BU Industrial Applications (R-IA)

The business unit Industrial Applications specialises in

selected segments in general industry where comprehensive

know-how in specific sectors can generate additional

customer benefits. Switchgear engineering, air conditioning

systems, building installations as well as storage

facilities are just some of the many areas, in which BU

R-IA is active. In line with GESIPA® philosophy, the main

attention is focused on application-oriented procedures.

The vast experience, extensive technical know-how and

specialist expertise in selected sectors sustainably enhance

customer advantages. The customer benefits from a

range of joining elements tailor-made to suit his specific

requirements as well as comprehensive advise in selecting

the most suitable equipment for the job. Special emphasis

is always placed on the complete system, consisting of

joining elements, riveting equipment and joining method,

with the aim of creating the most cost-effective and efficient

solution for the customer. Customer segmentation is

systematically expanded in domestic and international

markets. thus consolidating customer relations in the long

BU Automotive Riveting (R-AR)

Motor vehicle manufacturers and suppliers to the automobiles

industry with their diverse range of demands are

looked after by the business unit Automotive Riveting.

Since the individual demands give rise to very specific

requirements, the BU is further subdivided into areas

Seating, Door Modules and Safety Parts. The renowned,

technologically leading key customers who challenge and

thus also decisively advance GESIPA® are looked after

by highly qualified Key Account Managers.

BU Solid Riveting (R-SR)

W+O Niettechnik GmbH based in Olpe, North Rhine-

Westphalia, produces solid, semi-hollow and cold formed

parts almost exclusively to customer drawings. W+O's

core market is the German automobiles and commercial

vehicle industry. Frame rivets with a specially developed

anti corrosion coating the so-called SheraBlack® coating

are produced specifically for Daimler commercial vehicle

and truck construction More complex cold formed parts

for Tier One suppliers are additionally gaining in significance

for W+O. In recent years mobiles riveting solutions

have been further developed in close cooperation with

GESIPA®. Modified TAURUS® systems are used together

with modular C-frames as setting and press-out tools.

More dimensions and Types available on request.

We reserve the right to make changes for the entire catalogue.

We do not accept liability for errors or misprints. All prices specified

are net prices. The value added tax is invoiced separately.

Pricing terms are ex works excluding packaging.

All devices purchased after 1st May 2013 have a

24-month warranty, 12 months for batteries, in accordance

with the conditions of the instruction manuals.

Device colours

The housing and parts colours for certain devices will be

adjusted in the course of the year. In future, all devices

for blind rivets will be coloured in blue and all devices

for blind rivet nuts in red. It therefore possible that the

illustrations in the catalogue deviate from the devices delivered.

The relevant devices are marked with the following

symbol:

Perfect products are secured by continuous investment

in staff qualification and production machinery.

Permanent controls during manufacturing guarantee

outstanding setting characteristics and a firm hold,

batch after batch after batch...

Better than the standard

The locations of the mandrel break-points inGESIPA® blind

rivets is matched to the body length in such a way that the

setting tool needs only to be triggered once to set the rivet

and extract the spent mandrel, no matter how long the body

is. GESIPA® rivets also have a longer mandrel than other

rivets as a standard, so that nosepieces extended by up to

10 mm can be used without any problem.

A clean solution

GESIPA® blind rivets are thoroughly cleaned and fitted

with high-quality, bright-galvanised mandrels. Soiling of

the tool‘s jaws is minimised, thus extending significantly

the service life of the setting tools.

Great connection

GESIPA® blind rivets always produce a high-quality and

visually attractive finish thanks to their matched geometries

and the high-quality materials of the individual components

Fast and flexible

GESIPA® blind rivets are stocked so that all standard

dimensions, and even some non standard sizes, are normally

100 % available.

Orders placed by 2 pm (or by 11 am on Fridays) are

usually despatched the same day. Our repair department

will deal with your tool repairs in the usual, professional

manner within 48 hours.

Perfect interaction

GESIPA® blind rivets and GESIPA® setting tools are perfectly

matched to each other and use of the correct nosepiece

will produce the perfect finish.

GESIPA® setting tools offer minimal wear, short working

cycles and a long service life, thereby guaranteeing minimum

costs.

60 years of experience

Since 1955, GESIPA® has concentrated on creating the

greatest possible customer benefits with the GESIPA® blind

rivet and GESIPA® setting tools. 60 years of experience,

which fully reflect in our products.

Special challenges in industry demand special solutions

with regard to efficiency, function and innovation.

GESIPA® has decades of experience in consultancy and

development of blind rivets for specific applications.

Requirements such as surface treatments, appropriate

shear strength and/or tensile strength and setting process

reliability are defined by Technical Sales according to

the project, and guarantee millions of consistent quality

fastenings.

Quality

From the traceability and documentation of the raw materials

to the checking of dimensions and tolerances during

production, GESIPA® attaches the greatest value to quality.

But GESIPA® also goes one decisive step further. For blind

rivets for specific applications, thorough functional tests

are carried out and documented step-by-step.

Functional test /setting curve

For every production batch of blind rivets for specific

applications, the setting curve is measured on a

sophisticated test bench. The measured results of shaft

deformation, insertion characteristics, mandrel shear load

and tensile force are compared with the target values in

order to ensure that the blind rivet forms as intended in the

application and produces a secure fastening.

Function tests/

mandrel push-out force (1)

The remaining part of the mandrel enclosed in the set rivet

is pushed out. The measured force can be used to determine

whether the remaining part of the mandrel is properly

locked and will not cause any rattling noises or even fall

out. The batch is only released if both these values are

within tolerance.

Monitored process –

Reliable connection (2)

Safety relevant processes in the industrial use of blind

rivets make 100% reliability of riveting operations essential.

Process-monitored GESIPA® tools of the TAURUS®

series and the fully automatic GAV 8000 riveting machine

enable economic application solutions, from the basic

system to systems with barcode scanners and process

computers.

One fastener for several applications

The versatility of GESIPA® fasteners often means that several

application cases which previously required different

fasteners can be served by a single specially designed

blind rivet. This saves costs and simplifies handling.

Cost advantages at a glance

• Reduction of downstream quality costs due to

GESIPA® setting process monitoring

• Reduction of wearing parts costs due to identical parts

strategy and modular design of the tools

• Reduction of logistics costs due to multi-functionality

of the fasteners and corresponding reduction of parts

diversity.

In June 2013, the EU Regulation No 305/2011,

laying down harmonised conditions for the

marketing of construction products, came into

force. A large number of our blind rivets are used for

construction products. In order to comply with the new EU

Regulation on construction products we have chosen more

than 200 blind rivet sizes which meet the requirements

and assessment guidelines of the European Technical

Approval, thus being allowed to carry CE marking.

A European Technical Approval (ETA) for a construction

provides proof of its fitness for an intended use according

to the Construction Products Directive.

When the ETA has been granted, the manufacturer is

allowed to place CE marking on his products.

The CE marking confirms that all evidence has been provided,

all required assessments have been made and all

requirements been met. The manufacturer herewith shows

that his products complies with ETA requirements and

guidelines.

GESIPA® blind rivets – Efficient technology

Life without blind rivet technology from GESIPA® can

no longer be imagined in modern industry production

where fastening technology is required due to its

efficiency and versatility. It combines the advantages

of overcoming restricted component accessibility,

permanently safe connection of different, and

specialised materials, and even documentation of

the setting process if required.

Technically speaking, the blind rivet consists of two parts:

the rivet body and the mandrel. During screw-connecting,

clinching and punch riveting etc. the application must

always be accessible on both sides but the special thing

about blind riveting is that the application only needs to

be accessed from one side.

GESIPA® blind rivets – Connections that last

During the setting process, the mandrel is pulled by

the jaws of the setting tool and forms the rivet body to

the predefined fixed position in the application.

The mandrel then breaks off at the intended point (the

target breakage point) and can be recycled. The filling

cut (this is the remaining rest of mandrel in the rivet body)

can provide an additional securing function depending on

the application.

GESIPA® blind rivets – For every application

Blind rivets are available in a variety of designs, materials,

forms, lengths and even colours. Depending on the

task which the blind rivet should fulfil, GESIPA® can

choose between a standard model available from stock

or a blind rivet specially designed for the application.

GESIPA® blind rivets – Concepts

• The blind rivet consists of two parts:

the rivet body and the mandrel.

• The rivet body consists of the setting head and

the shaft.

• The setting head is found on the processing side and

is variable in diameter and shape. There are dome,

countersunk and large flange versions. The rivet body

is available in different lengths depending on the

material thickness to be riveted.

• The rivet mandrel is used to deform the rivet body.

It contains the predetermined breaking point. This is

where the rivet mandrel breaks after the rivet has

deformed.

• The rest mandrel is the remaining part of the rivet

mandrel in the rivet body. The residual mandrel is

the part of the rivet mandrel that is disposed of from

the set rivet via the blind rivet setting tool.

The basic features of the standard blind rivet are defined

by various DIN EN ISO standards. These features primarily

involve the geometric dimensions and mechanical

properties. Other fastener properties, such as the choice

of material and surface coating, are defined very generally

by the standards and are left up to the manufacturer.

These specifications about the blind rivet features seriously

limit the tolerances of the connection parameters and the

feasible requirements. Blind rivets that comply with DIN EN

ISO standards are always designed for fixed parts

The application-specific fastener can be used for a larger

number of tasks and satisfy higher requirements thanks to the

targeted specification of the material, surfaces, geometric

dimensions and in particular the functional properties. For example

the following customer requirements can be satisfied:

• Elimination of access problems to rivet positions

• Adaptation to corrosion requirements to ensure

higher resistance to environmental influences

• Production of splashwater protected joints whilst

maintaining good mechanical properties

• Compensation of larger fluctuations in the part

parameters

• Adaptation of the mechanical connection properties

to the various joining materials

Advantages

• The force increases when the handle is closed. This is

made use of via the special arrangement of the lever

when setting blind rivets: ergonomic design

• The required manual force is reduced by aroand

40 percent if actuated several times.

• Actuation lever with an opening spring for easy

single-handed operation

• Jaw mechanism with spring reset for safe and

automatic mandrel ejection

• Rivet mandrel collection container can be clipped to

the body casing and is easy to empty

• Larger device lift: a benefit when handling extra long

blind rivets

• Sturdy body casing in high-quality die cast aluminium

• Sturdy actuation lever made of tempered steel

• Link pin on anti-twist bearings

• Ergonomic lever positions and handle design

• Pliers casing in high-quality die cast aluminium, its

sturdy design protects it against soiling

• Link pin on anti-twist bearings and with inner axial

protection, wear-proof and smooth running

• Tooth segment transmission with favourable lever

arm arrangement reduces the force required and

dampens the tear-off effect

• Fixed casing lever and ergonomic handle design:

simple and easy handling

• Actuation lever: repeated re-engagement very easy,

even on workpiece; highly beneficial for oversized

blind rivets

• Gear rack: supported on a brass plate;

smooth running

• Rivet mandrel collection tank: swivel-mounted to

The Bird Pro series

GESIPA®, which invented battery-powered blind riveting

technology, has been producing the Bird series for over

twenty years now. To this day, it sets the standard for the

battery-powered blind riveting devices market. Not least

due to changing customer requirements, the Bird family‘s

modular system is updated on a regular basis. GESIPA®

has therefore built a new platform that will supplement the

current Bird series to meet the highest customer requirements.

The first two tools of this new series are the

PowerBird® Pro Gold Edition and the AccuBird® Pro.

BLDC technology

A BLDC motor is a brushless DC motor that, instead of

brushes that are susceptible to wear, uses electrical sensors

to detect the rotor‘s position and commutate the stator

coil via circuit breakers. A special software in the electronics

controls the motor.

The advantages of a BLDC motor include high efficiency,

long service life, particularly smooth running with a

precision ball bearing and a reduction in electrical noise

radiation.

Li-ion batteries

The GESIPA® Bird Pro series is equipped as standard with

a new rechargeable 2.1 Ah li-ion slide-on battery. These

rechargeable li-ion batteries feature the new Deep Sleep

function. To keep intrinsic consumption

as low as possible, after

a set idle time, the battery automatically

assumes "Deep Sleep"

mode. The battery can then only

be woken in the battery charger and is immediately ready

for use.

3. Sliding battery

New sliding battery with exact optical and acoustic

charging status display prevents unpleasant

surprises. The deep sleep function and the electrical

feedback of the braking energy extend the battery

range − a battery charge lasts for up to 2,000 riveting

operations. Additional catching grids prevent

falling.

4. Charging unit

Charging unit with quick-charge function. The

battery can be used again after only 45 minutes of

charging, and is fully charged after just 90 minutes.

1. Autoreverse function

Immediately after mandrel break-off, this optional operating

mode stops the pulling process and moves the jaw

assembly back into the initial position. This saves time and

energy while making sure the tool is immediately ready

for use.

2. Lighting

The light-emitting diodes precisely aligned to the work

piece are integrated into the adjusting ring. There are

three possible switch positions:

Process-controlled: The diodes remain illuminated after

the setting process, which allows a continuous workflow

even in bad lighting conditions.

Torch function :

Steady glow of diode (max.10 minutes)

Well-proven and ergonomically designed

The AccuBird® Pro is equipped with the low-wear jaws system

and features the same ergonomic design as the TAURUS®

series, already proven a thousand times over.

The variable tool

Blind rivets from Ø 2.4 mm aluminium, up to Ø 5 mm all materials

and blind rivets up to Ø 6 mm aluminium. BULB-TITE®

blind rivets up to Ø 4 mm and 5.2 mm aluminium and steel.

G-Bulb blind rivets up to Ø 4.8 mm all materials.

Make sure the correct jaw pusher is used as

specified in the operating instructions!

Powerful and fast

The PowerBird® Pro enhances the new Pro series

and will be available during the course of the year.

With a setting force of 15,000 N and the well-proven

brushless motor, the PowerBird® Pro is powerful

and fast when setting blind rivets up to Ø 6.4 mm

in any material. The optional Autoreverse function

additionally shortens the pulling process, ensuring

the PowerBird® Pro is immediately ready for operation.

The stroke has been substantially increased to

25 mm for the purpose of setting particularly long

rivets.

Even faster, virtually no wear

Since no wear-prone brushes are use, the motor of the

PowerBird® Pro has an extremely long service life, is virtually

non-wearing and and reliably guarantees the fastest setting

frequencies.

Even faster, virtually no wear

Since no wear-prone brushes are use, the motor of the Power-

Bird® Pro Gold Edition has an extremely long service life, is

virtually non-wearing and and reliably guarantees the fastest

setting frequencies.

Well-proven and ergonomically designed

The PowerBird® Pro Gold Edition is equipped with the low-wear

jaws system and features the same ergonomic design as the

TAURUS® series, already proven a thousand times over.

The variable tool

Blind rivets up to Ø 6.4 mm all materials and up to to Ø 8 mm

aluminium. BULB-TITE® blind rivets up to Ø 7.7 mm all materials.

MEGA GRIP® blind rivets up to Ø 6,4 mm all materials.

Make sure the correct jaw pusher is used

The spring-loaded trigger system ensures that the parts to

be riveted reliably make contact without any gaps before

riveting. Furthermore, the operator will be certain that the

blind rivet has reached its end position in the hole before

setting and the setting head is in contact with the material.

The pressing force can be varied with springs depending

on the application.

Functional principle

The surface contact trigger mechanism is also installed on

the trigger button of the device. It only allows the riveting

device to trigger when a set compressive force on the part

is reached. This ensures that the various components in the

application are pressed correctly onto each other before

the riveting process. This means that uncontrolled deformation

of the rivet body between the materials is prevented,

which would otherwise go andetected.

The surface contact force can be varied in five steps. It is

set by either adding or removing springs. This rules out the

possibility of unintentionally changing the defined surface

contact force. A row of pushbuttons is arranged in front

of the standard trigger button. On overcoming the spring

force and reaching the defined surface contact force, the

riveting process can only be triggered by pressing the

yellow button.

The Bird family

The Bird family includes the rechargeable blind rivet setting

devices AccuBird® and PowerBird® and the rechargeable

blind rivet nut setting device FireBird®. The development of

this device series for professional use by specialists and industrial

users made GESIPA® the inventor of the cablefree

and hose-free blind rivet setting technology.

In 2012 the first of the devices, the AccuBird®, celebrated

its twentieth birthday. The maintenance-friendly Bird device

series thanks its enormous success to the following benefits.

Production

• Made in Germany

• GESIPA® developement, market launch and

further developement since 1992 (AccuBird®),

1996 (PowerBird®), 1995 (FireBird®)

• 2014 Development and market launch of the

new Bird Pro series

Packaging

AccuBird®, PowerBird® and FireBird® are supplied

in a metal carrying case (34.5 x 26.5 x 9 cm).

The versions of PowerBird® Solar, PowerBird®

Gold Edition, AccuBird® Pro, PowerBird® Pro and

PowerBird® Pro Gold Edition in a high quality

plastic carrying case (43.7 x 37.9 x 13.0 cm).

Casing and accessories

• Exchange for nosepieces and wrench for the

AccuBird® and PowerBird® on the device, for

the FireBird® in the spent mandrel container

• The spent mandrel container, has an approx.

volume of 190 cm³, which means it does not

need to be emptied frequently

• Accessories and special models have been

continuously

With Li-Ion energy

• No memory effect

• High energy yield through high voltage

and low weight for easy and fast operation

• Extremely low self discharge

• Battery shape allows the tool to be stored

standing on its battery

Practical aspects

• Exchange nosepieces and wrench always

included in the tool

• Compact, shockproof tool housing

• Spent mandrel evacuation into the mandrel

container through backfilling and forwards

through the nosepiece by gravity

• Fatigue-free working through well balanced

weight repartition and ergonomic grip

Mechanics, control system and battery

• Reliable connection of the mechanics and

control system

• Cast control system is water and dust-tight

• User-friendly pluggable rechargeable battery

As part of the implementation of Directive 2006/66/EC of

the European Community on the withdrawal of NiCd batteries,

GESIPA® decided in favour of the Lithium-Ion technology as

a mobiles power source for battery powered setting tools.

GESIPA® switched over to the new technology five years ago.

Li-Ion batteries

The GESIPA® battery-powered setting tools AccuBird® and

FireBird® are equipped as standard with a 1.3 Ah Li-Ion

battery. The GESIPA® PowerBird® is supplied with a 2.6 Ah

Li-Ion battery. These rechargeable li-ion batteries feature the

new Deep Sleep function. To keep intrinsic consumption as

low as possible, after a set idle time, the battery automatically

assumes "Deep Sleep" mode. The battery can then only be

woken in the battery charger and is immediately ready for

use.

The powerful 2.6 Ah battery is also optionally available as

a special accessory for the AccuBird® and FireBird®. Older

tools can of course also be operated with the new Li-Ion

batteries. Due to the different charging principle used in the

Li-Ion technology, the charging unit must also be replaced

when switching over to Li-Ion batteries; the proven charging

units for NiCd batteries are however still available.

Charging technology

A special, intelligent circuit in the GESIPA® Li-Ion batteries

protects against deep discharging, and ensures that the last

setting cycle can be completed, before the battery signals

its empty condition by switching off. The empty battery is

ready for use again after a charging time of only about one

hour.

The new GESIPA® Li-Ion charging units are of course also

available for the alternating voltages of 110 VAC and

The new interface developed by GESIPA® is based on an

embedded PC system and provides 24 digital in and out

control system ports, Ethernet connection via a RJ45 connector

as well as status LEDs. Connection ports for a protocol converter

supporting all common bus systems and for external

storage media as well as a USB port for fast data transfer

complete the features of the new interface.

In addition, the GESIPA® interface has a process database

for storing 250,000 of the most current process data (date,

time, rivet position, process curve, analysis, etc.).

Of course, the new interface is backward compatible

with its predecessor models

The parallel head for the TAURUS® series 1-4 was specially

developed for use in areas that are difficult to access. The

compact and sturdy design makes it possible to set blind rivets

with a high setting force even in working areas that are difficult

to access. Depending on the Type of tool, the parallel head for

the TAURUS® series 1-4 can set standard blind rivets up to Ø

6.4 mm all materials with a setting force of up to 20 kN. The

smallest edge spacing is 13 mm.

To cover various requirements, two balancer models

for suspending the TAURUS® Axial tools are available.

If the tube for evacuating the spent mandrel can be

kept very short, no external mandrel evacuation assistance

is necessary which means a balancer without

valve is sufficient. However, if due to the tube length

external evacuation assistance of the mandrel becomes

necessary it can be switched on and off by means

of the valve balancer in order to save cost-intensive

compressed air. In this case the valve interrupts the

compressed air necessary to generate negative

pressure when in its highest position. The balancer

with shut-off valve is used when the blind rivet is to be

inserted into the tool. The time delay valve on the other

hand is used when the blind rivet is to be inserted into

the part.

Applications

The special pistols of TAURUS® Axial eco offer the option

of installation in production systems and simultaneously

allow flexible and handheld ergonomic work in applications

with restricted accessibility that require a vertical,

downwards oriented riveting action.

In order to ensure that no gap is left between the components

to be riveted and the setting head effectively makes

contact with the application, the TAURUS® Axial eco can

be additionally supplied with a spring-loaded trigger

system.

A compressed air supply is additionally required for reliable

mandrel evacuation. Depending on the application,

this is preferably achieved via the balancer with valve or

the time delay valve (see Page 123).

Working range

• Blind rivets up to 6.4 mm Ø all materials and

up to 8 mm Ø alu (max. mandrel dia 4.5 mm)

• Same performance and technical data as the respective

individual units in the TAURUS® series

• All blind rivets and lockbolts up to a mandrel

breaking force of 50 kN

• Same performance and technical characteristics

as the respective individual units in the TAURUS®

series 1-4, 5-6 with different stroke

• 3 metres hose length between pressure

transducer and setting pistol

Common technical data

Operating air pressure: 5 to 7 bar

Air hose connection: 6 mm (1/4“)

Noise emission: max. 79 dB

Vibrations: < 2.9 m/s²

Advantages

• Low weight of the hand held tool

• Tubing connection with quick-connect feature

(upon request) on the pressure transducer side:

No oil leak and no air bleeding

• Ideally suited for setting of blind rivets and

lockbolts in poorly accessible locationss

• Also perfectly designed for fixed installation in

production lines or semi-automatic workstations

• Can be combined with almost all supplements

and options of the TAURUS® series: head

extensions, mandrel containers, rivet counting

units, process control, pressure trigger and

remote control

Applications

The TAUREX Axial is a particular advantage in restricted

spaces due to the separate pressure transducer mounted

in the working direction. The special pistols of TAUREX

Axial offer the option of installation in production systems

and simultaneously allow flexible and handheld ergonomic

work in applications with restricted accessibility that

require a vertical, downwards oriented riveting action.

In order to ensure that no gap is left between the components

to be riveted and the setting head effectively makes

contact with the application, the TAUREX Axial can be

additionally supplied with a spring-loaded trigger system.

It is essentialto use an external suction system

with the TAUREX Axial!

A compressed air supply is additionally required for reliable

mandrel evacuation. Depending on the application,

this is preferably achieved via the balancer with valve or

the time delay valve (see Page 123).

Advantages

• Also perfectly designed for fixed

installation in production lines or

semi-automatic workstations

• Very practical for processing blind

rivets in positions that require a

vertical rivet setting process

• Low weight of the hand held tool

• Tubing connection with quick-connect feature (upon

request) on the pressure transducer side: No oil leak

and no air bleeding

• The tool can be equipped with almost all TAURUS®

series options: e.g. extension units, blind rivet counter,

spring loaded trigger system and remote control

• The handle in the rivet axle allows ergonomic work –

especially in vertical applications

• Can be suspended on a balancer

Applications

The TAUREX Axial compact is a particular advantage

in enclosed spaces due to the pressure transducer mounted

close and parallel to the tool‘s axis.

The special pistols of TAUREX Axial compact offer the

option of installation in production systems and simultaneously

allow flexible and handheld ergonomic work in

applications with restricted accessibility that require

a vertical, downwards oriented riveting action.

In order to ensure that no gap is left between the

components to be riveted and the setting head

effectively makes contact with the application, the

TAUREX Axial compact can be additionally supplied

with a spring-loaded trigger system.

Operating range

• Processing blind rivets up to 6.4 Ø all materials and

up to 8 mm Ø alu (max. mandrel dia. 4.5 mm)

• Same performance and technical data as the respective

individual units in the TAURUS® series 1-4

Technical data

Operating pressure: 5 to 7 bar

Air hose connection: 6 mm (1/4“)

Noise emission: max. 79 dB

Vibrations: < 2.9 m/s²

Weight:

TaurEX 1 Axial compact 3.1 kg

TaurEX 2 Axial compact 3.4 kg

TaurEX 3 Axial compact 3.7 kg

TaurEX 4 Axial compact 4.1 kg

Advantages

• Pressure transducer attached in a space-saving manner directly

to the device, i.e. also for applications in tight spaces

• Technical design close to the TAUREX Axial

• Also perfectly designed for fixed installation in

production lines or semi-automatic workstations

• Very practical for processing blind rivets in positions that

require a vertical rivet setting process

• The tool can be equipped with almost all TAURUS® series

options: e.g. extension units, blind rivet counter, springloaded

trigger system and remote control

• The handle in the rivet axis allows ergonomic

work – especially in vertical applications.

Setting process monitoring is achieved by direct online analysis

of traction force and traction course recorded during the setting

of the rivet. All system components necessary for this operation

are integrated in the tools. Analysing a setting process takes

less than 1 μs.The results are directly shown by a green or red

LED installed in the tool base and optionally by an acoustic

signal. In addition to this individual analysis the system also

provides collective analysis for the complete workpiece. The

tool stores more than 260,000 setting process data which

can be retrieved at any time. The system also identifies failure

patterns and memorizes them for failure analysis and troubleshooting.

The tools can be operated as stand-alone devices or

as integrated part of a customer´s production system via the

GESIPA® interface.

GESIPA®-Interface

The new interface developed by GESIPA® is based on an embedded

PC system and provides 24 digital in and out control

system ports, Ethernet connection via a RJ45 connector as

well as status LEDs. Connection ports for a protocol converter

supporting all common bus systems and for external storage

media as well as a USB port for fast data transfer complete

the features of the new interface.

In addition, the GESIPA® interface has a process database

for storing 250,000 of the most current process data (date,

time, rivet position, process curve, analysis, etc.).

The spring-loaded trigger system ensures that the components

which are to be riveted are reliably placed one on top of the

other gapfree prior to the riveting process. Furthermore, this

ensures that the blind rivet reaches its end position in the bore

prior to the setting process and that the setting head is in the

right position. The pressure force can be variably applied

depending on the application.

The spring-loaded trigger system cannot be retrofitted but is

supplied completely attached.

Speed riveting technology, also known as Speed Rivet

Technology, is an assembly technique that requires access

from one side only and enables high rates thanks to the

pre-racked rivets and the automatic feed process. This

technology is used in the following industrial areas, for

example: electronics, housing manufacture, household

appliances, lighting, lightweight constructions, DIN connectors,

diecast aluminium housings and aeronautics.

Speed riveting technology completes GESIPA® Blindniettechnik

GmbH‘s product portfolio. The new speed rivet

setting tool by GESIPA® is the product of decades of expertise

and the unbeatable advantages of the well-known,

tried-and-tested TAURUS® series. Our engineers‘ main

objectives in its development were for the TAURUS® 1

Speed Rivet to be safe, quick and reliable. The very light

and ergonomically shaped device will set new standards

for the market.

Advantages

• Also perfectly designed for fixed installation in

production lines or semi-automatic workstations

• Very practical for processing blind rivets in positions

that require a vertical rivet setting process

• Can be suspended on a balancer

• Quick setting process, fast rates

• Safe working through disposable mandrel and

optional automatic switchoff

• Ergonomic handling for fatigue-free work

• Light and compact design

• Modular construction based on the TAURUS®

design

• Softgrip

• Tool-free conversion

Advantages

• Also perfectly designed for fixed installation in

production lines or semi-automatic workstations

• Very practical for processing blind rivets in positions

that require a vertical rivet setting process

• Can be suspended on a balancer

• Quick setting process, fast rates

• Safe working through disposable mandrel and

optional automatic switchoff

• Ergonomic handling for fatigue-free work

• Light and compact design

• Modular construction based on the TAURUS®

design

• Softgrip

• Tool-free conversion

Each device in the TAURUS® series 1-4 CF can be

fitted with a C-frame tool to process hollow, semihollow

and solid rivets. Further application options

include clinching, grouting, punching and caulking.

Optionally, the C-frame can also be operated stationarily

and fitted with a foot switch. Special solutions

are possible on request.

The C-frame tools are characterised by 360° pivoting,

an efficient workflow and a precisely adjustable

setting stroke.

The desk is adapted individually to customer requirements

and designed ergonomically (e.g. adjustable height).

Everything – be it the desk, work piece socket, compressed

air supply, electrical supply or processing tools – comes from

one source, with process monitoring on request.

The optimised work piece socket allows the desk to be

converted for different products and processing tools easily,

saving costs.

The GESIPA® assembly cell is produced from high quality

materials and components. Needless to say, you also have

the option of transferring system components already used

at your company.

Advantages

• Ergonomic working

• Individually adjustable

• Existing work tools can be integrated

• Easy and time-saving conversion for other

products from your portfolio

• Setting process monitoring possible

More information on the individually adjusted

assembly cell on request.

Contact: Uwe Herth,

Head of BU Equipment Manufacturer,

uwe.herth@gesipa.com

Features

• The patented broken mandrel disposal system with the

extraction option is an integral part of the tool. No retrofitting

required.

• The compressed air used for the setting process is then

used to automatically eject the broken

mandrel, an efficient and cost saving solution.

• High setting force with low weight

• Universal use, easy handling

• Large stroke (22 mm) – guarantees setting without reengagement

and increases the oil refillingintervals

• Pneumatic piston return – high working sequence

cylinder surface

Features

• Pneumatic cylinder and hydraulic head with jaw

mechanism arranged axially behind each other:

simple and easy handling when used vertically

(e.g. desktop assembly points)

• Integrated blind rivet suction and rivet mandrel

ejection system: does not need to be retrofitted,

secure disposal of the spent mandrels in a central

container via a hose

• Hydraulic head in aluminium with wear-proof

cylinder surface

• Pneumatic cylinder made of die cast aluminium

• Working piston made of hardened and hard

chromium plated steel macke the device easy to

handle and wear-proof

• Compact seals are wear-proof with large scraper

effect, long service life

• Fast venting system: faster return; high work sequence

• Low-noise pneumatic switching

• Simple valve structure: interruption free

The universal nosepiece replaces five nosepiece sizes.

The integrated rotary star in the steel sleeve can be unlocked

easily without tools in order to select the appropriate

size of nosepiece.

Working range

Blind rivets from 2.4 up to 5 mm Ø alu, copper

and steel and up to 4 mm Ø stainless steel.

Operation

Operate the tool and hold trigger, then push back

adjusting ring to end position (1).

By turning the rotary star (2).

The universal nosepiece includes: Special steel sleeve,

complete adjusting ring, rotary star and sealing ring.

For HN 2, PH 1, PH 2 and PH 2000

Universal nosepiece — 16

Part no. 717 1188

Für AccuBird®

Universal nosepiece — 17

Part no. 725 1637

• All GESIPA® blind rivet machines are perfectly

suited for use in industrial large-scale production.

• GAVs can either be operated manually or used as

component in a robot-controlled system;

integration into a production system is also possible.

• The automatic riveting machines support the setting

of a wide range of blind rivets from 2.4 – 8 mm in

diameter.

• Up to 40 riveting processes per minute can be

realized depending of the Type of application.

Working range

• 2.4 mm up to 6.4 mm Ø alu and copper

• Up to 6 mm Ø steel

• Up to 5 mm Ø stainless steel

• Up to flange diameter 11.4 mm

• Rivet body lengths above 30 mm

• Traction power up to 11,770 N at

6-7 bar air pressure

Productivity and savings potential

• Up to 40 blind rivets can be processed

every minute

• No trained personnel required for operation

• Can be easily integrated into fully-automatic

production systems

System description

• Electronic system controls

• Intuitive menu guidance via navigation

and function keys

• Function display

• Maintenance display and simple fault

diagnosis

• Customer-specific software modification

is possible

• Ideal for applications that do not require

any process monitoring

• Rivet mandrels are disposed of by vacuum system

• Spring loaded trigger system as an optional extra

available

• Can be integrated into the system or

operated independently

• Interface for external memory programmable

control system (SPS) can be realised via the

GESIPA® interface

Working range

• 2.4 mm up to 6.4 mm Ø alu and copper

• Up to 6 mm Ø steel

• Up to 5 mm Ø stainless steel

• Up to flange diameter 11.4 mm

• Rivet body lengths above 30 mm

• Traction power up to 11,770 N at

6-7 bar air pressure

Productivity and savings potential

• Cost effective from an annual quantity of aroand

500,000 blind rivets (in relation to the german market)

• Up to 50 % time and costs savings compared to

standard blind rivet devices

• Rivet pistol has a large action radius thanks to the

hose package that is up to 5.0 m in length

(Standard length 3,75 m)

• No trained personnel required for operation

• Can be easily integrated into fully-automatic

production systems

• Up to 40 blind rivets can be processed

every minute

System description

• Electronic system controls

• Intuitive menu guidance via navigation and function

keys

• Function display

• Maintenance display and simple fault diagnosis

• Customer-specific software modification is

possible

• Rivet mandrels are disposed of by vacuum system

• Spring loaded trigger system as an optional extra

available

• Can be integrated into the system or operated

independently

• Interface for external memory programmable control

system (SPS) can be realised via the GESIPA®

interface

Specific workstation configuration

For all GAV versions, three different setting pistol variants

are available for the ideal configuration of the workstation.

For manual workstations, pistols are available as overhead

versions with overhead hose assembly or standard pistols

with floor-mounted hose assembly. Both versions are equipped

with a balancer to ensure fatigue-free working. The robotic

pistol has been developed exclusively for use in fully automatic

production systems or robot-controlled systems. It is

supplied from stock with corresponding drilled holes for

easy installation. For further questions, please contact our

Technical Sales team.

A setting pistol suitable for your application is supplied at

time of delivery.

Standard pistol

Interface for connection to external control

The new GESIPA® interface developed by GESIPA®

is based on an embedded PC system and provides

24 digital in and out control system ports, Ethernet

connection via a RJ45 connector as well as status

LEDs. Connection ports for a protocol converter

supporting all common bus systems and for external

storage media as well as a USB port for fast data

transfer complete the features of the new interface. In

addition, the GESIPA® interface has a process database

for storing 250,000 of the most current process

data (date, time,

rivet position,

process curve,

analysis, etc.).

Of course, the

interface is backward

compatible

with its predecessor

models.

Electrical foot pedal

The electrial foot pedal is a good

solution wherever applications require

both hands to affix the parts that need

to be riveted.

Special length tube packages

A larger working radius can be achieved, e.g. for use on fully

automatic production lines, by using packages of special hose

lengths. These are available in various dimensions between

3.75 m and 5.0 m to meet the requirements of the various

applications.

GAV carriage

The trolley that has been specially designed for the GAV

enables it to be mobiles thereby allowing the workplace to

be changed quickly and easily.

The combination of the use of function-documented

blind rivets and the use of the setting process monitoring

function of the GAV 8000 electronic guarantees process-

secure connections.

The quality management system comprises of three areas:

• Dimensional review

• Function test

• Setting process monitoring

The dimensional review and the function test are carried out

at GESIPA®, whilst the setting process is monitored during the

riveting process at the customer‘s premises.

Function documentation / Setting curve (1)

In addition to other parameters, the setting curve is measured

using calibrated testing equipment for every batch of

application-specific blind riveting. The measuring results of the

shaft deformation, slip-in behaviour, mandrel break load and

torque are compared to target values to ensure that the blind

rivet in the application is deformed as required and creates

a secure connection.

Function documentation /

Mandrel ejection force (2)

The remaining part of the mandrel enclosed in the set rivet is

pressed out with the aid of a needle. The measured force can

be used to determine whether the remaining part of the pin is

properly locked and will not cause any rattling noises or fall

out. The batch is only released if both these values are within

tolerances.

Monitored process – Reliable connection

100% inspections of the riveting processes are required for

safety-relevant applications for industrial processing of blind

rivets. In this case, the fully-automatic rivet device GAV 8000

electronic allows application-compatible efficient solutions

ranging from the basic system through to a system with a

barcode scanner

The process monitoring system is

an integral part of the GAV 8000

electronic.

It offers the following benefits:

• Optimum process security thanks to

integrated quality concept

• Blind rivet-specific process monitoring

• System can be operated independently

• No memory-programmable control system (SPS)

required to operate the device

• No system calibration required when system

is exchanged

• Little installation effort required

• Interfaces to the control integration

Advantages

• Conveyor pot filling level display

• Operating pressure: 5 bar

• Vibration-dampened pressure intensifier attachment

• Multiple monitoring of the blind rivet pistol by

means of sensors

• Industrial control with an 8“ colour display

• Conveyor distances of up to 25 m are possible when

used in fully-automatic production systems

• Electronic system controls

• Intuitive menu guidance via navigation and function keys

• Function display

• Maintenance display and simple fault diagnosis

• Customer-specific software modification is possible

• Ideal for applications that do not require any

process monitoring

• Rivet mandrels are disposed of via a vacuum system

• Surface contact trigger available as an optional extra

• Can be integrated into the system or operated independently

• Interface for external memory-programmable control

system (SPS) can be realised via the GESIPA®-Interface

Advice, price and delivery time on request

Electrical foot pedal

The foot pedal is a practical solution wherever applications

require both hands to affix the parts that need to be riveted.

Surface contact monitoring with dual-hand

operation

This special Type of surface contact monitoring guarantees

the manipulation-proof processsecure joining of parts. In

applications that are relevant for safety, it is often necessary

to completely rule out manipulations in the riveting process.

GSM radio modul

In the event of any deviations to the target status e.g. nearly

empty feed unit, the GSM radio module (GSM = Global

System for mobiles Communications) reports this to a mobiles

telephones or a process control centre via a call or an SMS.

This allows short response times.

Electronic key system and safety switch

An electronic key system and a safety switch guarantee

safe access control for at least two user groups and lock

the covering hood to prevent unauthorised access to the

components in the supply unit.

Interface for connection to external control

The new GESIPA® interface developed by GESIPA® is based

on an embedded PC system and provides 24 digital in and

out control system ports, Ethernet connection via a RJ45

connector as well as status LEDs. Connection ports for a

protocol converter supporting all common bus systems and

for external storage media as well as a USB port for fast

data transfer complete the features of the new interface.

In addition, the GESIPA® interface has a process database

for storing 250,000 of the most current process data (date,

time, rivet position, process curve, analysis, etc.). Of course,

the interface is backward compatible with its predecessor

models.

Special length tube packages

A larger working radius can be achieved, e.g. for use on

fully automatic production lines, by using packages of special

hose lengths. These are available in various dimensions up

to aroand 25 m to meet the requirements of the various applications.

Operatingstatus display

The signal lamps attached to the device in the colours red,

green and white indicate the operating status of the system.

An empty rivet tank, any deviations from the target operating

status etc. are indicated immediately.

Lockbolts are used where there are particularly high

requirements regarding the durability and vibration safety

of the connection. The connection requires the components

of the lockbolt to be accessible from two sides. Because

the locking ring moulds into the retaining grooves during

the setting process, the connection is extremely durable

and secure against coming loose on its own.

The GESIPA® lock bolt setting devices in the TAURUS® and

Bird® series have been developed using a modular concept

and are an ideal composition of experience and consistent

further development by our experienced engineers.

The lockbolt setting devices guarantee high-quality setting

processes and therefore long-lasting and permanently

tight connections. In the truck & trailer field in particular,

GESIPA® devices ensure fast, trouble-free working processes.

Your benefit

The specified forces and torques correspond to

calculated values or values determined in tests.

They aim to help the user select the suitable fastener.

GESIPA® recommends testing the blind rivet nuts in

the application. The actual values may differ from

the information in the catalogue due to different

circumstances.

Please contact our technical team for further help

and advice.

The setting process

The picture shows a diagram of the force-stroke curve

for setting a blind rivet nut in the lower clamping range.

Initially the force rises steeply because the deformation

zone of the blind rivet nut is first compressed. Once a

certain force is reached, the deformation zone starts to

fold outwards. Due to the fact that the resistance of the

material is lower during the deformation and creation

of the closing head, the force drops slightly.

The two charts show the torque curve when screwing

differently set blind rivet nuts. The pictures show the corresponding

cross section of set blind rivet nuts. The upper

picture shows the flat and completely formed closing head

in the black frame. In contrast, the setting stroke of the

blind rivet nut in the picture below is lower. This means

that the closing head is not completely formed. A gap is

still visible here in the folded forming zone. The incomplete

closing head is framed in red.

In the upper chart, the torque curve increases until the maximum

thread load is reached before it fails. In the case of

incompletely set blind river nuts, the torque curve runs as

shown in the lower chart.

The torque only increase briefly and then runs at almost

the same level for some time. The screw is screwed in

further, however the preload force does not increase. Almost

all the force resulting from the torque is used to form

the final closing head. The torque only increases again

once the forming zone is completely folded as shown in

the upper picture.

In an angle-controlled screwing process, the process is

always stopped after the pre-set rotation angle. If the blind

rivet is not set properly, the screwing process is interrupted,

again after the same rotation angle.

However in this case, the required clamping force has not

yet been reached.

Torque (Nm)

Tightening

torque

Safety factor

Angle of rotation (°)

Technical data on GESIPA® blind rivet nuts

Alu

Nm (lb-ft)

Steel

Nm (lb-ft)

Stainless steel A2 /A4 / Monel

Nm (lb-ft)

M4 2.5 1.8 3.0 2.2 5.5 4.1

M5 5.0 3,7 8.0 5.9 14.0 10.3

M6 9.5 7.0 12.0 8.9 27.0 19.9

M8 17.5 12.9 30.0 22.1 40.0 29.5

M10 28.0 20.7 38.0 28.0 -

The tightening torque (Nm) and (lb-ft)

The shear strength [(N) and (kp)] states the minimum transverse

force up to which the set blind rivet can be loaded before it fails.

The load is exerted as a single shear and without a screw at a

clamping length of 3.0 mm.

The stated values only apply to roand flat head blind rivet nuts.

The values for other models depend on the material of the application

and the head shape. These can be determined on request.