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During the assembly of complete vehicles and automotive parts, a large quantity of hexagonal-head (external hex) bolts is used for fastening. As labor costs rise and Industry 4.0 smart manufacturing accelerates, many manufacturers have begun adopting automatic screw-feeding and tightening equipment to meet the demands of modern, high-volume production and full automation. For hexagonal-head bolts whose length-to-diameter ratio is either too small or too large to be conveyed by air-blow feeding, the prevailing solution is vacuum pick-and-place tightening: the bolt is separated by a screw feeder to a designated position or blown to a pick-up station; once the bolt is in place, a motion mechanism moves the pick-and-place tightening module to the bolt location, vacuum is turned on to pick up the bolt; after vacuum detection confirms the bolt is secured, the module moves to the tightening station, the tightening cylinder actuates, the tool starts and completes the tightening cycle, then resets.

However, vacuum pick-and-place tightening of hexagonal-head bolts often presents several problems. During tightening, the socket must rotate while descending to align the six sides of the bolt head with the six sides of the socket; vacuum leakage can cause this engagement to fail. Bolts with spring or flat washers can tilt easily, and the bolt can drop during module movement, denting the product. In addition, poor part-to-part consistency of the vehicle body can lead to inaccurate positioning of bolt holes. All these factors affect bolt tightening quality. Danikor’s automatic hexagonal-head bolt tightening technology effectively resolves these issues.

Improving “cap-recognition” (engagement) success

Danikor optimized the dimensions and structure of the tightening socket head. The external hex head of the bolt meshes precisely with the internal hex of the socket, achieving positive engagement and significantly increasing both the efficiency and success rate of cap recognition.

Preventing bolt dropping

During vacuum pick-up, a unique suction-seat sealing structure and through-hole design keep the inside of the vacuum tube connected to the vacuum source, ensuring stable bolt retention. The system can also monitor whether the bolt has dropped during motion.

Correcting positional inaccuracies

For tightening processes where positioning is inaccurate, Danikor employs a “blow-plus-suction” floating socket technology for the hexagonal head. Multi-directional floating with a defined float range can accommodate a certain positioning error, significantly improving hole entry and tightening success rates. This eliminates the need for additional camera-based positioning, shortens cycle time, and delivers cost savings and efficiency gains for customers.