Bollhoff Amtec Installation Methods

7/30/2019 Bollhoff Amtec Installation Methods

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Precision processing competence from AMTEC

0271/03.02

A joint project between


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Overview of installation methods forAMTEC threaded inserts

HES HES (heated tool welding) is a tried-and-tested method forinstalling metal threaded inserts in thermoplastic moul-

dings. This is a one-phase process in which contact heat

is transmitted via the metal insert to the joining zone of the

plastic moulding. the two parts are joined as the plastic

material melts around the contact area. The plasticized

material is displaced into defined recesses and undercuts

to produce a positive connection.

Suitable Bllhoff threaded inserts: HITSERT 2 and 3,

SONICSERT.

EWS EWS (electromagnetic resistance welding) is a methoddeveloped by KVT Bielefeld for interconnecting metal and

thermoplastic parts. The threaded insert is heated without

contact through an electromagnetic field, thus plasticizing

the contact area of the plastic part. The molten material is

displaced into any size are heated within a very short

space of time (approx. 2 6 seconds). Since the melt

cools rapidly as soon as the energy is switched off, parts

can be fitted with an accuracy of up to 0.05 mm.

Suitable Bllhoff threaded inserts: HITSERT 2 and 3;

SONICSERT.

USS USS (ultrasonic welding) was originally developed forjoining thermoplastic mouldings. The plastic material is

plasticized very rapidly through friction between the mating

surface and vibration absorption of the parts to be combi-

ned. This is then followed by the actual joining process.

The required energy is produced by the ultrasonic genera-

tor in the form of an AC voltage which is converted into

mechanical vibration (20 40 kHz) and then applied to the

parts by a vibrator (sonotrode). The molten material isdisplaced into recesses and undercuts as the threaded

inserts (metal parts size M 2 M 6) are installed in the

thermoplastic.

Suitable Bllhoff threaded inserts: HITSERT 2 and 3;

SONICSERT.

RSS RRS (rotational friction welding) is used to connect thermo-plastic parts with rotosymmetrical joining zone. The joint

effect of the bonding force and rotation produces frictionheat at the mating surfaces, thus causing both parts to

plasticize and enter into a positive connection.

Suitable Bllhoff threaded inserts: plastic in plastic

Type 163.

Cold fitting Process for connecting thermoplastic and thermosetmaterials without producing fusion heat. The range of

Bllhoff products for this application extends from self-tap-

ping screw-in parts through thread-cutting parts to expan-

sion anchoring systems.

Suitable Bllhoff threaded inserts: HITSERT 3;

QUICKSERT; EXPANSIONSERT 1 and 2; SPREDSERT.

HES

EWS

KVT Bielefeld


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AMTEC threaded insert

M 2

< 50.000

< 0,05

kk

0,1

0,2

< 0,05

kk

0,1

0,2

< 0,05

kk

0,1

0,2

500.000 > 1 Mio.

Selection of suitable fitting methods

KVT Bielefeld

> 1 million

HES EWS USS = Ideal = Good = OK = Not so good k = Not recommended

Quantity

fitting accuracy


M2 M8

< 50.000 500.000 > 1 Mio.> 1 million

Quantity

fitting accuracy


> M10

k

fitting accuracy

< 0,05

kk

0,1

0,2

< 0,05

kk

0,1

0,2

< 0,05

kk

0,1

0,2

< 50.000k

< 0,05

kk

0,1

k

0,2

k

< 0,05

kk

0,1

k

0,2

k

< 0,05

kk

0,1

k

0,2

k

500.000k

1 millionk

Quantity

e. g. for telecommunications

e. g. for furniture

e. g. for automotive applications




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Thermal installation of metal threaded inserts (HES)

Equipment types Range of sizes Economic batch size

Thermofitting gun M2 - M6 up to 5.000

Lever-type hand-operated thermofitting tool M1.4 - M8 up to 20.000

Pneumatic thermofitting machine M1.4 - M8 over 50.000

Thermofitting unit with automatic fitting head Type AEK I M2 - M8 over 50.000

Automatic thermofitting head Type AEK I M2 - M8

Thermofitting components M2 - M8

Dimensions: Possible: M 1.4 - M8

Recommended: M2 - M6

Insertion time: M 4 approx. 3 - 4 seconds

Special features: - Low tension

- Multiple insertion possible

- Highly suitable for threaded bolts- Tolerance +/- 0.1 mm

- Can easily be converted to other insert sizes

Materials: - Thermoplastics

- Thermoplastic elastomers

HES

HES

KVT Bielefeld

Toggle-operated thermofitting tool

Thermofitting unit with automatic

fitting head Type AEK I

3-axis thermofitting machine

Thermofitting gun

Lever-type hand-operated

thermofitting tool

Thermofitting machine

for multiple insertion


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Thermal installation of metal threaded inserts through electromagnetic resistance

welding (EWS)

Dimensions: M1.4 - M40

Insertion time: M5 approx. 3 seconds

Special features: - Low tension

- Multiple insertion possible

- Specially for inserts < M2 and for inserts with sealing ring

- Tolerance up to 0.05 mm- Choice between one and two-phase process


- Thermoplastic elastomers


Hand-operated EWS gun M1.4 - M8 up to 5.000

Lever-type hand-operated EWS thermofitting tool M1.4 - M12 up to 20.000

Pneumatic EWS thermofitting machine M1.4 - M40 over 50.000

EWS thermofitting unit

with automatic fitting head Type AEK II M3 - M8 300.000

EWS thermofitting components M2 - M8

Automatic thermofitting head Type AEK II M2 - M8 100.000

EWS

EWS

KVT Bielefeld

EWS thermofitting machine for

multiple insertionPneumatic EWS thermofitting

machine

Hand-operated EWS gun

Lever-type hand-operated EWS thermofitting tool

EWS thermofitting unit with

automatic fitting head

Type AEK II

EWS thermofitting components

Automatic thermofitting head

Type AEK II


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Ultrasonic installation of metal or plastic in plastic threaded inserts (USS)

Dimensions: Possible: M2 - M6 for metal inserts

Recommended: M2 - M12 specially plastic in plastic-inserts

Insertion time: Approx. 2 seconds

Special features: - High noise levels when fitting metal inserts

- Considerable abrasion when fitting metal inserts

- Unsuitable for threaded bolts- Can easily be converted to other insert sizes



Hand-operated ultrasonic welding gun M2 - M6


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Friction installation of threaded plastic in plastic inserts and screw-welded connections

(RRS)

Dimensions: M 3 - M 8 plastic in plastic inserts

Insertion time: Approx. 2 seconds

Special features: - Screw connections can also be welded

- Can easily be converted to other insert sizes



Rotational welding components M2 - M8 < 5.000

Semi-automatic rotational friction welding machine M2 - M8 > 5.000

RRS

KVT Bielefeld

Rotational welding components

Rotational friction welding machine


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Thermal installation of metal threaded inserts (HES)

Thermal installation of metal threaded inserts through electromagnetic

resistance welding (EWS)

Ultrasonic installation of metal or plastic in plastic threadedinserts (USS)

Friction installation of plastic threaded inserts and screw-welded

connections (RRS)

KVT Bielefeld


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Overview ofAMTEC threaded inserts

Thermal installation HITSERT2Tapered metal threaded insert for all thermoplastics.

Particularly suitable for installation by transfer of heat

and induction heating.

Thermal installation,screwing-in and cold insertion

HITSERT 3 all-purposeTapered metal threaded insert for thermoplastic materials.

Particularly suitable for thermal installation using the HES

and EWS processes, for screwing-in and for cold

insertion.

Ultrasonic installation Plastic in plastic Type 163Tapered plastic threaded insert for thermoplastic

materials.

The plastic part and the plastic in plastic insert can be

jointly recycled.

SONICSERT

Metal threaded insert for all thermoplastics. Particularlysuitable for fitting by means of ultrasonic processes, as

well as by the HES and EWS processes.

This insert which can be used from both ends is

particularly suitable for automatic insertion. Available on

request with defined screws....


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EXPANSIONSERT 1

Metal threaded insert for all plastics and their

composites.

EXPANSIONSERT 2

Metal threaded insert for casting resins, polyurethane,

structural foam, elastomers and wood composites.

QUICKSERT Type 1230

Metal threaded insert for chipless insertion in smooth

locating bores. Creates a loadable screw connection in

light metals, thermoplastics and thermoset materials

.

SPREDSERT 1

Metal threaded insert for all thermoplastics and their

composites. Also vibration-proof screw connection.

SPREDSERT 2

Metal threaded insert for all thermoset materials, also

vibration-proof screw connection.

SPREDSERT with locking collar

Metal threaded insert for through-holes in all plastics

with high pull-out values.

Expansion anchoring

Overview ofAMTEC threaded inserts

Self-tapping QUICKSERT

Self-tapping threaded bush for brittle and ductile pla-

stics, e. g. unsaturated polyester resins (SMC, ZMC),

polyethane and glass fibre reinforced thermoplastics.

High load capacity, can be used for all purposes,

optimum fitting properties.

Plastic in plastic Type 173

Plastic threaded bush for components made from rigid

foam, PE and PP thermoplastics, as well as wood

materials. The plastic part and the plastic in plastic

insert can be recycled together if paired accordingly.

The innovative solution for metal-free components

(e.g. for use in radiography).


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EXPANSIONSERT 1, EXPANSIONSERT 2,

SPREDSERT 1 and 2

Fitting mandrels for manual insertion of

EXPANSIONSERT 1,

EXPANSIONSERT 2 threaded inserts

QUICKSERT expansion insert Type 1230

EXPANSIONSERT 1, EXPANSIONSERT 2

The tool can be integrated into lever-type hand-operated units or other presses.

QUICKSERT self-tapping insertion,

plastic in plastic Type 173, HITSERT 3

Can be mounted in adapters on pillar drilling machines and battery-operated power

screwdrivers.

EXPANSIONSERT 1, EXPANSIONSERT 2, SPREDSERT1 and 2

- Automatic fitting machine, including helical conveyor, separation and automatic

infeed

For large volume production

QUICKSERT self-tapping insertion,

plastic in plastic Type 173, HITSERT 3 pneumatic screwdriver

High performance through automatic reversal upon reaching the set torque

Stationary operation when mounted by adaptation to parallel guide

Medium to large volume production

QUICKSERT expansion anchoring

Setting tool P 2001 is used for rapid and reliable insertion.

For large volume production

QUICKSERT self-tapping insertion, with collar

plastic in plastic Type 173

Universal quick-action screw system BM 2100

UNIQUICK system

with hand-held telescoping screwdriver, special version with automatic infeed ofthreaded inserts.

For large volume production (dimensions on request)

KVT Bielefeld

Overview of tools for fittingAMTEC threaded inserts by expansion anchoring and self-tapping

insertion


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KVT

Brief description

A powerful representative of the compact toggle units with temperature controller and

various thermal tips for heating several metal threaded bushes (inserts) of the same

size. The inserts are heated and simultaneously fitted in the plastic part.

Suitable for multiple insertion of standard inserts in sizes from M 3 to M 6 or for

individual insertion of standard inserts in sizes from M 8 to M10.

Technical data Method: Thermal, one-phase

Heating time: 3 - 7 seconds (multiple insertion)

Insertion force: Max. 10.000 N

Fitting tolerance: 0.15 mm

Temperature: Up to 400C, variable

Brief description

A compact hand-operated unit with temperature controller and various thermal tips

for heating metal threaded bushes (inserts).

The thermal tips can rapidly be changed, thus making this unit ideal for fitting different

insert sizes in small batches. The inserts are heated and simultaneously fitted in the

plastic part.Suitable for insertion of standard inserts in sizes from M3 to M 5.


Heating time: 3 - 5 seconds

Insertion force: Max. 200 N



Brief description

The photograph shows the patented electromagnetic thermofitting head for contact-less heating of metal threaded bushes (inserts). The inserts are fed to the thermofitting

head by a vibratory conveyor and electromagnetically heated to exactly the melting

temperature of the plastic part. They are then introduced into the locating bore in the

plastic part via the guide tube and accurately pressed into place by the subsequent

insertion mandrel. Suitable for thermofitting standard inserts without collar in sizes

from M5 to M8.

Technical data Method: Electromagnetic, two-phase


Cycle time: 4 - 5 seconds


Fitting tolerance: 0.05 mmPower output: 650 - 1500 W

KVT Bielefeld


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KVT

Brief description

Rotational friction welding machine for installing plastic in plastic inserts or for

welding rotosymmetrical thermoplastic parts.

Spin welding components are also available for integration in customized machines.

Technical data Method: Rotational

Welding time: Approx. 0.4 seconds

Insertion force: Max. 6.5 kN

Drive type: Pneumatic, motor-driven or motor-

driven with precise angular positioning,

as preferred, depending on the

application in question.

Brief description

The photograph shows the single patented thermofitting head for electromagnetically

heating metal threaded bushes (inserts).

The fitting heads are used for plastic parts (such as suction tubes) into which a large

number of inserts must be fitted simultaneously and in large batches. The number of

inserts present and the depth reached are scanned, thus ensuring optimum produc-tion reliability when thermofitting the inserts.

Suitable for thermofitting standard inserts in sizes from M5 to M 10.





Power output: Up to 1000 W

KVT Bielefeld

Brief description

The photograph shows the automatic fitting head for heating metal threaded bushes(inserts).

The inserts are delivered to the thermofitting head by a vibratory conveyor and heated

to exactly the melting temperature of the plastic. They are then introduced into the

locating bore in the plastic part via the guide tube and accurately pressed into place

by the subsequent insertion mandrel.

Suitable for thermofitting standard inserts without collar in sizes from M 4 to M 6.

Technical data Method: Thermal, two-phase


Cycle time: Depends on the number of inserts


Fitting tolerance: 0.10 mmTemperature: Up to 400C, variable


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KVT

Brief description

The photograph shows an automatic fitting head for multiple insertion of metal

threaded inserts in an all-automatic thermofitting machine operating in 3-axis mode.

Two NC axes position the plastic part so that the locating bores for the inserts are

located under the fitting head. The fitting head is lowered onto the plastic part by the

third axis. Heating and insertion by the fitting head are then performed automatically.

Suitable for thermofitting standard inserts without collar in sizes from M 4 to M 6.

Technical data Method: Thermal, two-phase


Cycle time: Up to 20 inserts per minute




Brief description

The photograph shows an electromagnetic thermofitting machine for contactless hea-

ting of special inserts (e. g. vent valve with sealing ring). It is a special feature of this

machine that the vent valve is pneumatically picked up by the upper tool and then fit-

ted in the fuel distributor after being heated. This eliminates the need for time-consu-

ming preassembly of the insert in the plastic part. Thermal damage to the sealing ringis prevented by controlled heating of the valve.

Suitable for thermofitting special and standard inserts in sizes from M6 to M 12.







Brief description

The photograph shows a fitting machine for thermal installation of metal threadedinserts in the front panelling of motocycles with the aid of individual thermofitting

heads.

Independent operation of the fitting heads permits controlled insertion of every single

insert by adjusting the depth stop. The thermofitting process is not complete until the

monitor for each fitting head signals OK.







KVT Bielefeld


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KVT

Brief description

The photograph shows a set-head machine for thermofitting metal threaded inserts

with four electromagnetic single-setting heads. Heating and insertion are started

simultaneously by the machine when the number of prefitted inserts in the plastic part

has been established. The process is not complete until all inserts have been inserted

to precisely the set depth. This is realized by means of an OK signal from an electro-

pneumatic monitor.


Technical data Method: Electromagnetic, one-phase





Brief description

Ultrasonic welding machine for installing plastic in plastic inserts or for welding

thermoplastic parts.

In addition to complete ultrasonic welding machines, we also supply components for

integration in customized machines.

Technical data Method: UItrasonic


Insertion force: Max. 6.5 KN

Working frequency: 35 kHz

Power output either: 300 W, 400 W, 800 W, 1000 W


Power output either: 1000 W, 1500 W,

2000 W, 3000 W, 4000 W

Brief description

Compact hand-operated ultrasonic welding unit for installing plastic in plastic insertsor for welding thermoplastic parts. Complete with ultrasonic generator, ultrasonic wel-

ding unit and sonotrode.

Rapid replacement of the sonotrode makes this unit ideal for welding different plastic

inserts in small batches.

Of limited suitability for installing metal inserts.

Technical data Method: Ultrasonic




Power output either: 300 W, 400 W, 800 W, 1000 W

KVT Bielefeld


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Business Unit Fastening and Assembly Technology

P.O. Box 140229 33622 Bielefeld

Archimedesstrae 14 33649 Bielefeld

Germany

Telephone (+49)521 / 4482 - 03 (2 32)

Telefax (+49)5 21 /44 82- 3 71

Internet: www.bollhoff.com

E-Mail: [email protected]

KVT Bielefeld GmbHPlastics and connection systems

Werkering 6 33609 Bielefeld

Germany

Telephone (+49)5 21 /9 3207 - 0

Telefax (+49)5 21/ 932 07 -11

Internet: www.kvt-bielefeld.de

E-Mail: [email protected]

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Bollhoff Amtec Installation Methods

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