CLEVELAND—The new BRF30PB-20 cordless riveting tool from Stanley Assembly Technologies captures data from the rivet-setting process in real time. By measuring variables such as force and distance, the tool detects errors such as incorrect rivets, missing parts and incorrect hole sizes.

The tool can set open- or closed-end rivets from 4.8 to 6.4 millimeters in diameter. The tool can store 16 jobs in memory. It can operate independently, or it can be integrated with an MES system. It supports various communication protocols, including Open Protocol, Modbus, ToolsNet, XML and PFCS. Additional protocols are available with a controller. An optional bar code scanner can be connected with the tool.

An onboard display can be used for configuration and application observation. The tool stores 30,000 fastening curves and rundowns. It’s powered by a widely available Dewalt battery platform.

Field trials at a manufacturer of truck and trailer bumpers demonstrated the tool’s effectiveness in reducing errors in a just-in-time production environment. The manufacturer faced several challenges, including maintaining quality standards and recording fastening data in real time. The manufacturer wanted to prevent missing rivets; recognize incorrect rivets; detect incorrect hole sizes or deformation issues; identify missing parts, such as washers; and catch extra space or gaps between surfaces in the assembly. It also wanted to count all the rivets installed in each assembly, to ensure that every fastener has been installed.

Stanley conducted field trials at the manufacturer, using the tool to install 4.8-millimeter POP Vgrip rivets.

The trial found that the tool was able to capture riveting data in real time. Using Lean Six Sigma methodology, setting a tolerance of ±7.5 percent, Stanley engineers calculated a defect rate of 6,200 per million opportunities, with Sigma of 4 and a CpK 1.33, which is an improved result compared with the manufacturer’s previous riveting tools. 

In addition, the tool enabled the company to produce a detailed audit trail that facilitated accountability and compliance with industry standards. Overall efficiency increased and errors were reduced.