In Practice No. 24/2012

Content

08 Daimler Development Director Prof. Dr. Thomas Weber on the drives of the future.

16 BLUM have reached a new milestone in the development of architectural hardware with their latest product: BLUMOTION. Components from SFS intec are helping the system perform effortlessly.

04 Short reports News in brief from the world of SFS intec

08 What does the future hold for drivers? In discussion with Prof. Dr. Thomas Weber, Board Member at Daimler AG with responsibilities for research and Mercedes-Benz vehicle development

10 A fantastic new glass facade fixing system A new skin for the university building in Bergen, Norway

12 High tech for hi-fi pleasure SFS intec has been developing speaker baffles in expanded

metal-look plastic

14 Market differentiation thanks to perfectly honed development and manufacturing skills Product innovations leading the way to new strategic targets

16 Precision in the kitchen Pushing back technological barriers through systematic collaboration

18 A rivet insertion tool with countless applications Extending the application spectrum for rivet insertion systems

20 Reliable corrosion protection with A4 and A5 steels Long-term fastening whatever the weather

22 Russia’s steel industry: future-proof thanks to SFS intec fastener technology Fitting the roofing structure to Russia’s largest tube mill

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Editorial teamStaff of SFS intec

Frequency of publicationAnnual

Graphics and editingMarketing Services SFS intec

English translationTerra Firma International Limited, Welshpool, UK

Printgalledia ag, Berneck

PublisherSFS intec

Front Cover Museo de las Ciencias, constructed with extensive use of SFS intec fasteners (Source: Corus Kalzip)

Editorial

22 Installing the gigantic flat roof covering Russia’s largest tube mill called for the efficiency offered by SFS intec fasteners.

Achieving successful solutions starts with recognising customer needs

Innovations require a profound understanding of customer needs. Active listening, exchanging ideas, setting targets – always with their practical and safe achievement in mind: these are the collaborative maxims embraced by our employees in their daily interactions with our customers.

It is after all the marriage of technological excellence and well-honed engineering skills, coupled with the entrepreneurial interactions, which really provides the successful results we all seek.

In this edition of SFS intec In Practice, we once again present specially selected examples of our day-to-day work, illustrating how, working hand-in-glove with our customers, we have been able to create future- focused solutions.

We hope you enjoy reading about some of our many project successes, and that this SFS intec In Practice report will help you generate many exciting new ideas.

Alfred SchneiderGeneral Manager / AutomotiveProducts

Imprint

Efficient fastening for the A350 Airbus

Never before have efficiency conside- rations and the environment been so central to a new aircraft development. Light-weight alloys and composite materials have been extensively used to reduce fuel consumption. Specially developed clip fastening techniques speed up assembly and enable tight build schedules to be hit.

The cabin area modular fastening system, developed by SFS intec, also speeds up assembly. From the first prototype design, right through to the series production, SFS intec were there, actively supporting their part-ner’s goals with a comprehensive project management system.

A user-friendly ordering procedure with the barcode scanner

“La qualité, ça ce voit” or “Quality that’s plain to see”. That’s the sales concept of Huis Clos, the French manufacturer of quality uPVC, alumini- um and timber doors and windows. Their products are distributed through a sales network throughout France. That means that customers can view samples and assembly systems on the spot.

But this service became increasingly difficult to manage. That’s why Huis Clos decided to systemise their range and simplify their logistics processes. They called on the expert assistance of SFS intec’s French Market Organi-sation.

Following a joint variety control exer-cise, attention focused on improving existing logistics systems. The answer was streamlining the entire order process using barcode scanners. The system, called “Mini eScan,” consists of a compact barcode scanner with

specially developed logistics software. This enables individual sales outlets to produce and print their own labels and barcode lists.

Another advantage of the scanner is its mobility. Codes can be scanned in the warehouse or in the plant. Printed barcodes can be read quickly and efficiently anywhere. The scanner is

subsequently linked to a PC via a USB port, and the scanned articles are displayed on screen. It’s then a simple matter to check the details and complete the order.

The Mini eScan demonstrates the willingness of SFS intec to get involved with e-procurement, offer-ing ingenious solutions, simplifying processes and reducing costs.

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One of Germany’s largest solar energy systems was hooked up to the mains in the Summer of 2011. SFS intec fasteners were part of that success story.

Renewable and low-emission energy is the future. Above all photovoltaic sys-tems, i.e. those converting solar power into electrical current, have boomed over recent years. Large scale industrial roofing offers the ideal basis.

That was certainly the case at the Delitzsch Industry Park in the state of Saxony. A 40000 square metre solar energy plant installed on a roof there produces a staggering 3.2 megawatts of electricity. The new SOL-R proved the ideal fixing system.

An extremely efficient installation was made possible by the continued sup-port of SFS intec fastener specialists. The black SOL-R retainers are fixed directly to the support structure with power tool fasteners. A thick water-tight strip underneath the retainers serves to provide long term sealing. Among the additional support services offered by SFS intec was the training of all installation operatives.

Thanks to the flexible height adjust-ment of the SOL-R system, uneven roof areas presented no problem. Even unexpected variations in the roof struc-ture could be readily accommodated, thanks to the wide range of approved fasteners available.

The simple installation system won over everyone concerned. Self-tapping screws eliminate the time-consuming pre-drilling operation. Cutting out this step alone saved two weeks’ work. Hence the fasteners were already installed long before the cells them-selves were delivered.

All this means that the SOL-R is setting new standards in solar energy installa-tion. Quite simply, a secure, flexible and rapid solution for installation pro-fessionals.

n The SOL-R has been specially developed for mounting solar panels on industrial buildings. Thanks to its geometrical design and the numerous alternative fixing possibilities, it is universally suitable for virtually every roof structure.

Fitting the solar cells of the future

n The solar panels on the roof of the Delitzsch industrial park cover an area of 40 000 square metres; mounted rapidly, securely and with complete flexibility.

Cockpit electronics under control

Modern cars contain literally dozens of electronic control systems. They help conserve power, improve fuel economy and increase passenger comfort. But all this places a big strain on vehicle batteries; and a voltage interruption could lead to a system failure.

The German first tier automotive sup-plier, Continental, has been working on the issue and developed a revolutionary stabiliser system for cockpit electron-ics. Working like a heart pacemaker, the device provides the fastest “start/stop” system on the market, delivering completely reliable electronic network support.

The system is mounted using fasteners from SFS intec, which, thanks to a special coating, are highly conductive; while an integral sealing ring also inhib-its any water ingress into the housing, which might badly affect the system.

A new hand tool for blind rivet insertion

Since its market launch two years ago, the FireFox® blind rivet insertion tool has consistently demonstrated its capabilities in a wide range of applications. Now blind rivet specialist GESIPA’s addition of an integrated process monitoring system marks another step towards the goal of zero defect, fully monitored rivet insertion.

The precursor to the development was the long-estab- lished TAURUS®C system, which has an on-board electronic monitoring system to evaluate and record the installation procedure. Thanks to specially developed software, the user can set the mechanical insertion parameters up-front. The equipment monitors and displays the results of the rivet insertion process via coloured LED’s. Data can even be statistically evaluated using a data transmission interface.

With its unique technology, the FireFox® represents the ideal extension to the existing product range.

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The requirements for future bulk manufacture were met well ahead of the time schedule.

Of course, a secure “lifetime” corner fastening for our windows is of para-mount importance to us. The over- riding positive feedback from our customers tells us we made the right decision. The MC fixing underlines the high quality of our products.

could find. We completed tests with different fastener types. In the end the MC was the undisputed winner.

SFS intec’s added value was also a factor. Technical support and a comprehensive service package are convincing arguments for increased collaboration.

After the first test runs, we worked jointly on various honing procedures; in particular the accuracy of the fasteners.

Sig. Vitali, looking back for a moment, when did the collaboration with SFS intec take shape?

It goes back to 2008. Restructuring our assembly operations led us to look for a quality mechanical fastener supplier. We happened upon the MC timber fixings during a visit to a trade show in Milan.

What impressed you about these fasteners?

Their future capability: you have to understand that we had just invested in a complete new manufacturing line. So the time was right to look for new fastener ideas. The objective was to use flexible production con-trols to react quickly to the needs of our customers. When you consider how customers are able to design their own individual windows from sixty different design variants, you realise that a unitary fastener system was a must.

What concrete benefits did the introduction of the MC fasteners generate?

The system speeds up and simplifies our window manufacturing opera-tions; not to mention installation on site. That’s a decisive advantage for us. Not least because we are not only active in Italy, but also work extensively in other countries like Spain and Russia. The time and money saved replacing individual window elements is enormous. Previously, the entire window had to be replaced every time.

One last question: what is it about the MC that you like best?

Following the radical changes to our manufacture, it was necessary to look at every assembly system we

Simple, secure fasteners for timber frame windows

The Italian PB Group belongs to the international market leaders in the manufacture of timber and timber-alumini-um window systems. The company seems to be able to come up trumps on design and innovation again and again, with every product exuding exclusivity; all perfectly married to the individual living space of the customer. In the following discussion, company CEO Andrea Vitali explains why the PB Group uses SFS intec MC mechanical corner fixings to finish their timber frames.

n PB Group CEO Andrea Vitali was convinced from the outset of the concept and advantages offered by the MC fixing system:

– permanent corner fixing: without glue– releasable fixing– shrinkage and expansion totally under control– tested to ift standards

You cannot simply shy away from the reality of fossil fuel exhaustion, any more than from the issue of CO2 emissions from continuously increasing personal vehicle usage. But what are the alternatives to conventional Otto engines? Here, Prof. Dr. Thomas Weber, Daimler board director, discusses the current state of affairs and the ongoing development of fuel cell-driven vehicles.

The term “alternative propulsion systems” covers a multitude of tech- nologies, such as electro-drives, gas-burners – like methane systems, for instance – hydrogen cell vehicles and the various hybrids. Where do you see the greatest potential for success; and why?

Speculations about propulsion systems of the future are legion. I myself am convinced that a range of alternative technologies will exist in parallel on our streets. The drive the customer chooses will depend on their particular application or usage profile. What is clear is that we will need made-to-measure solutions ensuring the mobili-ty of our global customer base. That’s why we are developing a three-fold strategic initiative: alongside efficient Otto engine development, we are working on hybridisation techniques. Simultaneously, we are developing electro vehicles with batteries and fuel cells for more localised, emission-free driving. This year, we are already mar-keting the smart “for two” electric drive in more than thirty markets. By 2014, the B class with fuel cells will be available in series production.

So can conventional engine types be improved in terms of fuel consumption and emissions? If so, just what has to be done?

We have achieved a lot over recent years in terms of optimising conven-tional engine technology, but we need to grow even cleaner and more

efficient. Our strategy is to make the diesel engine as clean as the petrol engine and the petrol engine as effi-cient as the diesel. We are now apply-ing to the petrol engine those technolo-gies which have already become well established in diesel engines. Things like turbo charging and direct injection. Our Blue EFFICIENCY programme also covers multi-model ranges. In fact, going way beyond engine technology itself, this intelligent system interacts all around the car. This covers engine management systems proper, chassis weight saving measures, low rolling resistance tyres and aerodynamic optimisation measures. Even things like the ECO start/stop function, and an awful lot more.

We are routinely generating fuel savings of over 20%. To give you an idea of what can be achieved, we have actually reduced the consumption of the current C-class by 31% by using the latest efficiencies such as new engine models, the updated automatic transmission 7G-TRONIC PLUS and the ECO start/stop function. For instance, the latest C220 CDI uses just 4.4 litres per 100 km.

What are the greatest technical or economic challenges to the automotive and energy industry sectors con-cerned?

For vehicle manufacturers and system suppliers alike, with the enormous diversity of emerging technologies, it is a question of keeping abreast of the latest know-how, alongside a clearly defined strategy in every area. Of course, that requires appropriate finan-cial and human resources. Daimler AG spent five billion euros on R & D in 2010. More than half of the expendi-ture was dedicated to green technolo-gies and products.

But in addition to our own initiatives, we also pursue co-operations with empowered partners. Pooling our strengths can help to move forward more quickly and efficiently. Particular-ly in the case of emerging technolo-gies, utilising synergy effects with powerful partners is vital to know-how exchange and knowledge transfer. We work on the one hand with scientif-ic institutes such as our research partnership on electro-mobility with KIT (Karlsruher Institut für Technologie), and on the other we pool our activities with partners from various value added levels throughout the automotive and other sectors. Examples are our joint venture electric engine developed with Bosch, or the battery development work with Evonik Industries. Employee qualification is another critical factor. Mastering technologies of tomorrow and building up the capabilities needed requires highly skilled personnel and corresponding training programmes.

What does the future hold for drivers? In conversation with Prof. Dr. Thomas Weber, main board member of Daimler AG,with responsibility for corporate research and Mercedes-Benz car development

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What does all this mean for a second tier automotive supplier like SFS intec?

Continuously strengthening your tech-nological profile and the competitive strength of the parts being offered is obviously central. To achieve that, you have to be attuned to future trends through continuous dialogue with customers and intensive monitoring of market and technological trends. Then you need to grasp these as an oppor- tunity to develop your business in a properly thought-through manner. In future, classical evaluation criteria like top quality and adherence to delivery schedules will be superseded by speed of response, flexibility, a willing-ness to embrace innovation and even a certain commercial boldness as far as successful suppliers are concerned.

In the end the buyer decides on an engine type for his vehicle of the future. What are the prerequisites to providing broadly-based alternative power sources?

We already have electric vehicles in service using batteries or fuel cells. But to increase the demand for these vehicles, we need to increase con- sumer acceptance of new vehicle concepts. If electric vehicles are ever to find favour with our customers, we cannot accept shortcomings in terms of user-friendliness or driving range as compared to conventional systems. Moreover, a fully-functioning infra-structure is needed. As far as electric vehicles are concerned, a network of re-charging facilities is required. Like-wise, bringing fuel cells up to commer-cial viability requires a comprehensive infrastructure to be in place. Advanc-ing this development, we are investing with the technological leader, Linde, to create twenty more hydrogen stationsaround Germany. The first one will be up and running this year and that means we are on the right track.

The cost of an electric vehicle needs to be brought down to an attractive level too. To that end, we developed our innovative “sale&care” marketing programme for the electro smart generation. The “sale&care” scheme enables customers to purchase, lease or finance the car and to hire the battery at a monthly cost of sixty euros. The price of a car under the “sale&care” system is well under 16000 euros: in short, a very attractive offer. This makes electric driving a joy in every respect!

n From the two- seater smart car to the SLS AMG sports car, Daimler is now offering low-con-sumption vehicles across the range; steadily heading towards emission-free motoring.

A fantastic new glass facade fixing system

Werner Zwicky, FasteningSystems, zwer@sfsintec.biz

The flamboyant glass architecture of the new Bergen Medical Faculty occu-pies a prominent position, right next to the University Hospital. Here on the west coast of Norway would-be doctors and dentists are made ready for their vital future roles. The impres-sive new building is an open, inviting construction; due in no small part to its colourful glass façade, which creates a powerful optical impact.

The glass panels were mounted by the Swedish construction company SKANSKA. Retainers for the glass panels had to be discussed during the pre-project round. SFS intec’s Nor- wegian Market Organisation offered their support here; with the choice finally falling on the ALW fixing system.

The ALW system was fitted to the steel sub-frame, pre-fabricated by the

company SKANSKA in the Czech Re-public. Once the retainers have been fitted, the glass panels can be easily slid into place in the clamping profiles and tightened. This created an overlapping façade with the optical impression of a smooth, continuous glass surface.

Total service package

The way in which this façade came so smoothly to fruition had a lot to do with the dedication of the SFS intec personnel involved in the project. Their knowledge helped see the project from the design phase, through the planning stage and onto successful completion of the construction, thanks to systematic support throughout.

Before the work itself could begin, all sorts of details had to be worked out, from glass type, dimensioning,

inclination and static calculations. The development team then matched the fastener dimensions to the specific application parameters. At that point, it was also agreed to use spedcaps® thread sealing and security fluid on the fasteners.

Since the university is located so close to the sea, a corrosion-proof material for the glass retainers was also needed. For that reason, high-end stainless material was chosen. Finally, tamper-proof drives were chosen to eliminate any unforeseen adjustments to the fittings.

All-in-all, the planners, together with the general contractor SKANSKA, benefited from a comprehensive support service from start to finish.

The University of Bergen, Norway, recently opened a new Faculty of Medicine and Dentistry. The building features an ultra-modern architectural concept with huge glass façade panels. Central to the extreme design of the new building façade were powerful fixings with multi-faceted properties.

n The modern architecture of the new university building blends harmoniously with the Bergen city-scape. The recessed window panels enable fresh air circulation, even in inclement weather conditions.

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In discussion with Miroslav Peknik, Project Manager of SKANSKA, CZ

How were technical queries addressed?

I worked directly with the project manager of the market organisa-tion in Norway. He provided full technical support and helped steer the project to successful comple-tion. He organised special fasten-ers quickly and easily, such that efficient deliveries could be made both to the Prague workshops and the Norwegian site.

How did you find the local technical support from SFS intec in Norway?

As the ALW is so easy to use, and all the relevant details were sorted out in advance, the need for site

In discussion with the architect Kristin Jarmund

Ms. Jarmund, what message were you intending this building to convey?

My aim was to create a trans- parent, inviting façade, completely in tune and in harmony with its surroundings.

technical support was minimised. Our very positive experience from previous projects also helped us a lot.

How were the logistical requirements, such as the direct supply of the fasten-ers to Prague, handled?

The huge amount of material required on this project was a big issue. It was important that only those components needed at any one time were made available for the build. Individual delivery batches were supplied by SFS intec as needed, on time and with tremendous flexibility.

Would you say that maximum efficien-cy and flexibility also applied to the installation process?

Absolutely: the precise manufacture of the sub-framework in Prague, coupled with the pre-fabrication of the ALW retainers, enabled efficient and very precise installation work. Thanks to the flexibility of the SFS intec fixing system, it was possible to quickly and easily adjust for minor deviations on site.

n The redesign of the medical faculty in Bergen followed stringent guidelines. The glass façade adds a touch of cosmopolitan flair to these northern latitudes.

n Fix the carrier to the sub-frame, insert the glass panel and tighten the fasteners: thanks to the ease-of-use of the ALW system, there was no issue over hitting completion target dates.

Why was the building designed as it was?

Sited opposite to many residential buildings, the exterior had to exude a quiet neutrality. Moreover, it was important for the new build to blend in harmoniously with the existing buildings and the local landscape.

What part did SFS intec play in terms of supporting your architectural concept, and why did you opt for the ALW retainers?

The solution was proposed by the SKANSKA construction company of the Czech Republic. Our impression was that the ALW system offered a good response to the secure fixing and aesthetic aims for the glass panels. A beautiful, even pattern has been created for this façade.

Plastic or metal? That was always the question when it came to manufacturing baffles for high-end speakers. But it’s a thing of the past, now that SFS intec have succeeded in merging the particular advantages of each material in a single product.

Easy on the eye and ear. Loud speaker covers have been a very prominent feature of modern vehicle cockpits ever since the car radio was invented. Over recent decades, the manufacture of speaker grilles has been governed by several critical issues. The aesthetic design appeal, high build quality in metal, fashionable colours and last but by no means least, the sound quality! Each of these factors came to the forefront at different times.

These days, the key issue is harmo- nising technical innovation to cost reduction targets: a trend which has not left loud speakers untouched.

Metal versus plastic

Two materials set the tone when it comes to manufacturing loud speaker baffles. Metal offers high-end design and hi-fi sound quality; but also high prices. Plastic baffles, by contrast, offer not only cost but weight savings in vehicle interiors, making them almost ubiquitous across all vehicle segments.

Loud speaker baffles in metallic finishes

High quality vehicle interior compo-nents are developed and manufac-tured by SFS intec at their Korneuburg, Austria facility (among other sites); where there is also a loud speaker grille development centre. An excel-lent basis then for a major speaker technology breakthrough. Two years’ work was needed by a multi-discipli-nary team to get a plastic baffle with a metallic finish to market. Various technologies were investigated and extensively tested. By the end of 2010

they were there: the first expanded metal design gauze could be supplied to various German premium vehicle marques.

That was the start of a new era at SFS intec in the manufacture of loud speaker baffles. For the first time, it was possible to combine both the tonal and aesthetic qualities of the metal cover in a plastic variant. The baffles’ appeal lies in their subdued matt finish, conveying a sense of luxury to any vehicle interior.

Whether it’s for a limo, estate, coupé or cabrio; these new SFS intec loud speaker covers will soon be gracing an awful lot of quality automobiles. They possess all the qualities of the significantly more expensive perfo- rated metal covers; offering the last word in vehicle interior sound quality.

Roman Bergler, AutomotiveProducts, berr@sfsintec.biz

High tech for hi-fi pleasure

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n The view of an expert: Roman Bergler is totally convinced that loud speaker baffles in expanded metal designs will meet both aesthetic and tone quality require-ments.

n Nothing but the best: the filigree gauze structureachieves perfect tonal response.

n Loud speaker grilles in metal-effectplastic now contri-bute to the joy ofdriving, thanks to their superb tonal quality and elegant design.

“This development project was of strategic importance for us. Introducing perforated metal-look baffles into an already mature market was a massive technological stride.

The original perforated metal baffles have been around for some years, but their use was always associated with high cost levels. Our objective was to create an economical alternative to these expensive products – without compromising on performance or design.

Extensive test runs finally enabled us to produce plastic baffles in a totally convincing expanded metal design. These demonstrate the same feel, look and acoustics as the original metal versions. That opens up all sorts of advantages for our customers:

n Between 70 and 80% component cost savings with a weight saving of up to 50%

n The expanded metal finish emphasises the exclusive vehicle interior finish

n Expensive and easily damaged paint operations are eliminated

n A genuine feel thanks to the use of premium ABS-PA polymers

n Countless matt colour alternatives [e.g. for special premium series vehicles]

n Perfect acoustics and harmonic integration in the vehicle interior

The project team is convinced that the future lies in plastic baffles in high-quality designs such as expanded and perforated metal finishes. On the one hand, vehicle manufacturers can enjoy reduced costs, and on the other, sound engineers can match the tone precisely to the interior acoustics.

Roman Bergler was closely involved in the development of the new speaker grilles in an expanded metal design. Here he talks about the objectives the project team were addressing from the start.

Roger Bösch, AutomotiveProducts, boro@sfsintec.biz

The core capability of the Austrian STIWA Group lies in production automation, as well as their own manufacture of high-value auto- motive assemblies. Their APF production support systems com-pany achieved tier one status for transmission assemblies for a leading European car maker. SFS intec contributed to the success of this strategically significant development with newly-developed components.

APF operates under the STIWA umbrella as a quasi-independent, well-respected automotive system supplier. To maintain their technologi-cal leadership position, APF focuses strongly on their strengths in innova-tion, quality and cost optimisation, together with the logistical and service support generating maximum customer satisfaction.

Achieving these strategic aims requires strong suppliers. That’s why APF strives for In-depth partnerships and continuous improvements with their suppliers. Only true co-engineering can achieve such elevated targets. As a supplier of diverse components for steering systems over many years, SFS intec is among their key partners.

Entering a new market segment

Just recently, APF again extended their product portfolio. By bundling their key capabilities of pressing, laser welding and assembly techniques, it proved possible to win transmission drive projects. For the first time APF were able to supply directly to the OEM, elevating them to tier one status. Getting into a new market segment was no easy matter. APF’s declared objective was to create a competitive alternative to the solutions already available in the marketplace. From the outset, it was clear that the project’s success was dependent on achieving a competitive price level: that made cooperation with tried-and-trusted suppliers all the more critical.

Market differentiation thanks to perfectly honed development and manufacturing skills

The knowledge gained could then be used to adjust and hone the defined component requirements.

Where necessary, various prototypes were produced during the later project phases for test runs on the actual production equipment. That enabled all sorts of determining factors on subsequent series production to be recognised and optimised. Thanks to their resources, working hand-in-glove with their customer, SFS intec were able to respond quickly to any necessary adjustments. Those respon-sible at APF were certainly satisfied with the results. The targeted project aims could be achieved; namely the safe functioning of their first transmis-sion, a considerable cost saving thanks to development and manufacturing efficiencies and a more than 30% weight saving over previously available

SFS intec provided several compo-nents for the new transmission system. The greatest challenges lay in the complex design geometries and extreme tolerances of the cold formed components concerned.

Meeting the requirements more efficiently

Co-operation between the project teams from the two companies was, to say the least, intensive. Using state-of-the-art development tools, SFS intec were able to view the geo- metry and forecast both the func- tionality and producibility of the designs envisaged. That meant the customer’s requirements could be combined with the capabilities of the cold forming technique from the very outset. The cold form material flow was, for in-stance, simulated using 3D modelling.

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n Thanks to state-of-the-art development systems, production feasibility for the final design could be established up front. By way of example, the material flow during cold forming was established via graphic 3D simulation. This not only shortened the overall development time, but also massively reduced the level of tooling cost.

n These various components from SFS intec all contrib-ute to the perfect functioning of the APF gear box.

n In passenger car transmissions, various gears transmit the energy from the engine to the wheels and drive the vehicle. A series of conver- sion ratios covers the range of speed requirements trans-ferred to the drive wheels.

products. These led to the desired differentiation in the market place; together with the associated success that APF had been looking for with this market entry.

Achieving our customers’ stringent requirements calls not only for the optimum use of our own capabilities, but also for co-operation with strong, competitive external suppliers.

From a technical standpoint this development project was extremely important for us. The extreme re-quirements in terms of component geometry and the very tight toler- ances could only be achieved by working very closely with SFS intec.

Multiple design modifications – necessary to progress the particu- lar product development – were only possible thanks to short com- munication paths. This dedicated and professional approach to every challenge was demonstrated throughout the entire development procedure.

SFS intec demonstrated superior capabilities in cold forming, contrib- uting significantly to the successful achievement of the project aims.

The engineer Thomas Böckl, Quality and Production Manager for bought-in parts, comments on the collaboration with SFS intec.

© ATZ extra: the new VW Up

Daniel Schmid, IndustrialProducts, schd@sfsintec.biz

Precision in the kitchen

Functional assemblies just keep getting smaller. That calls for miniature componentry with often complex design geometries. Cold forming enables even complex shapes to be manufactured in bulk with a high degree of repro- ducibility.

Easy opening and smooth, quiet closing – the hinge systems of the Austrian hardware specialist BLUM have been taking care of kitchen comfort for fifty years. Their BLUMOTION damper system represents one of their compa-ny highlights. Thanks to their refined design technology, doors and drawers close gently – whatever force is used to shut them.

BLUM recently premiered its newest BLUMOTION product generation. The latest trick is integrating the damping

system into the hinge housing, setting in motion a precise mechanism akin tothat found in a watch movement. The heart of the hinge consists, among other components, of two rivets: a retainer rivet and a return rivet. Together with other parts these produce a remarkably smooth closing process, and are responsible for the free running of the component.

Small parts can play a big part

At first glance the parts concerned look relatively easy to produce. Only on closer inspection do the manufacturing demands emerge. Cost issues meant that only cold forming was a potential option for the engineers responsible for the project.

The demanding component geometry presented an obvious challenge to the

team from the start. Chief among their difficulties were achieving a precise external drive and perfectly finished contours.

Their long-term supply partner, SFS intec, was called on to support the development project. Design engineers from the two companies worked closely together to develop the optimum solution. SFS intec were able to demonstrate the basic producibility of the cold formed parts early on, thanks to empirical trials.

Advance planning

Engineers at SFS intec looked at the required components from both a functional and a manufacturing aspect. Requirements of development parts and subsequent series manufacture at BLUM had to be matched. SFS intec

n The innovative technology of the CLIP top BLUMOTION produces quiet, gentle closing of furniture doors. Cold formed rivets from SFS intec enable perfect move-ment of any cupboard door.

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were able to furnish initial samples in record time. Detailed design improve-ments were then undertaken together with engineers from BLUM, with the focus on series manufacture.

Close co-operation

Close collaboration between SFS intec and BLUM engineers enabled the parts to be rapidly designed for cold forming. As the development progressed, details of parameters like tolerances to hun-dredths of a millimetre and appropriate production measurement techniques all had to be elaborated.

A readiness to leave the well-beaten track behind and take on appropriate risks certainly paid dividends for both companies.

Simon Eberle from Purchasing sums up the co-operation with SFS intec

The collaboration between the two technical teams was really intensive. We would not have been able to achieve the efficient development of the parts without this. These parts represent what you might call virgin territory for us; particularly the external drive and precise contours – that is to say, getting them right for manufacture represented a major challenge.

Together we explored the frontiers of cold forming technology, and even pushed them back a little! In the end it is often the abilities of quality suppliers that enables BLUM to achieve technical differentiation in their products.

CLIP top BLUMOTION from BLUM

Slamming doors are now a thing of the past. Thanks to the innovative CLIP top BLUMOTION function, kitchen and lounge furniture doors now close softly and quietly, what- ever their weight or the force applied to closing them.

Notwithstanding the demanding technology housed in its hinge case, the CLIP top BLUMOTION does not differ from other CLIP top hinges in size or proportions. The elegant product design serves to underline the exclusive character of the hinge.

Reference length5 mm

Jens Achenbach, W+O Rivet Technology, achenbach@wo-niettechnik.de

A rivet insertion tool with countless applications

Working together, GESIPA and the rivet specialists W+O have greatly extended the range of applications for the TAURUS® blind rivet inser-tion tool.

Inserting solid or semi-hollow rivets is generally done using a stationary rivet system. Assemblers now have much more flexibility.The rivet specialists W+O set them-selves the target of extending the possibilities of the TAURUS® range of rivet guns.

The big technical change was the addition of a G-clamp front extension bracket replacing the blind rivet head. It ensures completely constant con- nection strength values; even with thin substrates. A range of jaw widths from 60 to 180 mm makes the tool extremely versatile. It means rivets can not only be inserted around the edges of the workpiece, but much deeper; with total reliability.

Broader application range

The ability to switch heads by hand now turns every TAURUS® tool into a “TAURUS® tool kit.” The application range now extends to situations and materials which have hitherto present-ed great difficulties for riveters. The new tools offer enormous potential for vehicle bodywork. Bodywork repairs no longer have to use welding; riveting is now an entirely feasible option. Adhesive bonds can be enhanced with semi-hollow rivets using the G-clamp.

But that’s not all: alongside classic bodywork repairs, the TAURUS® tool can now be used for replacing brake linings in truck repair shops. In addition to its multiple uses in the vehicle repair sector, the TAURUS® range offer numerous further industrial applications; in particular in scaffold-ing, machine building and graphics.

Applications in automated systems

The new G-clamp also offers numer-ous advantages in large scale auto- mated assembly situations; a typical example being a German car-maker which has converted its entire steering column production to the system.

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The TAURUS® features at a glance

Application

ninserting solid, semi-solid and hollow rivets

npunch riveting

nclinch riveting

nhole punching rivet

nrepairs to punch and clinch rivet

Technical data

ninsertion force 5000 to 20000 N at 5 bar

ninsertion stroke from 15 to 25 mm

noperating pressure 5 to 7 bar

ntube feed diameter 6 mm (1/4 inch)

nweight: 1.3 to 2.0 kg without G-clamp attachment

nG-clamp gap according to specific depth (a): application

nG-clamp gap according to specific width (b): application

Advantages

ntotal flexibility

nsafe and simple pneumatic power control

nrapid and simple exchange of the original blind rivet head for a G-clamp attachment on any standard TAURUS® range unit

nsimple tool changes

n360° rotation of the G-clamp

nfast, efficient installation work

nprocess monitored units also available

A special arrangement based on the G-clamp system utilises two TAURUS® base units mounted to a double G-clamp, which inserts two semi- hollow rivets in a process-monitored, totally automated production line. It is a continuous feed system without costly interruptions.

Compact, flexible and versatile

The slim, ergonomic design of the unit, with its secure, slip-free grip makes for safe, efficient work. At once powerful and precise, the hydro pneumatic driven tools deliver between 5000 and 20000 N of insertion force. This kind of power opens up innumerable potential applications for the professional users they are designed for.

n A TAURUS® fitted with a double G-clamp in use in a fully automated steering column production at a German car-maker.

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Reliable corrosion protection with A4 and A5 steels

Build projects in difficult environ-mental conditions call for special steels like classes A4 and A5. This makes extraordinary demands on the manufacturers concerned. Thanks to extensive experience of these sorts of materials, SFS intec offers a massive range of stainless products.

Building in a climatic and chemically aggressive environment represents an enormous challenge to any con-struction company. Examples include buildings close to the sea, ones in high humidity environments or per-haps with particularly long lifetime requirements. All these factors demand particularly high quality materials. Answering this need means that in addition to conventional carbon steel fasteners, SFS intec offers a broad range of top class A4 and A5 products.

Ready availability completes the service package. That derives from a global network, wide-ranging know-how, coupled with professional engineering support and finely-honed logistics. This total dedication to cus-tomers is highly prized throughout the world.

From China...

The Nine Dragons Paper Group, China’s largest paper producer, decided on a flat roof for its new production plant in Tianjin. This roof covers an area of 43000 square metres, all held in placewith the ISO-TAK® flexible fastening system from SFS intec.

A decisive factor from the outset was the very high corrosion resistance called for, as the atmosphere in the paper mill has a relative humidity of over 70%. Following extensive consul-tations with the Chinese Market Orga- nisation of SFS intec, the planners de- cided on using SFS intec A4 stainless steel fasteners. These have demon-strated excellent corrosion resistance even under extreme conditions.

…via Singapore...

The Singapore Cruise Centre promises to be a hyper-modern passenger ter- minal in one of the world’s biggest harbours. The Chinese Market Orga- nisation of SFS intec was brought on board to assist with the new cruise centre construction. The close proxi- mity to the ocean and the anticipated long life expectancy of the building were central to the discussions. It was agreed that SX power tool fixings in A4 stainless fitted the bill.

…and London...

This year, England’s capital is buzzing with plans for the Olympics. The new Aquatics Centre is certainly one of the architectural highlights of the newly- built sporting venues. Safety was not the only engineering design considera-

tion, but also the extreme humidity in a swimming complex. Numerous tests were carried out to verify the security of the chosen fasteners. An A5-rated stainless steel fastener system was chosen, providing the client with a truly high quality solution, well up to the demands of the project.

...all the way to Qatar

A number of prestigious building pro-jects are under way in Qatar. Exclusive buildings in every conceivable form present the ultra-modern face of the emirate on the Persian Gulf. The new Doha International Airport is one bene-ficiary of the building boom. Last year as well as the new Departure Terminal B, an entirely new catering centre was created for Qatar Airways.

n In the Chinese coastal metropolis Tianjin, the packaging manufacturer Nine Dragons decided to construct a production facility with an initial 800000 ton capacity (1).The planners chose SFS intec ISO-TAK® fasteners for fixing the roof seal (2).

Sonja Oesch, FasteningSystems, oson@sfsintec.biz

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The building’s location directly on the shores of the Gulf with its corrosive climate called for special high-end fasteners. In any event, the construc-tion planners saw a certified fastener system as a prerequisite. SFS intec were able to meet that demand with A4 grade stainless steel fasteners. The planners were also impressed by the associated ancillary services, like on-site direct support, special test series conducted specifically for this project and extensive back-up docu-mentation from previous projects.

When it comes to builds with extra- ordinary requirements, as in these four projects, SFS intec has so much more to offer, above and beyond its role as a qualified partner. It wasn’t just global-reach service arrangements and com-prehensive technical know-how which convinced these customers, but the wide range of special A4 and A5 grade stainless steel products.

n The cruise terminal in Singapore (3), the Olympic swimming pool in London (4) and the Qatar Airways catering centre (5) have two things in common: they all have imposing roof designs and they are all exposed to extreme corrosion attack. That meant high-end fasteners were impera-tive in all three cases.

n In developing the new ranges of fas- teners in A4 and A5 stainless, the engi-neers were able to call on extensive previous experience of numer-ous building projects, and the results of internal research and development work. The outcome was a range of corrosion proof fasteners capa-ble of withstanding even the most extreme conditions.

Othmar Koch, FasteningSystems, ok@sfsintec.biz

Russia’s steel industry: future-proof thanks to SFS intec fastener technology

One of the most modern tube mills in Russia is under construction on the border between the mid and southern Urals. The Russian marketing partner of SFS intec, F-Systems Ltd., supported the project from the planning stage to completion.

During the days of the Soviet Union, this was home to one of the biggest tank factories in the country. Today, here on the outskirts of the city of Chelyabinsk, 1760 kilometres east of Moscow, it is being replaced by an ultra-modern tube mill to produce pipes for oil and gas pipelines.

The project to build what was at that time Russia’s largest steelworks was launched by the Chelyabinsk tube mill in 2010, with the code name “VYSOTA 239” – the building being

239 metres above sea level. This state-of-the art facility covers an area of 100000 square metres, and has an annual output capacity of 600000 tons of pipes for long-distance pipelines.

“White metallurgy”

VYSOTA 239 is also the first project in Russia to sign up to the so-called “white metallurgy” ideal; in other words, the Chelyabinsk tube mill fully embraces modern manufacturing culture, with ecological, social and economic considerations all in tune throughout the added-value chain. Thus, products are not just high value but future-focused, with an absolute minimum of emissions.

Thanks to the latest technology, white metallurgy makes the “black country” a thing of the past. Workers even wear

white uniforms to visibly demonstrate their commitment to the new produc-tion culture.

Know-how and...

Our Russian marketing partner F-Systems Ltd. was involved in the project from the outset. So all relevant questions surrounding the fixing of the roof and wall cladding panels were clarified early on.

...fastener technology

The planners turned to the proven reliability of the ISO-TAK® fastening system for the roof area. SFS intec sandwich panel fixings were also chosen for the walling work.

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Alexandra Makarova and Ivan Demkin, sales personnel at F-Systems, discuss the project.

The demands on fasteners for the roof and walling of a steelworks are considerably greater than for conventional buildings. Fasteners are called for that fulfil the enhanced security and longevity requirements without compromise. As the marketing partner of SFS intec, it was our respon- sibility to choose the right product and make sure it was delivered on schedule.

Architects, general contractors, sub-contractors, even tradesmen – everybody benefits from this service. They do not just get products. They get a complete service package from us. Starting with the technical support in choosing the right fasteners right through to documented test runs and product training.

Even changes to the roof design at short notice were handled quickly and without bureaucracy. That helped us achieve the target dates; with no compromise on quality. The extensive stockholding at our Moscow facility also helped on that issue. And with products from SFS intec meeting international standards, users and investors alike can count on products of proven quality.

n SFS intec also offers a compatiblerange of installation tools covering match- ing power tools, drive shafts, bits and drills; all perfectly matched to the job. This enables even single fasteners to be installed efficiently.

But support was not limited to the selection and supply of the appropriate fixings. The assembly team were fully trained from the start of installation on the correct application of SFS intec fasteners. This comprehensive support package helped them achieve all their quality and delivery targets.

n The ISO-TAK® fastening system enables different roofing structures to be fitted easily. Whether the substrate is a trapezium steel section, or a concrete roof, installers can rely on a consistently strong bond.

n A view of the manufacturing area. The new Chelyabinsk tube mill produces 600000 tons of tubes for oil and gas pipelines annually.

One company – one spirit

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