The Baltec STF-1 Expert is based on revolutionary new hardware and intelligent software; this system offers users a broader application spectrum for continuous quality assurance allowing for effective monitoring of any riveting variable in assembly applications.
The STF-1 Expert process controller is comprised of a microprocessor control system, which is used as an option with the standard Baltec RC-20A riveting machine control. This new, extremely user-friendly system has been designed to work with an even wider range of applications.
Previous system functions were re-evaluated and consequently optimized or fully redesigned to improve set up, programming and user-comfort standards enormously. These features have resulted in numerous user benefits, for example: A maximum 2-mode, 64 rivet program storage capacity; rivet spindle speed display, sensor calibration adaptable to mode of operation (e.g. riveting from below); hiding of unwanted data or functions; RS 232 interface for data recording and processing; collection of all relevant riveting process parameters with each parameter being selectable as a "controlling parameter" and a lot more features beside.
The industry-proven projection control and Auto-Compensation modules are also available. The projection control option is no longer restricted to merely monitoring rivet projection; it can now collect and analyze other process data as well. The innovative Auto-Compensation module is directly connected to the rivet projection control and can automatically compensate for high part tolerances. The projection control option can produce constantly impressive rivets and connections even with high deviations in rivet lengths or rivet projection.
A practical example: A manufacturer of door locking systems processes approx. 100,000,000 rivets per year at an average price of $ 0.06 per rivet. As the rivet is regarded as a functional part, it is manufactured as a turned part. A cold-formed rivet, on the other hand, would cost only $ 0.02. From the application perspective, approx. 20%, i.e. 20,000,000 of the turned rivets could be replaced with formed rivets, which would represent cost savings of around $ 800,000.00. A certain amount of rejects do have to be calculated into the equation, however, which, at an assembly price of $ 5 and an assumed 1% reject rate as well as the use of 2 rivets per part, could lead to a loss of 1 million dollars. Nevertheless, as up to 7/8 of rejects can be avoided using the Auto-Compensation function on the new STF 1-Expert process controller, an $ 875,000 profit could be made on a cost basis of a 1 million loss.
This saving potential is an excellent reason for investing in the new STF 1-Expert rivet process control system and the Auto-Compensation option. It is also worth mentioning the fact that the flexible Auto-Compensation can be used for other pairs of parts that tend to have high part tolerances, such as connection parts with different thickness or multi-layered sheet metal. BalTec's leadership in riveting process control with this new STF-1 Expert process controller provides an enormous competitive advantage - without enormous investments - not only to automotive suppliers but also to manufacturers in other industries.
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