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.