6780/09.

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RIVCLINCH
Devices and systems for joining sheets and profiles without fasteners

RIVCLINCH Joining without fastener!

What is clinching?
Upon clinching, double- or multi-layer joints of sheets and/or profiles are joined form-fittingly and non-positively in a push-button-like cold-forming process. With the RIVCLINCH joining technology, apart from steel and stainless steel materials, also aluminium and other non-ferrous materials can be joined efficiently and environment-friendly. Furthermore, coated as well as precoated sheets can be joined without any damage to the surface. Depending on the chosen RIVCLINCH joining tools, round or rectangular joint points result.

The advantages at a glance

Form-fitting and non-positive joining of sheets and profiles in cold-forming No additional fasteners

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No thermal load on the joining zone No surface damage to coated workpieces No preworking or reworking required Very good reproducibility of the joint Minimum maintenance costs Films or adhesive as intermediate layer possible in most cases Environment-friendly at the workplace since there is no gas or noise emission Non-destructive testing of the joint possible

Low power consumption

The joining technology

The first step of RIVCLINCH joining is to draw the materials to be joined through the punch into the die. As soon as the bottom material touches the die anvil, it starts flowing to the sides and forms a button. After that, the punch moves back into the initial position and the joined part can be removed. A form-fitting and non-positive joint results from local forming.

Tailor-made solutions

The tool kits

The central component of the RIVCLINCH joining system is the tool kit. It is individually adapted to every application. Bllhoff provides different possibilities of integration into a clinch unit, presses or multistage tools.

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The hand tools
Our comprehensive RIVCLINCH hand tool program provides you as the user with the possibility to use clinching technology in your business without high investment costs. The program structure allows to find the right solution for almost every application.

Modular systems

With the Modular systems product series, we have set up a standard clinching program from which we can combine individual clinching tools according to your desired application from different modular systems.

Joining together!

Joint point geometry

Round point For round points, the workpieces to be joined are formed locally. A form-fitting and non-positive joint results which is also visually appealing.

Rectangular point The rectangular point results from a combined cutting and forming process. It is particularly suitable for hard materials as well as for stainless steel.

5.5 5 4.5 Material thickness, punch side [mm] 4 3.5 3 2.5 2 1.5 1 0.5 0

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Joinable materials
E D B C F A
0 0.5 1 1.5 2 2.5 3 3.5 Material thickness, die side [mm] 4 4.5 5

With the RIVCLINCH joining technology, apart from steel and stainless steel materials, also aluminium and other non-ferrous materials as well as hybrid joints with foil or adhesive intermediate layers can be joined. Furthermore, coated as well as precoated sheets can be joined without any damage to the surface.

Evaluation of suitability for clinching of different materials depending on the material thickness Round point Rectangular point

Higher-strength steel 500 N/mm2 < Rm < 700 N/mm2 Austenitic, stainless steel Structural steel, aluminium

Only rectangular point tools should be used for austenitic stainless steel.
A B

Steel 0.5 mm Steel 0.5 mm

Steel high-strength, 2.0 mm Steel high-strength, 2.0 mm

Steel 0.7 mm Adhesive 2 x steel 0.7mm

Aluminium 2.45 mm Steel 1.4 mm

Steel 3.0 mm Steel 1.25 mm

Aluminium 1.5 mm Aluminium 1.5 mm

Workpiece design
1. Consider accessibility for design!

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2. Provide for sufficient flange width! 3. Leave sufficient space for extension of die. First relieve the button from the die (1st step), then move the C-frame forward (2nd step)!

Consider interference edges!

1. 2.

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4. Preferable direction thick into thin

Joining technologies a comparison

Clinching Self-pierce riveting Riveting Screwing Spot welding Adhesion

Corrosion on coated material

low

low

low

low

high

none

Changes in structure and strength at the joining location

none

none

none

none

yes

none

Dynamic strength

very good

very good

suboptimal

suboptimal

suboptimal

good

Crash resistance Static strength: 1. Shear tension 2. Pull-out tension

suboptimal

very good

suboptimal

suboptimal

suboptimal

good

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good good very good very good optimal very good very good possible very good very good possible optimal poor none none none edges none none self-pierce rivet rivet screws nuts washers thread none none feeding feeding, caulking feeding, screwing very low low very high very high high low low high high very good good poor poor very good very good good good poor very easy easy easy easy easy very good very good good good low none none low high none none drilling drilling

very good very good

good good

Method in combination with adhesion

Edges burrs chips

none

Required fasteners

adhesive

Additional process steps

coated surfaces

pressing curing

Costs per joint

high

Energy input

very high

very high

Economic efficiency

suboptimal

suboptimal

Environmental friendliness at the workplace

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very poor

Handling

complex

Reproducibility

satisfactory

good

Dependence of resulting joint on surface condition Pre-operation

very high

washing pickling

washing pickling

Economic efficiency of the RIVCLINCH joining technology

The primary aim of the clinching technology, apart from providing an up-to-date and innovative fastening technology, is to save production costs. Cost saving results from different factors:

Investment

Operating costs

Comparison of costs for different joining processes and materials

200 180 160 140 120 100 80 60 40 20

Low investment costs No exhausting devices required (toxic vapours of spot welding)
No cooling water and thus no complex installation

required
No expensive electrical installations for welding

transformers required
Particularly when welding zinc plated steel sheets

and aluminium, very high costs result (figure 1)

Number of clinching points until tool change

Costs / joining element ()

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0 Clinching Welding St 1403 Welding Welding St zinc plated St zinc plated 0.01 mm 0.02 mm Welding aluminium Normal range of number of pieces per die

Low operating costs Low power consumption during operation of the tools
No power consumption during idle time (operation

with booster) kits (figure 2)

350,000 300,000 250,000 200,000 150,000 100,000 50,000 0

Low costs for wear parts due to long life of the tool No additional power consumption resulting from

Number of clinching points until tool change

operation of exhausting devices

No cooling water required as medium

No reworking costs No damage to coating of, for example, zinc plated surfaces
No burn-off as with spot welding and thus no

Steel

Steel zinc coated coated

Aluminium Stainless steel

resulting complex re-zinc-plating to avoid undesired corrosion (figure 3)

Joining parts material: Aluminium sheet

0.2

0.15

Short cycle times Short joining process (approx. 0.5 s for forming plus feed motions depending on feed stroke and design of the used system)
High automation level with high numbers of pieces

0.1

and few personnel possible!

0.05

Clinching without cutting

Self-pierce riveting with semitubular rivet

Resistance spot welding

Easy handling No expensive highly qualified operating personnel required

Total costs of a joint point

The costs of a joining element result from three main factors:
Operating costs (current, air, water, exhaustion, ...) Wear parts (tools, electrodes, ...) Costs of additional elements (self-piercing rivet)

As an example, a joint of two aluminium sheets was chosen. For other material combinations such as steel + steel, different weighting can result.

A joint that lives up to its promise!

Strength parameters
There are three areas when it comes to strength values: 1. Static strength (quasi-static shear and cross tension testing) 2. Dynamic strength (swinging load / fatigue test) 3. Crash resistance (impact load / impact test) Strength values of clinched joints mainly vary depending on the following factors: Diameter of the clinching point
Material type Material thickness Joining direction (thin into thick / hard into soft) Geometry of the clinching point

6.00

5.00

4.00

3.00

2.00

1.00

0.00 0.50+0.50 0.75+0.75 1.00+1.00 1.25+1.25 1.50+1.50

Force F in kN

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0 0 103 104 105 106 107

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Static shear tension strength depending on sheet thicknesses 2 3b 3a 1, 2 1 3b
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Shear tension strength (kN)

3a

RIVCLINCH joining Static shear tension strength depending on sheet thicknesses material: steel sheet, tensile strength = ~ 300 N/mm2 1. Round point, 5 mm 2. Round point, 8 mm 3a. Rectangular point diagonally to the direction of stress 3b. Rectangular point longitudinally to the direction of stress

Sheet thickness (mm)

Dynamic strength of a RIVCLINCH point

Compared to spot welding, the dynamic strength of a clinching point is higher! Through mere mechanical forming without thermal load and accompanying edge zone carburisation, a permanently reliable fastener results. That means that a RIVCLINCH joint point has a longer life than a welding spot.

Number of cycles to failure

RIVCLINCH Spot welding

Factors determining the quality of a clinched joint

Joining equipment Design of the joining equipment

Type of force generation Static deformation behaviour Dynamic deformation

Joining tool
Geometry of punch Geometry of die Stripper / holding-down

device Process forces Joining forces

Stripper forces

behaviour
Kinematics Control

Joining parts Number

Materials Material thicknesses Surface condition Geometry Accessibility

Joining process Alignment

Cycle times Environmental effects

Quality check of the RIVCLINCH joint

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Joining direction

Quality surveillance

For clinching, there is a causal relationship between joint quality and the geometry of the joining element. It is therefore possible to estimate the quality of the joint from a visual evaluation of the joining element and by measuring geometric parameters.

Testing the RIVCLINCH joint

Non-destructive testing of the RIVCLINCH joint can be realised by measuring the residual material thickness (ST) and the joint point diameter D. Those values are determined in pre-tests for the corresponding application and documented in a test report with test report number. By simple measurement of those values at the component and a comparison with reference data, the quality of the RIVCLINCH joint can be checked without damaging the component. For a simple test of the residual material thickness, conventional quicktest gauges, as illustrated, can be used. This way, during production, quality surveillance can be performed in sampling tests without damaging the component which also improves the value-added process of your company.

ST D Testing the residual material thickness ST

RIVCLINCH in action

We offer the suitable joint for different target groups and industries. We are specialised in developing consistent and attractive solutions side by side with you.

Modular system, handheld for subassemblies

Heat shield made with hand tool

0706 IP hand tool with multi-axis suspension in door and gate manufacturing

Hand-held clinching systems, for example in the sheet metal industry, optimise your work processes

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Large component dimensions in energy and climatic engineering as illustrated here can be joined with semiautomated systems

The RIVCLINCH modular system

The tool kits

As a standard, tool kits for round points with nominal diameters of 3, 4, 5, 6, 7, 8 and 10 mm as well as for rectangular points with nominal dimensions of 4.3 mm, 5 mm and 6 mm are available. The tool kit is integrated into a clinch unit depending on the application. Bllhoff offers many possible combinations, starting from a hand tool with a joining force of 25 kN to modular systems with a joining force of 50 kN to fully automatic systems and special machines. However, integration into presses or multistage tools is also possible.

Punch

Holding-down device / stripper

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Die

The dies

RIVCLINCH dies comprise a basic die body and individual die segments that are held in position by a steel spring. The individual segments are captively fastened to the basic die body with a safety cage. Thus, the segments cannot fall out. The ring can be divided into 2, 3 or 4 segments. The selection of the suitable die geometry depends on the individual application.

Example: tripartite RIVCLINCH die SR 503

Advantages over methods with not segmented die

RIVCLINCH joining bears the following advantages thanks to the segmented die:
Very high pull-out tension values due to improved flow behind the material because the die opens during

clinching and the material can flow to the side.

Higher flexibility for clinching of different sheet thicknesses with one tool kit. A flat button results from the RIVCLINCH method (see figure). No material build-up inside the die (particularly for zinc plated or coated sheets), due to high radial

forces. Bursting of the die due to a reduced die volume is therefore not possible. This also allows longer life of the die.
No stripper required on the die side to remove material from the die this can cause problems

particularly for automation. Thus, the material cannot get stuck inside the die.
This allows a thinner tool design on the die side resulting in an improved accessibility of the workpiece.

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Die design

The tool kits

dnom

Die for RIVCLINCH round point The nominal diameter (dnom) of a RIVCLINCH die is measured in closed no-load condition. During clinching, this diameter increases depending on the application. The following formula serves as a guide value for the button outside diameter (Dbutton): Dbutton = dnom x 1.4. Compared to processes with not segmented die, a clinching point with nominal diameter dnom = 6 mm corresponds to a die inside diameter of approx. 8 mm for a not segmented die. Die for RIVCLINCH rectangular point Just as for the round point, the nominal width (wnom) of the die for the RIVCLINCH rectangular point is measured in closed no-load condition. During clinching, both die segments are pressed outwards. From that a button with an applicationdependent width results. The following formula serves as a guide value for the button width (wbutton): wbutton = wnom x 1.4.
Jm: wnom

Jm:

Round polymer stripper

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Rectangular polymer stripper

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The tool code
Codification of dies S: Single D: Double

Die depth mm /10

SR 504 14

Number of die segments Die diameter Die width (rectangular) in mm

R: Round point T: Rectangular point

Codification of punches S: Single D: Double

SR 60 10

Radius code Punch diameter Punch width (rectangular) in mm

R: Round point T: Rectangular point

The stripper
As a standard, polymer strippers with an outside diameter of d = 16 mm are used. Due to the particularly small design, accessibility of the joint points and very smooth positioning of the stripper on the component surface are ensured. This can be of particular advantage for coated sheets, for example in the coil coating process. The use of a polymer stripper is the most cost-effective variant. Another advantage is that punch and die can usually be replaced. For bipartite dies and very narrow flanges, it can be useful to use a rectangular polymer stripper. The optimised design corresponds with the die design.

RIVCLINCH hand tools

Manual

Fully automatic

Our comprehensive hand tool program provides you as the user with the possibility to use clinching technology in your business without high investment costs, e.g. for special machines. The program structure allows to find the right solution for almost each of your applications. The same tool kits fit into almost every hand tool so that they can be interchanged. Our technical marketing consultant in the field will help you to choose the optimised hand tool for your application.

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A handle or two-hand start (with feed stroke > 8 mm) A tool kit for the specific application A booster (with transformation ratio

A complete RIVCLINCH hand tool system consists of the following components: A work head; design depends on series

A hose package 2 m (hydraulic and pneumatic hoses in protective conduit)

1 : 60 = compressed air : hydraulic pressure) for pneumatic/hydraulic systems

Available as an option: Compressed-air conditioner

Balancer for weight-reduced suspension

Rotator ring for more flexible suspension of small hand tools Multi-axis suspension for C-frame hand tools Clinch cycle control

Mechanical stripper on the plunger (system-specific)

Compressed-air conditioner

Booster

Balancer

Rotator ring

Clinch cycle control

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The FS series

RIVCLINCH 0201 FS

RIVCLINCH 0301 FS

RIVCLINCH 0501 FS

Technical data
Weight work head incl. handle Total weight incl. pressure intensifier Compressed-air connection min. Compressed-air connection max. Hydraulic pressure at 6 bar Joining force at 6 bar Opening (dist. betw. punch + die) Cycle time 1.7 kg 10 kg 5 bar 6 bar 360 bar 25 kN 6.5 mm 2.5 mm 1.8 mm 2.5 mm

Technical data
Weight work head incl. handle Total weight incl. pressure intensifier Compressed-air connection min. Compressed-air connection max. Hydraulic pressure at 6 bar Joining force at 6 bar Cycle time 3.5 kg 12 kg 5 bar 6 bar 360 bar 35 kN 6.5 mm 3.0 mm 2.0 mm 3.0 mm

Technical data
Weight work head incl. handle Total weight incl. pressure intensifier Compressed-air connection min. Compressed-air connection max. Hydraulic pressure at 6 bar Joining force at 6 bar Cycle time 3.9 kg 11.5 kg 4 bar 6 bar 360 bar 35 kN 8 mm 0.8 to 1.2 s 3.0 mm 2.0 mm 3.0 mm

Max. sheet thickness total, steel (SR, ST) Max. sheet thickness total, aluminium

Max. sheet thickness total, stainless steel (ST)

The figure below shows the extremely small fitting space in which the RIVCLINCH 0201 FS can work. 27

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The advantages at a glance

Considerably reduced weight High dynamic Extreme power development Optimal accessibility due to reduced interferences Low operating costs and quick amortisation Cost-effective alternative to spot welding Use of round and rectangular points Laboratory-tested, joint-optimised tool selection No complex tool adjustment required Easy setting stroke adjustment Ready to operate immediately after connection to

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compressed-air supply

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Opening (dist. betw. punch + die) 0.7 to 1.0 s 0.7 to 1.0 s Max. sheet thickness total, steel (SR, ST) Max. sheet thickness total, aluminium Max. sheet thickness total, stainless steel (ST)

Opening (dist. betw. punch + die) Max. sheet thickness total, steel (SR, ST) Max. sheet thickness total, stainless steel (ST) Max. sheet thickness total, aluminium

Fields of application:
Small and medium series Narrow flanges Corners Narrow installation space

Technical modifications reserved. Data depend on variants. Dimensions on request.

The IP series

RIVCLINCH 0404IP

RIVCLINCH 0706 IP50

Technical data
Weight work head incl. handle* Compressed-air connection min. Compressed-air connection max. Joining force at 6 bar Cycle time 4.7 kg 5 bar 6 bar 35 kN 0.9 to 1.5 s 6.5 mm 35 mm 44 mm

Technical data
Weight work head incl. booster Compressed-air connection min. Compressed-air connection max. Joining force at 6 bar Cycle time Opening (distance betw. punch + die) 22 kg 4 bar 6 bar 50 kN 8 mm 0.8 to 1.0 s 4.5 mm 3.0 mm 4.5 mm

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Working stroke, closed Total stroke, open Opening depth Max. sheet thickness total, steel (SR, ST) Max. sheet thickness total, aluminium Max. sheet thickness total, mild steel 3.0 mm 2.0 mm 3.0 mm Max. sheet thickness total, stainless steel (ST) Max. sheet thickness total, aluminiumz

Max. sheet thickness total, stainless steel (ST)

* Different designs with slightly different weight

The advantages at a glance

Mere pneumatic drive Increased joining force at reduced tool interference Tiltable C-frame for joining over interference edges Ready to operate within minutes Cost-effective alternative to spot welding Use of round and rectangular points Laboratory-tested, joint-optimised tool selection Easy setting stroke adjustment with parameter screw Flexible and mobile use, also open air Integrated rotator ring as a standard

Fields of application:
Lightweight and finished steel

construction engineering
Corners Narrow flanges Reaching over interferences

Technical modifications reserved. Data depend on variants. Dimensions on request.

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Work head automation

With many of our hand tools, the work head without handle can also be used in automated production. For that, a sliding support can, for example, be adapted to the rear of the corresponding work head to compensate positioning inaccuracies in the machine or device.

TAGGER

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TAGGER 320 TAGGER 320 V1 (for corner joints) The advantages at a glance Technical data Tool weight Total weight incl. pressure intensifier Operating air pressure Hydraulic pressure at 6 bar Cycle time Max. material strength, mild steel Max. material strength, stainless steel 2.1 kg 9.7 kg 6 bar 365 bar 0.9 s 0.9 mm 0.6 mm
Low noise and no recoil User-friendly

RIVCLINCH 0301 FS with sliding support

Quick, cost-effective joining of sheets Cycle time shorter than 1 second Easy access to narrow corners No separate holding devices or fixing tool One tool for all material thicknesses No sparks, smoke or toxic gases

Suitable for coated, painted material and for

sandwich sheet
No drilling or pre-punching No preworking or reworking No auxiliary fasteners, no adhesive No combustion residues, no oil, no waste

Fields of application:
Production of domestic appliances Heating, air-conditioning and ventilation

technology
Filter production Large, bulky components

System components

The booster

The booster is a pressure intensifier that increases conventional compressed air of 6 bar by the factor 60 so that an operating pressure of 360 bar is achieved on the hydraulic side. Advantages over conventional hydraulic power packs:
Closed, leak-proof hydraulic circuit No power consumption during idle time Particularly low-maintenance and easy-to-handle -

power source
High speed and therefore short riveting cycle

times
Simple mere pneumatic control

Accessories

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system is ready to operate

Just connect compressed air and the RIVCLINCH

The rotator ring

Increased movability

Joining in every position

Ergonomic tool handling

The balancer
To make life even easier for you, there is an adapted balancer for every RIVCLINCH tool to compensate the tool weight. There are balancers for the different weight classes:
Work head weight from 2 kg to 3 kg, 1.6 m cable length Work head weight from 4 kg to 6 kg, 2 m cable length Work head weight from 10 kg to 14 kg, 2 m cable length Work head weight from 14 kg to 18 kg, 2 m cable length Work head weight from 18 kg to 22 kg, 2 m cable length Work head weight from 22 kg to 25 kg, 2 m cable length Work head weight above 25 kg on request

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Accessories

Clinch cycle control OCC

Minimum process monitoring Just one brief trigger is sufficient Automatic clinching process Hydraulic pressure is controlled (pneumatically

controlled pressure sensor)

No maloperation by worker due to too brief triggering

compressed air 6 bar

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In the illustration you can see the preferable suspension of RIVCLINCH hand tools:

conditioner with water separator (1) and oiler (2)

booster work head hose package consisting of: hydraulic hose line pneumatic control lines punch with stripper

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humidity: ISO 8573-1 class 4 > water dew point + 3 C

The compressed air conditioner

RIVCLINCH machine systems work with 6 bar conventional compressed air. In any case, a compressed-air conditioner with water separator and oiler must be connected in series. Required compressed air can be classified as follows:

max. oil content: ISO 8573-1 class 2 > 0.1 mg / m3 compressed air

Tip for practical use: Since the oil content cannot be measured in practical use, the residual oil content can be checked connecting an air gun downstream of the conditioner at a branch and blowing air against white paperboard from a distance of about 10 cm for 10 seconds. Only a slight yellowish colouring shall be visible on the paperboard. Dropping oil is a definite proof that the residual oil content is too high this can lead to plugging of the pneumatic system.

The optimum suspension

To avoid collision at sudden movements, booster and balancer should be installed on one common trolley. Depending on the system, for more flexible handling, we recommend to also order a rotator ring or multi-axis suspension. All hand tools are reduced-weight tools and designed according to ergonomic aspects. This particularly affects the acceptance of tools for production. Thanks to the easy handling of RIVCLINCH hand tools, the machines become increasingly important, especially in small- and medium-series production.

trolley balancer rotator

guide rail

die

The modular systems

Semiautomatic

With the Modular systems product series, we have set up a standard clinching program from which we can combine individual clinching tools according to your desired application from different modular systems. According to the maximum joining force, the modular systems are subdivided into three main groups:
RIVCLINCH P35 with 35 kN max. joining force RIVCLINCH P50 with 55 kN max. joining force RIVCLINCH P75 with 75 105 kN max. joining force

Together with our technical marketing consultants, you can choose the clinching systems suitable for your application from a great variety of possible combinations and within no time start production.

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The P35 series

The RIVCLINCH P35 series can surely be described as the variant of our modular systems with most commonly used on the market. The focus of the series is definitely on the ratio of the lowest possible weight and small dimensions with at the same time a powerful and dynamic setting behaviour of the clinching tool. General technical data: Required compressed-air connection Max. press force at 6 bar Cycle time Max. sheet thickness aluminium (SR) Max. sheet thickness aluminium (ST) Max. sheet thickness steel (SR) Max. sheet thickness steel (ST) Max. sheet thickness stainless steel (ST) Adapted tool kits

The P50 series

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Standard stroke lengths P35 S cylinder * Above 3 mm only with mechanical stripper Technical modifications reserved. Data depend on design. P50 S with axle compensator slide mount General technical data: Required compressed-air connection Max. press force Cycle time Max. sheet thickness aluminium (SR) Max. sheet thickness aluminium (ST) Max. sheet thickness steel (SR) Max. sheet thickness steel (ST) Max. sheet thickness stainless steel (ST) Adapted tool kits Standard stroke lengths * Above 3 mm only with mechanical stripper Apart from the standard S cylinder, we also offer a PASS cylinder. See page 23.

6 bar 35 kN 0.8 2 sec 3.0 mm 3.5 mm* 3.0 mm 3.5 mm* 2.0 mm round point with die design: bipartite: SR 302, SR 402, SR 502 tripartite: SR 403, SR 503, SR 533 quadripartite: SR 504 rectangular point type ST 432 10 15 mm (selection below) 25 50 mm (selection below)

Compared to the RIVCLINCH P35 series, the RIVCLINCH P50 series provides a joining force of 55 kN. Just like for the sister series, the focus of this series is definitely on the ratio of the lowest possible weight and small dimensions with at the same time a powerful and dynamic setting behaviour of the clinching tool.

6 bar 50 kN 0.8 1.5 sec 4.0 mm 4.0 mm* 4.0 mm 4.0 mm* 3.0 mm round point with die design: bipartite: SR 302, SR 402, SR 502 tripartite: SR 403, SR 503, SR 533 quadripartite: SR 504 rectangular point type ST 432 10 15 mm (selection below) 25 50 mm (selection below)

The P75 series

The RIVCLINCH P75 series is the most powerful variant of our modular systems. The focus of this series is on the high precision and the possibility to work with multistage tools. Apart from that, great sheet thicknesses, such as total steel thicknesses of up to 6 mm, can be joined with the corresponding tool kits.

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P75 S spring single-acting P75 S double-acting As the drive for the RIVCLINCH P75 setting cylinder, there are two variants: 1. Variant with booster (single-acting) The tool is equipped with a hydraulic cylinder driven by a booster. The hydraulic cylinder is single-acting, i.e. the cylinder is moved down by the booster drive. Reverse motion of the setting cylinder is realised via spring force by a spiral spring in the setting cylinder. General technical data: Required compressed-air connection/hydraulic pressure Max. press force Required oil volume Max. total stroke Cycle time Max. sheet thickness aluminium (ST, SR) Max. sheet thickness steel (ST, SR) Max. sheet thickness stainless steel (ST) * Others on request Variant 1 6 bar 105 kN (75kN) 3.75 cm3 / 1 mm stroke 20 mm 0.8 2.0 s 6.0 mm 6.0 mm 4.0 mm

2. Variant with oil hydraulic system (double-acting) As opposed to the single-acting variant, the setting tool is hydraulically driven for the forward and the reverse motion. With respect to the hydraulic system, geometry data deviate from the single-acting variant.

Variant 2 350 bar (250 bar) 105 kN (75 kN) 3.12 cm3 / 1 mm stroke 50 mm (100 mm*) depending on used hydraulic power pack 1 3 s 6.0 mm 6.0 mm 4.0 mm

Data in brackets ( ) relate to the reduced joining force of 75 kN at a hydraulic pressure of 250 bar.

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System components

Since the basic design is identical for all series, we give you an overview of further system components. We offer the service of our technical marketing consultants who, together with you, can choose the suitable clinching system for you. We are looking forward to your request.

Application analysis
To set up a complete RIVCLINCH system, accessibility to the component must be thoroughly checked. After that, the appropriate tools are chosen for your application using the sampling in our test field The tools are then documented in a test report. These data can later be used upon production as quality characteristics.

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C-frame
Window w = 91 mm A 47 47 47 47 47 C 35 70 110 205 305 D 40 55 70 108 150 Weight kg 7 11 12 32 70 A 47 47 47 47 47
w

For a definite choice of the RIVCLINCH work head, the throat depth of the C-frame must be defined. Here, we recommend to already consider future projects. Therefore, it may be useful to choose the C-frame slightly larger than absolutely required, even if this may not be necessary for the present application.

Window w = 126 mm C 35 70 110 205 305 D 40 55 70 108 150 Weight kg 9 13 20 37 78 A 47 47 47 47 47

Window w = 161 mm C 35 70 110 205 305 D 40 55 70 108 150 Weight kg 10 14 22 36 77

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PASS setting cylinder

Particularly for opening strokes from 60 mm, we offer the innovative RIVCLINCH PASS setting cylinder which allows to work with a foot pedal switch or in one-hand operation. The patented powerless partial prestroke performs 53 mm of the total stroke at small force (50 N). Triggering is performed with a 2-pedal foot switch or a small pushbutton on the trigger handle. If the setting piston is below 8 mm of remaining feed stroke, the pushbutton or the foot pedal switch can be actuated to trigger a working stroke of 35 kN or 50 kN as many times as desired. After that, the piston returns to the start position when the small pushbutton or the 2-pedal foot switch are actuated again. As an additional safety feature, the partial prestroke allows to precisely position the tool with respect to the component without causing any damage since prestroke is performed at very small force.

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P50 PASS cylinder

Mechanical stripper

It may in some cases happen that the stripper force of the polymer stripper is insufficient to pull the punch out of the joined material. This problem can occur particularly with soft materials such as aluminium. For this case, we offer especially adapted mechanical hold-down units with increased stripper force (of a maximum of 2.6 kN or 3.6 kN depending on the series).

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Drive

The easiest and most common way to operate RIVCLINCH systems is the drive with conventional compressed air of 6 bar. To control the operating pressure and for separation of water which can accumulate in the line system of your compressed-air system, a maintenance unit with water separator and oiler must be installed.

Required compressed air can be classified as follows:

Humidity: ISO 8573-1

class 4 -> water dew point + 3 C Optional: compressed-air conditioner

Max. oil content: ISO 8573-1

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es Fo @ r lo ac w ei es nd t p su ric pp es lie : s. co m
handle power source times Booster with distribution manifold and pressure sensor Power Unit

class 2 -> 0.1 mg/m compressed air

To achieve an operating pressure of about 360 bar on the hydraulic side, a booster is used as a pressure intensifier which increases compressed air by the factor 60. Advantages over the conventional hydraulic power pack are the following:

Closed, leak-proof hydraulic circuit No power consumption during idle time Particularly low-maintenance and easy-to High speed and therefore short riveting cycle Simple mere pneumatic control Just connect compressed air and the

RIVCLINCH system is ready to operate.

Depending on the required oil volume, several clinching tools can be operated with one booster. For that, a distribution manifold with four suboutlets as a standard is connected to the outlet on the hydraulic side. The not required outlets are sealed with sealing plugs. Please note that the tools connected to the same booster can only be operated together and at the same time.

If boosters cannot be used or if the technical design of the system does not allow to use a booster, modular clinching systems can also be driven with an oil hydraulic system. However, this requires the use of an electrical control, i.e. then, there is not the advantage of the mere pneumatic control.

Handling

Apart from the integration into a system, most modular clinching tools can also be used as hand tools. For that, the tools are additionally equipped with a multi-axis suspension as well as a handle or a two-hand start device. This allows you to perform manual clinching even at joining locations of difficult access.

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Multi-axis suspension Axle compensation

Particularly for automatic systems it is often necessary to achieve tolerance compensation of the tools towards the workpiece so that the component is not deformed in the clinching process. For small- to medium-size clinching tools, we offer a standard axle compensation (up to 10 kg) which can easily be screwed to the rear of the standard C-frame. For larger C-frames and for the pneumatically supported active axle compensation, there are special application-specific solutions on request.

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Control

The simple pneumatic control is integrated in the booster and controls the complete clinching process. Up to a total stroke of 8 mm, the clinching process can be triggered with a foot pedal switch (stationary systems) or a one-hand switch (hand-held systems). With a total stroke > 8 mm, two-hand operation or external protective devices are prescribed to prevent personnel from reaching into the tools and thus minimise the risk of injury. This does not apply to the use of RIVCLINCH PASS setting cylinders. The pneumatic control is complemented with clinch cycle control. A control box with integrated pneumatic logic control is installed on the corresponding booster. Via a hydraulic pressure switch installed between booster and compressed-air tubing, the control receives the signal that the required and previously set pressure has been reached. The control sends the signal to the main valve in the booster and the hydraulic cylinder returns to the initial position. To trigger the complete riveting cycle, the trigger must only be actuated briefly to start a completely automatic clinching process. Maloperation by the worker due to too brief triggering, for example, can therefore be ruled out.

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The booster starts the clinching process via the internal pneumatic valve

The return outputs a Tool in start position signal to the PLC

Clinching process completed, System clear

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Booster with OCC Piston return sensor

When RIVCLINCH systems are integrated into another system, it must be ensured that the clinching process has been completed and the clinching tool has returned to the initial position. For that, a return sensor is installed on the cylinder of the clinching tool. It outputs a signal when the tool is in the start position. To ensure that the force required for the clinching process is achieved at the joining location, a pressure sensor can be positioned on the hydraulic side of the booster. When the required pressure is reached, the sensor outputs a signal to the system control.

The PLC sends a start signal for clinching to an external electro-pneumatic valve

This is what we offer you!

Optimum joints are no coincidence.

We are the partner for your projects from the very first concept to the final realisation.

Up-to-date 3D CAD systems allow customer-specific designs.

Sampling for your components with competent application engineering.

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Assembly Quality
Manufacturing, assembly, commissioning as well as training of your employees. Our quality management complies with EN ISO 9001 and ISO / TS 16949:2002.

From A to Z

Technology

Analysis

Service

Twenty-four-seven, our maintenance, repair and service personnel make your production a reliable process.

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Bllhoff International with companies in:

Argentina Austria Brazil Canada China Czech Republic France Germany Hungary India Italy Japan Mexico Poland Romania Russia Slovakia Spain Turkey United Kingdom USA

Apart from these 21 countries, Bllhoff supports its international customers in other important industrial markets in close partnership with agents and dealers.

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Bllhoff Group Please find your local contact on www.boellhoff.com or contact us under [email protected]

es Fo @ r lo ac w ei es nd t p su ric pp es lie : s. co m

Subject to technical change. Reprinting, even in extract form, only permitted with express consent. Observe protective note according to DIN 34.