AUTOMATION


The ‘greening’ of fastener installation presses


Roger Patton, engineering manager for PEMSERTER® products, PennEngineering


Among the processes performed by sheet metal fabricators, the efficient installation of fasteners can be one of the most challenging. The work typically can be labour intensive, often requires time consuming tooling changeovers to install different types of fasteners, may be handled with equipment for which energy efficiency was an afterthought, and can jeopardise goals for ‘green’ and sustainable operations.


T


he growth in applications for self-clinching fasteners over the years has helped to mitigate labour concerns by reducing the amount of required hardware to handle and install in thin metal assemblies. Along the way, advances in automated fastener installation press


technology have contributed significantly toward resolving traditional equipment related issues and promoting both ‘green’ and cost effective operations.


Installing self-clinching fasteners Self-clinching fasteners offer reliable attachment solutions for


thin metal assemblies by providing permanent and reusable load bearing threads. Generally, they will be specified for applications where good pullout and torque loads are required in sheet metal too thin to provide secure fastening by any other method. More often than not, they are


installed during fabrication. These types


of fasteners (in dozens of types and thousands of variations) often will dramatically reduce or


eliminate the amount of attachment hardware (such as loose washers, lock washers, and nuts) and usually require only a single


mating piece to 14 Fastener + Fixing Technology • Issue 5 Apr - Jun 2012


complete final component attachment. Fewer parts to install enable quicker assembly and lower production costs and, when installed properly, the fasteners will not loosen or fall out and never have to be handled again. Fabricators install self-clinching fasteners permanently


in thin ductile metal sheets by pressing them into place in a properly sized mounting hole and applying sufficient squeezing force. This causes displaced sheet material to cold flow into a specially designed annular recess in the shank or pilot of the fastener, permanently locking the fastener in place. A serrated clinching ring, knurl, ribs, or hex head prevents the fastener from rotating in the metal when tightening torque is applied to mating hardware. While all presses to install self-clinching fasteners will


provide necessary squeezing force to allow the fastener to become an integral part of an assembly, press similarities end there. Some of the considerations in deciding which type of press to utilise include overall job volume, fastener sizes and how many different types of fasteners will be installed, and work piece size and configuration. For high volume applications, press options in the


marketplace historically have been limited to hydraulic, air over oil, oil over oil, air over air, or mechanical versions to deliver the necessary force generation. All have comparative advantages, depending on the job, but all tend to fall short in the areas of efficiency, energy costs, and potentially adverse environmental impact. The engineering behind the world’s first automated electro-


mechanical press to install multiple types of self-clinching fasteners has introduced a practical and cost-effective alternative to competing technologies, especially for high volume and multiple fastener installations.


A ‘green machine’ The heart of the unique PEMSERTER®


Series 3000™ press


system (pictured left) is a custom built, full servo controlled dual axis electro-mechanical actuator integrating advanced technologies and optimised for efficiency. The system operates without hydraulic oil and is sealed and lubricated for life, which eliminates environmental issues and the maintenance costs associated with oil leaks, spills, changes, and disposal fees. In addition, the system has recently undergone independent testing for energy efficiency and earned unprecedented flying colours compared with conventional hydraulic presses. Overall, the Series 3000 stands as a one of a kind ‘green


machine’. Key innovations offer distinct benefits for fabricators, particularly in energy efficiencies and improved productivity on the shop floor.


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46  |  Page 47  |  Page 48  |  Page 49  |  Page 50  |  Page 51  |  Page 52  |  Page 53  |  Page 54  |  Page 55  |  Page 56  |  Page 57  |  Page 58  |  Page 59  |  Page 60