Troubleshooting
The PierceForm Studs (CP/CS) are property class 9.8 fasteners.
They are system fed to automatic installation tools. The CP
style Stud pierces its own hole in a sheet metal panel (.75-2.50mm
thickness) and retains the resulting slug. The CS style Stud
requires a pre-pierced hole and is used in heavier thickness panels
(2.00-6.00mm). The installation tool requires a regulated,
clean air supply for operation. A proximity sensor is
positioned in the tool to identify that a Stud is positioned for
installation. The System Controller regulates the various
functions required for normal operation.
How The PierceForm Stud Installation System Works:
After aligning the PierceForm Stud Installation Head in the die it
is necessary to establish the proper shut height with respect to the
thickness of the panel being used. Use visual inspection of
the Stud installation as well as the Multifastener "Registry Marker"
for establishing the proper shut height and as a continuous means of
control installation integrity.
- A PierceForm Stud is sent into the Head via an air feeder.
The Stud is held in position by the PierceForm Stud Installation
Head until the customer part is in place, supported by the die
button and retainer, underneath.
- The Head is partially closed with the use of a valve.
Stud displaces part probe rod which activates sensor and signals
system controller that Stud is in position for installation.
- As the die closes, the nose of the installation head
contacts to the metal panel and the plunger inside the Head
begins to push the PierceForm Stud through the panel, piercing
its own hole.
- When the PierceForm Stud has penetrated the panel it
contacts the Die Button which forms the Stud barrel into a 360°
mechanical attachment onto the back of the metal panel.
You now have a complete radial engagement of the Stud to the
panel and, as the die starts to open, another cycle is ready to
start.
Note: The pierce slug is retained in the barrel of the Stud to
simplify die designs and eliminate scrap handling, with the
exception of an SBK Stud, which has no slug.
Tooling Requirements
PierceForm Head Assembly
| CPA/CSA |
-XX |
X |
-XXX |
-XXX |
| |
|
|
|
Identification Suffix |
| |
|
|
|
Indicates amount of extension in mm (15 mm
or 30 mm) |
| |
|
|
|
3 letter suffix indicates alteration |
| |
|
|
Component Number |
| |
|
|
00 indicates standard Head
Assembly |
| |
|
Stud Length |
| |
|
B1 = 12 - 19 mm long studs |
| |
|
C = 28 - 35 mm long studs |
| |
|
D = 36 - 50mm long studs |
| |
|
No Letter - 20 - 27 mm long
studs |
| |
Stud Diameter Number |
| |
Number indicates the assembly
used: |
| |
05 = M5 stud size |
| |
06 = M6 stud size |
| |
08 = M8 stud size |
| |
10 = M10 stud size |
| Head Type |
| CPA = PierceForm CP Stud |
| CSA = PierceForm CS Stud |
Die Buttons
| CPB/CSB |
-XX |
-XXX |
-XX |
| |
|
|
Identification Suffix (if required) |
| |
|
|
Indicates special or altered unit |
| |
|
Nominal Panel Metal Thickness |
| |
Stud Number |
Die Button Retainer
HRAM-32
Stud Feeder
| FP |
-2X |
-XXXXX |
-X |
| |
|
|
Valve Package Designation |
| |
|
Multifastener Stud Number |
| |
Tracks |
| |
2 = 2 track w/o aux. bin |
| |
2A = 2 track w/aux. bin |
| Feeder Type |
| FP = PierceForm Stud Feeder |
Registry Marker
MSM-26-30 - Use for all Stud Sizes
Electrical Proximity Probe Requirements
PFD-531A-4PNP Electrical Panel
MSE-85 Die Wiring Kit
Plastic Chuting
| PSC/SBK |
-XX |
-12 x 20' |
| |
Stud Number |
Pneumatic Control Valve
| PFD |
-76 |
-PX |
-120VAC (120 VAC Valve) |
| |
|
Number of Heads in Die |
| PFD |
-76 |
PX |
-24VDC (24 VDC Valve) |
| |
|
Number of Heads in Die |
* No letter indicates standard length
"Y" Nose Sub-Assembly
(Standard) |
| Detail No. |
Description |
Part No. |
No. Req'd |
| 1 |
Nose Assy. - "Y" Style |
CP-XX-01Y-XX |
1 |
| |
|
CS-XX-01Y-XX |
|
| |
|
CP-XXB1-01Y-XX ‡ |
|
| |
|
CS-XXB1-01Y-XX ‡ |
|
| 1.1 |
Nose - "Y" Style |
CP/CS-XX-01NY |
1 |
| |
|
CP/CS-XXB1-01NY ‡ |
|
| 1.2 |
Protection Sleeve |
PFD-XX-01S |
1 |
| |
|
SBKD-XX-01S |
|
| 1.3 |
Stop Pin |
PFD-COM-01P1 |
2 |
| 1.4 |
Nose Fingers |
PFD-XX-06 |
1 set |
| |
|
SBKD-XX-06 |
|
| 1.5 |
Internal Retaining Ring |
MS-174 |
2† |
| 1.6 |
Washer |
MS-175 |
2† |
| 1.7 |
Compression Spring |
MS-176 |
2† |
| 1.8* |
Nose Extension |
PFD-XX-01E-XX |
1 |
| 1.9* |
Roll Pin |
MS-164 |
2 |
| PFH Stud Holder Assembly |
| Detail No. |
Description |
Part No. |
No. Req'd |
| 1 |
Stud Holder Body |
PFH-XX-01-XX |
1 |
| 2 |
Part Probe Rod |
PFH-XX-02-XX |
1 |
| 3 |
Stud Holder Retainer |
PFH-COM-03 |
1 |
| 4 |
Back-Up Plate |
PFDS-COM-04 |
1 |
| 5 |
Lock |
MSM-25 |
1 |
| 6 |
Button Head Cap Screw |
MS-167 |
2 |
| 7 |
Proximity Probe Assy. |
PFD-COM-7PNP-CA |
1 |
| 7.1 |
Proximity Probe w/Male Quick Disconnect |
PFD-COM-7PNP-C |
1 |
| 7.2 |
Socket Head Cap Screw |
501311 |
1 |
| 7.3 |
Female Quick Disconnect w/Cable |
502353 |
1 |
| 8 |
Compression Spring |
MS-163 |
1 |
| 9 |
Socket Head Cap Screw |
501517 |
1 |
| Chute Attaching Block
Sub-Assembly |
| Detail No. |
Description |
Part No. |
No. Req'd. |
| 18 |
Detent Pin |
MS-162 |
1 |
| 9 |
Chute Adaptor Assy |
CP-XX-N23 -or-
CS-XX-N23 |
1 |
| 9.1 |
Chute Coupler |
CP-XX-44 -or-
CS-XX-44 |
1 |
| 9.2 |
Coupler Cap |
CP-XX-45 -or-
CS-XX-45 |
1 |
| 12 |
PierceForm Stud Chuting |
PSC-XX-12 -or-
SBK-XX-12 |
1 |
* For 15 and 30 mm Nose Extensions only
‡ For stud lengths 12-19m long
XX = Stud Size (Specify 05, 06, 08, 10, 12)
XX (bold) = Stud length range
12 (12-19 mm long studs)
20 (20-29 mm long studs)
30 (30-39 mm long studs)
40 (40-50 mm long studs)
Part Probe Rod Chart
| Stud Length |
Ext. |
Head Assembly Part No.* |
Part Probe Part No. |
| 12-19 mm |
STD |
CPA-XXB-00Y |
PFD-XX-13AY |
| CSA-XXB1-00Y |
| 12-19 mm |
15 mm |
CPA-XXB1-00Y-15 |
PFD-XX-13AY-15 |
| CSA-XXB1-00Y-15 |
| 12-19 mm |
30 mm |
CPA-XXB-00Y-30 |
PFD-XX-13AY-30 |
| CSA-XXB-00Y-30 |
| 20-27 mm |
STD |
CPA-XX-00Y |
PFD-XX-13Y |
| CSA-XX-00Y |
| 20-27 mm |
15 mm |
CPA-XX-00Y-15 |
PFD-XX-13Y-15 |
| CSA-XX-00Y-15 |
| 28-35 mm |
15 mm |
CPA-XXC-00Y-15 |
PFD-XX-13AY |
| CSA-XXC-00Y-15 |
| 28-35 mm |
30 mm |
CPA-XXC-00Y-30 |
PFD-XX-13AY-15 |
| CSA-XXC-00Y-30 |
| 35-50 mm |
30 mm |
CPA-XXD-00Y-30 |
PFD-XX-13Y-15 |
| CSA-XXD-00Y-30 |
| Base/Shank Sub Assembly |
| Detail No. |
Description |
Part No. |
No. Req'd. |
| 2 |
Shank |
CP/CS-XX-02Y-XX -or-
PFD-10-02-XX † |
1 |
| 3 |
Base Assembly
Sleeve Bearding PFD_xx-09 |
PFDS-XX-03 |
1 |
| 4 |
Back-Up Plate |
CP/CS-COM-04 |
1 |
| 5 |
Plunger |
PFD-XX-05-XX
SBKD-XX-05Y-XX |
1 |
| 6 |
Feed Housing |
CP/CS-XX-36-Y -or-
CP/CS-XXB1-36Y ‡ |
1 |
| 7 |
Proximity Probe Assembly |
PFD-COM-7PNP-CA |
1 |
| 7.1 |
Proximity Probe with Male Quick Disconnect |
PFD-COM-7PNP-C |
1 |
| 7.2 |
Socket Head Cap Screw |
501311 |
1 |
| 7.3 |
Female Quick Disconnect with Cable |
502353 |
1 |
| 8 |
Bushing - Feed Housing |
CP-XX-08 -or-
CS-XX-08 |
1 |
| 10 |
Cylinder Cap |
PFD-XX-26-XX |
1 |
| 11 |
Piston |
PFD-COM-27 |
1 |
| 13 |
Part Probe Rod |
See Rod Chart |
1 |
| 14 |
Plastic Tubing |
MSE-05 |
1 |
| 15 |
Plug |
MS-20 |
1 |
| 16 |
Retaining Ring |
MS-161 |
|
| 18 |
Compression Spring |
MS-163 |
1 |
| 19 |
Roll Pin |
MS-164 |
2 |
| 20 |
Spring |
MS-168Y-XX |
1 |
| 21 |
O-Ring |
MS-169 |
1 |
| 22 |
O-Ring |
MS-170 |
1 |
| 23 |
O-Ring |
MS-171 |
1 |
| 24 |
Hose Fitting |
MS-183 |
1 |
| 25 |
Button Head Screw |
500240 |
2 |
| 26 |
Spring Plunger |
503297 |
1 |
| 27 |
Dowel Pin |
N/A |
2 |
| 28 |
Socket Head Cap Screw |
N/A |
3 |
XX = Stud Size (Specify 05, 06, 08, 10, 12)
XX (bold) = Extension length in mm (15 or 30) leave blank for no
extension
CS part numbers in blue
† Shank for M10 studs only
‡ For stud lengths 12-199 mm long
Visual Inspection of the Stud Installation
CP Stud
- Proper Ram Setting - the flange of the Stud is 0.13mm to
0.25 mm below flush with the panel
- Too Light - The flange of the Stud is above flush with the
panel
CS Stud
- Proper Ram Setting - The post side of the Stud barrel is
flush to 0.20 mm below the panel.
- Too Light - the post side of the Stud barrel is above flush
with the panel
PierceForm Stud Head Set-Up Adjustments
During die tryout of the PierceForm Stud Installation Head (and
during normal operation) certain conditions may occur which may be
easily corrected.
No Stud Is Deposited in Panel (Causes)
- No Studs in Head (check Stud supply for obstruction in feed
system chuting)
- Head improperly assembled (check for proper assembly)
- Head failing to open fully
- Improper shut-height setting (check ram setting - nose
contacts base).
- Obstruction in chuting or chute attaching block (shut off
Stud flow and clear blockage at Feeder).
- Stud jammed in Head (remove chute attaching block and clear
jammed Stud from Head).
Head Fails To Open Fully (Causes)
- Check main compression spring.
- Check for obstruction in air port.
Air Pressure
- A constant air supply of 40-60 PSIG is required at air port.
This air supply will insure that the Head is in the proper
position before Stud installation.
Stud In Head - Press Will Not Cycle
Assembly/Disassembly
The PierceForm Stud Installation Heads may be easily repaired
using the following procedures. Most repairs can be
accomplished without removing the Head from the die or fixture,
keeping 'downtime' to a minimum.
Chute Attaching Block
Removal:
- Shut off Air/Deactivate Hopper Feeed before disconnect of
Chuting
- Remove Detent Pin
- Slide Chute Attaching Block Sub-Assembly off of Feed Housing
Bearing
Installation
- Slide Cute Attaching Block over Feed Housing Bearing
- Insert Detent Pin through Chute Attaching Block and Feed
Housing
Nose Assembly
Removal (turn off air)
- Support Nose/Assembly and push Roll Pins out of Feed Housing
and Nose Body
- Pull Nose/Assembly down off of Feed Housing
Installation
- Position Nose/Assembly up against bottom surface of Feed
Housing
- Insert Roll Pins into Nose/Assembly and through Feed
Housing. Turn on Air.
Feed Housing and Nose Body Assemblies
Removal
- Remove Chute Attaching Blcok as described previously
- Support Feed Housing and pull Feed Housing Bearing out of
Feed Housing
- Slide Feed Housing and Nose Body/Assembly off of Shank and
Plunger
Installation
- Position Feed Housing and Nose Body under Base
- Slide Feed Housing Bearing through Feed Housing and Shank
- Attach Cute Attaching Block as described above. Turn
on air.
Head Assembly
Removal
- Disconnect Plastic Tubing
- Disconnect Proximity Probe by loosening socket head cap
screw (SHCS)
- Remove Head Assy by removing socket head cap screws
- Tap base with soft hammer and pry from the die show dowel
pins
Installation
- Position base assembly on dowel pins in die shoes and
install SHCS
- Attach Proximity Probe with SHCS
- Attach Plastic Tubing. Turn on air.
Operation
The PierceForm Stud Feed System operates in unison with your
press equipment to produce Stud to panel attachments that are
consistent time after time. For details concerning each
component's setup and operation, plus maintenance and
troubleshooting procedures, contact your Multifastener sales
representative.
Components
System Controller - PLC
This unit controls all functions of the system. The timing of
all solenoid valves, the release of a Stud to the Installation Head,
and the sensing of a Stud within the Head are all sequenced through
this Controller. All functions are timed to take place within
single or continuous cycles. Note: if the speed of the
press is changed from original setting the controller must be
reprogrammed.
Feeder
Because PierceForm Studs are blown by air pressure from the feeder
to the Installation Head in the Feed System, the feeder can be
mounted at any level you choose. The Feeder has internal
solenoids that control the blowing of Studs to the Head Assembly.
Stud Guide
The plastic Stud Guide is connected between the Feeder and the
Installation Head. When setting up the system, careful attention
must be taken not to kink this component. Generally a three
foot radius is used to ensure efficient operation.
Installation Head
The PierceForm Stud Installation Head is mounted in the upper die
shoe of the press. It is air-controlled and designed to
accurately install PierceForm Studs using the mechanical force of
the press.
Die Button and Retainer
The Die Button is secured in a Retainer, which is mounted in the
lower die show. When the press closes, the Installation Head
punches the PierceForm Stud through the metal panel supported by the
Die Button. The Die Button forms the barrel of the Stud around
its circumference to securely lock it in place and coins the slug
into the barrel, thereby eliminating scrap disposal.
Pneumatic Control Valve
This system consists of a Solenoid, which controls the movement of
the Installation Head. The Solenoid is initiated through the
system controller. This timing shall be pre-set and adjusted
to the stroke and speed of your press.
Probing
The PierceForm installation system includes a probe in the
Installation Head which, when properly connected through the system
controller with the press, will prevent cycling the next stroke
unless a Stud is correctly positioned in the nose. Note:
The customer must monitor removal of stamping prior to the next
cycle of the press.
Maintenance Procedures - PierceForm Installation Head
Head Assemblies do not require continuous lubrication.
However, careful maintenance means longer product life and hours of
trouble-fee operation. Internal lubrication must be an
integral part of air supply system. It is recommended that a
thorough internal cleaning and lubrication be completed between
80,000 and 90,000 cycles. External lubrication should occur
every 25,000 cycles.
The head should be removed from the die and disassembled, as
outlined in "Assembly/Disassembly'> Clean all grease and metal
particles from parts. Coat parts with a lithium soap base
grease Molykote BRZ-5 or equivalent and reassemble the head.
Troubleshooting Chart
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