ADAPTIVE DFS GEN6 – Screwdriving System for Automated Flow Drill Fastening
ADAPTIVE DFS Generation 6 sets new standards for automated flow drill fastening. The system combines adaptive screwdriving technology with a completely new software platform, a web-based operating concept, and integrated Industry 4.0 communication. This enables flow drill screw joints to be integrated into automated assembly processes with high precision and repeatability, even in demanding material combinations.
More Information ADAPTIVE DEPRAG Fastening System (ADFS) Product Catalog
The Next Generation of Flow Drill Fastening
With ADAPTIVE DFS Generation 6, we are expanding our proven screwdriving system with a completely new software platform and modern system architecture. The new generation significantly improves usability, diagnostic capabilities, and system integration while preparing the system for future requirements of digital manufacturing. The new software platform has already been developed with the requirements of the Cyber Resilience Act (CRA) in mind and supports the implementation of modern security and compliance requirements. With these enhancements, ADAPTIVE DFS GEN6 becomes a future-proof platform for automated fastening processes.
Benefits for Maximum Process Reliability
- Adaptive fastening process for repeatable screwdriving results
- Automatic compensation for component tolerances and material variations
- Optimized cycle times through dynamic process control
- Minimized stress on both screw and component
- High process stability even with demanding material combinations
- Flexible integration into automated production lines
The Key Innovations of GEN6:
Web-Based Visualization
Location-independent access via standard web browsers without additional software installation.Modular Screw Sequence Editor
Flexible process configuration with drag-and-drop modules for complex fastening strategies.Synoptic 3D Diagnostics
Faster fault localization and higher system availability through visual real-time diagnostics.Industry 4.0 Communication
Secure real-time data exchange via MQTT, OPC UA, and REST API.Modern CRA-Compliant Security Architecture
TLS-encrypted communication, centralized user management via Active Directory, and complete change tracking for modern cybersecurity and compliance requirements.
Automated Flow Drill Fastening with Reliable Process Control
Flow drill screws create a load-bearing thread directly in the component during the fastening process. This results in high-strength joints without pilot holes or additional threaded elements. The ADAPTIVE DFS screwdriving system combines an electronically controlled screwdriving spindle with a controlled feed motion. Adaptive process control continuously monitors torque, speed, and feed force and dynamically adjusts them as needed. This enables even demanding flow drill fastening applications to be automated with repeatability and cost efficiency.
Technology Highlights of ADAPTIVE DFS
The core of the system is the adaptive control of both the screwdriving and feed motion. An electronically controlled EC servo screwdriving spindle operates in a closed-loop control system together with a servo-electric feed axis.
This allows key process parameters to be continuously monitored and dynamically adjusted throughout the entire fastening process.
Technological Advantages
Electronically controlled screwdriving spindle
Servo-electric controlled feed motion
Dynamic adjustment of torque and feed force
High process stability even with material tolerances
Generation 6 introduces a fully web-based visualization system for the first time. The user interface can be accessed directly via the system's IP address on the network – without any additional software installation.
This enables fast access to diagnostic and system functions from any workstation within the production network.
Highlights
Access via standard web browser
No software installation required
Operation from a workstation or directly at the machine
Touch-optimized user interface
The new screw sequence editor enables flexible configuration of complex process sequences. Individual process steps can be freely combined and conveniently configured via a graphical user interface.
Supported Process Modules
Torque-controlled fastening
Differential torque-controlled fastening
Angle-controlled fastening
Waiting times between process steps
Configuration is performed via an interactive editor with drag-and-drop functionality.
With the optional Synoptic software solution, the screwdriving system is represented for the first time as an interactive digital twin.
Key system components such as the screwdriver head and control cabinet are displayed in a 3D visualization and monitored in real time.
Benefits
Rapid fault localization
Visualization directly at the affected component
Linking of fault indication, root cause, and solution
Reduced downtime
Automating Flow Drill Fastening
Flow drill fastening is a proven joining technology for thin-walled materials and multi-material joints. During installation, the screw generates a localized plastic deformation in the component through frictional heat. This creates an extruded collar that is subsequently fastened with a form-fit connection.
The process is particularly suitable for applications involving:
Thin-walled metal structures
Multi-material joints
Single-sided component accessibility
With ADAPTIVE DFS GEN6, this process can be fully automated and controlled with high precision.
The ADAPTIVE DEPRAG Fastening System can be combined with and expanded by a wide range of additional DEPRAG software solutions.
→ Overview of all software solutions
Service & Integration
From Planning to Serial Production
Step 1: Analysis of the Joining Technology
Joint evaluation of components, materials, and fastening strategy.
Step 2: System Design
Definition of the screwdriving system, feeding technology, and automation concept.
Step 3: Integration
Integration with robots, PLCs, and production systems.
Step 4: Commissioning
Integration with robots, PLCs, and production systems.
Step 5: Serial Production
Long-term process stability through service, maintenance, and software updates.
Future-Proof Flow Drill Fastening for Automated Assembly
With ADAPTIVE DFS GEN6, DEPRAG combines proven flow drill fastening technology with a modern software platform, advanced diagnostic capabilities, and Industry 4.0 integration. The result is a screwdriving system that delivers maximum process reliability, outstanding flexibility, and long-term investment security. GEN6 helps companies confidently meet future requirements for digitalization, cybersecurity, and compliance. Our experts will be happy to advise you on integrating the system into your assembly application.
