Benlong 
What is a Contactor Riveting Machine Benefits Specifications and Industry Applications
Specialized Industrial Equipment for Riveting Contactors – The contractor riveter is designed exclusively to create permanent connections between contact tips typically composed of silver-alloy material and terminals, springs or armature components comprised of copper or brass (see Figure 3). Unlike conventional riveters, contractor riveting machines are dedicated to the assembly of small and fragile pieces while maintaining mechanical and electrical reliability.
To put it simply, this is the machine that ensures that the contacts in the contactor remain tightly fastened for many millions of switchings. If the riveting is not done properly, the contact tips can become loose, causing an increase in contact resistance, creating arcing and/or overheating, and ultimately failing in service.
How does a contactor riveting machine work?
The traditional procedure consists of inserting a rivet or contact tip into a carrier part (for example, a copper-blade) that has had a pre-punched hole in it, followed by deforming the tail of the rivet to achieve permanent mechanical attachment. Most contemporary equipment utilizes either servo-electric or hydraulic servo technology for accurate control of force, stroke length and rate of movement. Key steps:
- Part feeding: Contact tips and carrier parts are fed via vibratory bowls or trays.
- Positioning: Sensors ensure correct alignment of the tip and hole.
- RivetingThe press typically applies two-stage profiles, by first using high speed approach and then transferring to low speed forming; this provides greater control over how much force gets applied and at what rate while forming metal part on the Machine.
- Monitoring: In-line force-displacement curve analysis rejects out-of-spec joints.
Core components of a contactor riveting machine
- Servo press head: Provides programmable force and stroke.
- Tooling (punch & anvil): Custom-designed for specific contact tip shape and size.
- Fütterungssystem: Bowl feeder, tape feeder, or pick-and-place.
- Force-displacement sensor: Monitors each rivet in real time.
- PLC + HMI: Controls recipes, data logging, and fault detection.
- Optional: Vision system for post-rivet inspection.
Key benefits of using a dedicated contactor riveting machine
- Defect rates below 0.1% – compared to 2-5% with manual riveting.
- 100% traceability – every joint recorded with force/displacement data.
- Consistent contact resistance (typically <0.1 mΩ) – critical for high-current applications.
- Fast changeover (<10 minutes) between different contactor models.
- Reduced operator fatigue and injury risk (ergonomic).
- Payback period usually 6 to 14 months for medium to high volumes.
Technical specifications you should know
When selecting or comparing machines, look for these specifications:
| Specification | Typical range | Why it matters |
|---|---|---|
| Riveting force | 500 N – 30 kN | Must match contact tip size and material hardness |
| Stroke length | 50 – 200 mm | Longer stroke needed for deep components |
| Force accuracy | ±1% of reading | Ensures consistent deformation |
| Displacement repeatability | ≤±0.01 mm | Avoids under-/over-riveting |
| Sampling rate | ≥1000 Hz | Detects micro-cracks |
| Cycle time | 1.5 – 5 seconds per rivet | Depends on automation level |
Industry applications of contactor riveting machines
These machines are used in manufacturing of electromagnetic contactors. Some examples of the major industries that utilize these machines include:
- HVAC & refrigeration – contactors for compressors (high volume, cost-sensitive).
- Industrial motor control – contactors for motor starters (require long mechanical life).
- EV charging infrastructure – DC contactors for fast chargers (demand low contact resistance).
- Renewable energy (solar/wind) – grid contactors exposed to harsh environments.
- Railway and transportation – main contactors for trains (require vibration resistance).
- Stromverteilung – AC contactors for capacitor banks and switchgear.
Who manufactures contactor riveting machines?
Several global and regional companies specialize in this equipment. Examples include:
- Benlong Automation (China) – Known for servo-driven, MES-integrated solutions for low-voltage electrical components.
- BalTec (Switzerland / USA) – Radial riveting technology for delicate parts.
- Schmidt Technology (Germany) – High-force servo presses.
- Promess (USA) – Electro-mechanical assembly presses with advanced monitoring.
- TOX PRESSOTECHNIK (Germany) – Pneumatic and servo riveting systems.
The price range of machines will depend largely on how customized they are. A few factors affecting pricing: 1) single-station vs. rotary-table; 2) ability to incorporate vision into the machine; etc.
Price range (indicative, 2025)
Prices are for new equipment and vary by region and customization. Approximate ranges:
- Benchtop semi-automatic unit: $8,000 – $18,000
- Single-station automatic machine (servo): $25,000 – $55,000
- Rotary indexing table with dual heads: $60,000 – $120,000
- Fully integrated line (including feeding & vision): $150,000+
Refurbished or used equipment may vary by as much as 30-50% from new prices, however, it’s important to evaluate the equipment’s calibration status and its availability of spare parts.
Häufig gestellte Fragen (FAQ)
What is the difference between a contactor riveting machine and a standard riveting press?
Standard presses generate pressure, but do not offer any form of force/displacement measurement or even custom tooling for the manufacture of tiny silver tips. Furthermore, the machines that manufacture contract-specific products are designed to gently process very delicate plastic housings while also providing traceability data per automotive/IEC regulations.
Can one machine handle multiple contactor sizes?
Definitely, but only if they have both quick change tooling and also recipe storage. Typically, you are looking at about 5 to 15 minutes to change over. If you are changing to a very different component size (e.g., a 9A vs 200A frame) it is much more effective to have separate dedicated machines.
How long does a typical machine last?
With proper upkeep, machines controlled by servos could run for more than 10 million cycles. The punch, anvil and guide bushings are critical wear parts that require replacement roughly every 500,000-1 million cycles.
Does the machine require compressed air?
Air is sometimes utilized for feed or clamp purposes for riveting; however, riveting forces are produced through a servo motor (electric). Fully electric versions do not require any air.
What about training and installation?
A lot of suppliers will offer onsite support (2 to 5 days) with a yearly guarantee. It is also common practice to use remote assistance through a VPN. A spare parts kit that contains frequently worn components is helpful as well.
A contactor riveting machine is an important part of making high-quality, long-lasting electromagnetic contactors with consistent, reliable performance, and is an alternative to manual (or general) methods of riveting. Using a contactor riveting machine results in defect rates less than 0.1%, full data traceability, and typical payback periods of less than 14 months. When evaluating contactor riveting machines, consider force range, repeatability of displacement, and the speed of sampling. Major industries utilizing these machines include HVAC, EV charging, industrial automation, and rail. Basic benchtop models start at about $8,000 to more than $150,000 for completely automated lines. If evaluating machinery for your production process, make sure to complete a trial run of your parts and ensure that the supplier has the capability to support you with custom tooling and any type of after-sales service.
