Development of high speed screwing technology

for manual door module assembly

Materials and Process Engineering
PWT/VFT Christoph Grevener, Martin Düker
Development of high speed screwing technology

Problem:
Doors BR221 buckle when riveting.
Furthermore there are joining and leakage problems.

offset of
hole position
between
door frame
and module

blind riveting of door module BR221 deformation when riveting (2 - 4 mm)

leads to rework 2
 Development of high speed screwing technology

Solution:
Tolerance compensation
by screw connection
1,25mm

rivet connection screw connection

Screwing the door module enables a tolerance compensation up to 1,25mm without
generating tension. Therefore rework can be reduced.
In addition, improvements regarding ergonomics, repair and maintenance can be
achieved. 3
Development of high speed screwing technology

Requirement:
Screwing solution with short process time
comparable to blind rivets

Concept: Knipping
Extrude-Tite
• thread rolling screws: M5x15
(A0029844829)
 no weld- or insert nuts required
 direct screwing in pre-cut aluminum-diecasting
screw connection in
 collar forming in thin steel sheet metal AlMg5Si2Mn 2,6 mm
(pre-cut ∅ 4,3 mm)
• manual screwdriver with analog depth-control
and automated screw feeding system
thread collar
in thin steel sheet metal
 control by analog depth signal
 high revolution speed 1.500 - 2.500 rpm
 process time < 1sec (approx. 3 sec with handling)
screwdriver with
 stable screwing process depth-sensor
4
Development of high speed screwing technology

Load-carrying capacity
quasi-statically shear tension Fmax
comparison blind rivets/screws
10

105

F
8
F
maximal force Fmax [kN]

35
105

0
Knipping Extrutide M5x15 Knipping Extrutide M5x15
Blindniet 6,4mm
(gestanzt 4,3) (gestanzt 4,2)
Fmax 3,29 4,37 3,96

5
Development of high speed screwing technology

Typical failure pictures of shear

tension test

blind riveting screwing

rivet failure material failure

6
Development of high speed screwing technology

Load-carrying capacity
quasi-statically cross tension Fmax
comparison blind rivets/screws
10

Vorlöcher gestanzt: 4,3mm

Matrize 4,4mm / Stempel 4,2 mm

Vorlöcher gestanzt: 4,2mm

Matrize 4,3mm / Stempel 4,1 mm
8
50
maximal force Fmax [kN]

150
6

0
Blindniet 6,4mm Knipping Extrutide M5x15 (gestanzt 4,3) Knipping Extrutide M5x15 (gestanzt 4,2)
Fmax 3,22 3,14 2,94

7
Development of high speed screwing technology

Typical failure pictures of cross

tension test
blind riveting screwing

material failure material failure

module sided door frame sided
by unbuttoning rivet by ripping out the threads