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To automate riveting processes or not?

The guide to automatic riveting

 

We help you to find the right riveting solution


With this guide, we would like to help you to better understand the automated riveting process on the one hand and to work out the advantages of automated riveting for your company on the other. We answer questions about whether you should automate riveting processes in your company and what different types of automated riveting are available.
types of automated riveting actually exist.

1. automation is becoming increasingly important in production
2. the advantages of automatic riveting
3 Should my company automate riveting processes?
4 Choosing the right solution: semi-automatic vs. fully automatic riveting
5 Conclusion

Automation is becoming increasingly important in product

Unsurprisingly, more and more manufacturing companies of all shapes and sizes are investing heavily in automating their production processes.
As Industry 4.0 has proven to be a key factor in improving process efficiency in manufacturing operations, automation within production processes is paramount to reducing or replacing work that has traditionally been done exclusively by employees. Automated riveting is also following this tre

As riveting is a repetitive process that requires a high level of accuracy, switching from a manual to an automated riveting process is a decision that many companies are making, especially in the automotive, aerospace and industrial manufacturing industries.

The advantages of automated riveting

Firstly, it is important to understand the benefits of automated riveting. In any manufacturing environment, automation offers the obvious benefits of increased efficiency, greater flexibility and improved workplace safety. However, there is an even longer list of benefits when automating a riveting operation.
Automating your riveting process allows companies to

1. reduce inconsistencies

Inconsistencies in the setting of blind rivets are a common factor that occurs when using manually operated or hand-held riveting tools in mass production, as a high level of accuracy and repeatability is required to manually align a blind rivet with each setting operation.
Inconsistencies in the setting process can lead to problems with product quality further down the production line. The use of an automated riveting solution, such as the integration of a robot that repeatedly performs exact processes and specified work sequences with precision, significantly reduces the risk of potential rejects.

2. improvement of riveting cycle times

Riveting cycle time refers to the time it takes to set a single rivet from start to finish. This includes the operator(s) picking up the blind rivet, placing it in the application and using the blind riveting tool to set the rivet. GESIPA® has found that it takes an average of 4.8 seconds to set a single rivet with a battery-powered riveter, which equates to 12 rivets set per minute per operator at peak utilisation. With an automated riveting solution such as the GAV8000 from GESIPA®, the time for the riveting process is more than halved and up to 40 rivets can be set per minu

3. eliminate the risk of injury due to repetitive strain

As manual daily riveting over long periods and a large number of setting processes is usually a strenuous movement for the wrist and forearm, there is a risk of repetitive strain injury. The use of a semi-automatic riveting solution already eliminates the risk of muscle or tendon damage caused by continuous riveting.

Should my company automate riveting processes?

Is automating the riveting process right for your company and for your application? It is important to assess whether your company is ready to automate riveting processes, or if it is even necessary. Below are some questions to help you assess whether or not your riveting application is suitable for automation:

1. how many blind rivets do you set?

Does your current riveting process only consist of setting one or two rivets in an application? If this is the case, then an automated solution is not right for you. As an automated riveting solution is usually more expensive than a manual riveting tool, you need to make sure that the investment is worthwhile.  
A recent study by the GESIPA® research and development team in Germany has shown that an automated blind riveting system is cost-effective for an annual volume of more than 500,000 blind rivets (based on the German market).

2. what is your current rivet setting process?

If the current riveting process in your company is a burden on your employees or the process flow is not standardised, then the decision to automate the riveting process would be the right one.  Even if you only automate parts of the riveting process, personnel can be saved at this point and deployed in other ar

3. do you need to record data from the rivets to be set?

Especially in the production of safety-critical components, it is becoming increasingly important for manufacturers to collect and store data during the manufacturing process.
The data is used by manufacturers to ensure safety and efficiency, and can even help companies avoid legal liability due to quality control standards. Automatic riveting systems from GESIPA® can be equipped with setting process monitoring, if required, to accurately document that each blind rivet has been correctly set to suit the applicatio

Choosing the right solution: semi-automatic vs. fully automatic riveting

Once you have decided that automation is the right solution for your business and riveting process, it is important to understand the different types of solutions. Like all automated systems, automated riveting systems are categorised into two groups - semi-automatic and fully automatic.

Semi-automatic riveting

Semi-automatic riveting systems are useful for companies that need to improve their rivet setting process but are unable to completely eliminate operator assistance due to space constraints or particularly complex applications. By using a semi-automatic riveting system such as GAV8000 or GAV HF from GESIPA® with a standard gun, the operator has full control of the setting process but no longer has to manually insert each blind rivet into the tool and remove spent mandrels.

Fully automatic riveting

Fully automatic riveting systems start the riveting process and finish it without any assistance from an operator. Companies that opt for fully automatic riveting systems usually already have automated systems in use in their plants and want to keep costs low in the long term. The full range of GESIPA® automatic blind rivet tools can be easily integrated and assembled with robotic technology, reducing the need for labour.

Conclusion

Automated riveting offers an efficient solution for companies looking to optimise their production processes. The trend towards automation in manufacturing, driven by Industry 4.0, is also reflected in the riveting sector. The advantages lie in the reduction of inconsistencies, the improvement of cycle times and the elimination of injury risks for employees. However, the decision to automate should be carefully considered. Companies should evaluate their current riveting processes and check whether automation makes economic sense. The choice between semi-automatic and fully automatic solutions depends on individual requirements and budget. Ultimately, automation enables an increase in efficiency and quality in production.

Are you ready to automate or do you need more information?
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