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All Parts Filed Under Orbital Attachments

In-Process Torque Check

Manufacturing requires consistency and repeatability.  When your assembly process is inconsistent and you experience quality issues, where do you turn?

Orbitform is the leading expert in forming fastening and assembly solutions.  We partner with manufacturers to find the best possible assembly process.  Recently, we were approached by a manufacturer on an articulating joint with a very specific, low torque specification.

Upon review of the manufacturer’s current joint forming method, it was found there was a high scrap rate due to inconsistent torque.  The forming method they were using for the rivet, which held together two handles, simply did not provide enough control to ensure the proper torque specs while holding all components robustly. 

Orbitform partnered with the manufacturer to test the assembly in our Solutions Lab.  Many assemblies were formed to different forces.  After testing the assemblies, a precise forming force was found to provide the required joint functions. 

Orbitform experts worked to develop a new, accurate, repeatable process for the manufacturer.  The system combined a servo-driven orbital powerhead with process monitoring, a servo-driven wedge to raise and lower the assembly for forming, and a rotary servo for in process torque check. 

Upon initiation, the orbital head advances to locate the bottom of the rivet head in the assembly.  The overall length of the rivet is detected, and the stick-up is verified within its specification limits. Based on the specific information received, the rivet is then formed to a specific overall length from the rivet head.  Once formed, the tool retracts, and the assembly exercised a set number of times to release pressure in the joint.  Then, using the rotary servo, the torque of the joint is measured.  If the torque spec is met, the powerhead fully retracts and part unload.  However, if the spec is not met, the forming cycle repeats.  Upon development of this new system, the manufacturer received a repeatable, robust process that produces consistent assemblies every time. 

Partnering with the experts at Orbitform on your assembly process provides many positive results.  The many fastening, forming and assembly processes offered provide the right solution for your functional requirements every time.  Orbitform is the only orbital riveting company able to provide in-process torque check, and eagerly awaits partnering with you on your next assembly process.  Contact us today to have our experts review your application and begin developing your unique solution.

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Through Spindle Pressure Pad

What is the Through Spindle Pressure Pad?

The through spindle pressure pad is an optional accessory that compresses the components being assembled prior to forming. As the name states, the through spindle pressure pad works through the center of the powerhead and is installed directly in line with the forming process. When a through spindle pressure pad is incorporated it is necessary to use an offset motor mount on the powerhead also.

Why is the Through Spindle Pressure Pad important?

The through spindle pressure pad is important because it allows for the components to be compressed prior to conducting the riveting process.

How does the Through Spindle Pressure Pad help?

The through spindle pressure pad helps your product assembly process by seating the components together prior to riveting the components together.

Examples of Where an Through Spindle Pressure Pad is used?

There are several examples of where an through spindle pressure pad is used during an orbital forming assembly process:
  • When a specific compression force is required, such as when forming a seal
  • When it is necessary to have the assembly components pushed together tightly prior to performing the permanent riveting process

Types Of Through Spindle Pressure Pads

Orbitform offer two types of through spindle pressure pads to meet your application needs:
  • Pneumatic actuated
  • Servo Controlled for greater accuracy and control

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Servo Adjustable Hard Stop

Why is the Servo Adjustable Hard Stop important?

The servo adjustable hard stop is important because there are product assembly scenarios where one machine is used to assembly multiple products. The servo adjustable hard stop allows for different parts with different form heights to be assembled on the same machine.

How does the Servo Adjustable Hard Stop help?

The servo adjustable hard stop helps your product assembly process by supporting the assembly of different parts with different form heights to be assembled on the same machine.

Examples of Where an Servo Adjustable Hard Stop is used?

There are several examples where a servo adjustable hard stop is used during an orbital forming assembly process:
  • Automated assembly lines where different parts are assembled
  • Machines that are designed to assemble two or more different form heights on separate part designs

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Programmable Height Sensing Pressure Pad

What is the Programmable Height Sensing Pressure Pad?

The programmable height sensing pressure pad is an optional accessory installed on Orbitform powerheads when it is required to check the rivet length or component "stack up" prior to initiating the forming or riveting operation. The programmable height sensing pressure pad is incorporated in conjunction with other assembly process monitoring or process control equipment and application specific machine programming.

Why is the Programmable Height Sensing Pressure Pad important?

The programmable height sensing pressure pad is important because it is sometimes necessary to validate the presence of components prior to completing the riveting process. Also, there are times when the pre-formed rivet height must be checked before the rivet is upset by the Orbitform peen.

How does the Programmable Height Sensing Pressure Pad help?

The programmable height sensing pressure pad helps your product assembly process by ensuring the required pre-formed rivet height is present and/or that the necessary components are inserted appropriately prior to allowing the riveting process to commence.

Examples of Where an Programmable Height Sensing Pressure Pad is used?

There are several examples of where an programmable height sensing pressure pad is used during an orbital forming assembly process:
  • When it is important the the pre-formed rivet height is accurate prior to forming
  • When the installation of the necessary components is critical before permanently riveting the assembly

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Offset Motor Mount

What is the Offset Motor Mount?

The offset motor mount is an optional powerhead modification allowing the powerhead motor to be mounted to the side of the powerhead.

Why is the Offset Motor Mount important?

The offset motor mount is important in applications where the powerhead must be shorter (as is common with inverted or horizontal powerhead orientations), or when a through spindle pressure pad is to be incorporated in a roller forming application.

How does the Offset Motor Mount help?

The offset motor mount helps your product assembly process by allowing for the installation of a through spindle pressure pad in a roller forming application and/or by allowing the powerhead to be mounted in an inverted or horizontal orientation when a special assembly machine design requires the non standard orientation.

Examples of Where an Offset Motor Mount is used?

There are several examples of where an offset motor mount is used during an orbital forming assembly process:
  • When a a through spindle pressure pad is required in a roller forming application
  • When the powerhead is to be mounted in an inverted or horizontal orientation

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Loadcell Force Monitoring

What is Loadcell Force Monitoring?

Loadcell force monitoring is an optional powerhead accesory installed on Orbitform powerheads when the assembly application requires process monitoring or process control.

Why is Loadcell Force Monitoring important?

Loadcell force monitoring is important because there are several assembly processes that require the riveting force to be monitored or controlled in order to attain the desired finished assembly parameters. Loadcell force monitoring allows for machine stroke position feedback.

How does Loadcell Force Monitoring help?

Loadcell force monitoring helps your product assembly process by allowing for the monitoring or control of the force applied to the forming or riveting process. With loadcell force monitoring you are able to optimize the assembly process to form the best possible rivet head every cycle.

Examples of Where Loadcell Force Monitoring is used?

There are several examples of where loadcell force monitoring is used during an orbital forming assembly process:
  • Forming to a minimum force during a riveting process
  • Monitoring the forming force applied during an assembly operation
  • Using the force applied information to differentiate between good parts and bad parts

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LVDT Stroke Monitoring

What is LVDT Stroke Monitoring?

LVDT stroke monitoring is optional powerhead accesory installed on Orbitform powerheads when the assembly application requires process monitoring or process control.

Why is LVDT Stroke Monitoring important?

LVDT stroke monitoring is important because there are several assembly processes that require the riveting distance to be monitored or controlled in order to attain the desired finished assembly parameters. LVDT stroke monitoring allows for machine stroke position feedback.

How does LVDT Stroke Monitoring help?

LVDT Stroke Monitoring helps your product assembly process by allowing for the monitoring or control of the forming or riveting distance achieved with the assembly process. With LVDT stroke monitoring you are able to optimize the assembly process to form the best possible rivet head every cycle.

Examples of Where LVDT Stroke Monitoring is used?

There are several examples of where LVDT stroke monitoring is used during an orbital forming assembly process:
  • Forming to a minimum distance during a riveting process
  • Monitoring the forming distance achieved during an assembly operation
  • Using the distance reached information to differentiate between good parts and bad parts

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Gear Reducer

What is the Gear Reducer?

The gear reducer is an optional mechanical accessory installed between the powerhead housing and the motor.

Why is the Gear Reducer important?

The gear reducer is important because it is sometimes necessary to reduce the rotational speed of the forming tooling being used to assembly the parts in a roller forming and/or multi-point forming or assembly application.

How does the Gear Reducer help?

The gear reducer helps your product assembly process by allowing the roller forming tooling or multi-point forming head to engage with the product being assembled at the correct RPM. The gear reducer helps provide greater consistency and precision for the forming process by allowing the fine tuning of the forming speed.

Examples of Where an Gear Reducer is used?

There are several examples of where an gear reducer is used during an orbital forming assembly process:
  • Roller forming applications as a method of: 1) reducing the rotation speed of the roller forming head, 2) to extend the performance life of the bearings within the roller forming head, and 3) to prevent the rollers from skidding across the part(s) being roller formed
  • Multi-point forming and assembly applications

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Clutch Brake

What is the Clutch Brake?

The clutch brake is an optional accessory sometimes incorporated with Orbitform powerheads to stop the spindle from rotating without shutting down the powerhead motor. The clutch brake is installed between the motor and the powerhead housing and can be used is most applications including when a gear reducer is required and/or when an offset motor mount is installed.

Why is the Clutch Brake important?

The clutch brake is important because sometimes it is necessary to stop the spindle from spinning without shutting down the powerhead motor. The clutch brake allows the machine's motor starter to operate longer since the motor starter will perform for a longer duration of time if there are fewer stops and starts of the motor.

How does the Clutch Brake help?

The clutch brake helps your product assembly process by allowing the orbital forming spindle to stop rotating while keeping the powerhead motor running.

Examples of Where an Clutch Brake is used?

There are several examples of where a clutch brake is used during an orbital forming assembly process:
  • Roller forming applications require a clutch brake
  • Safety considerations due to operator interaction with the machine or when required by law as in Canada
  • When the assembly process involves many stops and start of the powerhead motor

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Anti-Rotate Device

What is the Anti-Rotate Device?

The anti-rotate device is a tool mounted to the side of the orbital powerhead that maintains the orientation of the peen forming tool during the orbital riveting or orbital forming assembly operation.

Why is the Anti-Rotate Device important?

The anti-rotate device is important because there are various orbital forming and orbital riveting applications where it is necessary to maintain the orientation of the peen tool to the rivet (or post) being orbitally formed.

How does the Anti-Rotate Device help?

The anti-rotate device helps your product assembly process by ensuring the proper orientation between the orbital peen tool and the workpiece being formed.  The anti-rotate device also helps prevent or reduce galling or rubbing that can be caused by the peen tool interacting with a small diameter rivet.

Examples of Where an Anti-Rotate Device is used?

There are several examples of where an anti-rotate device is used during an orbital forming assembly process:
  • When there is a need to maintain the orientation of the forming peen in relation to the rivet or post being formed.  An example of this is when there is a ledge that is higher than the final form height of the rivet.  The peen may need to have a flat shape machined into the side of the peen in order for the peen to have clearance to the side of the ledge.  The anti-rotate device is applied in this case to maintain the orientation of the flat sided peen so the flat side stays clear of the ledge.
  • When riveting a product with a small diameter rivet, depending on the material of the rivet, it is possible that the peen tool could actually cause the rivet to rotate.  This rivet rotation can cause galling or rubbing to occur which can damage or disfigure the rivet.  The installation of an anti-rotate device helps to reduce or eliminate this galling effect and helps improve the product quality and assembly process.  The galling can be a negative cosmetic or negative functional aspect to be avoided.
  • All Orbitform multi-point forming heads require the use of the anti-rotate device as part of the multi-point forming head design.

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