Minimizing tooling cost and change-over time to maximize throughput is always at the forefront of manufacturers’ minds. Finding an equipment solution to help with both of these issues is much like finding a needle in a haystack. Recently, an HVAC manufacturer reached out to Orbitform looking for their “needle”.
The Needle
This manufacturer was forming multiple components with odd shapes and phalanges using impact riveting machines. Due to machine constraints, each part required separate tooling and a lengthy change-over. While this customer required multiple machines due to production volume, they also wanted to standardize on the machines and tooling so each part could be formed on any of the machines.
One Standard Machine
When working with Orbitform’s Engineers, it was found that a Milford 305 fit the forming requirements for all rivets. To successfully rivet each part, the throat depth of each machine was increased from 12” to 13”by off-setting the head to the column – this was the easy part. From there, the team then worked on standardizing all tooling. The customer required both self-piercing and standard rivets – a tough task for common tooling.
Engineered Solution for Tooling
Our experienced team of Engineers brainstormed tooling design to accomplish forming both types of rivets. Upon review, they found that common jaws and drivers could be used for each part – only the roll set would need to be changed out to create the required finished form. This discovery eliminated costly tooling change over between each part.
Clearance Issues
The final challenge to solve was the clearance from part to part with the Milford standard safety probe. When loading oddly shaped parts, a standard safety probe could not fit within all of the design restraints. Orbitform’s engineers collaborated on a new design to create a jaw-lowering safety device. This new concept places the safety controls in the jaws of the machine – any clearance issue present when the jaws lower immediately triggers the machine to stop and will not allow the driver to advance to form the rivet. Finally, a total solution had been created.
Defining Challenges
Through partnering with this HVAC customer and completely defining the challenges they were experiencing, the experts at Orbitform were able to design a full assembly solution. This came in the form of 4 standardized Milford 305 machines with standard tooling to form all components and eliminate costly tooling change-over.
Are you experiencing equipment challenges for your current manufacturing process? We stand ready to support your efforts and find your unique solution. Contact us today to find how we can help.