Roll forming piston seals
The task was to roll aluminum seals inwardly onto the pistons used in an air compressor. The assembly is part of the tire puncture management system in the compressor and needed to be robust and function reliably. Failure could indirectly affect safety and endanger others and themselves.
The joint for this application had to ensure high process reliability with short cycle times. The seal also had to be flat and secure to ensure proper function.
Roll forming replaced radial forming, resulting in significantly higher process reliability while reducing cycle time and NOK parts due to the reduced forming force. The parts are now not subjected to high force during the forming process.
The BalTec subsidiary in southern Germany verified this roller forming solution in cooperation with the customer and the application team at the headquarter in Pfäffikon/Switzerland. Implementing and automating this process was carried out by the customer.
Facts & Figures
|Riveting Force||max. 1.5 kN|
|Riveting Process||Roller forming|
|Rivet head geometry||Folding inwardly|
|Forming Tool||Customized roller forming head with 3 rollers|
|Performance Data||Forming time: approx. 0.8 to 1.0 sec.|
1 x roller forming unit RLE 01-HPP with process control
|Process Control||HPP-25 Process Control|
|Interfaces||USB, LAN, X4, X6, X9|
|Area of Application||
Automotive supplier, general industrie, compressor equipment, industrial compressor, piston pump
|User Benefits: Process||High process stability, short cycle time, no rework. Low force applied to work piece, which resulted in reduced scrap rate. Tool is self-centering.|
|User Benefits: Economic||Higher productivity and lower reject rate|