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Fastening Solutions for Lightweight Assembly Challenges

• ARaymond & Rayce

• Trends and Methods in Lightweight Assembly

• „Simplifying Fastening“

• Bonding – Fastening of hybrid structures & diverse materials

• R & D – Fastening of lightweight composite materials

应对轻量化装配挑战的紧固方案

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RAYCE EURL / 05.11.2014

Today:

100 % family owned, 5th generation

> 5.500 employees

in 24 countries worldwide

11 development offices worldwide

8 % of turnover for R&D

> 30.000 fastening solutions out of metal and

plastic

5 areas of competencies:

- Engineering & Services

- Transformation of metal

- Plastic injection

- Adhesives production

- Assembly

…seit fünf Generationen unabhängig

Antoine Raymond

President of

Raygroup Since 1865

百年历程 5 generations of entrepreneurs

Family business since 1865, ARaymond has developed

and evolved over generations. Patents, innovation,

internationalization, diversification of markets. Each

generation adds its contribution to the company.

1865 ALBERT-PIERRE RAYMOND FOUNDED ARAYMOND IN FRANCE

1886 INVENTION OF THE PRESS-STUD. WORLDWIDE SUCCESS

1925 LAUNCH OF THE ZIP FASTENER VITEX®

1935 AUTOMOTIVE. FIRST CLIPS DEVELOPED IN SPRING STEEL

1955 BEGINNING OF THE PLASTIC INJECTION PROCESS

1997 INVENTION OF ARAYMOND QUICK CONNECTORS. WORLDWIDE SUCCESS

2000 FROM 2000, DEVELOPMENT OF GLOBAL FASTENING SOLUTIONS (Techbond® , RayNICE® , RayTOOL® )

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PRODUCTS

产品

Bonding Mirror bosses, rain sensors,

ball joints, etc.

Exterior

Roof moldings,

side door molding, rocker

panel, claddings, etc.

Interior

Trims, headliner, grab handle,

airbags, sun visor, dashboards,

carpets, etc.

Underbody

Spoilers, brake- and

fuel lines, heat shield,

wheel arch liner, etc.

Engine Quick Connectors,

AC-line fasteners,

swivel clips, brackets

etc.

Wire harness routing

Straps, tape-on,

connector brackets,

wire channels, etc. Washer system

Front & rear washer nozzles

Quick Connectors

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RAYCE EURL / 05.11.2014

New Center for Advanced Developments

高级研发新中心

• 2011: Inauguration of Advanced Development Center Rayce, located in Saint Louis (F).

• Today, more than 40 engineers, designer, mechatronicians, chemists & technicians work for ARaymond Center of Expertise (Rayce)

• Network of competencies • Interdisciplinary teams for advanced development

• Joint research projects with customers, universities and suppliers

• Participation at government-funded research projects

– State of the art laboratories

• Mechatronics

• Physical

• Chemical

• Environmental

• Area for testing product- and process-prototypes

• Benchmark-Area with product analysis capabilites

• Open Space Office Design

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RAYCE EURL / 05.11.2014

L – Light & Lean

- Light Weight Fasteners

- Fastening on Light Weight Materials (Composites, …)

E - Efficient & Ecological

- Fast assembly, time & cost reduction

- Process Efficiency

S - Smart & Sensitive - Add function to existing product range & materials

- Add value with sensors, electronic & mechatronic

S - Service & Speed - Simulation

- Lab services

* What is less complicated is often better

understood and more appreciated;

Simplicity is preferable to complexity;

less weight is the key to more efficiency

The Strategic Bullet Points - LESS is more *

尖点战略—少即多

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Trends & Methods in

Lightweight Assembly

轻量化装配的趋势和应对

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Manufacturing Costs Manufacturing Costs

Trends for future lightweight design

面向未来的趋势轻量化设计

ALUMINUM

COMPOSITE

Multi Material

Concepts

SUPERLIGHT

VEHICLE TARGET /

STRATEGIE

High

High

Low

Low

WEIGHT

Vision: Reduction of costs for lightweight assembly

TARGET

-40%

weight

New Manufacturing

Process for Composites

-20%

-40%

-60%

STEEL BODY

TODAY

Current costs for lightweight

Source: Brose

Lightweight solutions for

high volume segments are

currently not cost-effective

New high strength

steel types

New high strength

lightweight materials

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RAYCE EURL / 05.11.2014

Quick

Fastening

Technology Rivets

RayTOOL ®

ARaymond

Clips

RayNice ®

ARaymond

PowerClip

ARaymond

High Load &

Crash

Structure

Semi

Structure &

Trim Parts

Bonding

UV

Technology

(Blue Point

LED)

Acrylic

Ester

1K PUR

TechBond ®

ARaymond

1K Epoxy

Hybrid

Joining

Laser

Soldering

Bond-

Welding

Bonding of

punch

rivets Metal

Inserts for

Composites

High Speed

Joining

Punch

rivet RIVSET

® Böllhoff

Nailing RIVTAC ®

Böllhoff

Solid

punch rivet RIVCLINCH ®

Böllhoff

Direct

screwing Delta PT ®

EJOT

Screw

Flow Drill

(FDS) ®

Böllhoff

Joining & Fastening Technologies for Lightweight

轻量化中的连接和紧固技术

Electric

resistance

Welding

Welding

Laser MAG

MIG

Ultrasonic Induction

Friction

Welding

Joining and Fastening

Technologies for MMD

and Light Weight

Construction

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RAYCE EURL / 05.11.2014

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Simplifying Fastening

简化紧固

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Vehicle analysis with focus on fastening technologies

车辆分析-关注紧固技术

• Average amount of fastening elements per vehicle ≈ 2900

• Average weight of fastening elements per vehicle ≈ 32 Kg

• Average weight of cold-rolled fasteners (studs, screws, nuts) ≈ 24 Kg

• Average weight for clip fastening elements ≈ 8 Kg

Source:

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Source: Volkswagen AG

Reduce Cost by “Downsizing” the Joining Technology

通过连接技术的简化降低成本

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Advantages

Clip for fixing Head Airbag

Clip instead of screw

Pre-assembled to Airbag module

Simple clip-on assembly (20 N)

High retention forces (partially over 3000 N)

Simple disassembly with standard pliers

Important reduction of weight

Reduction of assembly time

No assembly tool necessary

PowerClip for fixing Head Airbag

紧固头部气囊的强力夹

Application

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FEM (Finite elements method)

有限元分析

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Saving per part: approx. 0.06 € = 2,40 € per vehicle

Saving of assembly time per vehicle: 2 €

Saving of weight per vehicle: 320 g

Estimated saving per car: 4,40 €

New Situation

(11) Plastic Rivets Endless Assembled with RayTool® ,

which creates Clamp Load

Old Situation

(11) M6 Screws

(11) M6 Weldnuts

Advantages

Reduction of assembly time, weight and

material cost

RayTOOL® - Plastic Rivets vs. Screws

RayTOOL® -塑料铆钉与普通螺钉的对比

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Industrial automation with WBK KIT and AMTC

和WBK KIT 及 AMTC一起来工业自动化

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Bonding –

Fastening of hybrid structures & diverse materials

粘联-连接混合结构和复合材料

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RAYCE EURL / 05.11.2014

A family of adhesive tablets, pre-dosed and tack free,

designed according to your need and specification…

• Pre-dosed, pre-shaped tablets for precise dosage, “digital” bonding

• Tack & solvent free adhesive, delivered as bulk or in cartridges

• No special curing conditions are needed

• Immediate green strength is achieved through heat activation

• 80% curing is ensured in 5 minutes. No off-line curing time is required

• No waste & clean process

• 12 month shelf life

Techbond® PUR Tabs for Lean Bonding Process

Tablet positioning Tablet-Picking “Ready to bond” Bonded part on glass

Techbond® PUR 胶精益粘联过程

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RAYCE EURL / 05.11.2014

http://www.netcarshow.com/mclaren/

http://www.needforspeed.com/sites/default/files/imagecache

Serial Application of Bonded Studs on Carbon Fibers

系列应用的粘联在碳纤板上钉

Before:

Long Curing

Special Stocking Conditions

Use of Tape to Hold in Place

Trimming off Overflow

After:

Immediate Usable Strength

No Special Stocking

Fast Curing

Perfect Dosage of Adhesive

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RAYCE EURL / 05.11.2014

Steel Ø 24, M6 - 12 g Tensile Strength ≥ 12 kN

Austempered Sheet Metal Ø 25, M6 - 4,2 g Tensile Strength ≥ 6,5 kN

Aluminum Ø 24, M6 - 3,6 g Tensile Strength ≥ 6 kN

Light Weight Studs for Bonding

重量轻的粘联钉

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RAYCE EURL / 05.11.2014

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R & D – Fastening of lightweight composite materials

研发活动-轻量化紧固复合材料

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RAYCE EURL / 05.11.2014

HYBRID INSERTS

Project Partner

Development of load

transmission elements for

Composite-Structures

Collaborative Project

合作项目

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RAYCE EURL / 05.11.2014

Challenges of Joining CFRP

参与CFRP挑战 • CFRP-Components have to be integrated in the Multi-Material-Design of the vehicle

structure

• Joining of CFRP-components are currently neglected in R&D, even though there are

new challenges to face:

Current joining technologies are only limited suitable for hybrid joining of CFRP and metal

Bilder: Kuka, DHV, wbk

E.g.: Metal-welding in car body

manufacturing

Common joining technologies for

FRP partially not usable

Mechanical methods are not appropriate

for the material

E.g.: Disruption of the fiber continuity and

component damage caused by drilling;

Damage due to bearing stress

in a bolt/rivet connection

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RAYCE EURL / 05.11.2014

Material-specific joining of CFRP through inserts

通过嵌件定制材料参与CFRP

No disruption of the fibers

Baseplate Threaded

bushing

Insert

Large-area load transmission

No need to drill

Bilder: wbk, Akkerman

F

Inserts offer the ability of material-specific force transmission in FRP components

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RAYCE EURL / 05.11.2014

• The geometry of inserts play an important role regarding the performance

• Currently used processes:

Stamped inserts Advantages / disadvantages:

Cost efficient

Optimized for bonding (holes)

Investigations show early failure of inserts

Current insert-technology

目前的嵌件技术

Turned inserts Advantages / disadvantages:

Hihger mechanical load capacity

More expensive in production

Not completely investigated

High load capacity not possible Manufacturing not cost effective

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RAYCE EURL / 05.11.2014

Research cooperation ARaymond - wbk

Advancement of insert-technology

阿雷蒙-WBK研发合作---先进的嵌件技术

• Zusammenbringen der Expertise aus Industrie und Forschung

Global leadership in manufacturing fastening

elements for the automotive industry

Experience from automotive industry enable

definition of relevant requirements and

boundary conditions

Raymond

Holistic investigation on new designed inserts, technology of automatisation

and relevant aspects regarding the RTM-Process.

The aim of the collaborative project is to develop a joining technology

suitable for serial production for the automotive industry.

Experience in

CFRP-Elements/RTM-Process

Automatisation

Existing installations engineering

RTM-Process

Tooling for inserts

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RAYCE EURL / 05.11.2014

Research cooperation ARaymond - wbk

Project content

阿雷蒙-WBK研发合作内容 • Approach

– Development of new load transmission elements

– Considering the RMT-Processchain

a) b) c) d)

Geometry: Increase load capacity of inserts

Surface & Material: Increas adhesion between CFRP and metal Avoiding of corrosion

Positioning/fixation of inserts in preform

Draping Infiltrate/sealing in RTM-process

Advancement of insert-joining technology on all relevant areas

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RAYCE EURL / 05.11.2014

Research cooperation ARaymond - wbk

Partial results

阿雷蒙-WBK研发合作部分成果 1. Optimization of design of standard insert

– Integration of a square bead-pattern into the blank. Inserts before and after the

mechanical validation

– Validation with tensile and bending test, integrated in fabric before infiltration

Enhancement of bending strength by 38 %

FT

FB

Inserst before testing

Left side: Standard insert

Right side: Optimized insert

Testing methods

FT: Tensile test

FB: Bending test

Inserts after testing

Left side: Standard insert

Right side: Optimized insert

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RAYCE EURL / 05.11.2014

Incre

ase

of

tensi

le s

trength

Incre

ase

of

bendin

g s

trength

Research cooperation ARaymond - wbk

Partial results

阿雷蒙-WBK研发合作部分成果 2. Optimization of surface on standard inserts

– Investigation of coatings, abrasive and additive technologies

– Validation with tensile and bending test, integrated in fabric before infiltration

Cataphoric

paint

Laser

structuring

ARC

spraying

LAM

pins

Selected

surface

coating

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RAYCE EURL / 05.11.2014

DISCLAIMER

© Rayce EURL

* “Rayce” means RAYCE EURL - 3 rue Alexandre Freund - 68300 Saint-Louis - FRANCE (Registered N°: RCS Mulhouse 502 901 044), which is an independent company of

ARaymond Network and which is responsible for this presentation.

** “ARaymond Network” means a network of independent companies which have a license of use of trademark.

“Presentation” means the information and any materials available in this Presentation including, without any limitation, pictures, datasheets, product descriptions, etc.

ARAYMOND™ is used as a trademark.

This Presentation does not constitute an offer or an agreement of any kind. This Presentation does not constitute a technical note. The Presentation is provided «as is» and only

for evaluation purpose. Rayce makes no warranty or representation whatsoever regarding the Presentation, its use or its suitability to meet specific needs. Rayce DISCLAIMS ALL

WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE ACCURACY, RELIABILITY, NOVELTY, COMPLETENESS, MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR

PURPOSE OF THE INFORMATION, NOR THAT WILL ITS USE NOT INFRINGE ON ANY THIRD PARTY'S RIGHTS. Rayce is not liable for any incidental, consequential or special damages of

any kind due to the use of the Presentation. Any rights not expressly granted herein are reserved. Except as expressly specified in these terms, nothing contained herein shall be

construed as conferring any license or right of any copyright, trademark, patent, or any proprietary rights. Any unauthorized use of this Presentation may violate rights, and so,

Rayce or any third party concerned may claim any damages or losses suffered. If you need further information, please contact Rayce.

Thank you very much for your attention!

感谢您的参与！

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