BTM ULBG 452-18 User manual
BTM Scandinavia AB ●Franska vägen 32 ●S-393 56 KALMAR ●Tel: +46 480 868 75 ●www.btmscand.se
IMPORTANT!
Read this manual in its entirety before using the system.
1.0 CONTENT
Sektion 1: 1.0 Content
1.1 Marking
1.2 Foreword
Sektion 2: 2.0 Manual
2.1 Safety information
2.2 Safety instruction
2.3 Product description
2.4 Function description
2.5 Material
2.6 Checklist for operator
Sektion 3: 3.0 Tooling
3.1 Control of clinch tools
3.2 Terms and definitions
3.3 Tool list
3.4 Change of clinch tools
3.5 Setting of CT, button diameter
3.6
3.7 Clinch parameters, Sample Process Sheet
Sektion 4: 4.0 Quality
4.1 Quality control tooling
4.2 Trouble shooting
Sektion 5: 5.0 Maintenance
5.1 Periodic maintenance
5,2 Error codes
Sektion 6: 6.0 Mechanics
Recommended spare parts
BOOM lists
Sektion 9: 9.0 Data sheets
Sektion 10: 10.0 CE-Marking
10.1 Declaration
BTM Scandinavia AB ●Franska vägen 32 ●S-393 56 KALMAR ●Tel: +46 480 868 75 ●www.btmscand.se
1.1 Marking
Customer:
Job No:
Model: BTM Battery powered hand machine
ULBG452
Machine No.
Supplier: BTM Scandinavia AB
1.2 Foreword
This manual should be used as a general instruction and assistance for maintenance
and operations staff.
The manual also contains description of Clinch tools its inspection and maintenance
as recommended. As an additional help for maintenance are drawings and parts lists.
Components and spare parts ordered from BTM Scandinavia AB
1. The punch must always be in its original position, posterior position. The punch is
hidden and protected by the holder (stripper). Punch tip is 1,3mm behind the holder
surface, to enable the punch to be protected from damage, and that the material is
compressed before Clinch process.
2. Never try to make a Clinch through another Clinch, through a spot weld or other
obstacles.
3. Never make a connection in stainless steel with these tools.
It is vital that the operator and maintenance personnel read this manual to become
familiar with Clinch equipment and associated tools
BTM Scandinavia AB ●Franska vägen 32 ●S-393 56 KALMAR ●Tel: +46 480 868 75 ●www.btmscand.se
2.0 OPERATOR MANUAL
2.1 Safety information
This instruction applies for BTM Battery powered hand held unit ULBG452
This unit is specially designed for clinching with BTM Tog-L-Loc system®.
Operating personnel are expected to have read and understood the safety
instructions supplied with this equipment, be familiar with the location and operation
of each safety component, to be trained in the safe use and be aware of the risks that
are specific to this type of equipment.
The machine requires the following connection
a) Rechargeable battery Li-Ion 18V
2.2 Safety instruction
2.2.1 User responsibility
Every person who operates or maintains this unit/machine must know this and all
other safety measures before using or servicing equipment.
The owner of the equipment is responsible for the safety and education of all staff.
Read this manual carefully
2.2.2 Safety system
Do not alter or modify the control system in any way. If no monitoring function or
actuators are damaged or not functioning as it should, the use of the machine to
cancel immediately. Do not use the equipment until it has been inspected and
repaired, and tested by qualified and trained personnel.
BTM Scandinavia AB ●Franska vägen 32 ●S-393 56 KALMAR ●Tel: +46 480 868 75 ●www.btmscand.se
GENERAL WARNINGS AND INFORMATION SECURITY.
NOTE! Unintentional operation or a damaged controller can lead to serious injuries.
NOTE! Always keep your hands away from the work area.
NOTE! Always follow instructions and procedures accurately and disconnect the unit
from the power source, before inspecting or servicing the equipment.
NOTE! Beware of moving parts.
NOTE! Do not use the machine standing in water or in wet environment.
Spare parts: Use only original BTM components to this system.
Warning messages: If the safety signs or warning signs on the machine are worn or
damaged, ensure exchange before using the equipment.
Personal Protective Equipment (PPE):
No special personal protection equipment is required to operate the machine.
2.2.3 General
Never attempt to join something other than what your tools are specified for.
Never try to make a Clinch through another Clinch or by a spot weld, rivet, or other
obstacles. This will damage the tools.
Never try to make a Clinch more than once. This will damage the tools. If there are any
doubts about joint design, always remove the work and inspect.
Never try to make a Clinch of stainless steel. This will damage the tools
BTM Scandinavia AB ●Franska vägen 32 ●S-393 56 KALMAR ●Tel: +46 480 868 75 ●www.btmscand.se
2.4 Function description
The equipment is intended for joining steel. Material combinations accoding to
material list, see section 2.5
Clinh-Tools for this purpose isTog-L-Loc® 3,8.
The hand held unit power supply is done with a rechargeable battery The battery
capacity is approximately 200 strokes per charge. The battery can be recharged in
approximately 30 min.
The hand-held units weight is about 2,3 kg, which allows for use without a balancer.
Below is a general description of the steps involved in joining two plates/profiles with
Tog-L-Loc®
Pull the C-frame over the plates to be joined, place the punch and the die where you
want to clinch.
Press start button, hold down until the punch turns. The reversal takes place automatically
after reaching the moment.
Start
BTM Scandinavia AB ●Franska vägen 32 ●S-393 56 KALMAR ●Tel: +46 480 868 75 ●www.btmscand.se
2.5 Material
Material thickness: 0,7 –2,0mm
Clinching Max combined thickness 3,0mm
When mixing material thickness always the thicker material must be on the punch-
side and the thinner material at the die-side.
BTM Scandinavia AB ●Franska vägen 32 ●S-393 56 KALMAR ●Tel: +46 480 868 75 ●www.btmscand.se
2.6 Checklist for operator
1. Check continuously that the Tog-L-Loc® tools are unharmed
a) Punch without pressing cracks
b) Stripper without damages
c) Die without taps, whole leafs
d) The Elastomer (blue ring) provides good resiliense of the spring
e) Clean and remove dirt
Die
Elastomer
Stripper
Punch
BTM Scandinavia AB ●Franska vägen 32 ●S-393 56 KALMAR ●Tel: +46 480 868 75 ●www.btmscand.se
3.0 Tooling
3.1 Tool check
1. Constantly check that the Tog-L-Loc® tools are not damaged.
Check the condition of the punch, look for signs of damage. If it is damaged,
replace the damaged part with a new one, follow the instructions that are
provided later in this section.
Check the condition of the die. Make sure the blades are properly closed and
is not kept open because of dirt or other debris. If so, remove and clean the
die as instructed later on in this section.
Check the condition of the elastomer. If signs of wear, dehydration or visible
cracks, elastomer needs to be replaced. See instructions later in this section.
Check the dimension of the joint, Button Cap Thickness and Button Diameter.
If not in accordance mesuring what is recommended, contact BTM
Scandinavia for additional support.
CT
Tn –Hals T f –Låsning
CT –Knapptjocklek, restmått h –Knapphöjd
BD - Knappdiameter
BTM Scandinavia AB ●Franska vägen 32 ●S-393 56 KALMAR ●Tel: +46 480 868 75 ●www.btmscand.se
3.2 Terms and definitions
A.D. (Anvil Depth)
The die depth is the measurement from moving blade edge down to the bottom in the die. This
dimension is fixed and present of BTM for each specific application. A shallow-AD causes a bad
interlock (latching) and therefore lower peel strength. With a deep-AD the wall thickness at the
"neck" thin, this leads to a non-optimal shear strength.
B.D. (Button Dimension)
The diameter, at the back of the joint can be used as a non-destructive test of the joint
strength and quality. The optimal measure is a compromise between strength and tool life, this
measure of tolerance defined by the BTM.
C.T. (Cap Thickness)
The button thickness or residual measure the thickness of the material between the punch and
die when tools are together in reverse mode. The optimal measure is a compromise between
strength and tool life, this measure of tolerance is set by BTM for each specific material
combination.
PTR. (Punch Tip Radius)
The punch tip radius is an important parameter for a Tog-L-Loc ® punch. A small PTR used for
thin material, a large PTR is used for thick material, or when thin material is joined with a thick
material.
Stripper/Stripper Force
The “stripper” or scraper should close tightly the the punch tip to ensure a proper shaping of
the material, it is also important that the plates are pressed hard against each other. After the
joint the scraper pull the material from the punch. Preload and stripper force is dependent on
the material and thickness.
S.H. (Shut Height)
Shut Height is the lower position where the tool stops against the stop. By ensuring that this
positions is solid and repeatable, so CT and BW maintain its set dimension and optimal value -
which in turn ensures a consistent quality of the joint.
CT is the main measure to control, depending on the material thickness variation affects the
diameter (BD)
BTM Scandinavia AB ●Franska vägen 32 ●S-393 56 KALMAR ●Tel: +46 480 868 75 ●www.btmscand.se
3.4 Tool change
All tools are signes with an article numner. After every tool change, check wether the article
number of the new tool is correct. Wrong tool may cause problems as decreasing the strenght
of joints and the life time of a tool.
3.4.1 Disassembly of C-frame
1. Remove battery from the power unit.
2. Losen the 2 allen screws (M4) on the ring between the power unit and the C-frame (pic
1).
3. Remove C-frame by turning counterclockwise from the power unit.
Pic 1
Skruv M4
BTM Scandinavia AB ●Franska vägen 32 ●S-393 56 KALMAR ●Tel: +46 480 868 75 ●www.btmscand.se
3.4.2 Change the die
1. Remove battery from the power unit.
2. Remove the C-frame, section 3.4.1.
3. Remove the die by losening the mounting screw (pic 3).
4. Make sure it is the right article number of the new die
5. Mount the new die, tighten the mounting screw and mount the C-frame (section 3.4.4)
Pic 2 Pic 3
Pic 4
BTM Scandinavia AB ●Franska vägen 32 ●S-393 56 KALMAR ●Tel: +46 480 868 75 ●www.btmscand.se
3.4.3 Change the punch.
1. Remove battery from the power unit
2. Remove the C-frame see section 3.4.1.
3. Loosen the allen screw which hold the punch (pic 5).
4. Remove stripper from the punch (pic 6)
5. Make sure it is the right article no at the new punch
6. Mount the new punch, tighten the mounting screw
7. Montera den nya stansen, dra åt låsskruven (bild 5).
8. Återmontera C-bygeln, se avsnitt 3.4.4.
Kontrollera CT (knappens tjocklek) och/eller BD (knappens diameter) mått efter varje byte av
stans eller dyna.
Pic 5 Pic 6
Pic 7
Stripper
BTM Scandinavia AB ●Franska vägen 32 ●S-393 56 KALMAR ●Tel: +46 480 868 75 ●www.btmscand.se
3.5 Setting CT, Cap Thickness and BD, Button Dimension
Button diameter (BD) and Cap thickness (CT) is firmly adjusted by BTM before delivery. If these
measurements differ with more than +/- 0,3mm from the recommended values, check that the
punch and the die are flawless. Is it still anomalies, please contact BTM Scandinavia AB for
support.
3.7 Clinch parameters
Periodically check that CT (thickness of the button) and BD (button dimension) is consistent
with the values (JD, Joint data) Sample process sheet.
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