FLEXITOL® tolerance compensation systems were developed to compensate tolerances with economical assembly solutions and thus ensure a safe sequence in series production.
Not only in the automotive industry do production processes based on modular construction succeed.
Here, individual components are supplied to the assembler where they only have to be assembled.
To ensure flawless series production certain tolerances are assumed. The automatic tolerance compensation system FLEXITOL® provides a technically and economically optimised solution.
- Compensation of wide tolerances
- High performance reliability
- Access from one side only
- Easily integrates into a variety of applications
- High end product quality
- Fast and easy installation
Manual and automatic tolerance compensation system
Today we have manual and automatic tolerance compensation systems. Use of one or other depends on the field of application. When positioning a component in an assembly without any auxiliaries, then manual solutions are considered most appropriate. For a component spacing predefined by a preceding step, then we would rather recommend automatic solutions.
However, manual and automatic tolerance compensation systems may also be combined.
Manual tolerance compensation
The tolerance compensation system is screwed into the receiving parts to a defined position. During screwingin, the component tolerances can be compensated (Zero tolerance at delivery of the component).
Further alignment is possible during installation. The adjusted position is maintained when the joint is loosened.
Automatic tolerance compensation
Two components are aligned toward each other / positioned. During screwing, the spacing between both components is automatically adjusted. The tolerance compensation system fixes the originally aligned position. If the joint is loosened, the system resumes the initial position.
Currently, there are four FLEXITOL® types.
Different ranges of use present different requirements and require application-optimised tolerance compensation systems.
- FLEXITOL® metal
The two-piece system is highly wear-resistant and can very well be retrofitted. Manual adjustment for re-adjustment is possible as well. The adjustment element can also be installed in solid material.
The fastening element is available in different designs.
Assembly is easy due to approved blind rivet technology.
- FLEXITOL® hybrid
FLEXITOL® hybrid is a multi-component system mainly designed for use in large-scale production. Due to its modular construction, a variation of different inserted heights and tolerance compensation dimensions may easily be implemented.
To ensure high force transmission, the force transmitting components are made of metal. They are enclosed by a nut cage made of plastic.
Fastening is executed via the integrated blind rivet nut which can also be replaced with alternative connections (e. g. clips).
- FLEXITOL® plastic
FLEXITOL® plastic for self-tapping screws
The two-piece FLEXITOL® plastic is screwed into the mounting hole of the component. Connection with the bayonet method is also possible. For this method, FLEXITOL® plastic has to be inserted into a keyhole-shaped receiving opening and locked with a quarter turn.
The FLEXITOL® plastic consists of a plastic adjustment element and a plastic fastening element and is supplied as a pre-assembled assembly.
This assembly should be screwed into the mounting hole in the plastic receiving part. A bayonet variant offers another way to attach the basic element. The FLEXITOL® plastic is then inserted into a keyhole-shaped receiving opening and locked with a quarter turn. The subsequent installation is the same as for the self-tapping variant. Depending on the version, a self-tapping metal screw or a metric screw can be used as fastening screw.
- FLEXITOL® K’ in K’
FLEXITOL® K’ in K’
Example of the banjo screw
For “banjo screws”, the function of the K’ in K’ thread is extremely important.
The K’ in K’ thread creates its mounting thread into the existing plastic bore hole. Due to a resistance effect, the banjo screw can then only be screwed further in or out with a higher torque. We can offer different variants according to your requirements.
Possible applications of FLEXITOL® in general industry
Possible applications in general industry
- Machine housings
- Drawer slides
- Cabin coverings (in commercial vehicles)
- Drive units (washing machines)
Possible applications in the automotive industry
- Door frames
- Dash panels
- Roof rails
- Special solutions for the automotive industry
Special solutions for the automotive industry
Rear light fastening – FLEXITOL® Manual tolerance compensation
Component parts for rear light fastening
The spring unit (1) serves to ensure that the rear light is always tightened to the body with a defined tensile load. A further point of contact of rear light and body is provided with an adjustable spacer (2).
Furthermore, the surface offset between rear light and body side wall is achieve by means of an adjustable guide (3). During installation, the rear light is screw fastened to the body from within the trunk using the spring-loaded unit. After installation, an ideal gap width can be adjusted for the rear light. The spring compensates the alignment movement.
Schematic representation of rear light fastening
To be able to remove the rear light for servicing, the spring unit (1) can be unscrewed and the original position is maintained.
Fastening of roof rails – FLEXITOL® manual and
automatic tolerance compensation
Manual tolerance compensation
When roof rails are assembled no high forces may be transmitted through into the thin sheet metal of the roof panel. The tolerance compensation system specially developed by Böllhoff transfers these high forces into the supporting sheet layers below.
Tolerances within the cantrail do not affect the gap width between roof rail and roof panel. There are a variety of systems available which can be pre-installed on the roof rail or into the body.
Automatic tolerance compensation
Systems for stepless tolerance compensation
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