What do you do when you have a part you need to assemble with a specific functional requirement and do not know how to achieve it? Identifying the required process is often the first step, but sometimes there is more to solving the challenge that lies in the part design or part fixturing.
Recently, a bracket manufacturing tied to the alternative energy industry came to Orbitform to address a challenge in their assembly. They had a bracket that needed to be assembled between two stampings and be able to swing freely to allow for smooth articulation of the bracket. They required the Orbital Riveting process but did not know how to ensure the free pivoting motion during assembly.
Taking on the Challenge
Our Assembly Experts tackled this challenge by assembling sample parts in our Solutions Lab. This challenge had two key factors – determining the appropriate rivet length and designing a proper fixture.
Rivet Length Determination
In the Solutions Lab, the first step was to determine the proper rivet length. The customer provided a longer rivet, allowing us to test various lengths and recommend the ideal size for their production parts. This meticulous process ensured that the chosen rivet length met both functional and production requirements.
Fixture Design for Articulation
A critical aspect of the project involved designing a fixture that would guarantee the desired articulation. To achieve this, we clamped the rivet into a v-block that supported the stampings, preventing them from getting pinched together during forming, creating a gap. This design allowed the forming force to be transferred into the v-block instead of the stampings, maintaining the necessary gap within the assembly.
The Equipment Solution
After determining the part design and fixture requirements, Orbitform designed and built the appropriate assembly equipment. Based on volume requirements and part design, the equipment solution was an orbital riveter with a 2-spindle multi-spindle and 2-position slide. The simultaneous formation of two rivets significantly contributed to meeting the volume requirements of the bracket manufacturer.
Conclusion
Orbitform’s commitment to innovation and problem-solving in our Solutions Lab has again proven its value. By collaborating with the manufacturer and addressing their specific challenges, we improved their design and optimized the forming process to produce their desired outcome. Connect with us today to discuss your assembly challenges and how collaborating in our Solutions Lab can bring you closer to solving them.