As the manufacturing industry upgrades to high-end and large-scale production, engineering machinery, agricultural machinery, energy equipment and other fields have increasingly stringent requirements for the heavy-load capacity, vibration resistance, weather resistance and mass production efficiency of core structural connections.
From excavator arms to wind power towers, from agricultural machinery frames to nuclear power pressure vessels, traditional welding is prone to thermal deformation and stress cracks, bolted connections are prone to loosening under high-frequency vibration, and manual riveting is inefficient and uneven in quality, making it difficult to adapt to extreme working conditions.
Dunchuan (QUESTOK) rivet gun relies on core technologies such as hydraulic servo pressure control, ring groove high-strength fastening, and adaptive dissimilar material connection, and uses cold forming technology to build a “high-strength, long-life, traceable” connection solution. It runs through the entire process of mechanical equipment design, mass production, installation and maintenance, and has become the core equipment for leading companies to improve quality and efficiency.
Core Scenario 1: Heavy-duty structural assembly of engineering machinery
Core components such as excavator arms, loader frames, and crane booms need to withstand hundreds of tons of load and high-frequency impact vibration. Traditional welding processes are prone to produce heat-affected zones, leading to material embrittlement. Under long-term heavy loads, 30% of the connection points are prone to micro-cracks; bolted connections require regular tightening, resulting in high maintenance costs.
Industry data shows that the defect rate of traditional connection of construction machinery reaches 8%, of which failures caused by loose vibration account for more than 70%.
Dunchuan Hydraulic Servo Ring Groove Rivet Gun solves the pain point of heavy load in a targeted manner. It is equipped with high-strength alloy ring groove rivets and forms a permanent locking structure through the “high-pressure extrusion – collar filling” process. The shear strength reaches 50-80KN, which is 45% higher than ordinary bolts. It has passed 2 million fatigue vibration tests without loosening, and meets the service life requirements of engineering machinery for more than 10 years.
The equipment is equipped with a double closed-loop pressure control system with a pressure error of ≤±1.5%. It can automatically match 50-200KN pressure parameters according to 3-12mm thick steel plates and cast steel base materials. Single-point riveting only takes 3-4 seconds. It is adapted to the automated production line to achieve efficient operations of 8 pieces/minute.
After the introduction of a head construction machinery factory, the boom assembly repair rate dropped from 8% to 0.5%, saving more than 3 million yuan in annual maintenance costs, and reducing labor costs by 40%. It perfectly adapts to the flexible mass production needs of multiple types of equipment.
Core Scenario 2: Corrosion-resistant and anti-vibration assembly of agricultural machinery
Agricultural machinery and equipment such as tractor chassis, harvester headers, and seeder frames have been operating outdoors for a long time in dusty, humid, acid-alkali environments, and must take into account corrosion resistance, vibration resistance, and low-cost assembly.
Traditional rivets are easy to rust and loosen, and corrosion of the welded parts is accelerated after the coating is damaged, resulting in a high failure rate of agricultural machinery, with an average maintenance frequency of 4 to 6 times a year.
Dunchuan anti-corrosion rivet guns are paired with galvanized passivated alloy rivets to build a “corrosion resistance + anti-loosening” dual guarantee system. The salt spray test lasted more than 2,000 hours without rust, far exceeding the industry standard of 1,000 hours, and can effectively resist field moisture and pesticide corrosion.
In order to solve the problem that the riveting blade of the harvester is easy to loosen, a beam-type semi-hollow rivet is used, and the blade and the cutter bar are tightly engaged through precise cold pressing to avoid loosening caused by entanglement of debris during operation.
The handheld pneumatic equipment weighs only 6.8KG and is suitable for agricultural machinery operating in small spaces. The riveting time of a single harvester frame has been shortened from 8 hours to 3 hours. After an agricultural machinery company applied it, the annual equipment failure rate dropped from 18% to 2.3%, and the maintenance cycle was extended to 1.5 years, significantly reducing user maintenance costs.
Core scene three: Precision sealing riveting of energy equipment
Wind power towers, nuclear power pressure vessels, photovoltaic brackets and other energy equipment have extremely strict requirements on the sealing, pressure resistance and accuracy of connections.
The flange connection of the wind power tower needs to withstand more than 200 tons of axial tension and strong wind load. The end cover of the nuclear power pressure vessel needs to meet the “zero leakage” standard. Traditional welding can easily lead to material embrittlement and the bolt connection has insufficient sealing performance.
Dunchuan’s customized sealing and riveting solution achieves double protection through “hydraulic riveting + sealant composite process”.
The wind power tower assembly uses high-strength ring-groove rivets, combined with the two-stage process of “low-pressure preloading – high-pressure forming” to control the flange deformation within 0.3mm, and the anti-fatigue life reaches 2.5 times the design requirements; the end cover of the nuclear power pressure vessel is riveted using a cold pressing process, with a riveting temperature of ≤80°C to avoid changes in material properties. With multi-pass progressive riveting technology, the sealing reaches the 0.001MPa/min leakage standard, and the integrated helium mass spectrometer leak detector realizes riveting –
Integrated testing reduces the testing cycle from 72 hours to 2 hours.
After application in an offshore wind power project, the failure rate of tower connection points dropped to 0.03%, saving more than 5 million yuan in annual maintenance costs.
Core Scenario 4: Lightweight Connection of Dissimilar Materials
The lightweight upgrade of mechanical equipment promotes the application of dissimilar connections of aluminum alloys, carbon fiber composite materials and steel, accounting for 47%.
The thermal expansion coefficients of different materials can vary by up to 2 to 5 times. Traditional riveting can easily lead to stress concentration and loose joints. The scrap rate of dissimilar metal connections is as high as 15%, which has become a technical bottleneck in the industry.
Dunchuan adaptive rivet gun is equipped with material identification algorithm and elastic compensation technology, which can automatically match the parameters of dissimilar material combinations and disperse pressure with customized molds.
The steel-aluminum connection uses 410 stainless iron rivets, with elastic washers to compensate for temperature deformation, so that the connection point maintains a stable pre-tightening force in the range of – 40°C to 80°C. The carbon fiber composite connection uses a non-destructive riveting process, which softens the resin matrix through rotational friction to avoid fiber damage, and the structural strength loss is controlled within 5%.
Actual measurement data shows that the scrap rate of dissimilar material connections has dropped from 15% to 1%, and the pass rate has stabilized at more than 99.8%. After a new energy engineering machinery company applied it, the equipment’s weight was reduced by 12%, and the battery life was increased by 15%.
Core Scenario 5: Outdoor on-site installation and maintenance
In scenes such as bridge steel box girders, on-site splicing of large equipment, and maintenance of old machinery, due to space constraints, no air source power supply and other conditions, traditional large-scale equipment is difficult to enter the site, manual operation is inefficient and quality is difficult to guarantee.
In particular, the splicing of bridge steel box girders requires thousands of riveting points, and positioning deviations can easily lead to a lot of rework.
Dunchuan wireless hydraulic rivet gun creates a full-scenario operation solution. The 18V lithium battery can complete 440 consecutive riveting times when fully charged. The 35kN super pulling force is suitable for 5/16”~3/8” structural rivets, freeing them from the constraints of cables and air sources.
With the laser positioning system, the coaxiality error of the rivet holes is ≤0.05mm, the one-time positioning success rate reaches 98%, and the splicing cycle of steel box girder of a cross-sea bridge is shortened from 45 days to 28 days.
The matching electric rivet remover can quickly remove old rivets in 8 seconds, shortening the repair time of the old excavator arm by 60%, making it the preferred tool for on-site construction and maintenance teams.
Full industry chain empowerment: Helping machinery and equipment reduce costs and increase efficiency
Dunchuan Rivet Gun builds diversified solutions suitable for the machinery and equipment industry through the entire chain layout of “equipment + consumables + process”, and comprehensively solves the four core pain points of heavy load, vibration resistance, weather resistance, and efficiency.
In terms of economic benefits, manufacturing costs can be reduced by 18% – 25%, the scrap rate of dissimilar material connections is significantly reduced, the equipment has a trouble-free operation time of more than 10,000 hours, and the average annual maintenance cost is 40% lower than imported equipment.
At the same time, the intelligent parameter preset function lowers the operating threshold. Novices can get started after 15 minutes of training, which greatly saves technician costs.
As a local benchmark brand for precision riveting, Dunchuan provides full-cycle services from solution design, mold customization to remote operation and maintenance. Its response speed is 60% higher than that of imported brands, perfectly adapting to the short delivery cycle needs of the machinery and equipment industry.
Relying on domestic core technologies such as hydraulic servo and adaptive connection, we will realize the independence of the entire industry chain of rivets, molds and equipment, break the monopoly of imported equipment, provide core support for the transformation of the machinery and equipment industry towards high-end, intelligent and lightweight, and build a solid foundation for the manufacturing industry with innovative connection technology.
