Automated Rivet Die Inspection in Body Assembly

The Task

In automotive body manufacturing, punch riveting is a common joining method. In this process, high force is applied using pliers to press a rivet into a counterholder, known as the die. The rivet deforms, creating a strong mechanical bond between sheet metal components. Over time, dies are subjected to intense mechanical stress, which can lead to contamination or breakage. Traditionally, they’ve been replaced at fixed intervals—whether worn or not. The goal of this automation solution is to eliminate that inefficiency by implementing intelligent, sensor-based inspection. Dies should only be replaced when they are truly damaged or significantly worn, not just as part of a scheduled cycle.

The Challenge

The inspection of dies presents several difficulties. First, they are often made of shiny metal, which can interfere with reliable detection. In addition, available space within machines or tools is usually very limited, making it difficult to integrate additional components such as sensors. The wide variety of die shapes, sizes, and potential defects, such as cracks, breakouts, and contamination, adds further complexity. An effective inspection system must be able to detect all of these issues with high reliability.

Our Solution

The VISOR^® Object vision sensor enables fast and reliable detection of damaged or contaminated dies during production. With its powerful contour inspection and BLOB detector tools, the sensor can precisely identify breakouts, cracks, and shape deviations, as well as detect contamination on flat surfaces, even when dealing with shiny metal materials. Combined with an external ring light, the sensor delivers stable and consistent evaluation, even under challenging lighting conditions. Thanks to its compact design, the VISOR® can be easily integrated into existing systems, even when installation space is limited. The job change function also allows different die variants to be inspected using the same device.

Rather than replacing all tools on a schedule, only dies that are actually damaged or dirty are exchanged. This targeted approach helps reduce material costs, minimize downtime, and shorten setup times. The solution also supports predictive maintenance strategies and improves overall system availability.