0590/07.02
Colly Components AB. Box 76, 164 94 Kista. Tel 08-703 01 00. Fax 08-703 98 41. www.colly.se
FLEXITOL®
Stepless Tolerance Compensation Systems
■ FLEXITOL® technology
■ Customer benefits
■ When to use which system?
■ System descriptions
FLEXITOL® metal
FLEXITOL® hybrid
FLEXITOL® plastic
■ Fields of application
■ Technical information
■ Contact form
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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 carry
out the final assembly. In the so-called modular construction, standardised parts are assembled to complete
systems (modular design principle).
As part of the corresponding development process, appropriate tolerances have to be defined so as to be able to
implement series production. High demands on the producer and customer sides regarding reliable functioning
and 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 optimised
solution.
FLEXITOL® technology
A tolerance compensation element consists of at least two components – an adjustment element and a fastening
element.
First of all, the tolerance compensation element is installed in the receiving part. On the following pages, different
installation 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 automatically
compensated.
The friction element serves to move the adjustment element. The adjustment element is connected to the fastening
element 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 without
deformation.
Mounting part
Receiving part
Screw
Adjustment
element
Fastening element
Compensation distance
Min. height
Friction element
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Customer benefits
Quality demands regarding the final product are ever growing. Especially apparent quality aspects such as gap
dimensions are becoming more important.
FLEXITOL® also allows higher production tolerances and therefore saves manufacturing costs upon component
production while preserving high quality.
As the effectiveness of tolerance compensation does not depend on changing influential factors, high performance
reliability 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
potential
Saving
Efficient tolerance compensation system
Saves costs and time
Assembly
Costs
FLEXITOL®
Assembly
Component
production
Conventional
installation
Component
production
Employment of
FLEXITOL®
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 application 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
High stability
Small installation
space
Large number
of pieces
Low weight
High temperature
resistance
Mounting in
plastic
Recycling
FLEXITOL® metal
FLEXITOL® hybrid
++
++
++
+
++
++
+
++
++
++
+
+
++
FLEXITOL® plastic
++
+
++
FLEXITOL® hybrid
FLEXITOL® plastic
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FLEXITOL® metal systems
FLEXITOL® metal was Böllhoff’s first step towards developing tolerance
compensation systems.
This two-component system is entirely made of metal and therefore highly wear
resistant. Due to the small space required for installation in the separation gap,
this solution may easily be integrated and even retrofit into an existing installation
space.
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 ➂
No fastening element required.
Adjustment and fastening thread may be integrated directly into the attachment part.
➀
➁
➂
FLEXITOL® metal – installation
➀
Spin on the
blind rivet nut
➁
Setting the
RIVKLE blind rivet nut
®
Insertion into
receiving part
➂
Setting
➃
Spin off
➀
Positioning of the
FLEXITOL® adjustment
element on the
setting tool
➁
Installation of the
FLEXITOL® tolerance
compensation
Insertion
➂
Screwing in
➃
Working FLEXITOL®
tolerance compensation
system
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FLEXITOL® hybrid systems
FLEXITOL® hybrid is a multi-component system mainly designed for use in large scale
production.
Due to its modular construction, a variation of different inserted heights and tolerance
compensation dimensions may easily be implemented.
To ensure high force transmission, the force transmitting components of the hybrid
solution (plastic / metal) are made of metal. They are enclosed by a nut cage made
of plastic.
Upon delivery, the system is pre-assembled and may be installed into the receiving
part 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.
➀
Insertion
and riveting
➁
Positioning
of components
Blind rivet solution
➂
Compensation
of tolerances
Fastening
the assembly
Clips version
➃
FLEXITOL® plastic systems
FLEXITOL® plastic consists of an adjustment element and a fastening element made
of plastic. It is delivered as a pre-assembled assembly.
The assembly is screwed (self-tapping) into a mounting hole in the plastic receiving
part.
The bayonet method is another possibility to insert the fastening element.
Here, FLEXITOL® plastic is inserted into a keyhole-shaped receiving opening and
latched with a quarter turn. The following installation is the same as for the
self-tapping method.
Ideally, the fastening screw may be a plastic UNITEC® K’ in K’ self-tapping screw or a
self-tapping metal screw.
➀
Insertion
and twisting
➁
Positioning
of components
K’ in K’-type
➂
Compensation
of tolerances
➃
Fastening
the assembly
Bayonet-type
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All for cars
All for cars
Fields of
application
Fields of
application
■ Front-end fastenings
(headlight installation)
■ Stress-free
glass sunroof
installation
M H P
M H
■ Flush-mount
installation of
body elements with
exact gap measures
(wing to door)
■ Compensation
of tolerances
upon tail-light installation
M H P
M
H
■ Precise
gearshift surround
installation
■ Outside flush
bumper installation
with respect to
adjacent body parts
M H P
M H P
■ Tolerance compensation at the door handle
M H
■ Stress-free seat runner
installation with
four-point
suspension
M H
M = FLEXITOL metal
H = FLEXITOL hybrid
P = FLEXITOL plastic
®
■ Door frame
(integral carrier)
M H
M H
®
®
■ Tension-free installation
of the instrument
panel carrier in correct
position
■ Fastening of
roof rails
■ Stress-free
installation of
large plastic covers
P
M H
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All for the industry
Fields of
application
■ Orientation of
screens with respect
to covering
M P
■ Tension-free
installation of
complex machine
housings
M P
■ Parallel
alignment of
drawer slides
M H P
■ Orientation of
cabin coverings in
commercial vehicles
M H P
■ Fine adjustment of
optical elements inside
laboratory instruments
M P
■ Tension-free
installation of drive
units in washing
machines
M H
M = FLEXITOL metal · H = FLEXITOL hybrid · P = FLEXITOL plastic
®
®
®
Technical data FLEXITOL® metal
Article no.
Size
Minimum height
Clamping range
Compensation distance
Head diameter
2611 005 0002
M5
3,0 mm
3 – 4 mm
7 mm - e
SW 13
Article no.
Size
Minimum height
Clamping range
Compensation distance
Head diameter
2611 006 0001
M6
2,5 mm
0,5 – 3 mm
11 mm - e
SW 24
Article no.
Size
Minimum height
Clamping range
Compensation distance
Head diameter
0031 910 0012
M6
3,0 mm
0,5 – 3 mm
10 mm - e
SW 17
Article no.
Size
Minimum height
Clamping range
Compensation distance
Head diameter
2611 006 0003
M6
3,0 mm
0,5 – 3 mm
10 mm - e
SW 17
Article no.
Size
Minimum height
Clamping range
Compensation distance
Head diameter
2612 006 0002
M6
3,0 mm
1 – 4 mm
10 mm
SW 16
Article no.
Size
Minimum height
Clamping range
Compensation distance
Head diameter
2611 008 0001
M8
4,0 mm
0,5 – 3 mm
11 mm - e
SW 20
Article no.
Size
Minimum height
Compensation distance
Head diameter
Special
2640 006 0005
M6
1,5 mm
6 mm
SW 17
Installation directly to receiving
part, manual tolerance
compensation
Article no.
Size
Minimum height
Compensation distance
Head diameter
Special
2640 006 0004
M6
1,5 mm
6 mm
SW 17
Installation directly to receiving
part, automatic tolerance
compensation
e = material thickness receiving part
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Technical data FLEXITOL® metal
Mechanical insertion tool with
hydraulic-pneumatic drive for
medium 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:
2661 530 0001 P 2001 LH
2361 550 1002 P 2005 LH
Manual installation tool
for small series
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
Operating mode:
Manual rivet setting tool with crossed gears. Manual spindling and removing of blind
rivet 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
Technical data
FLEXITOL® hybrid
Article no.
Size
Min. high
Compensation
distance
Head
diameter
Tightening
torque
2707 080 1026
M8
16 mm
8 mm
31 mm
25 Nm
Other dimensions and connection methods possible.
Feel free to contact our application engineering department.
FLEXITOL® plastic
Article no.
2704 050 1001
Tolerance
compensation
extrusion force
K’ in K’
thread
pressure force
Compensation
distance
Self-tapping
screw tightening
torque
4,000 N
mind. 1,000 N
6 mm
2.5 Nm
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 Nm
Exact values have to be adapted to the individual application.
Feel free to contact our application engineering department.
Screw-in tool: 2799 000 1028
FLEXITOL® plastic bayonet
Article no.
2705 050 1021
Tolerance
compensation
extrusion force
Max.
axial thrust
Compensation
distance
Self-tapping
screw tightening
torque
4,000 N
2,000 N
6 mm
2.5 Nm
Material thickness: 1.5 mm
■ Screw-in torque: 3.0 Nm
Exact values have to be adapted to the individual application.
Feel free to contact our application engineering department.
Screw-in tool: 2799 000 1028
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Colly Components AB. Box 76, 164 94 Kista. Tel 08-703 01 00. Fax 08-703 98 41. www.colly.se
Contact form
■ Date
■ Company
■ Address
■ Phone
■ Fax
■ E-mail
■ Application / customer identification
■ Runtime
■ Annual production run
■ Sample / number
Mechanical requirements
Screw tightening torque
Thread size
D
Compensation distance
T
Inserted height
H
Max. length
Notes
MA
Lmax.
Material thickness
S1
Fastening element head diameter
D1
Adjustment element head diameter
D2
Material part 1
S1
Material part 2
S2
Nm