TOX RA6 MCU Series Microcontrollers Instruction Manual
- June 12, 2024
- TOX
Table of Contents
TOX® -Riveting Technology
Instruction Manual
Riveting – one of the oldest joining technologies – even reliably joins dissimilar materials
A simple joining technology
In many industries including automotive, aerospace and appliances joining of
metal components is achieved using riveting technologies. Riveting is a
proven, professional joining technology, permanently joining two workpieces
together. As opposed to screws, rivets have the advantage of not needing a
thread. Compared to thermal joining, they also join non-weldable materials,
thus making them ideal joining elements for lightweight designs and hybrid
components. Fast cycling and high production rates make riveting an attractive
and reasonably priced joining process.
In serial production, riveting processes without pre-drilled holes are
typically used. This means the riveting elements punch through and deform
themselves into the materials to join them in one work step. These joints are
characterized by high strength and one or both sides flush surfaces.
The styles of rivets
An important part of mechanical joining technology is riveting. It is based on
the principle of a positive locking and / or frictional connection. The rivet
itself is inserted into the parts to be joined where the rivet and / or joined
part material are formed. In some instances, punching processes accompany the
actual forming process.
Clinch Rivet®
The patented Clinch Rivet® is a simple, cylindrical rivet that deforms both
materials without cutting either layer.
- Simple, symmetrical rivet
- Allows for simple feeding and pressing
- Air and liquid tight joints
- Ideal for joining thinner sheet material
Self-Pierce Rivet
The self-pierce rivet (SPR) is a unidirectional element that functions as a
punch through the top layer(s) of material. It has the most available
applications.
- Higher joint strengths
- Air tight on the die side
- Ideal for high strength materials
Full-Pierce Rivet
The full-pierce rivet (FPR) is suited to joining highstrength, low elongation
punch side materials to formable die side materials. It is also good for
multi-layer applications.
- One rivet length for multiple material stack-ups
- Can be designed to be flush on both sides
- Ideal for joining lightweight and mixed materials
Rivet Comparison
Rivets| 
---|---
Measurements of the typical rivets| Ø = 3.5 mm
Rivet length 4.0 and 5.0 mm
Ø = 5,0 mm
Rivet length 5.0 and 6.0 mm| Ø = 3.3 – 3.4 mm
Rivet length 3.5 – 5.0 mm
Ø = 5.15 – 5.5 mm
Rivet length 4.0– 9.0 mm| Ø = 4.0 mm
Rivet length 3.3 – 8.1 mm
Ø = 5.0 mm
Rivet length 3.9 – 8.1 mm
Material strength| < 500 MPa| < 1600 MPa| < 1500 MPa
Multirange capacity (different joining tasks)| low| low| very good
Multijoin capacity| possible| possible| possible
Typical number of sheets| 2 – 3| 2 – 3| 2 – 4
Flush surfaces| punch side| punch side| possible on one side and two sides
Pull strength (typical)| up to 1900 N| up to 2500 N| up to 2100 N
Shear strength (typical)| up to 3200 N| up to 4300 N| up to 3300 N
Minimum flange width| 14 mm| 18 mm| 16 mm
Layers cut| none| all except on die side| all
Gas-tight| yes, both sides| yes, die side| no
Liquid-tight| yes, both sides| yes, die side| no
Minimum sheet thickness on die side| 0.7 mm| 1.0 mm| 1.0 mm
Punched piece (slug) removal| no| no| yes
System complexity| medium| medium| high
Electrical conductivity| good| average| average
Typical industrial riveting procedures
ClinchRivet®
The combination of clinching and riveting: A symmetrical Clinch Rivet® is
pressed into the materials and forms the clinch point in the die.
The Clinch Rivet® is formed and remains in the workpiece. This results in a
high-strength connection with a one-sided
flush surface. The Clinch Rivet is perfect for thin materials and leak-proof
joints.
Self-pierce rivet (SPR)
Universal and without slugs: The self-pierce rivet punches through the first
material layer and forms the second to a closing head.
The punched piece fllls the hollow rivet shaft and is enclosed within it. This
results in a high-strength and tight joint, which is flush at the top. This
riveting technology is ideal for extremely flexible joints.
Full-pierce rivet (FPR)
Punching and joining in one step: The rivet punches through all sheet layers.
The layer on the die side is formed in such a way that the material flows into
the annular groove of the rivet and forms an undercut. This rivet joint can be
formed flush on both sides and is ideally suited to joining high-strength
materials.
Proven Process Quality
Continuous Quality Monitoring
A signifi cant advantage of riveting is the simple quality control even in
series production. By continuously measuring the force-travel-curve, each
rivet connection can be checked. An additional analysis can be carried out by
cross sections (cut through the rivet). The shear and pull strength can be
determined in tensile tests.
Preliminary tests in the TOX® -Technical Center
Prior to collaboration, we will work on the most effective solution for you in
our lab. Here we will perform preliminary joining tests on your samples, which
we test and analyze afterwards. We will also determine all parameters for your
application, including the required press force and suitable rivet-die-
combinations, and we will establish which system can be used for your joining
application.
F inal Check of the Machine Parameters
Before we deliver a system, we check the real processing results. We will
create a cross section and analyze the joining process and the retention
forces of the rivet. Everything will be documented in a detailed test report.
The initial set-up of the delivered system is
based on these determined values and parameters.
Advantages
- Demonstrable joining quality in pre-tests and during series production
- Measurement and documentation of the shear and tensile strengths
- Documentation of the joining quality
- Production of pre-production parts
With a cross section (cut through the rivet), the exact formation can be examined under the microscope for analysis. If necessary, optimizations can be made.
System competence
The technology for industrial riveting
TOX® PRESSOTECHNIK, with its decades of ex-patience, provides you with
competent know-how of systems. Regardless of the manufacturer of your rivets,
we are able to customize your application using a wide range of components and
modules.
Your customer-specific requirements are met down to the last detail utilizing
standard system components thanks to our modular design.
The following modules are required for riveting applications:
TOX® -Tong
Setting tools 1
The rivet head and die together form the centerpiece.
They drive the rivet into the workpiece and are adapted individually to each
rivet.
Frame 2
The high forces occurring during riveting are absorbed
in a low-de fiection C-frame.
TOX® -Drives 3
The forces required are generated by electromechanical servo drives or
pneumohydraulic Power packages.www.tox.com
TOX® -Rivet feeding
TOX® -Feeding Unit 4
Preparation of the rivet occurs in our compact enclosure. The hopper,
vibratory bowl, escapement and blow feed prepare the rivet for delivery to the
setting head.
Loading Station (Docking) 5
The tong fills its magazine with the required rivet here.
TOX® -Control and process monitoring6
- Ranging from external impulse to complete PLC controls built to the highest safety standards
- Multi-technology controls available for additional processes
- Monitoring of process and machine parameters
System competence
Automatic Rivet Delivery for Tong Systems
Stationary Blow Feed System The rivets will be directly delivered to the
setting head through a chute. The robot positions the part inside the press
for the rivet to be set.
Advantages
- Simple
- Safe and reliable
- Cost effective
Robot-carried Blow Feed System
The rivets will be directly delivered to the setting head through a chute. The
robot will position the tong to the part for the rivet to be set.
Advantages
- For large workpieces
- Safe and reliable
- Fast
DockFeed System (Magazine)
The rivets will be delivered by chute to the docking station. The robot
carries the tong to the dock to fill the magazine. It then positions the tong
to the part to set the rivets until the magazine is empty.
Advantages
- For multi-technology applications
- Flexible
- Chute-free robot dress pack
Versions
Different basic designs are possible for rivet-systems.
Crucial factors for choosing one system over another include the potential
integration into production lines, optimum feed-in, the desired working speed
and the size of the components.
Stationary tongs
For integration in production lines and equipment, stationary machine tongs
are suitable. The workpiece will be presented by a robot and the rivet will be
inserted by the press.
Robot tongs
A mobile tong is moved and controlled by a robot. The rivets are either
supplied by a docking station or through a feed chute.
Hand tongs
For low volume production a hand-held tong can be utilized. The rivet can be
delivered from the chute, a magazine or be hand loaded.
Presses / Machines
Machines can be designed as fully automatic, semiautomatic or purely manual
workstations. The workpiece is manually loaded into the machine. The machine
will then rivet per a customized plan.
TOX® PRESSOTECHNIK is certified to build safety rated work stations.
TOX®
-Setting heads
You define the element – we develop the suitable setting system. The different
types of rivet place different demands on setting technique and rivet head.
Thanks to long-standing experience and the possibility of performing lab tests
at our facilities, we supply the suitable rivet head for each rivet and each
application. The structural design of the rivet heads differs depending on:
- Type of rivet
- Type of feeding
- Required press force
- Drive version
Advantages
- Die and setting head as an integrated solution
- Process-reliable separation of the rivets
- Slim tool design for tight spaces
- Maintenance-friendly design
- High guide accuracy
- Piece parts with low wear
Versions
| TOX® -Setting Head for self pierce riveting
---|---
| TOX® -Setting Head for full pierce riveting
| TOX® -Setting Head for clinch riveting
TOX® -Dies
The die is the crucial counterpart of the setting head and ensures the correct
formation of the joint. Feeding hoses
A fiter sorting and singulation, the rivet is transported through a specially
shaped chute to the setting head.
TOX® -Feeding Unit
The TOX® -Feeding Unit includes the sorting and delivery equipment for safe
and reliable rivet delivery. This system is outside of the robot cell for easy
refill. It includes:
Hopper: This is the fill location that holds large quantities of
elements. The feeder bowl receives its rivets form here.
Feeder Bowl: This feature orients and delivers the element to the
escapement for delivery. ****
Escapement:
The oriented rivets are singulated here for delivery to the setting head.
From here the rivet is typically blown through a chute to the setting head.
The TOX® -Feeding unit can fit many processes thanks to our modular system. We
also validate our designs for each systems offered to ensure that manual
manipulation is not required.
Flexible control-software for the integrated
production
Flexible Multi-Technology Control
One system – many possibilities! Our multi-technology control operates and
monitors all functions. It is drive independent and can be used for any
technology. When a robot changes its tong, the system recognizes the
parameters and can continue working immediately. This yields the highest
degree of fiexibility.
Additionally, the intuitive TOX® -HMI software allows easy installation and
operation of the system. It is clearly structured and internationally
understandable.
Integrated Production
Using numerous interfaces, it is easy to connect the TOX® -Equipment to a
company network. The system components communicate with each other via
fieldbus.
Processes can be continuously monitored and improved with the data collected
here. Feedback from the production process can be used to optimize the
technology parameters. Unnecessary maintenance work and downtime can be
avoided thanks to predictive maintenance.
Advantages
- One control for different application technologies
- Import of process parameters from customer network
- Auto-configuration of system components
- Condition Monitoring: Storage of operating hours, maintenance counter, tool information etc.
- Preventive Maintenance avoids downtime
- Dynamic process monitoring
- Numerous interfaces for connecting periphery units (e. g. measurement sensors, feeding systems etc.)
- Network communication via OPC UA / MQTT
Process Monitoring Devices The quality parameters of the riveted joint
can be examined and documented by a sperate device.
Sensors
Optional sensor systems can be used to check and display fill levels, process
progress and also quality characteristics of the elements.
Frames and Columns
The forces that occur during riveting are absorbed by a C-frame or the columns
of a column press. The design takes into account interfering contours, total
weight, piece part accessibility, working conditions and occupational safety.
Frames
Robust frames are used for tongs and presses. We respond to the specific
requirements with standard frames or individual designs.
Column presses
Column presses are particularly useful for multi-point tools. They can be
manufactured in various sizes, but all have the same precision and ease of
access.
TOX® -Drives
Large forces are needed to set a rivet joint. These required joining forces
are generated by electromechanical servo drives or pneumohydraulic Power
packages.
TOX® -Electric Drive
The modular electromechanical servo drive systems generate press forces up to
1000fikN. A maximum of 80 kN is required for riveting therefore most drives
used have 30 – 100 kN.
TOX® -Power package
The strong pneumohydraulic drive, which is already used worldwide in thousands
of machines. Available with press forces of 2 – 2000 kN. Additional
Components
Information about additional components like controls, part xtures, safety
devices and accessories can be found on our website tox-
pressotechnik.com. 
Individual Solutions for our Customers
TOX® PRESSOTECHNIK designs process flows more economically – with special
systems, intelligent assembly systems and fully automatic feeds with
integrated additional functions. We possess long-standing experience and
comprehensive know-how in the
development and design of these systems.
We look to create highly efficient systems to match our customer’s designated
work flow. We are committed to finding the best solution for optimizing the
manufacturing processes according to our customer’s requirements.
For this reason, our machines are the product of close cooperation between our
customers and our project managers. Our service team will also be on hand
quickly and reliably at all times following delivery.
Identify demand
An extensive consultation forms the basis of each concept for us – for special
machines as well as production systems. We use our experience and high level
of expertise to identify the basic needs, determine the required components,
and sketch out an initial layout. In our lab we can produce samples with
original materials, components and elements in parallel.
Development process
The specific system concept is forwarded to our design department, which
creates the machine layout and generates detailed drawings for production. We
produce or procure the mechanical components according to the design and
assemble the system. There after the electrical components are installed and
the controller is configured.
Commissioning
Once complete, a trial run of the system is performed. Once everything meets
customer expectations, the customer approves the system. Following delivery,
set-up and installation of the system, commissioning is performed by our
qualified personnel.
After-sales service
We train the operating personnel extensively –either at our premises or on
site using the delivered system. Often, we also support initial production and
provide advice and assistance. When everything is running smoothly, we are
happy to perform regular maintenance tasks on request.
Application examples
TOX® -Riveting robot tongs are often used in the automotive industry.
TOX® -Press with partially automated workpiece handling for the setting of 16full pierce rivets into a clutch housing.
TOX
PRESSOTECHNIK GmbH & Co. KG
Riedstrasse 4
88250 Weingarten / Germany
Find your local contact partner at:
www.tox.com
936290 / 83.202004.en Subject to technical modifications.
References
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