Бенлонг 
Автоматический клепальный станок для настенного выключателя с серебряным контактом
Automatic wall switch silver contact riveting machine with servo drive and vision positioning (±0.02mm). Feeds and rivets silver dots (1‑8mm) onto switch/socket terminals. Multi‑point riveting. Reduces defect rate from >2% to <0.2%. Customizable. Ideal for high‑volume switch assembly.
Full Automatic Wall Switch Silver Contact Riveting Machine
The machine features the latest technology in stationary and mobile equipment installations, manufacturing operations and is completely customizable based on your manufacturing application. The basic principle of operation of this silver contact wall switch automatic riveting machine is the same as with all riveting machines: it rivets a silver contact onto a wall switch or other low voltage electrical part using a high precision, fully automated process using a servo motor driving the machine and an integrated vision system for high speed placement and stability of the parts being riveted together. This machine provides high quality production through its high speed, high accuracy and consistent rivetting process and is well-suited for use in the electronics manufacturing industry or on switch assembly lines.
Automatic feeding and sorting of silver contacts, as well as multi-point riveting (one or more contacts per switch), together with integrated quality assurance for burr-free and secure joints, are among the key features of this machine. The servo-driven riveting head guarantees consistent depth and pressure, which eliminates the variability introduced by either manual or pneumatic riveting; leading to reduced material waste, lower labour costs, better electrical performance (low contact resistance) and long-term reliability of the finished switches. The machine is designed as a non-standard custom solution; it will be built to suit your specific switch base geometry, number of contacts and production volume requirements.
Standard delivery: 30-45 days | Vision accuracy ±0.02mm | Multi‑point riveting available
What is a Wall Switch Silver Contact Automatic Riveting Machine?
An automatic riveting machine for wall switch silver contact is a specialized automated assembly process for the permanent attachment of silver alloy contacts (silver dots) to the conductive terminals of wall switches, sockets and similar low‑voltage devices. The silver contacts are automatically fed and sorted, precisely positioned on the target terminal with the aid of a vision system, and riveted into place using a servo controlled press. Riveting with a machine will create consistent rivet head formation and burr free joints with the required precision of contact height that is necessary for low contact resistance and long switching life. The machine has the capability of single or multiple riveting points on each switch (1 to 4 contacts) and is intended to be used for continuous high volume production. Since this is a non standard custom solution, we will tailor the feeding system, riveting tooling and vision program to your exact switch design.
Programmable force, depth, and speed for consistent joint quality.
High‑resolution camera (up to ±0.02mm) aligns contacts precisely.
Vibratory bowl feeder sorts and supplies silver contacts (1‑8mm diameter).
Rivet multiple contacts per switch in one cycle with independent tooling.
Riveting Process & Key Features
Технические характеристики
| Riveting application | Silver contact (Ag, AgNi, AgSnO2) to copper/brass terminals of wall switches, sockets, or similar |
|---|---|
| Silver contact diameter | 1.0mm – 8.0mm (custom tooling for other sizes) |
| Riveting force | 100 – 1,000 N (servo‑controlled, programmable, accuracy ±3%) |
| Riveting stroke | 10 – 50mm (adjustable) |
| Vision positioning accuracy | ±0.02mm (repeatability) |
| Number of riveting points | 1 to 4 points per switch (customizable)None |
| Система подачи | Vibratory bowl feeder for silver contacts; manual or automated switch base loading – |
| Cycle time | Approx. 1.5 – 3.0 seconds per rivet (depending on contact size and number of points) |
| Контроль качества | Riveting force/displacement curve, optional vision check of rivet head formation– |
| система управления | PLC (Siemens/Mitsubishi) with HMI, recipe storage for 20+ switch models…… |
Core Technical Advantages (What Problems It Solves & Value Delivered)
Problem: Inconsistent rivet quality & high defect rates
Solution: Servo‑controlled force and depth, combined with vision alignment, eliminate the variability of manual riveting or pneumatic presses. Value: Defect rates reduced from >2% to <0.2%, lower rework, and higher customer satisfaction.
Problem: High labor cost & operator fatigue
Solution: Fully automatic feeding, riveting, and unloading. One operator can run multiple machines. Value: Labor cost reduced by 60‑80%, elimination of repetitive strain injuries.
Problem: Burrs or cracks on riveted contacts
Solution: Servo riveting with soft‑landing profile and optimized tool geometry produces burr‑free, stress‑crack‑free joints. Value: Improved electrical contact (lower resistance) and longer switch life.
Problem: Difficulty switching between different switch models
Solution: Recipe‑based changeover via HMI and quick‑change riveting tooling. Value: Changeover time under 20 minutes, allowing flexible production of multiple SKUs.
Customer Success Story – Switch Manufacturer
A prominent brand in Europe for wall switches had a field failure rate of 2.5% due to the looseness of the silver contacts as a result of the manual riveting operation not consistently applying the correct riveting pressure. After using our automatic riveting machine with servo force control and vision positioning for silver contacts, they have produced:
The machine serves itself within 9 months and solves all of our customers’ complaints about loose contacts.
Applications and Typical Components
Разработка и поставка по индивидуальному заказу
Request a Custom Silver Contact Riveting Quote
Provide us your switch base samples and silver contacts. Our design team can create a customized machine to attach or rivet your new switch base plates to the existing plates using a vision system for alignment as well as multiple point capabilities, plus calculate the full Return on Investment (ROI) for this project.
WhatsApp: +86 150 5837 0007 | Электронная почта: xsb@benlongkj.cn | Поддержка на английском и китайском языках
Why Choose Benlong for Silver Contact Riveting?
- Более 15 лет опыта в дизайне. automatic riveting machines for low‑voltage electrical components
- Proven servo + vision technology for ±0.02mm positioning
- Multi‑point riveting capability (up to 4 contacts per cycle)
- In‑house feeder and riveting tooling design – quick turnaround
- Глобальная сервисная поддержка и поставка запасных частей.
Типичная машина, изготовленная на заказ, включает в себя:
This machine includes the following components:
– Silver contact vibratory bowl feeder
– Vision camera system (5MP maximum)
– Servo Rivet Head (Force Range 100-1000N)
– Indexing Table or Linear Conveyor
– PLC with HMI (Siemens)
– Safety enclosure
– Changeable tooling package
– Reject bin
– 1-Year Warranty
Часто задаваемые вопросы
Through our Precision Computerized Vision System, the servo rivet head can reliably and accurately pinpoint the exact location of each target rivet hole or terminal on the base of the switch and make adjustments based on distance differences from all angles of the switch from its assembly to completion, eliminating the possibility of misriveting contacts that could lead to high resistance or loose connections.
Our standard machine accommodates multiple diameter ranges (2‑6mm) with one bowl & tooling setup for feeding and riveting. Tooling kits for extreme difference in size (i.e. 1mm and 8mm) will come with quick change tooling kits. Changeovers take less than 15 minutes.
Before proceeding with riveting, the system utilizes its vision capabilities to confirm contact is present. Any absence of a contact will result in the machine not completing the rivet at that location and optionally initiating an alarm. Automatically sorted rejected parts will be deposited into an isolated bin for manual inspection.
In a plant manufacturing 5000 switches every day, the typical return on investment will be approximately six to ten months due to savings in labor (in replacing 3-4 manual riveting machines) as well as a lower waste rate (1-3% with manual compared to automated).
Using either a conveyor or other method, the machine can receive switch bases directly from any injection molding machine or an earlier stage of production. And we can provide I/O handshaking or Ethernet communication (Modbus TCP, Profinet) allowing for completely integrated in-line production.
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