Digital process monitoring in blind rivet technology
Avoid errors and improve quality
Published on 30 October 2025
Quality assurance in blind rivet technology with GESIPA® WinTech
In industrial manufacturing processes, precision is crucial for safety and cost-effectiveness. Particularly in areas where blind rivets and blind rivet nuts permanently connect components, such as in the automotive industry or mechanical engineering, no setting process should be left to chance. With its setting process monitoring in the field of blind rivet technology, GESIPA® offers a technology that seamlessly integrates quality assurance into the manufacturing process – digitally, precisely and efficiently.
Contents
– Why process monitoring is indispensable in manufacturing
– GESIPA® WinTech – How setting processes are reliably monitored
– The GESIPA® interface – the digital bridge in the setting process
– Conclusion – Making quality visible with GESIPA®
Why process monitoring is indispensable in manufacturing
Blind rivet technology is an integral part of industrial connection technology. However, while demands for efficiency and manufacturing precision are increasing, skills shortages and increasing automation are making quality control more difficult. This is where GESIPA comes in: by using setting process monitoring with continuous recording of process data such as force, travel and setting time, every riveting operation is digitally monitored. The setting process monitoring system detects deviations immediately and makes it possible to avoid errors during production.
This turns a mechanical operation into an intelligent process with measurable quality and traceable documentation.
GESIPA® WinTech – How setting processes are reliably monitored
WinTech technology from GESIPA® stands for intelligent quality control within the riveting process. The aim is to monitor every setting process and thus ensure the reproducible quality of a connection. This is based on the continuous recording of two key parameters: the force applied during setting and the distance travelled by the rivet during the process.
This data is recorded by sensors and evaluated in real time by integrated electronics. Based on these measured values, the entire setting process can be represented in a characteristic curve. This shows how force and movement develop during the setting process and whether they correspond to the defined target values.
Up to three so-called evaluation windows can be defined within the WinTech software to assess quality. These windows define the permissible range within which the force-displacement curve may move. If the measurement result is within these limits, the process is considered acceptable; if it deviates, an error message is issued. A coloured status indicator on the tool immediately signals whether the set rivet or rivet nut meets the quality requirements.
All recorded process data can be logged via a data connection and further processed for documentation or analysis. This makes the entire process transparent and traceable – an important basis for efficient quality control and digital manufacturing.
WinTech setting process monitoring is available for both blind rivets and blind rivet nuts and can be used in both manually operated and automated riveting systems.
Setting process monitoring for blind rivet applications
TAURUS® C WinTech
The TAURUS® 1 – 4 series with integrated setting process monitoring stores over 260,000 setting process data points, which can be retrieved at any time.
TAURUS® C WinTech
GAV 8000 electronic
The GAV 8000 electronic for industrial production achieves time and cost savings of up to 50% and can be operated separately, integrated into a system or connected to a robot.
GAV 8000 electronic
Setting process monitoring for blind rivet nut applications
FireFox® 2 C WinTech
The FireFox® 2 C can be used to monitor and document the results in the manufacture of critical components or in automated setting processes.
FireFox®2 C WinTech
FireRex® WinTech
The FireRex® WinTech is capable of setting blind rivet nuts at any conceivable angle in industrial production. On request, it can be connected to a robot application.
FireRex® WinTech
The GESIPA® interface – the digital bridge in the setting process
In order for WinTech setting process monitoring to reach its full potential, it needs a reliable connection between the rivet tool, control system and evaluation. This is exactly where the GESIPA® interface comes into play. It is the digital communication interface that enables the exchange of information between the setting tool and the customer's control system, making the process transparent and controllable.
During the setting process, all relevant data is recorded, stored, and forwarded to the higher-level control system via the interface. This allows users to see whether a set blind rivets or blind rivet nut meets the quality requirements. In addition, all process curves can be displayed in real time on a monitor connected to the interface if desired.
Thanks to this close connection, the interface works hand in hand with WinTech technology: while WinTech measures and evaluates the riveting process, the interface ensures that this data can be securely transferred, analysed and reused in the manufacturing process. The result is a fully digitally monitored, traceable and controllable riveting process – regardless of whether it is manual or automated.
Two versions for different requirements
GESIPA® offers the interface in two versions, each offering different advantages depending on the application environment:
Interface 4.0 Universal
Interface 4.0 Universal serves as a link between GESIPA® setting tools and external production networks. In addition to transferring process data, Interface 4.0 Universal also allows individual device functions to be controlled and results to be forwarded to the line control system.
Interface 4.0 Universal
Interface 4.0 Profinet
The Profinet interface is specially designed for complete integration into industrial automation networks. It enables direct communication with the central plant control system, allowing all setting process data to be seamlessly integrated into the higher-level production logic.
Interface 4.0 Profinet
Conclusion – Making quality visible with GESIPA®
With WinTech setting process monitoring and GESIPA® interfaces, a mechanical work step becomes a digitally controlled quality process. Every riveting process is documented, evaluated and thus becomes a transparent part of modern manufacturing. The result is secure, reproducible connections and a verifiable increase in quality – regardless of whether in manually operated workstations or in automated systems.
Would you like to find out how WinTech technology or Interface 4.0 can be optimally integrated into your production environment? Get in touch with us: the GESIPA® team will advise you individually on the right solutions for your requirements.
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