flexitol - interempresas

Stepless Tolerance Compensation Systems

0590/09.02

FLEXITOL®

2 3

■ FLEXITOL® technology

■ Customer benefits

■ When to use which system?

■ System descriptionsFLEXITOL® metalFLEXITOL® hybridFLEXITOL® plastic

■ Fields of application

■ Technical information

■ Contact form

4

FLEXITOL® technology

Especially the automotive industry is ever more becoming a highly automated assembly industry.

The supplier industry mainly provides assemblies and the automobile manufacturing plant then only has to carryout the final assembly. In the so-called modular construction, standardised parts are assembled to completesystems (modular design principle).

As part of the corresponding development process, appropriate tolerances have to be defined so as to be able toimplement series production. High demands on the producer and customer sides regarding reliable functioningand firstclass quality such as small gap widths require economic assembly solutions with tolerance compensation.

The automatic tolerance compensation system FLEXITOL® provides a technically and economically optimisedsolution.

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FLEXITOL® technology

A tolerance compensation element consists of at least two components – an adjustment element and a fasteningelement.

First of all, the tolerance compensation element is installed in the receiving part. On the following pages, differentinstallation methods are introduced.

After that, the assembly to be installed is brought into the desired assembly position.

Upon screwing, compensation distance between receiving part and mounting part is steplessly and automaticallycompensated.

The friction element serves to move the adjustment element. The adjustment element is connected to the fasteningelement via a left-hand thread.

By screwing in the screw clockwise, the adjustment element drives out until touching the mounting part.

Afterwards, the screw is further screwed in until the entire assembly is secured by screw preload force.

The great benefit of FLEXITOL® is more than obvious:Without additional adjustments, the varying gap produced by tolerances is compensated automatically and withoutdeformation.

Mounting part

Fastening element Friction element

Receiving part

Compensation distance

Min. height

Screw

Adjust-mentelement

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Customer benefits

Quality demands regarding the final product are ever growing. Especially apparent quality aspects such as gapdimensions are becoming more important.

FLEXITOL® also allows higher production tolerances and therefore saves manufacturing costs upon componentproduction while preserving high quality.

As the effectiveness of tolerance compensation does not depend on changing influential factors, high performancereliability is ensured.

With our different systems, we can provide the perfect solution for your assembly task.For all components, only one-sided access has to be provided.

■ Cost reduction upon component production■ High performance reliability■ Assembly from one side only■ Easy integration into customer components

Compo-nent

production Compo-nent

production

Assembly

Assembly

FLEXITOL®

Sav

ing

pot

entia

l

Cos

ts

Conventionalinstallation

Employment ofFLEXITOL®

Efficient tolerance compensation systemSaves costs and time

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When to use which system?

Currently, there are three FLEXITOL® types:

■ FLEXITOL® metal■ FLEXITOL® hybrid■ FLEXITOL® plastic

Different areas of application mean different demands and therefore require applica-tion optimised tolerance compensation systems.

Which system to use depends on the specific application.The following table is provided as a help in the decision making process.

FLEXITOL® metal

FLEXITOL® hybrid

FLEXITOL® plastic

FLEXITOL® metal FLEXITOL® hybrid FLEXITOL® plastic

High stability + + + +

Small installationspace

+ + + +

Large numberof pieces

+ + + + +

Low weight + + +

High temperatureresistance

+ + +

Mounting inplastic

+ + +

Recycling + + + + +

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FLEXITOL® metal systems

FLEXITOL® metal was Böllhoff’s first step towards developing tolerancecompensation systems.

This two-component system is entirely made of metal and therefore highly wearresistant. Due to the small space required for installation in the separation gap,this solution may easily be integrated and even retrofit into an existing installationspace.

Adjustment element ■ Manual adjustment for re-adjustment possible■ Highly wear resistant metal adjustment element■ May also be installed into bulk material

Fastening element■ Compact system dimension■ Blind rivet nut available in different designs■ Easy installation due to approved blind rivet technology

Installation into thin-walled materials < = 5 mm ➀ + ➁

■ Integrated fastening thread■ Blind rivet nut as fastening element■ May be installed with adjustment thread above or below separation gap

Installation into thick-walled metals ➂No fastening element required.Adjustment and fastening thread may be integrated directly into the attachment part.

➀ ➁ ➂

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FLEXITOL® metal – installation

Setting theRIVKLE® blind rivet nut

Installation of theFLEXITOL® tolerance

compensation

Spin on theblind rivet nut

Insertion intoreceiving part

Setting

Spin off

Positioning of theFLEXITOL® adjustmentelement on thesetting tool

Insertion

Screwing in

Working FLEXITOL®

tolerance compensationsystem

➀ ➁

➂ ➃

➀ ➁

➂ ➃

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FLEXITOL® hybrid systems

FLEXITOL® hybrid is a multi-component system mainly designed for use in large scaleproduction.

Due to its modular construction, a variation of different inserted heights and tolerancecompensation dimensions may easily be implemented.

To ensure high force transmission, the force transmitting components of the hybridsolution (plastic /metal) are made of metal. They are enclosed by a nut cage madeof plastic.

Upon delivery, the system is pre-assembled and may be installed into the receivingpart using a setting tool.

Because of the integrated blind rivet nut, a fastening thread is already provided.Alternative connections such as clips may also be employed.

Blind rivet solution

Clips version

➀ ➁

➂ ➃

Insertionand riveting

Positioningof components

Compensationof tolerances

Fasteningthe assembly

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K’ in K’-type

Bayonet-type

FLEXITOL® plastic systems

FLEXITOL® plastic consists of an adjustment element and a fastening element madeof plastic. It is delivered as a pre-assembled assembly.

The assembly is screwed (self-tapping) into a mounting hole in the plastic receivingpart.

The bayonet method is another possibility to insert the fastening element.Here, FLEXITOL® plastic is inserted into a keyhole-shaped receiving opening andlatched with a quarter turn. The following installation is the same as for theself-tapping method.

Ideally, the fastening screw may be a plastic UNITEC® K’ in K’ self-tapping screw or aself-tapping metal screw.

➀ ➁

➂ ➃

Insertionand twisting

Positioningof components

Compensationof tolerances

Fasteningthe assembly

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All for cars

Fields ofapplication

■ Front-end fastenings(headlight installation)

■ Flush-mountinstallation ofbody elements withexact gap measures(wing to door)

■ Outside flushbumper installationwith respect toadjacent body parts

■ Stress-free seat runnerinstallation withfour-pointsuspension

■ Door frame(integral carrier)

■ Tension-free installationof the instrumentpanel carrier in correctposition


■ Stress-freeglass sunroof

installation

■ Compensationof tolerances

upon tail-light installation

■ Precisegearshift surround

installation

■ Tolerance compensa-tion at the door handle

■ Fastening ofroof rails

■ Stress-freeinstallation of

large plastic covers

All for cars

� � �M H P

� �M H

� � �M H P

� �M H

� �M H

� �M H

� �M H

� � �M H P

� � �M H P

�P

� �M H

� �M H�M = FLEXITOL® metal

�H = FLEXITOL® hybrid

�P = FLEXITOL® plastic

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All for the industry


■ Orientation ofscreens with respectto covering

■ Tension-freeinstallation ofcomplex machinehousings

■ Parallelalignment ofdrawer slides

■ Orientation ofcabin coverings incommercial vehicles

■ Fine adjustment ofoptical elements insidelaboratory instruments

■ Tension-freeinstallation of driveunits in washingmachines

� �M P

� �M P

� � �M H P

� � �M H P

� �M P

� �M H

�M = FLEXITOL® metal · �H = FLEXITOL® hybrid · �P = FLEXITOL® plastic

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Technical data FLEXITOL® metal

Article no. 2611 005 0002Size M 5Minimum height 3,0 mmClamping range 3 – 4 mmCompensation distance 7 mm - eHead diameter SW 13

Article no. 2611 006 0001Size M 6Minimum height 2,5 mmClamping range 0,5 – 3 mmCompensation distance 11 mm - eHead diameter SW 24



Article no. 2612 006 0002Size M 6Minimum height 27,5 mmClamping range 2 – 3 mmCompensation distance 10 mmHead diameter SW 16


Article no. 2640 006 0005Size M 6Minimum height 1,5 mmCompensation distance 3,5 mmHead diameter SW 17Special Installation directly to receiving

part, manual tolerancecompensation

Article no. 2640 006 0004Size M 6Minimum height 1,5 mmCompensation distance 3,5 mmHead diameter SW 17Special Installation directly to receiving

part, automatic tolerancecompensation

e = material thickness receiving part

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Technical data FLEXITOL® metal

Mechanical insertion tool withhydraulic-pneumatic drive formedium to large production runs

Operating mode: Spindling blind rivet nut at mandrel with touch automatic.Hydraulic / pneumatic riveting followed by removing through toggle lever actuation.Limited stroke due to adjusting collar.

Application: Medium to large series

Technical data: ■ Efficiency: up to 15 pieces /min■ Weight: 2.7 kg■ Max. setting force of 21.000 N at 6 – 7 bar

Article numbers: 2361 530 1004 P 2001 LH2361 550 1002 P 2005 LH

FLEXITOL® M 5 FLEXITOL® M 6 FLEXITOL® M 8

Mandrel 2661 530 8020 2719 100 1005 2661 531 2420

Nosepiece 2361 130 8030 2719 100 1006 2361 531 2030

Changeover unit 2661 530 8010 2719 060 1010 2661 531 2410

Manual installation toolfor small series

Operating mode: Manual rivet setting tool with crossed gears. Manual spindling and removing of blindrivet nut with crank and wrench (included in the scope of supply).

Application: Small series, single installations

Technical data: ■ Efficiency: up to 2 pieces /min

This tool is delivered with nosepiece and threaded mandrel.

FLEXITOL® M 6 FLEXITOL® M 8

Complete tool 2651 531 0000 2651 531 2000

Spare spindle 2651 531 0020 2651 531 2320

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Example: Screw-in paramaters in PP-LGF30■ Screw-in of tolerance compensation element into mounting hole speed:

200 min--1 max.■ Screw-in torque: 2.0 NmExact values have to be adapted to the individual application.Feel free to contact our application engineering department.Screw-in tool: 2799 000 1028

Technical data

FLEXITOL® hybrid

FLEXITOL® plastic

FLEXITOL® plastic bayonet

Article no. Tolerance K’ in K’ Compen- Self-tappingcompensation thread sation screw tighteningextrusion force pressure force distance torque

2704 050 1001 4,000 N mind. 1,000 N 6 mm 2.5 Nm

Other dimensions and connection methods possible.Feel free to contact our application engineering department.

Article no. Size Min. high Compen- Head Tighteningsation diameter torque

distance

2707 080 1026 M 8 16 mm 8 mm 31 mm 25 Nm

Material thickness: 1.5 mm■ Screw-in torque: 3.0 NmExact values have to be adapted to the individual application.Feel free to contact our application engineering department.Screw-in tool: 2799 000 1028

Article no. Tolerance Max. Compen- Self-tappingcompensation axial thrust sation screw tighteningextrusion force distance torque

2705 050 1021 4,000 N 2,000 N 6 mm 2.5 Nm

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Contact form

Notes

■ Date

■ Company

■ Address

■ Phone

■ Fax

■ E-mail

■ Application /customer identification

■ Runtime

■ Annual production run

■ Sample /number

Mechanical requirements

Screw tightening torque MA Nm

Thread size D

Compensation distance T

Inserted height H

Max. length Lmax.

Material thickness S1

Fastening element head diameter D1

Adjustment element head diameter D2

Material part 1 S1

Material part 2 S2

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Space for your sketches/notes

Subject to technical change.Reprinting, even in extract form, only permitted with express consent.Observe protective note according to DIN 34.

Böllhoff GroupPlease find your local contact on www.boellhoff.com

or contact us under [email protected]

Apart from these 22 countries, Böllhoff supports its international customers in other important industrial markets in close partnership

with agents and dealers.

Böllhoff International with companies in:

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Austria

Brazil

Canada

China

Czech Republic

France

Germany

Hungary

India

Italy

Japan

Mexico

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Rumania

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