying Systems
We Provide Services For:
- Assembly Analysis
- Tooling Development
- Batch Production Runs
A smooth, non-impact cold forming process used to create permanent joints with a high aesthetic appeal and a range of articulation potential.Visit Page
A process similar to Orbital, using a peen to form from the center outward. Best used with delicate or unsupported rivet applications.Visit Page
An assembly process using force to fasten two things together permanently using a wide variety of rivet and material options.Visit Page
A non-impact process using spinning rollers to symmetrically form a cylindrical part. Used for flaring, forming a lip, crimping, or forming a groove.Visit Page
A forming process using heat and pressure to form a fastener to produce heavy duty joints able to withstand high forces.Visit Page
We offer optional process monitoring and process control solutions on all of our systems.Visit Page
Use pallets to carry individual parts between forming stations, even allowing assembly operation to be performed directly on the line.Visit Page
Parts ride directly on roller or flat-top chain with minimum contact force. Used for high volume production and part buffering.Visit Page
All Orbitform tooling is developed in-house. Our engineers can make special recommendations based on your application to deliver ideal tooling for your machines.Visit Page
We utilize every single one of our areas of expertise to bring our customers the answers to their assembly equipment needs.Visit Page
Orbitform has you covered for your small production run needs. Whether you need 5, 50, 500, or 5000 parts, Orbitform can helpVisit Page
We offer welding systems in either Projection or Resistance configurations. Each system is designed to suit each application.Visit Page
Four Ways We Hold Things Together
We live in a world where things are put together. The computer you’re using, the desk it’s on, and the chair you are sitting in have all been assembled. At Orbitform, we specialize in permanent part assembly, processes like orbital forming, impact riveting, roller forming, and hot upset riveting and forming. These four processes are all unique and have their own strengths, weaknesses, and qualities. They have major advantages in assembling parts that don’t need to be taken apart, both in reliability and longevity. But what are they? Why do these processes excel when compared to non-permanent fastening solutions? If your product doesn’t need to be taken apart, consider these reasons to switch to permanent assembly.
Permanent Part Assembly Advantages
- Reduce the Costs of Fastening Hardware
- Reduce the Costs of Machining Operations
- Reduce the Costs of Assembly Operations & Cycle Time
- Superior Retention
- Improved Aesthetics
Leave behind the retaining rings, threaded fasteners, nuts, washers, and cotter pins. With permanent part assembly, the part and the fastener are formed together, creating a secure and permanent bond without the use of extra unnecessary hardware.
Save money by avoiding costly operations like machining grooves and threads, drilling and tapping holes, etc. With the time saved in these areas, quality and throughput is increased.
It’s the easy solution when it comes to reducing cycle times: reduce the number of hardware parts and operations that need to be done to a part. This could be installing a retaining ring or cotter pin, or driving a screw or a nut. Permanent part assembly means shorter cycle times and more parts moved down the line.
Compared to cotter pins, retaining rings, and Loctite® adhesives, permanent part assembly has a much better retention level. There’s a reason the word permanent is in the title.
If you’re concerned with how your finished parts look, permanent processes deliver some of the best aesthetics. As we mentioned earlier, loose the retaining rings and cotter pins; make it look clean and finished with a formed head instead.
There is not a “one size fits all” solution for permanent part assembly. But you could start receiving these benefits by switching your assembly process. If your product doesn’t need to be taken apart, for shipping, maintenance, or repair, then consider switching to a process like orbital forming, impact riveting, roller forming, or hot upset riveting. Orbitform is an expert in delivering unbiased approaches to help our customers find the very best process to fit their needs.
For more information on Permanent Part Assembly, read our white paper [attach link to whitepaper PDF]
Orbitform has been designing and building assembly equipment since 1984. One of the areas we have specialized in is Roller Forming. We have two different types, articulating and static. Both of these serve their own purposes, and can offer you an assembly advantage.
Roller Forming is a non-impact process using a spinning Roller Head with two or more rollers to apply a symmetrical force to form the part. Roller forming is used for flaring, forming a lip, crimping, or forming a groove in cylindrical parts too large for other processes. This is where the two types of roller heads come in.
Static Roller Heads
Static roller heads are used when forming a lip around a cylindrical part. These heads have spinning rollers that use down-force from one of Orbitform’s standard powerheads to create an aesthetically pleasing lip on a surface. These roller heads are both consistent and efficient, and the non-impact nature combined with precision and accuracy allow for the forming of delicate and brittle materials. Through use of an o-ring or gaskets, it is possible to form sealed caps on the end of cylindrical parts.
Articulating Roller Heads
Articulating heads are most often used for either forming a groove in a part or when there are obstructions to clear in order to form a lip. These parts use 360o Contact while forming, so there is consistent action while forming the part. These roller heads can deliver forming forces up to 5,000 lbs. @ 100 psi. These roller heads can bring new advantages to your forming process.
The Assembly Advantage
Orbitform has been delivering assembly solutions for manufacturing since 1984. With experience in riveting, forming, conveyors, assembly systems, and welding, we have the ability to offer you an unbiased assembly solution. For more information about Roller Forming or any other process mentioned here, visit our website at www.orbitform.com or call 800-957-4838.
When you need a small batch of parts assembled, Orbitform’s Assembly Solutions Lab can be a cost effective option. We have both the assembly equipment and the knowhow. The Assembly Solutions Lab offers a wide range of Orbital, Radial, and Impact Riveters, as well as Roller Forming and Hot Upset systems. With 30 years of assembly experience, or application engineers are the assembly experts. They know how to fabricate the proper tooling, and how to correctly fixture parts for a consistent and repeatable form. Orbitform customers are welcome to visit our lab and observe the assembly process in action. So whether you need 5, 50, 500, or 5000 parts, Orbitform has you covered.
The Assembly Experts
We have the know-how to bring your assembly goals into reality. To learn more about Orbitform, Production Runs, or anything talked about here, call us today at 800-957-4838 or click here.
At Orbitform, we are dedicated to helping our customers increase throughput and reduce costs. One of the ways which we do this is through multi-form heads. These options operate similar to Orbital, but make it possible to form multiple rivets on the same part or rivets across multiple parts at the same time. These heads are used throughout the assembly automation process, providing advantages like cost reduction, quality increase, and cycle time reduction for high volume production. Multi-forming is typically done with one of two options: Multi-Spindle and Multi-Point. Both of these options allow the possibility of forming multiple rivets
Multi-spindle heads use an Orbital Powerhead to produce forming motion and force. Multiple Orbital heads attach to the multi-spindle head, forming multiple rivets at the same time. These rivets can either be across multiple parts or on the same part. Center distances for multi-spindle applications are dependent on rivet size and corresponding Orbital head used for forming. Multi-spindle 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.
Run more parts per cycle, increase throughput, and reduce costs.
Multi-point heads use fixed center forming peens on a single eccentric driven head to form rivets set close together. Multi-point applications form multiple rivets on the same part to reduce cycle time and part handling, leading to more throughput and higher efficiency. Anyone manufacturing small parts with rivets set close together can benefit from multi-point forming. Center distances for applications can range from as little as .188” (4.7mm) to 3” (76 mm).
The Assembly Experts
Orbitform is an expert in assembly solutions. Multi-point and multi-spindle are just the beginning when it comes to optimizing your assembly process. Options like x-y shuttle automation, index dial tables, multi-station forming systems, and complex conveyor systems are all areas that Orbitform has experience in. If you are interested in any of these products, visit www.orbitform.com or call (800) 957-4838 for more information. Orbitform…solutions delivered.
Orbitform designs and builds assembly equipment solutions for manufacturing. Among this equipment is our Palletized Conveyor line, helping parts get from each stage of the assembly process both quickly and smoothly. Our palletized lines utilize pallets with specially designs part fixtures to carry parts between stations. Conveyor automation by Orbitform can help you boost throughput, saving time while doing it.
Our Palletized Lines Feature:
- High Volume Production
- Keep production levels up with the high capacity of Palletized Conveyors. Integrate with third-party assembly equipment to ensure high throughput.
- Part Buffering
- Reliable part buffering technology ensures that parts will be ready for assembly on the conveyor line.
- No Part to Part Contact
- Parts ride on individual pallets to eliminate contact with surrounding parts on the line.
- The Ability to Form Parts Directly on the Line
- With accurate pallet stopping technology, lines can feed parts into assembly stations located directly on the conveyor line.
We work with you to come up with a solution that will fit your specific needs. Orbitform is experienced in complex controls, trafficking technology, and RFID integration. Benefit from our knowledge and get your parts into the loop. Visit www.orbitform.com to learn more, or call (800) 957-4838 to speak with our assembly experts. Orbitform…solutions delivered.
If you need to install multiple rivets, you could benefit from our multi-head and multi-point Impact riveters. Multi-head riveters consist of two or more riveting heads, designed to work on the same part simultaneously.
We offer fixed and adjustable tool configurations to suit a wide range of applications. Consolidate equipment and reduce work area footprint with one of our adjustable center distance dual-head riveters, or increase production throughput with a multi-head fixed-tool riveter.
It is also possible to install multiple rivets simultaneously with a single fixed-tool or fixed-center (FC) riveter, configured with multiple rivet feeders, drivers, jaws, and rollsets.
- Dual fixed tool, adjustable, multi-head, and multi-point configurations
- Pneumatic, electro-mechanical, hydra-pneumatic, and hydraulic
- Offset Driver package provides minimum distance between rivets (rivet head diameter + 1/16”)
- Safety probe, light curtain, palm buttons, and Lexan ® and/or wire mesh guarding
- Custom fixturing and part clamping
- Vibratory rivet feeding system upgrade
- Integrated load cell for monitoring rivet forces
- Multi-head systems allows heads to be turned on/off separately, to use a single head for rework
- Rotary Hopper rivet feeding system, mechanical or pneumatic, with track assembly
- Install solid rivets up to .63” diameter
- Install semi-tubular rivets from 1/16” and up
- Multi-point riveting from a minimum distance (rivet head diameter + 1/16”) up to 4” apart.
The Assembly Experts
Additional options and features are available. Each machine is configured and tooled to suit your specific riveting application. To have our experts advise you on your application, visit our website or call (800) 958-4838. Orbitform…solutions delivered.
When customers approach us with rivets that are delicate, long, or unsupported, we often turn to radial forming as a solution. Radial 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. Radial is ideal for forming small or delicate parts. Radial heads are also available with the standard or long reach peen options, giving a wider range of forming possibilities.
Radial Form is for customers with unique or very light duty applications. It is also available as a “standard option” for new machines and systems and designed to retrofit existing Orbitform machines by means of a spindle change out. Additionally, Radial has been designed to accommodate an integral load cell into the spindle package. This allows radial to provide the same process monitoring capabilities as the rest of the Orbitform product line.
Orbitform is an expert in permanent part assembly. We pride ourselves in offering unbiased assembly solutions for manufacturing. Radial forming is just one of the processes we offer at Orbitform. For more information about permanent part assembly, or so send us your sample parts, visit www.orbitform.com or call 1 (800) 957-4838 to speak with the assembly experts. Orbitform…Solutions Delivered.
CategoriesRadial Forming & Riveting
At Orbitform, one of our specialties is in Orbital Forming and Riveting. Orbital forming and riveting is a cold forming process using a peen tool held at a fixed angle to create a sweeping line of pressure around a rivet, progressively forming the rivet throughout the process.
This peen is crucial to the forming process, making contact with the part being forming and doing the actual forming work. The peen fits into the orbital head and is typically held in place by a set screw.
There are a wide variety of standard peens that are used with orbital heads, each with a different purpose. Some ensure a certain aesthetic appearance while others are capable of flaring or crimping. Each peen is designed specifically for each customer part, developed by our engineers to custom fit the specific application.
The peen becomes the key to forming high quality parts. Orbitform will ensure that your peens and tooling will produce top quality parts with consistency. We are the experts in permanent part assembly, and we will put our knowledge to work for you. Orbitform…solutions delivered.
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 and cooling caused the bearing to walk-out. The customer tried adhesives to retain the bearing, but this added an addition expense and an additional process that was messy.
Orbitform Engineers a Solution
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 the housing assembly, and 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 used 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” in diameter. Wall thickness can vary from 1/32” to over 1/4" 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.
Orbitform is your source for Assembly Equipment Solutions for Manufacturing. To learn more about anything talked about in this article, click here to visit our website, or call 800.957.4838 today to speak to the assembly experts.
Here at Orbitform, we recently developed a unique riveting process called Hot Upset. This rivet/forming solution uses force and heat to form rivets or part tenons, providing greater strength, increased hole-fill, improved resistance to push-pull forces, and an overall tighter joint, due to material contraction during cooling.
Form with Heat and Pressure
Similar to electro-forging, the headed 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. Our customer, an automotive part manufacturer, needed to assemble a product with hardened rivets, each with a long tenon stick-out. To meet their production requirements, we needed to form two rivets per machine cycle. We examined both Orbital and Radial Forming options in our applications lab, but due to the extreme hardness of the rivets, final form characteristics did not meet our customer’s specifications. Also, some samples showed signs of cracking, which was unacceptable in this application. We then tested our Hot Upset forming solution, which resolved the forming challenges.
Orbitform designed and built a custom Hot Upset system. The design included two standard Orbitform modular Powerheads, the same Powerheads used in our Orbital, Radial, and Roller Forming products. Using standard Powerheads instead of traditional weld cylinders eliminated the need for an external air/oil tank and intensification valve. To stabilize the customer’s part during the forming process, the system was outfitted with a part clamping pressure pad. To verify a quality form, process monitoring included an LVDT, load cells, and Powerhead advance and retract sensors. The customer’s safety specifications included light curtains, guarding, and palm button activation.
Hot Upset typically has a 3-4 second cycle time, which is generally slower than Orbital, Radial or Impact Riveting. In addition, hot parts require special handing considerations. We offer both AC and DC Hot Upset systems. In the case of our customer, we built a DC system for its power consumption savings versus the lower initial cost of an AC system. DC powered systems are more efficient and precise than their AC counterpart, but come at a higher price. Cost of ownership includes power consumption and tooling electrodes. Hot Upset systems also require a chiller to maintain optimal tooling temperature.
Our Hot Upset process could help you in your assembly process. At Orbitform, we are experts in assembly processes. To learn more about permanent part assembly, or download our full white paper text. Visit our website at www.orbitform.com or call 800-957-4838 to speak to an expert today. Orbitform…solutions delivered.
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