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MADE IN GERMANY
HONSEL portfolio
engl
ish
www.honsel.de 2
Blind rivet nuts
Blind rivet studs Coils Studs
Blind rivets Special parts
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HONSEL Wire products 4-5 Produktion 6-7 Further processing 8-9 Quality 10-11 Worldwide 12-13
HONSEL blind rivet nuts 14-20
HONSEL blind rivet nuts 21-24
HONSEL blind rivets 25-28
HONSEL coils 29-32
HONSEL special parts 33-36
HONSEL bolts 37-40
HONSEL powertrain fastener (HPF) 41-44
HONSEL self-clinching fasteners 45-48 HONSEL coils tools 49-54
HONSEL setting tools 55-60
HONSEL DMSD 2G 61-66
HONSEL automation 67-71
AutomationSetting toolsSelf-clinching fasteners
HPF Tools DMSD 2G
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Cold forming is a complex technology. Ultimate-ly wire is brought into the desired form using large forces. The task is to achieve high deformation ratios using headers. HONSEL has constantly refined this production principle over the more than 90 years of the company history and can today offer high-preci-sion customised products that meet all the demands of the latest quality standards.
Today HONSEL is a sought-after supplier for sophisticated solutions and products that can be produced inexpensively in large series. The portfo-lio ranges from the simple cold formed part through individually finished special parts right up to the pro-cess-controlled system for automated riveting.
In-house processes such as partial annealing and hardening or injection moulding of plastic compo-nents are commonplace here.
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The other sites of the HONSEL Group are also being continuously expanded. For example, the pro-duction capacity at the Chinese plant in Wuxi has been almost trebled in recent years. In the mean-time the HONSEL Group has about 400 employees worldwide whose primary interest lies in keeping the quality demands on our products at the highest level – to the benefit of the customer.
100 % monitoring is the order of the day.
HONSEL is investing intensively in the Frönden-berg site. The production capacities are being continuously expanded, and the company regularly invests in further machines. In the meantime HONSEL has 25 five and six- stage headers. The production area was increased in 2014 to 10,000 m2. Further increases in capacity are already planned.
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• 90 years of experience in the automotive industry
• Sites in Germany, France and China
• 10,000 m² of production area in Fröndenberg, Germany
• Fully owned production facility in Wuxi, China
• Cold forming up to 20 mm wire diameter
• 25 five and six-stage headers
• High manufacturing depth for solid and hollow parts with complex bores and close tolerances
• Continuous expansion of the product spectrum up to 60 mm in length and 30 mm in diameter
• Lines for induction annealing and hardening
• 100 % opto-electronic inspection for all products
• In-house design engineering and toolmaking. Hence short reaction times for special dimensions
• Specialisation in prototype production
• Electrical and pneumatic/hydraulic setting tools, with and without process monitoring
• Customised special solutions for automated riveting: from the simple riveting device, through fully automated robot cells right up to complete transfer systems
• Everything from a single source: HONSEL
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Multi-stage headers are powerful machines that need to be controlled. The HONSEL staff plays an important role here: they are able to regulate the forces that are applied in such headers during forming of the wire with fingertip con-trol. Looking to the future, HONSEL trains its own apprentices, thus constantly ensuring that the “old hands” can pass on the secrets of cold forming to the younger generation.
It takes just a few weeks from the receipt of a concrete enquiry through the production of a prototype before HONSEL can deliver a serial product to the customer. The extremely short lead times for this sector can only be achieved by HONSEL by keeping the individual production steps in the house.
The in-house toolmaking shops work closely together with the internal design engineering department.
Short communication routes form the basis for short reaction times, both during planning and execution.
HONSEL technicians develop not only the actual production equipment, but also tailored solutions for feeding and automation, if necessary. From the semi-automatic setting operation through to the process-controlled all-inclusive auto-mation solution: HONSEL is a master in the craft of cold forming at all levels.
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Hybrid parts are products in which different material components are joined together du-ring production. The most common process used in the production of hybrid components is the plastic injection moulding of metal parts. HONSEL has been offering such products for a long time.
As a cold forming company, HONSEL products have been refined with plastic components in the past by external partners. In line with the premise „Everything from a single source“, HONSEL has consistently invested in both know-how and production capacity for in-house production of plastic parts and hybrid components. The advantages of this approach are immense: From the development of new products to toolmaking and plastics processing, all production steps are under one roof.
This automatically results in a much better coordination in project development, leads to significantly shorter develop-ment times and has the result that a HONSEL customer can also be supplied with pro-totypes and pre-series pro-ducts in a shorter period of time.
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Pressed, washed, annealed – in this order, products go through the cold forming process. For most of the HONSEL parts, the route through production at this point is not yet over.
In this way, pressed hollow parts can be provided with an internal thread from M4 to M10 and step bolts can be drilled. Pressed screws, which are provided with a rolled external thread, are one of the two components for a product for which HONSEL is parti-cularly well known: blind rivet studs, consisting of a sleeve and a screw.
The connection of these components is customer-specific. The one custo-mer prefers crimped blind rivet studs, the other wants them laser-welded. HONSEL can do both – in 3-shift opera-tion in-house.
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From the first to the last part: consistently flawless and good!100 % inspection and 0 ppm strategies: those are the criteria that a compa-ny has to meet today when it comes to defining targets in quality assurance. HONSEL has made enormous investments in this area in recent years.
As a result, a QA process has been developed that is process-monitored and exemplary. HONSEL is of course certified to ISO 14001 and ISO/TS 16949.
A key part of the HONSEL QA strategy is the use of opto-electronic inspection machines. HONSEL has a whole ran-ge of these machines. We can therefo-re assure that every product that leaves the company has been 100 % inspected, even with large order volumes. Ultimate-ly the Fröndenberg-based company has a good reputation – and one that it aims to keep in the coming years, for sure.
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One customer wants the HONSEL products delivered in KLTs, another prefers cardboard boxes while a third likes to have the products in individual bags.
HONSEL has invested in a variety of packaging installations in recent years and can now deliver the individually required packaging to every customer. HONSEL customers appreciate that.
Well packed:the customer determines how!
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HONSEL customers are located worldwide and need the products where they are to be used. This global market means that logistics concepts have to be geared to keeping the products available at all times.
HONSEL recognised this trend years ago and optimised the in-house proces-ses for product availability and logistics.
HONSEL has three centres where re-serve inventories are available at all times. The central warehouse is located in Germany. The two other warehou-ses in China and North America round off the logistics concept. That gi-ves HONSEL customers certainty: HONSEL can deliver, punctually, reliab-ly and in the desired quality.
HONSEL site in Wuxi, China
Available worldwide
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The logos and trademarks are the property of the respective holders.
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• For practically flush riveting in soft parts
• During the processing of blind rivet nuts with small countersunk head, countersinking of the bores is generally not necessary. If technically necessary, countersinking must be performed so that the countersunk head protrudes by min. 0.1 mm after setting.
Shaft forms
HEXAFORM® hexagon shaft for high torsional resistance and high force absorption
HEXATOP® partial hexagonal shaft for high torsional resistance
Round shaft, knurled, improved torque in soft parts (aluminium, plastic)
Round shaft, smooth for standard applications
Small countersunk heads• Large force absorption surface area
• Hole reinforcement for soft parts
Flat heads (FH)
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• Can be used as a spacer or for centering parts
• Customised geometries possible
Special head forms
With injection moulded seal
• •Simplify fully automatic feeding
• Designs to customer specifications
• Additional torsional resistance in soft parts
• Serrations on top of the head for torsional resistance even with components lying on the head
• For gas-tight and water-tight joints
• Optionally as fitted O-ring or with plastic injection moulded seal
• In order to meet the needs of many customers for gas-tight and water-tight screw threads, HONSEL has developed a blind rivet nut that combines these demands with the benefits of an efficient and reliable riveting process.
Long chamfers
Serrations under and on top of the head
The customers’ demands on blind rivet nuts are as different as the customers themselves. HONSEL has been producing blind rivet nuts in all conceivab-le variants for decades. Thanks to this vast experi-ence and innumerable successfully completed cus-tomer projects, HONSEL can justifiably claim to be THE specialist for blind rivet nuts in Germany and far beyond. The production in Fröndenberg, located between the Ruhr region and the Sauerland, is a further bonus and the guarantee for short distances to the customer and short delivery times.
The HONSEL development department knows the customers and their needs. On request, the in-house special machine production can also of-fer the necessary reliable automation solutions.That makes HONSEL the all-round producer “Made in Germany”.
Shaft knurling, hexagonal or round Chamfer
Serrations under headHead height
Shaft length
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M6
M8
M10
M6
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The HONSEL „HOCHFEST“ technology allows a significant increase in the load-bearing strength of the thread.
This ensures that in the event of mechanical over-loading, a bolt of strength class 12.9 (“HOCHFEST” steel) or 8.8 (“HOCHFEST” aluminium) fails far ear-lier than the HONSEL blind rivet nut.
This ensures greater safety in all applications where higher mechanical demands are necessary.
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• An alternative to welding nuts or piercing nuts• Absorbs high torques and axial tensile forces• Efficient processing• Weight saving• Pedigree recycling possible
(particularly with aluminium)• Corrosion-resistant
In order to measure the tightening torque, the blind rivet nut to be tested is set in a test plate, a twist-lock steel washer is placed on the nut and the bolt is tightened. The following conditions apply during the test:
Test plate structural steel – uncoated, dry, grease-free, thickness approx. maximum clamping length of the nut
Part bore nominal size of the nut shaft + 0.2 mm
Machine bolt oiled, strength class min. 8.8
Washer (twist-locked)
Test plate (fixed)
Blind rivet nut
Bolt
M
Available versionsShaft forms: full/partial hexagon, round shaft, closed designsHead forms: flat head, small countersunk head, countersunk head, large head
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15.000 N
23.300 N
27.000 N43.000 N
37.000 N68.000 N „H
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HONSEL blind rivet nutsHONSEL blind rivet nuts „HOCHFEST“
8.300 N17.200 N
15.000 N31.800 N
Test force (N)
Tightening torque (test configuration)
F/s
F
F
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General installation instructions• Set the blind rivet nuts up to complete formation of the blind head• It must be easy to unscrew the mandrel after setting• Installation at right-angles to the part surface• Countersink blind rivet nuts with standard countersunk head with a slight protrusion• When using blind rivet nuts with small countersunk head, countersinking of
the bore is generally not necessary• With blind rivet nuts without additional twist lock, the part surfaces must be dry,
clean and grease-free• The specified part bores must be observed; oversized bores cause problems
with the torque and load-bearing strength
The axial tensile force is determined using the test device to DIN EN ISO 14589.By contrast with the blind rivet test, the nut is riveted into a steel washer. This is placed onto the insert bushing, then the two parts of the device are bolted together.
The following conditions apply to the test:• Test device according to DIN EN ISO 14589• Deformation rate approx. 10 mm/min.• Strength class of the bolt min. 8.8• Tensile direction against the blind head of the nut
The value shown is the minimum value measured under the given conditions at which failure of the blind rivet nut can occur. Failure is regarded as tearing out of the thread or breaking off of the blind end at the blind rivet nut. The values shown should be regarded as indicative values for the design of the connection point.
In practice, different operating conditions generally prevail that can lead to a change in the failure mode and the forces. A load-bearing test is recommended for each concrete application.
Axial tensile force (test configuration)
Blind rivet nut
Blind rivet nut
Blind rivet nut
Blind end
Mandrel
Mandrel
Mandrel
Setting tool
Setting tool
Mouthpiece
Mouthpiece
Mouthpiece
Blind rivet nut with stud
Washer
Insert bushing
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... 360° laser welded or ...Welded all round by laser, the connection between sleeve and bolt is 100 % tight and withstands even the highest demands. Very few manufacturers can offer this very special and high-quality joint. Even here, HONSEL can supply an almost un-limited wealth of variants.
... tight ...
... crimped.Corrosion protection is the main reason for joining sleeves and bolts mechanically by means of crimping. It is thus possible to first coat the two individual components galvanically with corrosion inhibitor separately – on demand even using different processes. Only after the surface treatment, sleeve and stud are joined to produce the blind rivet stud.
• as fitted O-ring
• with injection moulded plastic seal
• for gas-tight and water-tight joints
Different thread designs ...Every thread is available in all lengths and forms (fine thread, coarse thread, etc.) on customer demand.
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Technical data
Sleeve + stud = blind rivet stud A blind rivet stud consists in principle of a sleeve (blind rivet nut without internal thread) and a stud that are joined to one another. HONSEL has been producing sleeves and blind rivet nuts for de-cades. With the increasing focus on the automotive sector, it quickly became clear that HONSEL can also use its existing know-how for the manufacture of blind rivet studs.
Here too, just as with the blind rivet nuts, the diversity of possible variants and individual customer demands are the decisive criterias. Irrespective of which sleeve needs to be connected with which stud to make a blind rivet stud, HONSEL manufactures both components in-house and can thus deliver all possible variants quickly and flexibly.
Scratch protection possible.In the automotive industry, and particularly during final assembly, the surfaces of the components are very susceptible to scratches and other damages. If a blind rivet stud is not positioned and inserted exactly – as it can easily happen during manual assembly – the surface of the component may be scratched. HONSEL has recognised this problem and developed a scratch preventative that can be ap-plied to the blind rivet stud. Easy riveting is thus still assured, but the component is protected from scratching.
Blind rivet studs are essentially used with the iden-tical setting principle as for the blind rivet nuts. The same tools can therefore be used. The mandrels of the setting tools must be replaced with threaded sleeves having the matching inside thread.
The sleeve inserted into the prepared bore is defor-med by the tool stroke and thus ensures a tight fit in the part. In order to increase the torsional resistance of the joint, knurled versions or sleeves with hexago-nal shaft are available.
Blind rivet stud before setting
Riveting by the stroke of the setting tool
Inserting the rivet sleeve into the part bore
Installed blind rivet stud
Screwing into the threaded sleeve of the setting tool
Spindling of the blind rivet stud
Set
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Hitze/Kälte
GaseChemikalien
Kräfte/Beanspruchungen
Feuchtigkeit
Anode (Eisen/Stahl)
Kathode (Kupfer)
ALFO® – The ClassicThe designation ALFO® stands for a range of products from the open HONSEL standard blind rivet that are available as flat head, countersunk head or large head rivets. It covers the versions and special types described in DIN EN ISO 15977 to 15984 as well as 16582 and 16584.
OPTO® – The All-rounderThanks to its design, the OPTO® multi-range blind rivet with specially embossed rivet shaft has a number of outstanding functional properties such as a large clamping range, excellent bore filling properties and positive locking of the mandrel inside the head.
CERTO® – The Leak-tightThanks to their cup-shaped rivet sleeves, CERTO® sealing blind rivets are the specialists when it comes to liquid-tight riveting. Based on this special design, the breakstem is also captive.The rivet forms a smooth, burr-free blind head and is suitable for automatic riveting.
FERO®-BULB – The StrongHONSEL FERO®-BULB blind rivets have been among the high-strength blind rivet types used in large quantities particularly in motor vehicle construction for many years. They guarantee very high shear breaking forces, a large blind head, are dust and splash water-proof and allow high tightening forces on parts.
FERO®-BOLT – The SecureFERO®-BOLT plane shaft breakage blind rivets are the high-quality connecting element for a vast array of industrial applications where particular attention is paid to the safety factor. Thanks to its design, the rivet is able to take on a load-bearing function.
Shear breaking force (test configuration)
The shear breaking force is the force that a rivet can withstand in radial direction before it fails due to fracture.
Depending on the riveting principle, the forces are determined with or without the breakstem overlapping the shear zone. The test device presented in DIN EN ISO 14589 is used for the static measurement (exception: FERO®-BOLT).
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Niethülse
Setzkopf (hier Flachkopf)
Setzkopf (hier Senkkopf)
Nietdorn
NietdornkopfSollbruchstelle
ggf.Aufquetschung
Spitze
Niethülse
Setzkopf (hier Flachkopf)
Setzkopf (hier Senkkopf)
Nietdorn
NietdornkopfSollbruchstelle
ggf.Aufquetschung
Spitze
Hitze/Kälte
GaseChemikalien
Kräfte/Beanspruchungen
Feuchtigkeit
Anode (Eisen/Stahl)
Kathode (Kupfer)
Technical explanations
The blind rivet is inserted with the mandrel into the setting tool and positioned in the rivet hole.
When the setting tool stroke is triggered, the mandrel is gripped by the clamping jaws and pulled.The mandrel head thereby forms the shaft end of the rivet sleeve.The process is completed when the mandrel head reaches the height of the part surface.
This position is signalled by a significant increase in force with which the mandrel breaks off at its predetermined breaking point.
The sheared mandrel is removed and the breakstem remains in the blind rivet sleeve.
The setting process always takes place in the following steps:
A matching riveting tool is required for processing of the blind rivet. This can be actuated by muscle force (hand-held tools) or external force (e.g. pneumatic or hydraulic settings tools or cordless riveters).
The rivet sleeve is the element that forms the joint.
It is formed by the mandrel and remains inseparably in the part. The sleeve version is selected according to the following criteria:
• the mechanical loads to be expected• the corrosion requirements• the form of the parts• the temperature loads and in some
cases also the appearance
Corrosion behaviour with different material combinations
Sleeve material Aluminium Steel Stainless steel CopperAluminium ++ ++–Steel, galvanised ++ ++ –Stainless steel ++ ++ +–Copper +++ ++Nickel-copper, galvanised +++ ++
+++ Very suitable combination++ Suitable combination– Unsuitable combination
Tensile breaking force (test configuration)
The tensile breaking force is the force that a rivet can withstand in axial direction before it fails due to fracture.
The test device presented in DIN EN ISO 14589 is generally used for the static measurement.
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The coil concept
Threaded inserts create high-strength joints in low-strength metallic materials and have been pro-ven in practice for decades.
HONSEL coils threaded inserts are available in a range of variants and are characterised by high wear resistance, low thread friction in close tolerances, high surface quality and outstanding corrosion and heat resistance.
Standard/specification to DIN 8140-1 or individual project-specific solution
Material A2, alternatively A4 with min. tensile strength 1.450 N/mm2
Diameter from M2, standard and fine thread available, on request also all UNC and UNF sizes available
Length up to 3 x d1, HONSEL coils “free” up to 2 x d1
Surface Standard: coloured to DIN 8140; Alternative: e.g. lubricant film, nickel-plated, silver-plated, cadmium-plated, tin-plated
HONSEL coils „plus“• High surface quality
• Sturdy installation
• Easy handling - system prooved by practise
HONSEL coils „poly-lock“• Additional polygonal winding
- screw clamping area
• High frictional locking - effectively prevents loosening of the screw
• Cost reduction - additional screw locking can be eliminated
HONSEL coils „free“• No journal
- time saving during assembly
• Installation on both sides possible
• Low tool wear
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• Structural aluminium castings
• Machine adjusting screws
• Castings
• Exhaust manifolds
• Repeat tightenings (oil sumps, etc.)
HONSEL coils are made from high-quality chrome-nickel steel (X5CrNi18-10). This material grade is the precondition for threads with high load-bearing strength, wear resistance and a low and constant thread friction torque. By contrast with conventional threads, a higher and constant preload force can be achieved with the same tightening torque even with repeat tigh-tenings. Furthermore, better use can be made of the yield strength of high-strength screws. In addition the surface roughness is up to 85 % lower in com-parison with conventionally cut threads.
With conventional screw fittings, the main load is exerted on the first three th-reads. HONSEL coils solve this problem. The main load is distributed uniform-ly over the whole length of the bolt and thus leads to significantly more stable screw joints – particularly with screws subject to dynamic loads.
StrengthPr
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normal screw thread with HONSEL coils
Prel
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Sleeves or studs that are perfectly suited to plastic sheathing due to their very low tolerances are commonplace in the HONSEL produc-tion. The ability to combine metal forming and plastic sheathing in-house is a typical HONSEL feature. In this case the sheathed knurling system has been developed for that particularly high tightening forces can be achieved.
HONSEL combines many years of experience in cold forming with a complex manufacturing depth. Special machining operations, knurlings and special types of finishing allow the right solutions to be found for many customised development projects.
Even asymmetric geometries with the highest forming rates are chal-lenges that HONSEL successfully masters at all times to the benefit of the customer.
Furthermore, in-house developed feeder systems offer economically attractive finishing possibilities for the further processing.
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Finite element simulation
All HONSEL products are parts developed individually for the customer that are produced in large quantities during the course of cold forming. But time and again, projects come along where HONSEL can contribute the whole band-width of possible in-house production methods. Even at the development sta-ge, HONSEL engineers can assess the general feasibility of products thanks to their decades of experience in cold forming.
The subsequent design work in which all relevant methods such as fini-te element simulations are used generally leads to the production of proto-types. Thanks to the in-house development- and toolmaking departments, HONSEL can supply pre-series products here in a minimum of time, on the basis of which the further planning processes can be coordinated with the customer.
During the subsequent series production, too, it is a HONSEL benefit that relevant processing steps such as partial annealing and hardening, cutting and plastic sheathing of individual parts can be carried out in-house.
This results into the short reaction times for which HONSEL is renowned.
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Beyond the standard: HONSEL special parts
21.150 18.506 15.863 13.219 10.575 7.931 5.288 2.644 0.000
Max. 21.150Min. 0.000
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Collar-type bolt• Always riveted from both sides
• Shaft diameters up to 12 mm
• Variable shaft lengths
• Shaft with and without bore
Spacer bolt• Riveted from one side• Up to 28 mm head diameter with max.
12 mm shaft diameter• Shaft and head round as standard• Oval geometries possible• Head punch designed individually to the
customer’s needs
Asymmetric bolt• Up to 12 mm shaft diameter• Variable shaft lengths• Asymmetric head geometries
possible to meet customer requests
As a specialist for cold forming, HONSEL manufactures customised solid parts with close tolerances in a wide range of geometries. The specialised manufacturing depth and the 100 % quality control of the produced parts are the hallmarks of the company.
HONSEL bolts, installed in millions of clutch systems worldwide, are a first-class example of this.
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Barrel finishingDuring the hardening process (Kein Komma) „scalings“ occur on the outer side of the bolts, (Komma) because the glowing hot metal reacts with the air oxygen. These thin residues from the oxidation process can be barrel finished so that the stud has a glossy surface again.
At the same time, barrel finishing reduces the friction coefficient (COF) of the studs – a precondition for longer service lives of the finished products.
As with all other process steps, HONSEL attaches great impor-tance here again to being able to carry out barrel finishing in-house.
Tolerance optimisedThe automotive industry accepts only minimal tolerances. Sup-pliers have to constantly ensure that every product supplied al-ways meets these stringent specifications. Less than 0.07 mm – that is the concentricity tolerance that HONSEL can guarantee the automotive customer.
And HONSEL is less tolerant also when it comes to the length: A coil may deviate in length by only +/- 0.05 mm. HONSEL customers appreciate this precision.
Hardened to the pointThe cold forming process alone changes the starting material in such a way that it beco-mes harder on its own. But this is generally not enough. The studs are exerted to huge forces when they are installed in the clutch of a motor vehicle. For this reason they have to be hardened so that they become more resistant. But they don’t have to be hardened all over, because if a stud is too hard, it will break during assembly. Partial hardening is the solution. Predefined partial areas are hardened to a precisely defined material depth to a defined degree of hardness.HONSEL has mastered the art of “hardening to the point” so well because this process takes place in-house.
Eddy current testingThe eddy current test is a non-destructive testing method for detection of cracks and pores near the surface and of defects in electrically or magnetically conductive surfaces. During the test, the surface of the test specimen is scanned contact-free using a probe. The prove generates a magnetic field which induces eddy currents in the surface of the object to be tested. These eddy currents in turn generate electromagnetic fields which are detected by the receiver part of the probe.
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Advantages• strain hardening of the sleeves guarantees high strengths
• large radial clearance compensation between bolt and sleeve
• maximum retraction of the bolt into the sleeve ensures a secure
joining process
• bolt and sleeve are permanently joined together
• large contact surface areas mean low surface pressures
• high cleanliness demands can be satisfied
HONSEL plastFIX® has been specially developed for use in plastic modules.Apart from the preassembly possibility for the sleeve/bolt system, HONSEL plastFIX® offers the benefit of a secure joint thanks to the limited application of axial force to the plastic. At the same time, the concept guarantees a hard bolt joint with expansion of the bolt for the highest possible protection against loosening.
Advantages• no torsional moment on the elastomer• hard bolt joint• Preassembly possible• telescoping of the bolt prevents damages
HONSEL soundFIX®
Applications which, due to their design, involve NVH (Noise, Vibration, Harshness) caused by vibrations of an adjoining part can now be effectively decoupled using HONSEL soundFIX®. HONSEL soundFIX® is used in plastic and metal modules.The captive elastomer ring insulates the part to be decoupled from the adjoining part by means of a sealing or additional elastomer.
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Application areas• cylinder head cover• intake manifold• oil pan• front cover (belt cover)• pump housing (water/oil)• oil filter module
Captive screws have become an integral part of modern fastening technology. System suppliers are able to deliver pre-assembled units just in time to the production lines of the OEMs. This creates huge savings potential in terms of logistics, assembly and quality costs. With its new products from the HPF-line HONSEL has created a portfolio that meets the high standards of automotive production. Key element to this development is the consolidation of all production steps inhouse as well as over 90 years of experience in working with automotive customer.
HONSEL Advantages• inhouse production of cold-formed screws, sleeves and plastic parts
• as a result individual combinations of sizes, thread types and pitches can be realized
• inhouse assembly of all components
• global availability because of own plant in Wuxi, China
• 100% inspection of the finished products
• development of customized solutions up to the manufacturing of prototypes possible
• individual solutions for automated assembly available
Advantages• typical punching burr in aluminium casting bore ensures
secure positive fit connection with HONSEL capFIX®
• changing climatic conditions can be neglected • bold height adjustable• radial play compensation• high cleanliness requirements can be met
HONSEL capFIX®
Today’s modules are delivered to the assembly line in complete subassemblies. HONSEL capFIX® facilitates this trend. The specially designed composite ring is mounted onto the screw and guarantees a perfect and secure fit of metric screws from M5 to M10 in module made from metal.
HONSEL plastFIX® has been specially developed for use in plastic modules.Apart from the preassembly possibility for the sleeve/bolt system, HONSEL plastFIX® offers the benefit of a secure joint thanks to the limited application of axial force to the plastic. At the same time, the concept guarantees a hard bolt joint with expansion of the bolt for the highest possible protection against loosening.
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Self-clinching nuts V-A/V-MA • Steel, galvanised• Suitable for use in sheet metal with hardnesses up to HRB 80
Self-clinching nuts V-CLS/V-CLSS • Stainless steel, non-rusting (AISI 300 Series)• Suitable for use in sheet metal with hardnesses up to HRB 70
Self-clinching nuts V-F• Stainless steel, non-rusting (AISI 300 Series)• Flush on both sides, especially for use in thin sheets of
aluminium with hardnesses up to HRB 70
Self-clinching studs V-FH• Steel, galvanised• Suitable for use in sheet metal with hardnesses up to HRB 80
Self-clinching stand-off V-SO• Steel, open, galvanised• Suitable for use in sheet metal with hardnesses
up to HRB 80
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Processing
Insertion process
During insertion, the base material is pressed into a corresponding groove by a knurling or hexagonal platform. Knurling and groove of the fastener are matched to one another in such a way that the deformation is limited to the immediate vicinity of the fastening element. A completely flush finish is obtai-ned on the one side, and a high thread stability is achieved by special heat treatment over a compact area.
Insertion is possible with the greatest precision. The surfaces on both sides of the part are not damaged. Install only using a press with continuous pres-sure – never by impact loading!
Self-clinching fasteners with inside and outside thread are particularly suitable for use in thin sheet metal above 0.5 mm. The thickness of parts as a whole can thus be reduced, with the benefits of lower weight and material saving. After setting, self-clinching fasteners are permanently joined to the base material. A screw can therefore later be removed again without the risk of the connecting element being displaced from its position.
HONSEL self-clinching fasteners help to make production processes more efficient and more reliable.
Rivet nuts are riveted into the part. The shaft is thereby inserted through a prepunched hole in the part and riveted over on the opposite side. The base material is not deformed. These threaded connecting elements are characterised by a toothed shaft that cuts into the sheet metal surface.
Benefits: • High torsional resistance and torque loading capacity
HONSEL self-clinching studs are fasteners that have a knurling under the head which, when inser-ted into the sheet, ensures that the material is pressed into the rivet ring thus securing the fastening element. Made from hardened steel, they are suitable for use in sheet metal with hardnesses up to HRB 80
Benefits:• High resistance to torque loads• No damage to coated surfaces – ideally suited to steel sheets• Always perpendicular to the sheet• Head flush with sheet after installation
HONSEL self-clinching studs stand-offs can be used as spacers. The hexagonal head is simply pressed into the sheet metal so that the material is upset in the groove.
It is pressed in on the head side completely flush. A wide variety of open or closed versions is availa-ble. For applications with higher loads, versions with larger heads and higher pulling forces can be produced.
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Designation Rpm Torque Weight Operating mode
ESV05 1.090 1,0-5 Nm ca. 1,1 kg Electric screwdriver, integrated transducer, torque / angle of rotation
ESV12 1.090 2,4-12 Nm ca. 1,1 kg Electric screwdriver, integrated transducer, torque / angle of rotation
Electric screwdriver BOSCH Rexroth
Designation Rpm Torque Weight Operating mode
ERS6/ERS6-M20/ERSF6 1.725 1,0 - 6,0 Nm 0,7 kgElectric screwdriver, integrated transducer,
torque / angle of rotation
ERS12/ERS12-M20/ ERSF12 950 1,5-12,0 Nm 0,7 kgElectric screwdriver, integrated transducer,
torque / angle of rotation
SLBN 050-L100-SQ4 1.000 2,0-4,9 0,8 kg Electric screwdriver, clutch actuation
Electric screwdriver Desoutter
Designation Rpm Torque Weight Operating mode
EXAKT ION 8-1100 1,5-8 Nm 110-1.100 1,5-8 Nm 1,3 kg Battery
Cordless screwdriver BOSCH Rexroth
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“Everything from a single source”: In addition to the production of coils, HONSEL also offers adviso-ry services for the application-specific working process. The spectrum of the coils specialists from HONSEL ranges from the design of the threads, through advice on the calculation of the pulling forces right up to the implementation of customised concepts for automation solutions. It goes without say-ing that the combination of the HONSEL tools for the application leaves nothing to be desired. Both manual and power thread taps are available in all sizes.
HONSEL installation mandrels can be used as manual mandrels or for mechanised assembly. HONSEL also offers the matching accessories, such as plug gauges, tang break-off tools and removal tools as well as electric and pneumatic inserters perfectly matched to the HONSEL coils.
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ACMonitoring Weight
CVIR II ERS, ERS-M20, ERSF, ERSA115 V/ 230 V single-phase
Power, transducer, torque, angle of rotation, KoALa, friction coefficient,
CVINETWEB, CVIPC20006,0 kg
ESP 2-A SLBN003 - SLBN120 110 V/ 240 V Torque, time 2,8 kg
Controller Desoutter
Designation suitable screwdriverVoltage
ACMonitoring Weight
CS 351E-D Interfaces for BOSCH Rexroth hand-held screwdrivers and spindles 230V yes 9,7 kg
SB356 6-CHANNEL
With the appropriate control and performance components, both stationary screwdrivers and ErgoSpin handheld screwdrivers can be con-nected and operated on the SB356 system box. The mixed operation of stationary screwdrivers and ErgoSpin handheld screwdrivers on a SB356 can be controlled at any time.
380V-500V
Only in conjunction with control unit A screw channel consists of the following components:• Stationary screw spindle
or handheld screwdriver ErgoSpin with
• access line• control• power section
55kg/75kg(unloaded/fully
equipped)
Controller BOSCH Rexroth
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Installation mandrel „plus“
Installation mandrel „free“
Installation mandrel “poly-lock”
Tang break-off tool “automatic”
Installation mandrel HONSEL coils „plus“Special surface coating, hence less adhesion to galvanic surfaces, optimised geometry and hardness for a long service life.
Installation mandrel HONSEL coils „free“Special installation mandrel for setting HONSEL coils „free“.
Installation mandrel HONSEL coils „poly-lock“Special surface coating, hence less adhesion to galvanic surfaces, optimised geometry and hardness for a long service life.
Tang break-off tool “automatic”Automatic tang break-off tool with spring-loaded release – up to M14
Drill Thread formsHolding thread DIN 8140
Thread formers HSSE TIN for coil thread inserts DIN 8140
„DURAMAX“ thread former
Solid carbide twist drill 5 x d M3-M16 with internal coolingM2 without internal cooling
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Thread plug gauge for installed HONSEL coils tolerance 6H/6G (further versions on request)
Removal tool “plus”/“poly-lock”
Removal mandrel „free“
Manual removal mandrelHONSEL coils „plus“/„poly-lock“
Removal mandrelHONSEL coils „free“Special removal mandrel for removing HONSEL coils „free“.
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e-BZ 4820SReady for Industry 4.0 – for the networked integration into modern production processes.
e-BZ 4820S is the new battery riveter from HONSEL that sets new standards. With its compact design and a weight of only 1.3 kg, it is one of the lightest riveters on the market. Nevertheless it can set rivets up to a maximum of 3.4 mm in diameter with a stroke of 20 mm and a force of 8,500 N. The e-BZ 4820S naturally has a brushless motor, an integrated stud holder and powerful 2.0 Ah Li ion batteries that are fully charged in less than 30 minutes.
Until then the e-BZ 4820S is a small and powerful battery riveter. When you consider the smart facts, however, the e-BZ 4820S becomes a trendsetting tool that can be seamlessly integrated into Industry 4.0 process structures.
Smartfacts• Convenient control via OLED display
• Mobile control via Android or IOS app
• Management of several devices
• SD card
• Many basic functions
• Useful service functions
• Wifi connectivity possible
• Individual interfaces on demand
• DMSD-lite process monitoring system inclusive
• DMSD-HR version with patented sensor system available
• Optional contact pressure monitoring
• VIP service with extended guarantee and service offering
2,4 3,0 3,2 4,0 4,8 5,0 6,0 6,4 8,0
Inkl. • 4 mouthpieces in a box• 1 stud collector• 1 Li ion battery
14.4 V/1.5 Ah• 1 fast charger 220 V• Assembly wrench• L-Boxx
Stroke: 21 mm max. pin Ø: 3,4 mm
Capacity: Up to 2000 blind rivets, depending on type and material
Tensile force: 10.000 N
Charging time 1,5 Ah: < 30 Min.
Weight: 1,45 kg plus battery
AluminiumSteelStainless steelCopper alloys
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High-performance electronicsIndividually developed, intelligent electronics unit for control of all operations.
Newly developed clamping mechanismVery fast and reliable gripping of the rivet mandrel is ensured by shorter nose pieces and optimised clamping jaws.
Completely tool-free maintenanceClamping jaws and nose pieces can be replaced quickly, anywhere and by anyone immediately on the spot.
Intelligent control• OLED display (1.5”) with 5 buttons
• Mobile control via Android or IOS app
• Service functions: information on clamping jaw
• change, service intervals, emptying of stud collecting
• bin, job counter, live statistics, countdown
• Wifi connectivity with radio frequencies 2.4 and 5 GHz
• Individual interface programming possible
Visual chargeState indicator on every battery, and via the app and the display.
The latest motor technology
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e-BZ 5021The entry-level model to the world of mobile blind riveting
As a cordless tool, the e-BZ 5021 is able to insert blind rivets up to 5 mm in diameter into all materi-als. This is ensured by the powerful motor and the optimum balance of the individual components. The replaceable Li ion batteries have a sufficiently large capacity and are quickly ready for use again thanks to the charger supplied.
Practical details show clearly that the demands of day-to-day working were taken into consideration in the development of the tools. The collecting box, for example, is made of transparent plastic so that the worker can see the filling level of the removed studs at all times. The riveting surface is illuminated by an LED for greater work safety. The HONSEL e-BZ 5021 is a cordless setting tool with an outstanding price/performance ratio.
2,4 3,0 3,2 4,0 4,8 5,0 6,0 6,4 8,0
Also suitable for use with breakstem blind rivets up to 5.2 mm
Incl. • 4 mouthpieces in a box• 1 stud collector• 1 Li ion battery
14.4 V/1.5 Ah• 1 fast charger 220 V• Assembly wrench
Stroke: 21 mm max. pin Ø: 3,4 mm
Capacity: Up to 2000 blind rivets, depending on type and material
Tensile force: 10.000 N
Charging time 1,5 Ah: < 1 hour
Weight: 1,54 kg plus battery(0,33 kg/0,53 kg)
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e-BZ, the cordless riveter family from HONSEL
Since its successful market launch in 2011, the HONSEL e-BZ Series is the innovative, modern solution in mobile blind riveting. The e-BZ Series impresses with excellent performance data and an outstanding price/performance ratio. The ergonomic design ensures comfortable handling during day-to-day work. All batteries are equipped with a convenient state of charge display. Interesting accessories are available as options, such as the VARIO mouthpiece for the processing of different diameters without having to change the mouthpiece.
“Developed by HONSEL” is the statement that shows clearly that the many years of experience in the development and production of hand-held riveters, pneumatic tools and automation solutions have been incorporated into the development of the e-BZ series..
e-BZ 6430Strong, yet still mobile:For the big jobs
The e-BZ 6430 is the powerful cordless riveter for blind rivets up to 6.4 mm diameter in all materials – also for high-strength variants.
With a setting force of 20,000 N and the large stro-ke of 30 mm, standard blind rivets and high-strength versions such as FERO®-BULB and FERO®-BOLT, and also breakstem blind rivets or optionally lockbolt pins can be quickly and reliably processed in one step.
The latest motor technology
The newly developed brushless BLDC DC motor gua-rantees a practically wear-free constant life-cycle. Low current consumption and reduced heat development increase the battery life and efficiency.
High speeds were achieved by smooth running and the integration of the complete tool electronics into the motor. The resultant : weight savings with the renowned perfect ergonomics ensure comfortable working.
• 20,000 N setting force
• 30 mm stroke
• Brushless motor
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Incl. • 4 mouthpieces in a box• 1 stud collector• 1 Li ion battery
20 V/2.0 Ah• 1 fast charger 220 V• Assembly wrench
Stroke: 30 mm max. pin Ø: 4,8 mm
Capacity: Up to 2.000 blind rivets, depending on type and material
Tensile force: 20.000 N
Charging time 2 Ah: max. 30 minutes
Weight: 1,63 kg plus battery(0,37 kg)
AluminiumSteelStainless steelCopper alloys
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• Connecting facilities for measurement transdu-cers with different output signals from DMS to incremental and piezo-measurement transducers without additional amplifiers.
• The resolution of the distance measurement has been improved from 0.1 mm to 0.01 mm. The re-solution therefore complies with the VDA require-ment for 10 times resolution when recording with regard to the evaluation.
• The facility for monitoring maximum force and two additional control windows has been sup-plemented by two freely parametrisable control windows, even to the extent of envelope curve monitoring. It is possible to evaluate up to 10 evaluation elements in one measuring program.
• Up to 108 measuring programs can be stored in the monitoring. Up to 20 master programs are available for the monitoring.
• Parametrisation and programming take place via the firmware installed in the controller – no additi-onal program is required.
• Operation and remote maintenance are possible using VPN tunnels via a VNC viewer, meaning that the operator can see what is being carried out via the remote maintenance. With the remo-te maintenance you can see which actions are being carried out by the operator. A large monitor can be attached via the VNC viewer.
DMSD has stood for process monitoring in fastening technology for more than 25 years. HONSEL re-ceived its first patent for process monitoring in blind rivet processing back in 1990. DMSD 2G has been continuously improved and optimised since this time. All HONSEL standard tool components such as RivSys BZ & VNG, automated solutions, work stations and hand tools for rivet nuts, blind rivets and coils can be connected to the DMSD 2G.
The new second generation DMSD 2G process monitoring is a consistent further development, since industrial requirements have been increasing constantly for the last few years.
New measurement transducers which require a fas-ter sampling rate, parallel and faster data processing and new networking options are the characteristics of the newly designed DMSD 2G.
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• The measurement evaluation module (MEM) can be used with a display module (DIM) or also without a display module as a black box module.
• Up to 8 MEMs can be connected to a DIM. 4, 5 or 9 MEM evaluation windows can be displayed simultaneously on a DIM.
• As well as the last process values, a history of the previous setting processes can be called up via the MEM.
• The process monitoring measuring programs and settings can be stored on a USB storage medi-um, from where they can also be restored.
• The process values can be archived on USB storage media or on a server via Ethernet (USB storage medium, server or QDAS).
• The process values can be stored in Q-DAS, XML, CSV, PDF, QDA-9 or IPM 5.0 format. Pro-cess values stored in CSV format can be subjec-ted to further processing using Excel.
• A scanner for recording the components can be directly attached to the MEM. If a scanner is in-corporated, the code that is read in is also stored, making tracking possible.
• Connection to a customer controller is possible via digital inputs and outputs and via a field bus (PROFINET, PROFIBUS DP and EtherCAT).
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Internet
Up to 8 measurement recording modules can be connected to a display module for extended application cases.
When using a VNC viewer, applications can also alternatively be implemented without a display module.
Connection MEM programming interface1. MEM fitted directly to DIM (piggyback)2. Distance between DIM and MEM up to 5 m via cable3. Operation via DIM connected via Ethernet4. Operation with VNC viewer on machine control unit via Ethernet5. Operation with VNC viewer on PC via Ethernet6. Remote maintenance via Internet and VPN
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1. Hand scanner
2. USB storage medium
3. Server
4. Digital inputs (5x) and outputs (8x)
- PROFINET
- EtherCAT
- PROFIBUS DP
5. eBZ Smart-Tool connection by WiFi (in preparation)
Example of connecting facilities with a handheld tool:
1. Machine control with PLC via digital inputs and outputs or field bus
2. Sensor system for process monitoring
3. Communication: PLC <-> MEM via digital inputs or outputs or field bus
Example of connecting facilities with an automation system:
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Automation and digitisation are the tasks that industrial companies have to face today. Where products used to be processed by hand, solutions for automated feeding and process-driven processing are now in demand. HONSEL reco-gnized this development years ago and with HONSEL automation has built up a business unit that can plan, project and implement customer-specific ap-plications. The bandwidth of the technicians, engineers and designers ranges from technical advice prior to the order, to project planning and production in
the own special machine construction department, to the documentation of each plant in accordance with the machine guidelines. HONSEL service technicians are also in demand as contact persons for pre-acceptance, acceptance and commissioning of a customer‘s plant. HONSEL can also provide production support servi-ces to ensure that all processes are optimally adhered to. HONSEL also offers a worldwide on-site service by experienced service engineers.
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“Everything from a single source” is the motto with which HONSEL controls not only the production of fasteners, but also offers reliable process solutions for the processing of the HONSEL products. The spectrum ranges from the semi-automatic manual worksta-tion through to the fully automated manufacturing cell in which the different work proces-ses can be imaged using the in-house HONSEL DMSD 2G automatic control system.
HONSEL knows the work processes in the automotive sector and uses this experience to develop automation solutions that are tailored to the needs of the customers.
Manual workstation for the semi-automatic processing of fasteners:
• Process monitoring with HONSEL DMSD 2G• Variably expandable up to five manual setting tools• Ergonomic thanks to height-adjustable working surface• Manual turning unit for left-hand and right-hand parts• DMC scanner• Signal lamp (OK or NOK)• LED lighting for the
working area
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Modular machining centre for the automated processing of fasteners:
• Process monitoring by HONSEL DMSD 2G• Man-robot collaboration, load capacity variable• High degree of automation• Q-Gate with 360° detection field• Modular application for different fasteners
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• Part identification (data matrix code)
• Separation and feeding of HONSEL blind rivet studs
• Process monitored setting of HONSEL blind rivet studs
• Separation and feeding of HONSEL coils
• Process monitored setting of HONSEL coils (M8 x 1.5, M10 x 1.5, M14 x 1.5)
• Automatic tang break-off (incl. discharge of the tang)
• Transfer system
• Total of 6 stations
Examples of an automated assembly line for separation, feeding and setting of HONSEL coils and HONSEL blind rivet studs
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HONSEL Umformtechnik GmbH Westicker Straße 46-52D-58730 Fröndenberg/Ruhr fon +49 (0) 2373 755-0 fax +49 (0) 2373 [email protected] www.honsel.de
VVG FRANCE 20 rue du Lhotaud25560 Frasne [email protected]
HONSEL Fastener (Wuxi) Co., Ltd.No. 55 Hongchang Road,Hongshan Street, New Wuxi District,Wuxi CityJiangsu Province, [email protected]
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