In Practice - Startpage SFS intec Daimler Development Director ... with responsibilities for research and Mercedes-Benz vehicle development ... Restructuring our assembly

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<ul><li><p>In Practice No. 24/2012</p></li><li><p>Content</p><p>08 Daimler Development Director Prof. Dr. Thomas Weber on the drives of the future.</p><p>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.</p><p>04 Short reports News in brief from the world of SFS intec</p><p>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</p><p>10 A fantastic new glass facade fixing system A new skin for the university building in Bergen, Norway</p><p>12 High tech for hi-fi pleasure SFS intec has been developing speaker baffles in expanded </p><p>metal-look plastic</p><p>14 Market differentiation thanks to perfectly honed development and manufacturing skills Product innovations leading the way to new strategic targets</p><p>16 Precision in the kitchen Pushing back technological barriers through systematic collaboration</p><p>18 A rivet insertion tool with countless applications Extending the application spectrum for rivet insertion systems</p><p>20 Reliable corrosion protection with A4 and A5 steels Long-term fastening whatever the weather</p><p>22 Russias steel industry: future-proof thanks to SFS intec fastener technology Fitting the roofing structure to Russias largest tube mill</p></li><li><p>3</p><p>Editorial teamStaff of SFS intec</p><p>Frequency of publicationAnnual</p><p>Graphics and editingMarketing Services SFS intec</p><p>English translationTerra Firma International Limited, Welshpool, UK</p><p>Printgalledia ag, Berneck</p><p>PublisherSFS intec</p><p>Front Cover Museo de las Ciencias, constructed with extensive use of SFS intec fasteners (Source: Corus Kalzip)</p><p>Editorial</p><p>22 Installing the gigantic flat roof covering Russias largest tube mill called for the efficiency offered by SFS intec fasteners.</p><p>Achieving successful solutions starts with recognising customer needs </p><p>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.</p><p>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. </p><p>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.</p><p>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. </p><p>Alfred SchneiderGeneral Manager / AutomotiveProducts</p><p>Imprint</p></li><li><p>Efficient fastening for the A350 Airbus</p><p>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.</p><p>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-ners goals with a comprehensive project management system.</p><p>A user-friendly ordering procedure with the barcode scanner</p><p>La qualit, a ce voit or Quality thats plain to see. Thats 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. </p><p>But this service became increasingly difficult to manage. Thats why Huis Clos decided to systemise their range and simplify their logistics processes. They called on the expert assistance of SFS intecs French Market Organi-sation.</p><p>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 </p><p>specially developed logistics software. This enables individual sales outlets to produce and print their own labels and barcode lists. </p><p>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 </p><p>subsequently linked to a PC via a USB port, and the scanned articles are displayed on screen. Its then a simple matter to check the details and complete the order.</p><p>The Mini eScan demonstrates the willingness of SFS intec to get involved with e-procurement, offer-ing ingenious solutions, simplifying processes and reducing costs.</p></li><li><p>5</p><p>One of Germanys largest solar energy systems was hooked up to the mains in the Summer of 2011. SFS intec fasteners were part of that success story. </p><p>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. </p><p>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. </p><p>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. </p><p>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.</p><p>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.</p><p>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.</p><p>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.</p><p>Fitting the solar cells of the future</p><p>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.</p></li><li><p>Cockpit electronics under control</p><p>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. </p><p>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.</p><p>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.</p><p>A new hand tool for blind rivet insertion</p><p>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 GESIPAs addition of an integrated process monitoring system marks another step towards the goal of zero defect, fully monitored rivet insertion.</p><p>The precursor to the development was the long-estab- lished TAURUSC 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 LEDs. Data can even be statistically evaluated using a data transmission interface.</p><p>With its unique technology, the FireFox represents the ideal extension to the existing product range.</p></li><li><p>7</p><p>The requirements for future bulk manufacture were met well ahead of the time schedule.</p><p>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.</p><p>could find. We completed tests with different fastener types. In the end the MC was the undisputed winner. </p><p>SFS intecs added value was also a factor. Technical support and a comprehensive service package are convincing arguments for increased collaboration.</p><p>After the first test runs, we worked jointly on various honing procedures; in particular the accuracy of the fasteners. </p><p>Sig. Vitali, looking back for a moment, when did the collaboration with SFS intec take shape? </p><p>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.</p><p>What impressed you about these fasteners?</p><p>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.</p><p>What concrete benefits did the introduction of the MC fasteners generate?</p><p>The system speeds up and simplifies our window manufacturing opera-tions; not to mention installation on site. Thats 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.</p><p>One last question: what is it about the MC that you like best?</p><p>Following the radical changes to our manufacture, it was necessary to look at every assembly system we </p><p>Simple, secure fasteners for timber frame windows</p><p>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.</p><p>n PB Group CEO Andrea Vitali was convinced from the outset of the concept and advantages offered by the MC fixing system: </p><p> permanent corner fixing: without glue releasable fixing shrinkage and expansion totally under control tested to ift standards</p></li><li><p>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.</p><p>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? </p><p>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. Thats 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. </p><p>So can conventional engine types be improved in terms of fuel consumption and emissions? If so, just what has to be done?</p><p>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 </p><p>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.</p><p>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. </p><p>What are the greatest technical or economic challenges to the automotive and energy industry sectors con-cerned? </p><p>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, a...</p></li></ul>