NORMA Group’s Engineered Joining Technologies and applications know-how provide cleaner, more efficient use of precious energy sources in areas such as Cooling Systems, Air Intake & Induction, Emission Control and Ancillary Systems.
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Customer Value through Innovation.
www.normagroup.com I ss u e 9 Ap r i l - June 2 0 1 3
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www.fastf ixtech n olo g y.co m
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Special Metals is Quick Delivery
Alloy Steel Carbon Steel
Over 250 Production Machines
Stainless Steel ASTM Grades 4140 - 4145 Cr-Mo-V
24-7 “SOS” Service Bolts • Nuts • Studs • Sockets • Bent Bolts
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304 304L 304 Cond B 310 316 316L 316 Cond B 317L
Specialty Steel & Metal Processing for Your Custom Bar Requirements 11710 Charles Street, Houston, TX 77041 USA • Global@GoBarStock.com
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“Passion for Precision” Assembly Components Machined Parts • ISO 9001:2008 Certified 11715 Charles Street, Houston, TX 77041 USA • Global@GoCAV.com
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our Business is our Specialty
Over 10,000 Tons of Inventory
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Superalloys Aluminum High Performance Alloys Titanium A286 Brass Copper Alloys Bronze Alloys
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Inconel K-Monel Monel Ferralium 255 Hastelloy Nitronic 20Cb-3 254 - SMO
Precision Forging / Machining
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Zeron 100 AL-6XN
editorial
Will Lowry - Editor
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From M42 size high strength bolts in rotor blade fittings to micro screws in electronics, the breadth of fasteners is almost limitless. In each issue of Fastener + Fixing Technology we focus on key fastener applications, across a wide variety of industries, but we know there is still more that we can cover.
hat is why we want to hear what you want to be reading. If you are having a problem with an application, let us know. If you would like to see articles focused on specific fastener topics or specific industries, contact us. We want to include articles that provide the solutions you are looking for. In this issue we have a bountiful selection of fastener technology and how it can help you improve applications, whilst also providing a cost-effective solution. Our Cover Story contains an exclusive interview with Mr Stephan Mann, director of product development EMEA at NORMA Group, and focuses on the importance of working with customers to develop new products. Our Renewable Energy feature looks at the vital role fastener standards play in preventing wind turbine failure; the advantages of using lock nuts on wind farms; as well as the key benefits of using automation to produce superior bolt for wind turbine blades. In addition to this we also take a look at the next generation of blind rivet nuts; the plus points of laminated shims; developments in tapes + adhesives technology; as well as how flexible assembly systems are helping to drive e-mobility. So enjoy this issue and let me know what you would like to see in our July issue…
Contents
Product news Latest fastener product news...............................44-50 Advertisers index....................................................... 50
4 Fastener + Fixing Te chnology • Issue 9 Apr - Jun 2013
Group Publishing Director Jamie Mitchell info@fastfixtechnology.com Editor Will Lowry editor@fastfixtechnology.com Executive Editor Phil Matten Assistant Editor Claire Edwards Senior Advertising Executive Harry Whyte harry.whyte@fastenerandfixing.com Senior Advertising Executive Claire Lake claire.lake@fastenerandfixing.com
Disclaimer
18-28
The Publisher cannot be held responsible or, in any way, liable for errors or omissions, during input or printing of any material supplied or contained herein although the utmost care is taken to ensure that information contained is accurate and up to date. The Publisher also cannot be held liable for any claims made by advertisers or in contributions from individuals or companies submitted for inclusion within this publication. The opinions expressed are not necessarily those of the Editor or Fastener Fairs Limited.
Copyright
Non-threaded technology Shims? Make mine laminated.................................... 34 Not just a simple rivet nut......................................... 36 New BRALO battery riveting tools............................ 38 Features EMC launches new electrophoretic coating plant... 40 ECOSIT® upgrades with RFID technology................ 42
www.fastfixtechnology.com
Production Manager Andy Clow andy.clow@fastenerandfixing.com
Cover story Developing specialist joining solutions................12-13
Tapes + adhesives Lohmann is pursuing ‘green’ paths.......................... 30 Solar-Flex provides bonding power......................... 30 Cut downtime and improve equipment performance.... 32 Solution for bonding polypropylene........................ 32 New Permabond epoxy adhesives........................... 32
Tel: +44 (0) 1727 814 400 Fax: +44 (0) 1727 831 033
Advertising Executive Emiliano Pagliaroli emiliano.pagliaroli@fastenerandfixing.com
Industry news Latest fastener industry news................................ 6-10
Renewable energy Reviewing fasteners standards may lead to fewer wind turbine failure-related accidents...... 18-20 Norbar launches new Handtorque™ Compact Series... 22 Using robotics for wind turbine fasteners............... 22 Precision parts to order............................................. 24 Never deal with seized up nuts again....................... 26 Intersolar Europe - The potential of renewable heating... 26 Flangeform® adds value to solar project.................. 28
Part of the Mack Brooks Group Romeland House, Romeland Hill, St Albans, Hertfordshire, AL3 4ET, UK
34-38
Entire contents copyright © Fastener Fairs Limited 2013. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means without the prior permission of the publisher.
Hilti engineering for earthquake applications
Build a future safer from earthquakes.
Hilti. Outperform. Outlast.
Seismic events are among the worst possible scenarios for engineers or architects designing structures. Hilti is proud to announce that HIT-HY 200 with HIT-Z rod has the first European Technical Approval for the seismic categories C1 and C2 according to the new EU regulations. No matter whether in the design office, on the jobsite or through online services, Hilti can provide its customers with the solid technical support necessary to jointly build a better future, safer from earthquakes.
Hilti Corporation I 9494 Schaan I Liechtenstein I www.hilti.com I www.facebook.com/hiltigroup
Fastener industry news
Bossard earns recognition as a John Deere ‘Partner-level supplier’ Bossard North America Inc has earned recognition as a Partner-level supplier for 2012 in the John Deere Achieving Excellence Programme. The Partner-level status is Deere & Company’s highest supplier rating.
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ossard, headquartered in Zug, Switzerland, was selected for the honour in recognition of its dedication to providing products and services of outstanding quality, as well as its commitment to continuous improvement. Bossard North America Inc is a supplier of fasteners, product solutions, application engineering, and customer logistics to John Deere’s operation. It is the second time in the last four years that Bossard achieved Partner-level status. Suppliers who participate in the Achieving Excellence Programme are evaluated annually in several key performance categories, including quality, cost management, delivery, technical support and wavelength, which is a measure of responsiveness. John Deere Supply Management created the programme in 1991 to provide a supplier evaluation and feedback process that promotes continuous improvement. www.bossard.com/ffm
Lesjöfors company receives Continental award The German Lesjöfors company - Stumpp + Schüle - has been awarded the ‘2013 Premium Supplier’ award from Continental. Only subcontractors who can live up to Continental´s high standards of quality and service receive this prestigious award.
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ontinental is among the world’s leading component suppliers to the automotive industry. It provides products such as brake systems, systems and components for powertrain and suspension, instrumentation, automotive electronics, security systems and tyres. Stumpp + Schüle GmbH, based in Beuren, Germany, was included in the 2013 list of premium suppliers thanks to its strengths in quality, supply service, competitiveness and willingness to improve and innovate.
“We are delighted by the fact that one of our major customers has awarded us with a top class seal. This distinction is recognised throughout the Schaeffler Group (which includes LuK, INA, FAG, Schaeffler and Continental) and offers an excellent opportunity to expand the shared business relationship,” says Wolfgang Hellman, sales manager of Stumpp + Schüle. Since 2012 Stumpp + Schüle has been part of the Lesjöfors Group that supplies the automobile industry worldwide with springs and pressings. www.lesjoforsab.com
Anochrome technical seminars return Anochrome Group has announced the return of its annual technical seminars, focusing on the latest technologies in the wide range of corrosion protection systems.
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he Anochrome Group technical seminar 2013 has been confirmed for Wednesday 26 th June 2013 at The Heritage Motor Centre Gaydon, Warwickshire, UK. Further details on the day’s sessions will be released shortly and will include guest speakers from major coating manufacturers as well as a group of technical personnel. The talks will focus on a broad range of the latest developments in coatings and processing technologies such as new ultra high performance zinc flake systems - new to the UK, high volume processing lines, thermal diffusion developments, heat resistance decorative coatings, new sealing and locking systems, anodising, and an update on the latest thoughts on REACH and EEC requirements. “Anochrome technologies enable us to meet the requirements of customers such as BMW and the VW group and maintain our plant’s position as one of the premier trade anodising facilities in the UK. Places for the technical seminar are limited to industrial professionals, for further details please visit our website.” www.anochrome.com
6 Fastener + Fixing Te chnology • Issue 9 Apr - Jun 2013
Fastener industry news
Alcoa supports Network Rail in fight against theft Products supplied by Alcoa Fastening Systems (AFS) have received official endorsement for use in the campaign to deter theft of valuable copper cable from the UK’s railway network, a crime which costs the industry GB£16 million per year.
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earching for a more robust solution to the easily removed nuts and bolts at spider junction boxes, Network Rail engineers in Newcastle upon Tyne approached the team at AFS. Following a series of rigorous trials and tests a Certificate of Acceptance was granted by the Network Rail Acceptance Panel, authorising the use of Huck ® fasteners and associated installation tooling. With installation training provided by AFS, Network Rail replaced the traditional nut and bolt system with Huck C50LR-BR20-12G and C6LB-R12-12G
fasteners and using additional galvanised casing to house them, attached the cable to the track, as well as the junction box. John Rickers, systems development manager at AFS, believes the solution is a superior upgrade. He said: “Stolen cable is not only expensive to replace but there are also the additional costs of labour and the inconvenience caused to railway customers. When a cable is cut or stolen, the area has to be located, isolated, jointed and tested, and depending on the level of the theft it may involve specialised teams to carry out the repair work. Nuts and bolts
can be undone relatively quickly, Huck fasteners cannot and the longer it takes to attempt this, the more chance thieves have of being caught or aborting the theft in frustration. Attaining the Certificate of Acceptance from Network Rail is recognition that our fastening systems offer positive, practical solutions to businesses and organisations that not only save them money, but as in this case, aim to minimise the disruption caused to people’s everyday lives. We look forward to working with Network Rail in rolling the system out.”
TR Fastenings in the driving seat TR Fastenings recently supplied plastic fasteners to the UK car manufacturer Ariel Motors for its latest Atom sports car, to help take weight out of the structure to enhance its world-famous performance.
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lastic fasteners are often the optimal solution for when a fastener has to be versatile, light and yet strong. This is especially true in the automotive sector, where the latest trend is for light-weighting - a lighter car uses less fuel, is more economic and more environmentally friendly. “The Atom is designed with an open structure based on frames,” explains Kevin Roger, TR Fastenings’ plastic products sales manager. “Therefore the use of plastic cable ties is a neat and subtle way of hiding the wiring harness throughout the body of the car. Additionally, where a part was needed near the engine, a stainless steel tie was required, which we could also provide.” Kevin adds: “The Atom is just one example of how we are currently approaching our clients and asking to see their processes to see if we can improve them and provide some production benefit. Also, plastic fasteners have the advantage of being multi-functional. Why use a nut, bolt and a washer, when you could use a two-piece plastic rivet that takes less time to apply? That is where the innovation is.”
SPRINGS - HIGH PERFORMANCE • Inconel • Nimonic • Hastelloy • Elgiloy • MP35N • Titanium • High-tech calculations
Lesjöfors Sales, Stockholm • Phone +46 8 445 88 88 • info.vby@lesjoforsab.com
A leading manufacturer of high performance springs and stampings – www.lesjoforsab.com
Ambrovit is one of Europe’s largest wholesale distributors of chipboard, self-tapping, self-drilling screws and bolts.Thanks to its new automated warehouse, Ambrovit is now able to store around 20,000 ready-to-ship pallets as well as offer a Special Service to guarantee quick delivery.
▸ HEX LAG SCREWS ▸ CHIPBOARD SCREWS ▸ DRYWALL SCREWS ▸ DOME SCREWS ▸
AND EURO SCREWS
MACHINE SCREWS
▸ NUTS, WASHERS, BOLTS ▸ THREADED RODS ▸ TAPPING SCREWS ▸ DRILLING SCREWS ▸ PVC SCREWS ▸ S.S. A2 SCREWS
Ambrovit S.r.l.
Via Giulio Natta, 29 - 27026 Garlasco (PV) Italy Tel. +39.0382.810280 Fax +39.0382.1760014 email sales@ambrovit.it
www.ambrovit.it
Fastener industry news Hilti builds a better future, safer from earthquakes, with…
The first ETA approval for an anchor pre-qualified for the demanding seismic category C2 Seismic events are among the worst possible scenarios for engineers or architects designing structures. Under seismic loading, the performance of the connections in a structure is crucial not only to overall stability but also with a view to avoiding casualties and the economic impact resulting from the collapse of non-structural elements. In Europe, up to now, no standard that pre-qualifies fastening systems for seismic loading has existed, so anchor selection and design has not been possible within the framework of EU regulations.
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ilti is proud to announce that the HIT-HY 200 chemical anchor in combination with the HIT-Z anchor rod has received the first European Technical Approval (ETA) for seismic categories C1 and C2. ETAs for anchors subject to these new test procedures will now incorporate all the technical data required for seismic design. Moreover, the ability of these anchors to withstand seismic loading will be classified as follows: • Seismic category C1: Similar to the US seismic pre-qualification procedure and suitable only for non-structural applications. • Seismic category C2: Very demanding seismic crack movement tests that classify an anchor as suitable for structural and non-structural applications. Hilti, as a world leader in fastening technologies, has been at the forefront of innovation in the field of both mechanical and chemical anchors for more than 40 years. The company’s commitment to building a safer future is obvious not only from its investments in high-performance products incorporating safer installation methods, but is now also confirmed by this first ETA approval for an anchor pre-qualified for seismic category C2. The design method to be used with seismic-qualified
HIT-Z is the first anchor rod in the world to qualify for ETA Seismic category C2 and requires no borehole cleaning
anchors will be released before the middle of the year and Hilti is preparing a wide range of technical services to help designers and structural engineers comply with the new, demanding, requirements. No matter whether in the design office, on the jobsite or through online services, Hilti can provide its customers with the solid technical support necessary to jointly build a better future. www.hilti.com
Lee Spring now in India Lee Spring has announced the latest expansion to its global network, launching Lee Spring Company PVT India, based in Bangalore. To introduce itself to the Indian engineering market, Lee Spring India will be exhibiting at Fastener Fair India, on stand B84.
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or 95 years Lee Spring has helped engineers and purchasing agents in companies of all sizes, in all sorts of places, to untangle the mystery of springs. A global supplier with headquarters in Brooklyn, USA, the company recognises the need to be close to its customers in many parts of the globe, with nine locations in the United States, Mexico, the United Kingdom, India and China. Lee Spring Company PVT India will now serve the growing market demands of India, SAARC and the Middle East. The latest Lee Spring Series 19 catalogue will be available to customers visiting the Lee Spring stand at Fastener Fair India in Mumbai from 17th - 19 th April and can also be downloaded from the company website. The catalogue features Stock Spring designs, including 2,000 recent Metric size additions, ranging from Compression, Torsion, Extension and Redux™ wave springs to the latest Leep™ plastic composite and Bantam™ mini compression springs. Lee Spring offers over 19,000 stock springs and a complete custom spring design and manufacturing sevice with engineering consultancy, innovative design, quality manufacturing, the highest standards of customer care and minimum delivery times. www.leespring.com
10 Fastener + Fixing Te chnology • Issue 9 Apr - Jun 2013
cover story
Developing specialist joining solutions NORMA Group prides itself on being a global solution provider of engineered joining technology, working with its customers to find the correct solution. We spoke to Stephan Mann, director of product development EMEA at NORMA Group, about why the Group works with customers to develop products, as well as it latest advancements in SCR technology. NORMA Group is a solution provider of engineered joining technology. How does the Group ensure it is providing the technology its customers need? “We ensure that we are providing our customers with the technology they need by working with them on their on-going developments, at a very early stage, to provide the right solution for the application. We look to build up strong relationships with our customers through the departments that are ‘steering’ the development of new product lines (such as car lines, engine set ups for stationary engines, etc). We do this so that we can discuss potential solutions at an early stage. This is a must because otherwise you are simply providing a product, which every company can do. At NORMA Group we do not provide just a product, but a solution to a problem, topic or issue that a customer may have. We have a very wide portfolio of products that covers more than 30,000 items. We can combine different types of products, for instance from our metal product section and our plastic product section, to provide unique solutions for the customer. We want to be pioneers and technology leaders, in cooperation with our customers.”
What are the usual steps you would take when working with a customer on a solution for an application? “The classic way would be to start with project management, which would clearly define what the customer is looking for to ensure that we are targeting the right product solution. We would then focus on the development steps including studying the feasibility of a concept or idea, and then go through the phases of validation of the new product. We are in constant discussions with the customer to make sure that the performance of the product is meeting the customer’s expectations. As important as the development of the product itself is the development of the processes to produce it. This means that in conjunction with the product we establish a secured process to enable us to produce this newly developed part - meeting the customers requirements not only in respect to the technical functions of the product, but also the quality.”
What are the benifits of NORMA working with customers on future developments? “The main benefits would be that we have a very wide portfolio of solutions. Take our Urea products as an example. We have the knowledge about SCR systems to design the Urea feeding systems into the exhaust, but with this knowledge we are also able to transfer it into other applications such as exhaust pipe couplings and profile clamps, which are all used in conjunction with the Urea fluid system. If you want to reduce NOx in the exhaust and you have to transport the exhaust from the manifold to the catalyst. It is important that this path is leak free, which is why we are designing leak-free exhaust pipe joints. Additionally, we know how the dosing unit works, what it looks like, and what the requirements are. Therefore we provide profile clamps to fix the dosing unit into the exhaust system. This is something outstanding from NORMA Group, the ability to provide products for a whole range of exhaust related products, not only the Urea systems, but the fasteners that are needed for a good working exhaust system. It is by using the knowledge from one side of our business and applying it to other products, that enables us to offer our customers the complete solution.”
SCR technology How does it work? SCR technology converts nitric oxides into water and harmless atmospheric nitrogen by injecting Urea into the exhaust gases.
12 Fastener + Fixing Te chnology • Issue 9 Apr - Jun 2013
NORMA heated SCR line
Urea-tank
“ It is by using the knowledge from one side of our business and applying it to other products, that enables us to offer our customers the complete solution.” NORMA Group has seen recent advancements in its Selective Catalytic Reduction (SCR) technology, what are these advancements? “We learnt a lot from the first Urea line system we introduced to the market a few years ago. We were one of the pioneers providing Urea lines for SCR applications, which were mainly driven by the demand from the automotive industry. Due to what we have learnt we now have the potential to improve the system, through the processes and process stability of the production of this product, as well as in regard to the performance of the system. An example of this is the heating system in the Urea system. In the beginning the first Urea system just had electric heating wrapped around the tube from the outside. You need to have heating in the system because the Urea fluid freezes at -11°C and so to ensure the function of the system you must have an electric heating to quickly de-freeze the system. Having the heating wrapped around the outside of the system was very inefficient, as whilst some of the heat would go into the system, there would be some lost to the surroundings. Because of this our generation two Urea system has the heating component inside the tube, in the fluid. This means that all the heating energy produced goes directly into the medium, and that the heating efficiency of the system is much better, helping to reduce the amount of electrical power needed, which in turn helps to lower fuel consumption.”
What effect will the latest edition of the European emission standard, Euro 6, have on the market and SCR technology? “The upcoming Euro 6 legislation will be introduced in Europe in January 2014 for newly registered trucks and buses and in September 2014 for newly registered passenger vehicles. It will be continuing to demand lower NOx levels in the exhaust. The root cause of this is that high efficient diesel engines are equipped with high-pressure injection systems and have a high compression ratio. This combination causes a very good fuel efficiency, but contributed to that is a high NOx reading. To make the engines greener, these NOx readings have to be lowered. Urea systems help bring down the NOx readings of the
exhaust and are needed to meet the Euro 6 requirements. To fulfil these requirements there are two factors that are relevant to NORMA Group’s systems. One is the downsizing of the engines, which means there is a need to work in tighter spaces and surroundings, because the Urea must be dosed in a very efficient way. The other thing is that the engine set up is varying now and the SCR catalyst is moving closer to the engine, which means there are higher requirements regarding temperature resistance. This means that the demands on our system are increasing – temperature wise – and with the temperature comes pressure demands.
NORMAFLEX® SCR system
If you are above 100°C you need to pressurise the system more and more to make sure you don’t get vapour into your line due to the fluid boiling. Decomposing of the Urea fluid has to be respected so we have to have a clear view on the handling and treatment of the Urea fluid in the system. We are looking at our next generation of line systems with a very detailed view on temperatures and pressures inside the systems. Our Urea systems already comply with the upcoming edition of the Euro 6 standard and we are constantly looking at other ways in which we can improve our product. For instance with the generation two Urea system we are using specialised plastic materials to ensure that we can provide components that are weight optimised, and that we can offer a lighter design. This means that we are helping reduce weight in the car, which again will help reduce emissions. In addition to this we are already working on further development on Urea lines, which will be introduced in the next 4/5 years.” www.normagroup.com
www.fastfixtechnology.com
13
AUTOMATION
Flexible assembly systems drive e-mobility A million electric cars on Germany’s roads by 2020 This is the ambitious target set by the German Federal Government in its bid to continue the battle against climate-destroying CO2 emissions. It believes that e-mobility is a significant key technology to create a sustainable transport system for the future, especially when the power is produced from renewable energy sources. Yet e-mobility is still in its infancy.
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hat is why all those involved - policy-makers, industrialists and scientists - are working flat out to resolve all the outstanding issues. A great deal more research and development work is required before electric cars are fully ready for the market and before consumers will accept them. Lithium ion batteries replace the fuel tank in an electric car. Intensive research is under way to improve these. In a statement, industry policy-makers said: “Our aim is to reduce the cost of the batteries since it is the battery that continues to be the most expensive component inside an electric car.” The German Ministry of Transport requires that the energy density of batteries - i.e. the charging capacity measured against the volume - be increased even further. At present a battery stores much less energy than is produced by a full tank of petrol or diesel. This means that an electric car has a much shorter range than a car with a combustion engine. The automotive industry and its suppliers are in a ‘catch 22’ situation. The government requires them to get e-mobility on the road as fast as possible, but they have to keep an eye on the competition as they do so. Due to the current low numbers of electric cars, assembling them on the customary fully-automated assembly lines would seem unprofitable.
“ Using our standard components and solutions, we were able to provide an efficient solution to what the customer had believed would be a difficult problem.” Jürgen Hierold, sales manager at engineering company DEPRAG SCHULZ GmbH u. Co based in Amberg, Germany,
14 Fastener + Fixing Te chnology • Issue 9 Apr - Jun 2013
explains the problems: “This industrial sector of the future is faced with a dichotomy in planning its assembly systems. Any technology selected today needs to be adaptable and flexible, so that as numbers grow it can be turned into a fully automated plant. Moreover, assembly work carried out now in small numbers has to be to the utmost precision since - as is the case with all automotive assembly - an assembly fault can prove to be fatal. Assembly lines with intelligent manual stations are the most efficient solution to meet this requirement.” DEPRAG recently designed and built an assembly line for a renowned automotive supplier in just six weeks - from receiving the order to delivering the first units. The power controllers for use in electric cars are assembled on some 40 manual workstations. Jürgen Hierold explains: “This is where the ‘brains’ of future electric cars are safely and reliably fastened together by means of several hundred screws.” DEPRAG, a full service supplier, won the order because it was able to meet all the technical requirements from a single source. Hierold added: “Our customer viewed this order as particularly complex because it needed to cover all the various requirements of the assembly process. The main requirements were to ensure and maintain maximum processing reliability for these safety-critical components. Furthermore, a high level of flexibility was also required to deal with the wide range of variants. The sensitive electronic components require that the parts used to build them possess reliable electrostatic discharge capabilities (ESD-capacity). In addition, these components require an assembly environment that reliably meets technical cleanliness guidelines. The manual workstations also have to be ergonomically designed.” “Using our standard components and solutions, we were able to provide an efficient solution to what the customer had believed would be a difficult problem. All the components had already been coordinated and harmonised with one another. We are able to avoid the major friction, losses and delays that sometimes occur when customers have to purchase components from different sources and then coordinate and harmonise them all. All the components, such as the
AUTOMATION sensor-controlled screwdrivers, feeder systems, position control portals, control and analysis electronics, tool-change monitoring systems, pick-and-place units etc, come from our standard range.” The yardstick for processing reliability of bolted connections is particularly stringent in the automotive industry (VDI standard 2862, category A). Every step of the assembly process has to be monitored and recorded. So how is this achieved at a manual workstation? DEPRAG designed a high-quality steel profile position-monitoring portal to ensure that the EC-servo screwdriver is guided into the correct vertical direction. The portal provides a high level of accuracy in controlling the screw fastening process. “The assembly worker is at their workstation using our MINIMAT® EC-Servo screwdriver system to carry out their screw-driving tasks. The new position-control portal guides them step-by-step through the job,” explains Jürgen Hierold. “At each screw position the sensor technology activates the fastening parameters, releases the fastener, indicates if a bit change is required for the screw position, monitors the screw fastening and analyses the results. The work surface can be height-adjusted, thus allowing workers to sit or stand as they wish. The different fasteners are fed through the sword feeder directly into the screwdriver or into a ‘receiver’ from which the screws can be picked. The entire assembly line ultimately comprises over 60 feed devices.”
Sword feeder with belt-driven hopper For this assembly facility DEPRAG deployed feeder technology that meets every criterion of what is known as technical cleanliness. The DEPRAG feeder technology differs from a vibratory feeder in that there is no vibration, and fasteners are subject to very little abrasion as they are conveyed. Moreover there are vacuum connections at every point where abrasion could occur. Any harmful contaminating particles are simply sucked away. “Changing the bit, which is necessary when changing from one screw size to another, takes no longer than the blink of an eye,” mentions Hierold. “A tool box with intelligent quick-
16 Fastener + Fixing Te chnology • Issue 9 Apr - Jun 2013
change equipment and vacuum guide sleeve ensures that workers can change the bit quickly and easily. ESD capacity over the complete line has also been taken into consideration.” DEPRAG is well known for its user-friendly and intuitive control and measurement technology to control and record the assembly processes. Every workstation on the new assembly line for fastening together electric car control units has its own IPC-based process controller. “Our DCOS software, developed in-house and proven a hundred times over, ‘recognises’ the different sizes and types of screw, the screw parameter configuration and the tightening procedure to be used, as well as the correct insertion tool for each position,” says Hierold. “The sequence for making the screw connection is also precisely configured. Whatever the job - a torque/angle-controlled tightening procedure, a friction coefficient procedure or a special tightening procedure - workers can use the clear and easy-to-read touch screen to record whether the screwdriving job has been carried out satisfactorily.” It’s not just the control and measurement technology that ensures good interplay between man and machine (HMI). The MINIMAT® EC-Servomotor screwdriver with its tried-and-tested sensor-controlled technology gives workers the option to start the screwdriver by pressing a button or a key on the keyboard. The ball-bearing at the position control portal and the reduced mass make the screwdriver extremely light and agile in use, so worker fatigue is reduced to a minimum. The ergonomically adapted screwdriver handle also helps to combat tiredness. Likewise, the ability of the DCOS control system to visualise the screwdriving job makes a huge contribution to optimum worker guidance on the entire system. Ultimately, all the requirements that needed to be in place to assemble the power controllers - processing reliability, flexibility, ESD capability, technical cleanliness, ergonomic design and cost effectiveness - have been achieved using DEPRAG standard components, and to the customer’s fullest satisfaction. While the progress of e-mobility and the expected numbers of electric cars that will be produced in the future remains unclear, one thing is certain: As time goes on, DEPRAG customers will be able to make use of many components of the assembly lines they acquire now, when - as is the intention more electric cars are in circulation on the roads. DEPRAG’s product manager, Dagmar Dübbelde, adds: “We can handle the anticipated rise in numbers. Besides our expertise in the fields of screwdriving technology, feed technology, control and measurement technology, we are also the right partner for automation. Our in-house plant engineers are able to include elements of the existing assembly line into an automated line. The investment pays for itself.” For several decades DEPRAG SCHULZ GmbH u. Co has been closely concerned with automation solutions. With over 600 employees in more than 50 countries, not only is DEPRAG an expert full-service provider in technologies encompassing screw fastening, feeders, control and measurement, DEPRAG standards components also combine to form complete, fully or partially automated assembly facilities. DEPRAG is a single source supplier - from the initial consultation through to the after-sales and maintenance service.
renewable energy
Reviewing fastener standards may lead to fewer wind turbine failure-related accidents By Morten Schiff, CEO, Vibrationmaster, www.vibrationmaster.com The number of wind turbine-related accidents globally reached a record high of 160 in 20111, including 11 fatalities. Turbine failure can also have a serious impact on energy supply security. Studies into wind turbine reliability show that vibration fatigue is the third most common reason for wind turbine failure2. When analysing the root causes of failures, the suitability of design methods and component standards has been called into question3. Introducing standards such as DIN 25201 may prevent vibration-induced fastener self-loosening, thus cutting turbine failure rates and resulting in reduced accident numbers and fatalities, increased energy security and lower operation and maintenance costs. Wind turbines are heavy consumers of industrial fasteners According to the American Wind Energy Association (AWEA), an average utility grade wind turbine with an output of 2MW - 3MW includes about 8,000 components 4. Depending on the design, there may be up to 25,000 fasteners in each wind turbine, including bolts and studs. As many as 500 large fasteners in the M30 - M45 size range are used in critical bolted joints, such as connecting the rotor to the main shaft and the bearing housings to the turbine’s nacelle5. Between US$15,000 and US$25,000 per turbine is spent on large fasteners5. AWEA estimates that in the United States alone, during 2009, over 5,700 turbines were installed consuming approximately 3.2 million bolts 6. The wind energy sector is a major consumer of industrial fasteners and demand is likely to increase as major windfarm projects continue across North America, Europe and Asia. The United States, for example, must install a further 60,000 new turbines by 2030 to reach its wind energy use targets7.
Impacts of turbine failure The UK based Caithness Windfarm Information Forum has published a summary of wind turbine accident data, showing that official figures point to an average of 133 accidents per year, during the period 2007 - 20111. However, it acknowledges that the actual number of accidents involving windfarms may be as much as 90% higher. Blade failure is the principal cause of accidents. It results in either whole blades or fragments being ejected by the turbine and causing damage when striking people and property. Fire is the second most common cause of accidents, followed by structural failure. Although structural failure is often caused by storm damage, the Caithness report notes that “poor quality control, lack of maintenance and component failure” cause turbine accidents. Turbine failure can have a significant impact on the security of supply and the costs of running a windfarm. The AWEA highlights that “the cost of repairing a nacelle – which must be dismantled on the ground – easily runs upwards of US$250,000
18 Fastener + Fixing Te chnology • Issue 9 Apr - Jun 2013
and repairs often cost 10 times that of original manufacturing.”4 Wind turbines are typically designed for a twenty-plus year lifespan. Because windfarms are either offshore or in remote land-based locations, maintenance and repair can be
disproportionately expensive. So it is in the interests of turbine original equipment manufacturers (OEMs) to design-out failure modes. Furthermore, if wind turbine equipment is considered to be less reliable and of increased risk of failing to generate power, then windfarm financing and interest rates become more expensive 3, which in turn reduces the commercial viability of wind energy projects.
Why turbines fail In-depth research into wind turbine failure modes shows that “vibration fatigue is the third most common occurrence of failure in wind turbines, after corrosion and mechanical overload.”2 As one wind power engineering commentator puts it: “Wind turbines, like helicopters, are fatigue machines – always vibrating and working to loosen their fasteners.” He continues: “More vibration will come as engineers develop longer blades to capture more wind energy and towers reach higher to accommodate them. These increased vibration levels may loosen some tower fasteners.”9
Testing innovation to its limits
Reduce wind turbine failure rates by vibration testing fasteners \ Vibration fatigue is the third most common reason for wind turbine failure \ With as many as 25,000 fasteners found in a typical wind turbine, bolted joint performance plays a critical role in reducing failure. Reduce maintenance, improve energy security and safety standards by analysing the self-loosening behaviour of fasteners and their locking elements. Vibrationmaster’s range of Junker Test benches can vibration test fasteners to the toughest international standards in sizes spanning M5 – M45 ISO Metric / #10 – 1 3/4 in UTS.
\ Contact us now to see how Vibrationmaster’s Junker Test Benches can help reduce wind turbine failure rates, improve safety and increase energy security: Call +45 53 55 53 45 Email info@vibrationmaster.com Visit www.vibrationmaster.com
Vibrationmaster Technology Center s.à r.l. \ 1, rue Lamartine \ L-1914 Luxembourg Tel: +45 53 55 53 45 \ Email: info@vibrationmaster.com \ Web: www.vibrationmaster.com
renewable energy Further research confirms that “bolt fatigue and vibration loosening account for over 75% of all bolted joint failures.”8 This points to fastener failure, or failure of fastener securing and locking mechanisms, as a primary root cause of wind turbine failure. However, as the AWEA confirms, wind turbine OEMs “are very conservative in their supplier qualification processes and have extremely demanding quality requirements. They require consistent and zero defect quality.”4 Why, then, are fasteners causing wind turbine failures if OEMs insist on such a high quality ‘cost of entry’? Could fundamental design and the types of component standards used be a significant contributory factor? Studies into wind turbine failures agree these factors may be the case.
Are standards and design methods causing wind turbines to fail? Quantitative research into wind turbine operation and management costs has flagged serious concerns about the suitability of existing design methods and standards. In the conclusions to his 2006 survey of wind turbine reliability in the US Federal wind energy programme, Christopher Walford of Global Energy Concepts says: “The large number of load-carrying component failures has led to concerns about the applicability of the standards that are used for component design. Existing standards and design methods should be reviewed.”3 A European Commission-funded study into the reliability of offshore windfarms reached the same conclusion: “It is necessary to increase our focus on the following aspects: design, procurement, quality, risk assessments and quality assurance. New standards or practices regarding risk assessment and quality assurance of offshore wind-farm installations are required, and existing IEC standards may not be sufficient.”10 These are studies dating back to 2006 and 2007 respectively. The key standard, DIN 25201, which relates to the self-loosening behaviour of fasteners under vibration conditions, was not published until 2010.
References 1. Caithness Windfarm Information Forum Summary of Wind Turbine Accident Data to 30 September 2012. [Online] Caithness Windfarm Information Forum. 30 September 2012. Available from: http://www.caithnesswindfarms.co.uk/accidents.pdf [Accessed 30 October 2012] 2. Arabian-Hoseynabadi H, Oraeea H, Tavner PJ. Failure Modes and Effects Analysis (FMEA) for Wind Turbines. International Journal of Electrical Power and Energy Systems 2010;32(7): 817-824 3. Walford C.A. Wind Turbine Reliability: Understanding and Minimizing Wind Turbine Operation and Maintenance Costs. [Online] Kirkland: Global Energy Concepts LLC; March 2006. Available from: http://prod.sandia.gov/techlib/access-control.cgi/2006/061100.pdf 4. American Wind Energy Association. Wind Energy Industry Manufacturing Supplier Handbook. [Online] Washington: American Wind Energy Association; May 2011. Available from: http://www.awea.org/issues/supply_chain/upload/Supplier-Handbook.pdf 5. The Crown Estate & BVG Associates. A Guide to an Offshore Wind Farm. [Online] London: The Crown Estate; February 2010. Available from: http://www.thecrownestate.co.uk/media/211144/guide_to_offshore_windfarm.pdf 6. American Wind Energy Association. Anatomy of a Wind Turbine. [Online] Available from: http://www.awea.org/issues/supply_chain/Anatomy-of-a-Wind-Turbine.cfm [Accessed 30 October 2012]
20 Fastener + Fixing Te chnology • Issue 9 Apr - Jun 2013
So, the wind turbine supply chain now has the tools to provide components that reduce failure risk.
Component standards that prevent self-loosening behaviour The self-loosening behaviour of fasteners under vibration conditions is a well-known engineering phenomenon and was first theoretically explored by German engineer Gerhard Junker. In his paper - ‘New Criteria for Self-Loosening of Fasteners Under Vibration’11, Junker developed what became known as the ‘Junker Test’, which tests the self-loosening behaviour of fasteners under transverse loading conditions by vibration testing. The Junker Test was incorporated into the German railways standard DIN 6515112 and became a standard fastener industry test to determine the self-loosening behaviour of a nut and bolt. More specifically, DIN 65151 was used to demonstrate the effectiveness of fastener locking mechanisms when under vibration conditions. In 2010, a much more demanding standard was introduced, DIN 2520113. The underlying principle of the new standard is that vibration testing of fasteners and their locking elements should as closely resemble real life conditions as possible. It sets out exactly how the test should be performed and the equipment that should be used. Fastener locking elements tested to, and satisfying the requirements of, DIN 25201 are significantly less likely to self-loosen and cause the failure of wind turbines. Adoption of DIN 25201 in the fastener industry is patchy so far, but as it becomes more widespread, specifiers in wind turbine OEMs will be able to genuinely compare the performance of competing fastener products and locking elements. OEMs will be able to choose better quality fasteners that are far less likely to lead to their turbines failing. This, in turn, will cut the costs of operation and maintenance and the total cost of ownership. It will also increase the security of energy supply, and by adopting DIN 25201, wind turbine manufacturers may be able to prevent turbine failures that lead to accidents and deaths. www.vibrationmaster.com 7. American Wind Energy Association. Market Growth Potential. [Online] Available from: http://www.awea.org/issues/supply_chain/Market-Growth-Potential.cfm [Accessed 30 October 2012] 8. Srinnivasan S. Advances in bolting technology. Wind Systems Mag. [Online] December 2010. Available from: http://windsystemsmag.com/media/pdfs/Articles/2011_Dec/1211_LCT.pdf [Accessed 30 October 2012] 9. Bushing S. 2012 Trends in Bolting. Windpower Engineering and Development [Online] 1 June 2012. Available from: http://www.windpowerengineering.com/design/mechanical/fastening_ joining/2012-trends-in-bolting/ [Accessed 30 October 2012] 10. Holmstrom O. Survey of reliability of large offshore wind farms Part 1: Reliability of state-of-the-art wind farms. Project Upwind/DONG Energy Generation A/S. Report number 250490, August 2007 11. Junker G, New Criteria for Self-Loosening of Fasteners Under Vibration, Transactions of the Society of Automotive Engineers, Vol. 78, 1969, pp. 314-335, New York 12. DIN 65151: 2002-08 Dynamic testing of the locking characteristics of fasteners under transverse loading conditions (vibration test), Deutsches Institut für Normung c.V., Berlin 2002 13. DIN 25201-4: 2010-03 Annex B Test specification for demonstrating the resistance to self-loosening of secured bolted joints, Deutsches Institut für Normung c.V., Berlin 2010
The Position Deviation Compensating Positive Fit Joint (PDC-PFJ)
Die Formschlussverbindung mit Lageversatzausgleich First fastener system providing positive fit also in multi-fastener joints Allows wider manufacturing tolerances (cost reduction) First free of play shear load fastener system No differential movement between joined members
Erstes Verbindungssystem mit Formschluss auch bei Mehrfachverbindung Ermöglicht gröbere Fertigungstoleranzen (kostenreduzierend) Erstes System entwickelt für spielfreie Schublastverbindungen Unterbindet Relativbewegung zwischen den Bauteilen
www.ibweiss.com
mailbox@ibweiss.com
National, European, and International Patents pending
RENEWABLE ENERGY
Norbar launches new Handtorque™ Compact Series Norbar Torque Tools has announced the launch of its Handtorque™ HT-92 and Handtorque™ HT-119 - ideal for bolt tightening in confined spaces such as wind turbine towers.
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oth the HT-92 and HT-119 combine new materials, better traceability and are the newest additions to Norbar’s new Compact Series of Handtorque™ multipliers. Key features of the multipliers include a stainless steel body, a calibration certificate, compact dimensions, lower weight and higher torque output. In comparison to the closest existing model from Norbar’s current range, the HT-30, the HT-92 is smaller in diameter (92mm versus 108mm), lighter (5.4kg versus 7kg) and has a 1,000Nm higher torque output at 4,000Nm. The HT-119, with fitted reaction plate, is 3.2kg lighter than the HT-60, the closest model in the existing Norbar range, but has a 1,000Nm higher torque output at 7,000Nm. The new multipliers are designed to satisfy customer demand for greater traceability. Every HT-92 and HT-119 will be supplied with a traceable calibration certificate stating its exact ratio. The nominal ratio for the HT-92 and HT-119 will be 25:1 and the calibration certificate will demonstrate that this performance guarantee is delivered within a tolerance band of +/- 4% by stating the exact ratio for every product delivered.
Philip Brodey, sales and marketing director at Norbar, said: “We set out to produce the best hand operated multipliers on the market and the HT-92 and HT-119 both live up to this. With new compact dimensions, higher torque output and better calibration traceability, both multipliers make great additions to our exciting Handtorque™ range. We have named this new group of products the ‘Compact Series’ as it also includes our HT-52 and HT-72.” Philip added: “The multipliers have stainless steel bodies for much more than just aesthetic benefits. We know that our Handtorque™ multipliers have tough lives and the use of a corrosion resistant material means that there is no plating that can be damaged or lifted off. The stainless steel we have chosen is also extremely strong, which will contribute to these products being the most reliable on the market. Removing the need for plating also means fewer production miles and no plating chemicals to deal with.” Both multipliers come with a new style operator’s manual, carry case and are in the new Norbar branding.
Using robotics for wind turbine fasteners Dokka Fasteners Inc, a manufacturer of large diameter, hot forged fasteners located in Auburn Hills, Michigan, USA, was created in 2010 to provide high tensile, large diameter hex bolts, double-ended studs, and threaded rods for the assembly and installation of very large wind turbines.
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he fasteners from Dokka Fasteners are used to attach the wind turbine blades to the hubs, attach the nacelle housings to the tower, connect the tower segments together, and attach the completed wind turbine to its foundation. “The wind turbine industry is committed to ensuring the highest levels of product quality in their towers, and these requirements are expected of the fasteners used as well. These fasteners are subjected to the most hostile and corrosive environments, and are expected to successfully perform in a highly stressed application for many, many years.” In order to consistently manufacture such a robust fastener, it was necessary for Dokka Fasteners to design its own manufacturing process using the latest technology available in automation and robotics. Additionally, there were ergonomic benefits to using the latest automation technology, as the weight of the average fastener made is approximately 25lbs (11.4kg). Dokka Fasteners held the robotics manufacturers to close tolerances in the programming for each robot, as each part has to be positioned in the fixtures exactly the same way each time to minimise rejections. Dokka Fasteners carried the automated process into tooling changeovers and preventative maintenance procedures, utilising automated machines and equipment to ensure a seamless flow and minimise downtime. Dokka Fasteners’ heat treat processes also feature automation to eliminate the need to manually program the cycles or to manually move material through the furnaces. By using automation to enhance the heat treat processes, each batch of product consistently receives the most accurate time and temperature for that heat of material. Dokka Fasteners automated processes have been approved to multiple customer quality management systems audits as well as registered to the ISO 9001:2008 standard.
22 Fastener + Fixing Te chnology • Issue 9 Apr - Jun 2013
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You specify the corrosion protective coating GEOMET® on your components, do you realise you are contributing to environmental benefits? GEOMET® offers the best performance/ thickness ratio for corrosion protection of metal components. The required quantity of zinc and other metals is reduced as much as possible. In addition, low thickness does facilitate the assembly of threaded parts.
www.nofmetalcoatings.com NOF METAL COATINGS EUROPE S.A. 120, rue Galilée 60315 CREIL Cedex / France Tel.: + 33 ( 0 ) 3 44 64 63 62 Fax: + 33 ( 0 ) 3 44 64 63 40 E-mail: infofr@nofmetalcoatings.com
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RENEWABLE ENERGY
Precision parts to order Rolevet Ltd is a manufacturer of industrial fasteners, specialising in non-standard and bespoke fasteners to customer specifications.
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anufacturing from specialist alloys, duplex stainless steels and high nickel alloys, Rolevet can supply products to a diverse range of industries, including the MOD, turbine manufacturers, power stations (nuclear and fossil fuelled), pump & valve manufacturers, oil & gas (FPAL certified), chemical refineries, process plants, heavy engineering and ship repairs both UK based and worldwide. From its factory in the Midlands, UK, Rolevet is able to manufacture fasteners to national and international standards or to bespoke customer specifications. On-site hot forging alongside a general machine shop and CNC workshop means that Rolevet is able to manufacture precision parts to order. This, combined with an extensive stock range of fully traceable materials in various grades, has helped it to establish a first class reputation for meeting customer demands and delivery schedules - no matter how large or complex the requirements. Rolevet has particular experience supplying the power generation industry and is able to offer a speedy supply of turbine studs, capnuts, waisted studs, hex bolts, coupling bolts and socket capscrews in high temperature materials including Durehete ® (950 T31) and (1055 T41), 21CrMoV57 and Jethete ® X19. In addition, a complete range of materials including Nimonic, as well as high tensile and stainless steels, is stocked giving Rolevet the ability to offer a rapid delivery for emergency breakdowns. Steve Hemming, recently appointed operations director, commented: “This year Rolevet celebrates its 25th anniversary and the company is now looking to develop further with plans to expand into new markets and increase our manufacturing capacity within the UK. A market of interest for us at the moment is the renewable energy market, where we think our product range is particularly relevant.” www.rolevet.com
www.rolevet.com
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You need to use Advance Spares Ltd! High quality fasteners from low cost sources Flange Bolts • Shoulder Rivets and Bolts Trilobular Screws and Bolts • SEMS Cold Formed Specials • Machined/Turned Parts Plastic Trim Panel Fasteners • Metal Edge Clips Tubular Brass Rivets • Kitting
t: +44 (0) 1978 823 900 e: sales@aslgroup.uk.com w: www.aslgroup.uk.com Supplier to the OEM and automotive industry
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RENEWABLE ENERGY
Never deal with seized up nuts again Flaig + Hommel GmbH Verbindungselemente has been producing nuts and fasteners since 1945. Apart from complex cold-forged parts, the company can also manufacture a wide variety of its own patented products - one of the most notable being hot-dipped FS-All-Steel Lock-Nuts for wind farms.
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anufacturers of wind farms in Germany and abroad use the FS-Lock-Nut to bolt down the nacelles, with the nuts used for interior and exterior screwed connections. The FS-Lock-Nuts can also be used for the fitting of weather vanes and rain protection, for the assembly of spinner housings, to secure gratings and to attach lighting units. The key benefits of FS-Lock-Nuts include high security, the ability to apply the nuts without damaging the mating thread, and the corrosion-resistant, hot-dipped surface coating, which is not available with other lock-nuts. The nut’s resistance to shaking and dynamic stresses, its reusability, and its maintainability, ensure that the FS-Lock-Nut is an investment that pays off. A new area of application is on tripods, where M42 nuts are used to connect the J-tubes to the stream plates. Many tower manufacturers also use the M42 nut to attach various interior components. One specific example is a plastic stargrip moulded around a lock nut for the fixation and vibration proofing of the manhole. So far, mainly hot-dip galvanised FS-All-Steel Lock-Nuts have been applied in offshore wind farms, but Flaig + Hommel is also able to manufacture the FS-Nuts from A2 and A4 (INOX) or saltwater-proof steel. The stainless steel nuts are specially coated in order to avoid the erosion of the nut during unscrewing. The FS-Lock-Nuts for those applications have been CE certified and comply with DIN 15048 regulations.
Intersolar Europe The potential of renewable heating One of the major topics at Intersolar Europe 2013 - taking place from 19th - 21st June 2013 at Messe München, Munich, Germany - covers the opportunities and potentials of renewable heating.
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olar process heat is one of the major growth markets within the field of solar thermal technology. Solar thermal installations can be used for not just a costefficient way of heating apartment buildings, but can also be used in industrial production processes. With relatively low-temperature heat accounting for two thirds of all energy used for industrial purposes, there is great potential here. In particular, companies requiring process temperatures of below 100°C are likely to benefit from solar installations. In view of rising electricity prices and legal regulations on CO2 reduction, switching to solar process heat enables companies to save money while making a significant contribution to changing the energy supply system.
Intersolar Europe 2013 Intersolar Europe is the world’s leading exhibition series for the solar industry and its partners. In 2012, 1,909 international
26 Fastener + Fixing Te chnology • Issue 9 Apr - Jun 2013
exhibitors and 66,000 trade visitors were welcomed to the show. The exhibition focuses on the areas of photovoltaics, PV production technologies, solar thermal technologies and energy storage. Since its founding, it has become the most important industry platform for manufacturers, suppliers, wholesalers, service providers and partners of the solar industry. The accompanying Intersolar Europe Conference consolidates the topics of the exhibition. In 2012, more than 400 speakers and around 2,000 attendees discussed current industry topics and shed light on the background of technological, market and political developments. Fastener related exhibitors at Intersolar Europe 2013 include Etanco GmbH, MAGE SunFixings GmbH, A. Raymond GmbH & Co KG, HellermannTyton GmbH, HECO-Schrauben GmbH & Co KG, Hilti Corporation, Reisser Schraubentechnik GmbH, Schäfers + Peters GmbH and OBO Bettermann GmbH. For a full list of exhibitors visit www.intersolar.de
Renewable energy
Flangeform® adds value to solar project Flangeform® is a unique captive sheet metal fastener for high strength attachments in thin gauge material. Originally developed for automotive and appliance applications, it provides torque and push/pull out values that PSM International says greatly exceed industry standard rivet or clinch fasteners. Installation time can also be much less when used in secondary operations or integrated with automated processes. Here PSM International uses a case study to illustrate how all of these advantages were used to add value to a large solar power project in the United States. Overview Utility scale solar farms typically use PV panels mounted on tracker or racking structures. Bolted joints enable assembly in the field but require construction personnel to handle massive quantities of individual fasteners. Captivating one half of these connections speeds up the erection process and minimises lost hardware. Mechanical performance is critical since wind loads can be dynamic. Hardware must also resist corrosion in a harsh outdoor environment. Project developers and other stakeholders often require their suppliers to provide performance warranties of up to 20 years.
Application This solar farm will generate 200MW of renewable power when completed in Q4 2013. It will occupy nearly 2,000 acres of land in the Southern California desert on an ideal site with especially high solar irradiance and grid access. A Power Purchase Agreement is in place with a major utility company. A singleaxis tracker structure will be used to mount thin film PV panels. This system is a bespoke design that includes rails roll formed from HSLA steel. Two of these include captive fasteners. More than 14 million bolted joint connections must be assembled on site during the construction process. One of the rails with fasteners is 1mm thick, about 250cm long, with 5 nuts and 2 studs pre-installed. Overall system design makes pull through values for these studs
especially important. The other section with captive fasteners is 1.5mm sheet, about 60cm long, with 2 nuts. Torque performance is the key requirement for these nuts. Stainless hardware is required throughout the project and future disassembly for maintenance is a must. Potential galling between mating fasteners was also a concern since both would be made from a similar grade of A2 stainless steel.
Fastener solutions considered The tracker designers initially believed industry standard rivnuts and studs would meet their structural requirements if fasteners and sheet thickness were both sized properly. A design was completed and sent to roll formers for proposals. Sub-contractors roll forming the rails would need to install these fasteners as a secondary operation – manually, and one at a time. PSM proposed Flangeform to a number of roll formers bidding on the project as a way to save on labour. Proposals were submitted that included installing all the fasteners required in each rail with a single press stroke. Additional automation in the form of a system that bowl fed five nuts simultaneously was also presented.
Why Flangeform was selected for production The tracker design team found Flangeform provided two structural advantages. Prototype testing confirmed
28 Fastener + Fixing Te chnology • Issue 9 Apr - Jun 2013
that pull out requirements for the studs would be higher than planned and could not be met with standard rivstuds. Flangeform studs exceeded the new requirements with no modifications. Improved torque performance in thin material also enabled them to downsize the two nuts in the short section one thread size, and reduce the steel thickness from 1.78mm to 1.5mm. The nut face profile on these two nuts was easily modified by PSM to help locate mating parts and aid in field assembly. Flangeform exceeded expectations again and was specified for exclusive use on both applications. All three Flangeform fasteners were specified with a coating to resist galling. Using A4 material was investigated, but rejected because of its higher cost. A zinc-rich, chrome free, dry film coating with proprietary chemistry was chosen as an economical alternative. The remaining nut was open to roll former choice; either Flangeform or rivnuts were approved for use. Volume on this was significantly higher than the other two fasteners. Two roll formers received orders for the rails needed to complete the project. Both of them elected to use Flangeform exclusively based on compelling labour savings. Custom bowl feed and press tooling was quickly designed, fabricated and commissioned by PSM. Mass production started Q1, both roll formers quickly achieved or exceeded the Flangeform installation rates they had projected. www.psminternational.com
FLANGEFORM® Latest generation high strength nuts and studs for demanding applications
FLANGEFORM® Installation Sequence
Key advantages of FLANGEFORM®
● Fast installation, high strength,
ideal for sheet metal gauges down to 0.5mm ● Replaces rivet, weld and
self-clinching technology with a stronger alternative ● High resistance to push-out /
pull through loads
Mini Die
● Exceptional resistance to high
bending moments ● High break-off torque resistance
PSM International is a global fastener manufacturer with production in the UK PSM International Fasteners Ltd., Ferry Lane, Pembroke SA71 4RE • Tel +44 (0) 1646 683 501 • www.psminternational.com • europe@psminternational.com
TAPES + ADHESIVES
Lohmann is pursuing ‘green’ paths The ideal power supply of tomorrow is ‘green’: from renewable production and effective storage up to temporal and mobile consumption. Connected with an economic sustainability, Lohmann strives to achieve this goal together with manufacturers and users.
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he Lohmann bonding engineers have developed adhesive solutions for renewable energy sources, including numerous solutions for the photovoltaics industry as well as new sealing adhesive bonds for electrolysers and fuel cells. As a trend-setting technology, fuel cells and electrolysers will play a particularly important role here, as they can economically convert chemical energy into electrical energy. Fuel cells are rapidly gaining in significance as they are becoming smaller and more efficient all the time, making them interesting for many sectors of industry. Sealing products are of enormous significance here, as they seal the bipolar plate cells to the fuels (e.g. hydrogen) in the fuel cell area. Self-adhesive sealant is particularly well suited to these purposes, because alongside its sealing properties, it also guarantees stability and can be applied precisely. Lohmann has therefore developed the sealing adhesive tape: DuploTEC FCT (fuel cell technology) with an acrylic base. The self-adhesive sealant is suitable for PEM (proton exchange membrane) fuel cells and for direct methanol fuel cells (DMFC). The sealing material is available in variable layer thicknesses from 150µm – 350µm (it is possible to produce further thicknesses on specific customer request). The adhesive material exhibits good initial tack and very good die-cutting properties that prevents it from slipping during application and can be applied true to contour. Unlike with liquid materials, there is no drying period. Its application allows the user to optimise sealing processes in terms of production speed and process reliability. Furthermore, the sealing material maintains distances, compensates for any irregularities in the profile of the bipolar plates in the fuel cells, and – last but not least – presents an affordable solution. “With their broad portfolio, the bonding engineers show how innovative adhesive www.lohmann-tapes.com solutions can make an economical contribution on the path towards ‘green energy’.”
Solar-Flex provides bonding power WEICON GmbH & Co KG from Germany has developed Solar-Flex, a special product for bonding and sealing numerous joints in the photovoltaic industry.
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olar-Flex is an elastic one-component adhesive and sealant on a MS polymer base, free of silicone, isocyanate and solvents. This WEICON product has a high initial bonding power and a fast development of adhesive strength that makes it suitable for applications on vertical surfaces both indoor and outdoor. Solar-Flex is used for fixing and sealing parts in solar power systems, junction boxes, marking systems, metalworking, ventilation and air conditioning and can also be used wherever silicone or products containing silicone are not permitted or desired. Since 1947, WEICON GmbH & Co KG has been producing speciality products for the industry in Germany. The range of products includes special adhesives and sealants, technical sprays and high-performance assembly pastes and greases for all areas of industry - from production over repair up to maintenance. Another field of activity is the development, sales and distribution of stripping tools. The company headquarters is located in Münster, Germany. WEICON has subsidiaries in Dubai, Canada, Turkey and Romania and is represented by WEICON partners in more than 70 countries all over the world.
30 Fastener + Fixing Te chnology • Issue 9 Apr - Jun 2013
Special Screws directly from stock!
Hexagon set screws with full dog point and half dog point According to DIN 561, 564
Fit bolts, plugs, knurled thumb screws, square head bolts, flat headed screws, hexagon set screws, brass screws and specials. Fon +49 (0) 40 532 852- 0 Fax +49 (0) 40 532 852- 52
info@pasvahl.de www.pasvahl.de
130101_FF_E21_13_Zapfen/Spitze 92x133.indd 1
09.01.13 10:56
The Bonding Engineers. The specialists for innovative and efficient adhesive solutions. Lohmann is the global company of choice whenever components need to be joined. As „The Bonding Engineers“, we have the experience and the adhesive know-how required to provide you with everything from a single source. From consultation to formulation of the adhesive and coating of rolls, spools and die-cuts through to process integration. Your benefit? Improved quality, improved efficiency, improved costeffectiveness.
Lohmann GmbH & Co. KG Irlicher Strasse 55 56567 Neuwied / Germany Phone: +49 2631 34-0 Fax: +49 2631 34-6661 info@lohmann-tapes.com www.lohmann-tapes.com
TAPES + ADHESIVES
Cut downtime and improve equipment performance Water engineers know the importance of equipment reliability and predictability. It is their responsibility to keep plants running 24 hours a day, 7 days a week. However, it’s a tough task in an industry where the environment is harsh and machinery is subject to heavy vibration, shock and corrosion. Nuts and bolts shake loose, hydraulic and pneumatic systems leak and bearings fail.
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o help engineers cut downtime, improve equipment performance and save costs, Henkel offers a wide range of Loctite ®, Nordbak ® and Hysol ® products for repair and maintenance. They are designed to rectify problems caused by wear, abrasion, chemical attack, erosion,
corrosion, impingement and mechanical damage. Typical applications range from concrete repair to extending the operating life of devices like pumps, gearboxes and centrifuges.
Rebuild, repair, protect Flow control mechanisms and influent structures are particularly prone to wear and corrosion making them less effective and susceptible to leaks and further damage. Components such as butterfly valves or grit chamber paddles and spindles are typical examples. They can be rebuilt or re-profiled by the application of Nordbak ® epoxy wearing compounds or Hysol ® polymer composites and/or Loctite ® brushable ceramics. Henkel points out that the key advantage is their capability to create a sacrificial and renewable working surface, protecting the structural integrity of the original substrate.
Secure, seal and safeguard Loctite ® threadlockers are widely used in the water utilities industry for
Solution for bonding polypropylene Techsil and Power Adhesives have developed a solution to the industry wide issue of bonding polypropylene to itself in a fast and efficient way.
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echsil and Power Adhesives have developed this new grade of hot melt to meet the changing demands for increased productivity in industries such as automotive seating, moulded parts and other industries looking to replace acrylonitrile butadiene styrene (ABS) for the more cost effective polypropylene parts. The companies state that the new high performance polypropylene based hot melt adhesive bonds polypropylene quickly and efficiently. The hot melt adhesive does not require pre-treatment of the surfaces and is applied hot from a standard 195°C gun and has a medium/long open time. Once the heat has dissipated, the surfaces will be bonded and high tear, peel and lap shear values are achievable. These values increase over time as the polypropylene elements of the hot melt cross link further with the substrates. “Polypropylene is a high tonnage polymer that is commonly used in many industrial sectors such as textiles, automotive, packaging and a wide range of consumer goods. The low cost processability and chemical inertness of polypropylene are the main reasons why it is used in a variety of applications and manufacturing processes.”
32 Fastener + Fixing Te chnology • Issue 9 Apr - Jun 2013
preventing vibrational loosening, leakage and corrosion between threaded and parts. They are available in a range of viscosities and also strengths, from semipermanent formulations to those that are removable with standard hand tools. Typical applications are bar screen and clarifier components which will loosen under high duty cycles requiring periodic shut downs for surface repairs and retightening of the threaded assemblies. Costly hydraulic and pneumatic leaks are eliminated using Loctite ® sealants. They fill the space between threaded parts providing an instant, low pressure seal. When fully cured they seal to the burst strength of most pipe systems. Anaerobic, silicone and sealing cord are available to suit the substrate. Complementing the threadlockers and sealants are Loctite ® retaining compounds that secure bearings, bushings and cylindrical parts into housings or onto shafts. They achieve maximum load transmission capability and uniform stress distribution and eliminate fretting corrosion.
New Permabond epoxy adhesives Permabond has expanded its epoxy adhesive line with a new range of two component epoxies formulated with FDA approved ingredients.
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hese toughened epoxies are manufactured in compliance with the FDA CFR 175.105 and 175.300. Permabond says the excellent shock and impact resistance coupled with environmental and temperature resistance makes these epoxies ideal for food processing and food packaging equipment. Typical food contact applications include bonding filter components, bonding and sealing appliances and food handling equipment. They cure at room temperature or can be heated for a faster cure. The range includes various viscosities, gap filling capabilities and working times to suit most applications, and Permabond custom formulates to suit individual manufacturing needs.
STAFA IS YOUR SUPPLY PARTNER FOR STRUCTURAL BOLTS IN ACCORDANCE WITH EN-15048 Stafa has the complete range on stock in both zinc plated and hot dip galvanized ISO-fitting.
To be able to design and execute
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Non-Threaded Technology
Shims? Make mine laminated By Russell R. Radant, chief engineer, Spirol International Corporation Laminated shims make life easier for designers and machine operators, as long as they are properly specified. It is often quicker and less expensive to use a shim, a thin piece of metal or composite, to level a machine tool or make components fit together rather than grinding and machining to make the same mechanical adjustments.
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hims act like those folded pieces of paper people place under table legs to prevent the table from wobbling. They are also used to quell vibrations and to silence noisy equipment. However, laminated shims are more versatile and economical than slivers of paper or machined wedges. Laminated shims have peelable layers of metal or composite, which are removed until the shim has the proper thickness. Adjusting them is as easy as peeling off laminations with a knife, or in the case of some materials, using no tool at all. They are built up from layers of precision-gauge metal foil or composites. Layers are bonded into a rigid structure that appears and functions as a solid sheet or plate. The finished shims withstand reasonable handling, including shearing and machining. Laminated shims are produced by surface-bonding layers of precisionmetal foils or composite films and resin adhesive into sheets. The foils can be aluminium, stainless steel, carbon steel and brass, among others. Final shims range from 0.15mm to 6.35mm (0.006 inches to 0.25 inches) thick. The bond is made by heat and pressure, which hardens and reduces the resin to a point where it is almost undetectable. At temperatures above approximately 150°C (300°F), however, the bonding agent may deteriorate and there will be a negligible loss of total thickness. Even heating the resin to above 230ºC (446°F) does not influence the performance of the shim. Designers, however, should know the forces that will be placed on the laminated shim before choosing a shim material. Furthermore, shim faces should not be exposed to frictioncausing motions unless the shim has a PTFE treatment – otherwise it could delaminate. However, if parts have location holes, the only forces will be those exerted by the tightening of screws. In this case there are no
limitations on using laminated shims. Laminated shims should be machined rather than stamped. Machining leaves clean edges that make shims easier to peel. Machining also prevents burrs from forming when peeling layers away. The burrs are a by-product of die rolls and stamping. Laminated shims can be partially solid and partially laminated. This type of shim is either half-solid or three-quarter solid, depending on the ratio of solid section to total thickness. Standard thicknesses for
the solid part are 1.57mm, 2.39mm and 3.18mm. (0.062 inches, 0.094 inches and 0.125 inches). Semi-solid shims are used to add rigidity to a design, accommodate a bearing surface on one side of the shim, meet requirements for a thick shim that will have minimal adjustments made to it, and to lower costs. There are some size restrictions on laminated shims. For example, brass laminated shims larger than 305mm (12 inches) in diameter must be made in
34 Fastener + Fixing Te chnology • Issue 9 Apr - Jun 2013
sections. As a general rule of thumb, all thicknesses should never be less than three times the total material thickness. Edges of laminated shims should not be rounded and deburring laminated shims may make them difficult to peel. There are three basic reasons for designing shims into assemblies and devices. Firstly there is tolerance compensation. Shims eliminate the time and cost of putting precision tolerances on mating components. They also compensate for accumulated tolerances during assembly. It is better to design in a shim than to discover later one is needed at the assembly stage. A further reason is precision alignment, since shims align parallel and angular surfaces when interfacing elements must be coupled. In terms of wear compensation, shims compensate for wear and are often designed to be the sacrificial component so the basic equipment retains its original accuracy. Laminated shims reduce assembly time and provide dimensional accuracy without machining components. Quick production line adjustments and field repairs can be carried out and there is no need for grinding. Costs are minimised, as is precision with fewer items to stock. Selecting the right laminate material is vital and typical material pressure resistances are: aluminium 98 MPa (14,223 psi), brass 440 MPa (64,004 psi) and stainless steel 685 MPa (99,562 psi). www.spirol.com
INTERNATIONAL EXHIBITION FOR FASTENER AND FIXING TECHNOLOGY 8 – 10 APRIL 2014 HANNOVER, GERMANY FOR FURTHER INFORMATION, PLEASE CONTACT MACK BROOKS EXHIBITIONS TEL: +44 (0)1727 814 400 EMAIL: HANNOVER@FASTENERFAIR.COM
WWW.FASTENERFAIR.COM
Non-Threaded Technology
Not just a simple rivet nut Blind rivet nuts are indispensable in the construction of machines and buildings. However, they do have some serious shortcomings that undermine structural stability and ergo safety. Bossard Group says that its Bossard ecosyn®-BCT rivet nut is the next generation of high-tech blind rivet nuts, and makes these concerns a thing of the past.
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lass reinforced plastic (GRP) and carbon-fibre reinforced plastic (CFRP) boards are every engineer’s nightmare. How does an engineer create a stable connection point using a blind hole? The obvious solution is a blind rivet nut. They do have their drawbacks, however. When a standard blind rivet is set into a blind hole, bulge formation is uncontrolled. That leaves stability and safety to pure chance. The Bossard ecosyn ® -BCT blind rivet nut is able to control the bulge without support from the base material. Crossholes deliberately weaken the shank material and thus define the bulge’s position and form. Like a standard blind rivet nut, the Bossard ecosyn ® -BCT can be set ‘blind’ from one side, efficiently and without rework.
Rivet nuts for tough places These properties make the Bossard ecosyn ® -BCT blind rivet the ideal product for tight
spots or where performance demands are high, such as in thin-walled, high-tensile, soft, porous or sandwich materials. They are suitable for use in GRP and CFRP structures, lightweight honeycomb panels, profiles, ductwork and other hard-to-access types of structures.
The perfect bulge The Bossard ecosyn ® -BCT blind rivet nut especially shines when multiple components must be joined. With standard blind rivets, the bulge forms uncontrolled in the plane of least resistance. In the worst case scenario, the bulge forms in the gap between the two riveted elements. The Bossard ecosyn ® -BCT blind rivet nut is different. With controlled deformation, all materials are drawn together between the flange head and bulge, creating a stable rivet. The bulge forms without bearing stress, with minimal tension on the surface of the bore. This keeps the risk of skewing or misalignment to a minimum. Often the hole diameter is undefined. Conventional blind rivet nuts need support from the shaft in the bore, causing skewing of the rivet, misalignment or reduced strength. In contrast, the Bossard ecosyn ® -BCT rivet nut forms the bulge first, eventually becoming flush with the base material.
36 Fastener + Fixing Te chnology • Issue 9 Apr - Jun 2013
It’s all under control If the material thickness is unclear, the Bossard ecosyn® -BCT Multigrip blind rivet nut offers the ideal solution. Depending on the thread diameter, it covers a grip range of up to 9mm. The standard grip range of a conventional blind rivet is only 2.5mm. If the material thickness does not match, either no bulge can form or the threaded axis sits off-centre. Varying material thicknesses present yet another problem. The risk of using the wrong blind rivet nut is higher when the thickness of the materials varies. In addition, the limited grip range of conventional blind rivet nuts requires keeping a large selection of sizes on hand. Since the Bossard ecosyn ® -BCT blind rivet nut covers a very wide grip range, the right rivet nut for the job is always available without the need for a large inventory.
Hard as steel Often connection points for high-strength screw joints are needed, a nearly impossible task for conventional blind rivet nuts. Achieving the required tensile strength requires increasing the number of attachment points or the thread diameter. Bossard ecosyn ® -BCT offers an elegant solution - blind rivet nuts of high-grade material. Versions made of steel are able to withstand the tensile strength of a 12.9 screw, and their aluminium counterparts can bear 8.8. These properties allow the rivet nut to be firmly anchored in virtually any material, even if it is much softer.
Small but powerful Where space is tight, e.g. small diameter tubes or interfering edges, standard blind rivet nuts are too long. Without contact to the base material while setting, the blind rivet nut will not seat securely. The Bossard ecosyn ® -BCT Micro provides just the right solution. It creates a sturdy attachment point even in tight quarters, including in steel up to a load of an 8.8 screw. This ensures a firm attachment where insertion depth is low and in narrow sandwich panels (e.g. M6 in 10mm aluminium panel) or round and square tubes with small diameters. Moreover the flange (head) that creates the bulge does not need to rest on the front of the base material; the crossholes just need to protrude out the back by approximately 1mm. This pulls the flange against the front as the bulge forms.
Light as a feather Sometimes it is necessary to keep the weight of the component light. Here, too, the Bossard ecosyn ® -BCT Micro is the rivet nut of choice. Unlike a conventional blind rivet nut, the Micro is made of higher grade material with fewer threads, which generally makes it lighter. www.bossard.com/ffm
PREPARE FOR THE BEST PERFORMANCE Our know-how as a fastener expert guarantees you significantly better performance and a lasting improvement of your competitive position. Free up your resources and reduce your Total Cost of Ownership with Bossard. With our high performance fastening technology and state-of-the art logistic solutions, we deliver excellent quality product solutions and service globally.
Bossard Ltd. Steinhauserstrasse 70 6301 Zug Switzerland
Phone +41 41 749 66 11 Fax +41 41 749 66 22 bossard@bossard.com www.bossard.com/ffm
We contribute to your success with our expertise in the following areas: • Productivity enhancement through proactive design and development collaboration • Efficient processes thanks to intelligent fastening solutions • Lean supply chain with ship-to-line solutions Call us today for a consultation or visit us online at: www.bossard.com/ffm
non-threaded technology
New BRALO battery riveting tools BRALO, a manufacturer and distributor of blind rivets, insert nuts and riveting tools, has added two new models of tools - BET-1 and BET-2 - to its wide range of products already offered.
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he new BET range is characterised by being highly portable as well as being able to execute to the highest technical performance that meets the most demanding applications. BET-1 and BET-2 are solid yet lightweight tools, which are appropriate for maintenance and assembly works both in and outdoors. The main features of the new BET range include: • A well-balanced design for best usage. • Minimal effort needed when pulling the trigger. • The mandrel collector is easy to dismantle, which ultimately contributes to the cleanliness and safety of the working area. • Ergonomic handles that facilitate the riveting process. • A handle ring that enables the tools to be hooked onto a production line. • A powerful li-ion battery with battery life indicator.
BET-1 has the riveting capacity from 2.4mm to 5mm in all materials. The BET-2 is designed for heavy-duty rivets such as structural, Hardgrip, Hardlock and S-trebol rivets. Both models cover all the fastener needs with blind rivets. The Bet-1 battery tool is supplied with a solid and durable carry case complete with battery charger. It is available with one or two 1.4 Ah batteries. BRALO can also provide a supplementary 2.8 Ah battery. Both tools will be available from June 2013. www.bralo.com
Starlock
Push-On Fasteners
Starpress™ Precision Pressings Baker & Finnemore Limited, 199 Newhall Street, Birmingham, B3 1SN, UK Tel: +44 (0) 121 236 2347 Fax: +44 (0) 121 236 7224 e-mail: sales@bakfin.com
Manufacturing and distribution of blind rivets, insert nuts and riveting tools Blind rivets and insert nuts More than 3,000 stock items Range over 50 RAL colours Fast delivery times Quality certifications
New BM riveting tools High speed placement Ergonomic and anti-slip handles Wider setting capacity An improved tool life Reduced air consumption
www.bralo.com
PRODUCTION PLANTS BRALO SPAIN - BRALO CHINA - BRALO MEXICO COMMERCIAL DELEGATIONS BRALO CZ - BRALO DEUTSCHLAND - BRALO FRANCE BRALO U.K. - BRALO TURKEY - BRALO PORTUGUESA BRALO ITALIA - BRALO SPAIN - BRALO CHINA - BRALO MEXICO
fastener + fixing technology
EMC launches new electrophoretic coating plant Electrophoretic coating is an immersion process that refers to the electrically induced transfer of a non-conductive organic coating onto a conductive surface. Adequate pre-treatment, application, and curing methods provide a controlled coating thickness, a relatively high speed of coating, compatibility with numerous topcoats and most importantly enhanced performance and duration of the coating itself.
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s applicators of performance enhancing coatings with 30 years’ experience, East Midland Coatings Ltd (EMC) is always looking for new, technologically advanced application methods that are readily available to the surface treatment industry. The introduction of Excellube EC10 into its newly refurbished state of the art electrophoretic coating line is a perfect example. EMC explains that as a fully automated process it offers a controlled uniform coating thickness with notable benefits. The high percentage of PTFE content gives the substrate an outstanding low friction performance, excellent corrosion protection and a very tough, durable semi-gloss black finish. With a strong working relationship built up over many years with the manufacturers of Excellube, optimum performance of the plant is maintained, with both the plant and its chemistry being checked weekly by the manufacturer and any recommendations from this assessment being actioned within 24 hours. For many years EMC has been applying a grey E-coat for a major international pneumatics company, but during 2012 this range of products reached the end of its life. EMC took this opportunity to upgrade its electrophoretic coating line to meet the requirements of a wider industry and customer base. “This change is an excellent opportunity for companies both new and old to take advantage of this high performance coating and adds to the wide variety of coating solutions that EMC already provide for small or medium sized components,” commented Alan York, sales and marketing for EMC. He added: “These solutions have a diverse range of benefits to the substrate depending on the combination of polymers in the specifically designed coating.” On a day-to-day basis, EMC applies brand names such as Xylan, Teflon ®, Nylon, Zinga, Molykote ® and many others. The benefits of which include: release properties, low friction,
40 Fastener + Fixing Te chnology • Issue 9 Apr - Jun 2013
chemical and corrosion resistance, as well as abrasion resistance properties, which make the coatings ideal for industrial fasteners and fixings in any environment. The coatings are applied for a wide range of industries including oil & gas, automotive, marine, engineering, military, aerospace, food and electrical. In addition, EMC’s flexible approach means it can process one off specials, pre-production samples, small/medium sized batch runs and on-going contracts in excess of 10,000 parts per week.
“We welcome the opportunity to discuss any existing products that potential customers have E-coated or for any new projects they may have on the agenda,” states Alan York. “With regard to our electrophoretic plant, there is capacity currently available; however this is quickly being taken up by both new and old customers, so be sure to contact us soon.” www.eastmidlandcoatings.co.uk
The ATLM* Fastener System * Advanced, Instantaneous Acting Thread Locking Mechanism
Das ATLM Befestigungssystem
Benzing retainingg elements....
... you can
rely on ! Fully integrated design Instantly locking – no loss of preload No prevailing torque No assembly errors Junker test passed
www.ibweiss.com
mailbox@ibweiss.com
National, European, and International Patents apply
East Midland Coatings
Applicators of performance enhancing coatings ideal for Fasteners and Fixings of all shapes and sizes Corrosion & Chemical protection Low Friction and Torque control properties Abrasion and Wear resistance Technical support provided by our vastly experienced staff Sampling service available upon request TS 16949 & ISO 14001 targeted for accreditation during 2013/4
Tel: 01455 619176
www.eastmidlandcoatings.co.uk
sales@eastmidlandcoatings.co.uk
fastener + fixing technology
ECOSIT® upgrades with RFID technology Bielefeld based BOGE Kompressoren has recently benefitted from innovative RFID technology incorporated in the Böllhoff ECOSIT® system.
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ince 2004 BOGE, an international manufacturer of compressors and compressed air systems with more than 100 years experience, has used a multi bin KANBAN system from Böllhoff. The two bin system proved a reliable solution for the last eight years. It was originally selected using the three-step implementation process of ECOSIT®, designed to establish which system best fits the customer’s requirements.
Step 1 – As-is analysis The customer’s needs are analysed in detail. Logistics and data processing structures, individual processes and basic conditions are all taken into account.
Step 2 - Project phase In cooperation with the customer, Böllhoff’s experts form a team that integrates all the affected operative sections. The results produced are the foundations for the action plan for customer-specific implementation of ECOSIT®.
Step 3 - Implementation First of all, the customer executes rough material planning for the parts to be covered by ECOSIT®. Past demands or a demand forecast regarding production planning serve as a basis. After completing the three steps it was decided that a multi bin system for each article was the best solution at the time for BOGE. Two or more bins are held on the customer’s shelf; when one bin is emptied it is replaced and refilled with the next delivery by Böllhoff. In 2011, however, Böllhoff introduced innovative RFID technology for C-parts management systems and BOGE reconsidered its options and decided to implement a new system. The new RFID technology gave BOGE the opportunity to further optimise its logistics process, as well as further reducing procurement costs and the number of suppliers. BOGE therefore decided it would introduce the ECOSIT® RFID Bin system, which works by saving all the relevant data needed to ensure timely replenishment on RFID-labels placed on the front of the bins. As soon as a container becomes empty, it is placed in a collecting bin positioned beside the rack. The data is automatically read off the RFID-tags and transmitted to Böllhoff’s ERP system. The whole process only takes a few seconds. Markus Hahn, purchaser at BOGE, approved the introduction of the new system: “The RFID technology provided by Böllhoff is the contemporary alternative to barcode scanning of empty bins.” The conversion to the new system was quickly implemented in a single day with the strong cooperation of BOGE. Böllhoff explains that customers who use ECOSIT® RFID technology benefit from a quick and easy order release and accordingly very short reaction times of the system. They get higher levels of security of supply and a higher flexibility of delivery frequencies for their company. In 2012 Böllhoff extended its RFID portfolio with the RFID Box variation. This system works in a similar way to the RFID Bin system with one significant difference - if a bin is empty,
42 Fastener + Fixing Te chnology • Issue 9 Apr - Jun 2013
the customer removes the RFID label from it and puts it into the RFID Box. At this moment, the order is transmitted to Böllhoff. In addition to the latest RFID technology, Böllhoff still provides a wide range of classical KANBAN systems including:
Single or multi bin systems • SingleBin - Per article, there is one bin on the customer’s shelf. Before the stock is consumed, the bins are refilled within agreed intervals. • MultiBin - For one article, there are two or more bins on the customer’s shelf. If one bin is empty the bin will be replaced and refilled with the next delivery by Böllhoff.
Scan solutions • ShelfScan - With a hand-held scanner, customers capture the required demand. Data transmission is executed fast and easily and directly via modem. • ScanCard - Supply is controlled with a KANBAN card and executed without bins.
KANBAN with weighing technology • SmartBin ® - The bins are placed on scales. Via the scales, the stock is transmitted to Böllhoff online. If a determined notification value is fallen below, demand-oriented delivery is executed. www.boellhoff.com
Joining together! – our company vision.
A vision that inspires our company culture
For four generations, courage, fairness and
and daily life.
loyality have been the cornerstones of our
This inspiration drives our product program
business culture. The foundation on which
in the world of fastening and assembly
we have built success for our company, our
technology. “Joining together” is much
customers, our business partners and our
more than just a neat slogan. It is also a
employees.
business vision that puts people first. Because it is people who put the vision
Böllhoff Group · Archimedesstr. 1–4
into practice and build the solid foundation
33649 Bielefeld · Germany
of our success today and in the future.
www.boellhoff.com · info@boellhoff.com
Joining together!
products
The new TAURUS® 5 compact GESIPA® says that its new development – the TAURUS® 5 compact – is an extremely light and versatile setting tool for lock bolts.
D
ue to its modular design, unique high setting force and weighing only 2.8kg, the TAURUS ® 5 compact is extremely flexible and allows fatigue-free operation for long periods of time. It securely sets 4.8mm and 6.4mm lock bolts from a variety of manufacturers. The TAURUS ® 5 can be operated with all pulling head modules available for the Taurus ® 5 and 6. The extraction of the broken mandrels and the large mandrel collection unit allow for a highly efficient operation. In addition, the TAURUS ® 5 compact reaches a very high setting speed because of its high traction force and optimised traction stroke. GESIPA® points out that the TAURUS ® 5 uses a technique typical to GESIPA® and unique throughout the world - compressed air is used twice, both for setting the rivets and extracting the spent mandrels. This, in turn, allows the user to reduce the consumption of expensive compressed air. The TAURUS ® 5 compact also comes with the patented jaw system of the TAURUS ® series which has been modified to provide safe form-fit connection to the pulling mandrels of the lock bolts, thus ensuring optimum service life with minimised wear and tear. “With this setting tool deliberately designed in a compact form, GESIPA® has developed a tool that not only benefits from the experience of the successful TAURUS ® series ensuring its full functionality but also offers an attractive price-performance ratio due to the use of compatible parts.” www.gesipa.com
www.staytite.com
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for all your fastener requirements...
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here are just of our unique fastener solutions...
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answer all your fastener questions...
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go to the No: supplier for all fasteners! Barb Nuts • Carp Nuts • SEMS Screws • Staytap Screws • Hi-Lo Screws • BT Screws • Staytite Nuts • Stover Nuts • Hardlock Nuts • Flange Nuts & Bolts • Serrated Flange Nuts • Serrated Flange Bolts •
Hardlock Nut - the proven solution in threaded joints
tel. + 44 (0) 1494 462 322 emaildistributors@staytite.com fasteners@staytite.com email
www.staytite.com
...dedicated to meeting all your fastening needs
PROTECTION & FASTENERS Rapid product search
Global Inch Fastener Solutions
for more than 40 Years
Catalogue free on request
www.bulte.com ®
BÜLTE GmbH Kunststofferzeugnisse Carl-Sonnenschein Str.22, D- 59348 Lüdinghausen Tel : 02591 / 91 94-0 - Fax : 02591 / 59 77 bulte@bulte.com
xe-Fastener-Fixing-2010_112x155-DE_salon.indd 1
Tel.: +49 (0) 71 32/99 60-0 • Fax.: +49 (0) 71 32/99 60-60
www.schroederschrauben.de
06/09/10 07:46
TAURUS® 5 compact INNOVATIVE, POWERFUL, SAFE The new lock bolt setting tool from the TAURUS® series in well-proven GESIPA® quality
NEW
Crucial advantages for the user: • specially adjusted tension path for setting of lock bolts • Setting of 4.8 and 6.4 lock bolts, versions C6L®* and MagnaGrip®* • very high tensile force for rapid setting • very light • extremely handy due to its compact design • economic air consumption • low wear due to traction head module with specifically adjusted chuck jaw design • efficient working, spent mandrels are ejected safely (6.4) • large container for collection of spent mandrels (4.8) • good price-performance ratio *partly registered trademarks of the companies TITGEMEYER GmbH & Co. KG or Alcoa Fastening Systems
GESIPA Blindniettechnik GmbH Nordendstraße 13-39 64546 Mörfelden-Walldorf Germany A company of
T +49 (0) 6105 962 0 F+49 (0) 6105 962 287 info@gesipa.com www.gesipa.com
products
IBW’s innovative solutions Ingenieuruero Wolfgang Weiss (IBW), based in Ottobrunn, Germany, has introduced two innovations that it says offer solutions to specific engineering problems. Instantaneous acting thread locking mechanism
A threaded fastener joint incorporating the Advanced Thread Locking Mechanism (ATLM) provides failsafe locked fastening for quick installation and de-installation. The ATLM incorporates a freewheel (roller clutch) that is securely installed in one of the two threaded members and detachably coupled with the engaged counterpart. While screwing the threaded members together, the freewheel allows free mating, including torqueing. Once the ATLM fastener is forced to unscrew by occurrence of torque in the undoing direction the freewheel locks instantly. Disengaging the members of the threaded joint requires decoupling of the freewheel by an ejector, preferably implemented in the wrenching socket. ATLM fasteners have successfully passed the Junker test per DIN 65151 and DIN 25201 Part 4. IBW points out that in contrast to commonly known self-locking threaded fasteners with integrated locking features, the ATLM fastener mates free running and thus torque values preset in the wrenching tool are not influenced by varying prevailing torque. The locking of the threaded members takes place automatically, with an instant lock – meaning that there is no loss of preload by unscrewing of threaded members. In addition, the anti-friction coatings on the threads have no influence on locking torque. The ATLM fastener produces stable retention (locking) torque with no limitation for the number of screw cycles – giving the potential for unlimited use of the fastener in respect to its self-locking capability.
No extra locking hardware or retaining compounds are required to install the ATLM fastener.
Positive fit joint with compensation of radial and angular displacement
A shear load fastener subject to multiple installation cycles does not establish positive fit due to the necessary installation clearance. For a shear load joint involving more than one fastener, manufacturing tolerances and thus additionally required play are further detrimental effects on achieving the desired shear load transfer capability. A core part of the Position Deviation Compensating Positive Fit Joint (PDC-PFJ) is a swivelling, double-spherical ring with corresponding surfaces at the structural (external) and at the fastener (internal) side, which results in each one of the two sphere segments having a differently placed centre at a common axis. The arrangement of the two spherical radii and their centres is aimed at balancing the moments induced on the double-spherical ring by the lateral forces through shear load, regardless of the angle the double-spherical ring allows for compensating position deviation (radial and/or angular). Additional benefits from using PDC-PFJ fasteners include: • Positive fit in multi-fastener joints. • It is a shear load fastener system free of lateral play. • No differential movement between joined members. • Enables fastener size reduction. • Allows wider manufacturing tolerances (cost reduction). • Reduces assembly time (cost reduction). www.ibweiss.com
Press-in inserts for stone Specialising in fastening applications for metal sheets and sections, solid parts and wood, and plastics and composite materials, Specialinsert is now presenting a new innovation in fasteners for stone materials.
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earching for innovative fastening solutions for the world of composites has become a crucial effort for Specialinsert in the last few years. It is with this purpose that its R&D department recently presented the press-in self-locking threaded insert IM series used to create structural fastening application in limestone, granites, glass and porcelain. The new press-in self-locking threaded insert comes in different lengths with or without flange in order to fit to several
different stone thicknesses. Specialinsert explains that it is easy to be installed since the user just needs to drill the stone with the correct hole diameter and press-in the insert. Specialinsert has three branch offices and warehouses, a production plant in Maerne (Venice, Italy) and a R&D office with testing laboratory. “Our technical department is available to study and test proper solutions in order to fulfil the most difficult fastening problems on any kind of material.” www.specialinsert.it
ISS Internal Clamping Screw Böhl Gruppe’s new ISS Internal Clamping Screw enables users to fasten to cylindrical components like rod material, sensors, threaded rods and tubes within seconds.
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he ISS standard size resists a tensile and compression load of at least 150kg and has a torque transmission capacity of 15Nm at minimum. Variants for counterboards and panels mainly used in furniture and wood processing industry are available. In plastic panels such as HPL, the thread can be tapped directly. To use the ISS in soft materials like wood, Böhl Gruppe recommends its knurled press-in nuts.
46 Fastener + Fixing Te chnology • Issue 9 Apr - Jun 2013
In mechanical engineering ISS with hex heads can be used. All threads on stock are in metric. Other threads are on request, with short delivery times. The sealing variant can connect hoses and is pressure-proof up to 3 bar, tubes up to 50 bar. Flexible tubes and hoses have to be used with reinforcing rings to prevent the parts from compressing. www.haboe-iss.de
METAL SHEETS
Fastening systems for metal sheets and tubular sections
SOLID PARTS
Fastening systems for solid wood-metal parts
PLASTIC
Fastening systems for plastic materials
COMPOSITES
Fastening systems for composite materials
All Technology Inside GROWTH INNOVATION EXPERIENCE SOLUTIONS ASSISTANCE
For more than 35 years Specialinsert have offered the most advanced and effective solutions for any kind of fastening problem. Specialinsert’s products range spans from threaded tubular rivet to self-tapping inserts, from 1/4 quick-turn fasteners to inserts for composite materials, from inserts for wood to blind rivets. Specialinsert production is 100% Made in Italy. Our mission is to establish ourselves on the market as an innovative and continuosly evolving company, in order to offer more and more state-of-the-art solutions and services in step with and even ahead of times.
Torino • Milano • Maerne di Martellago (VE) • export@specialinsert.it
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A Shakeproof® Bülte handles it solution EFC International says it is distributing the latest wave in thread locking technology - the Shakeproof® Thread - a part of ITW’s new WERCS® technology.
Bülte Plastics has added two new references - PF150 and PF180 - to its Handles Type PF product range, which it says are easy and quick to assemble for a perfect finish.
TW’s WERCS ® technology uses a curve in the helix of the thread at every 4th pitch to create mechanical interference at precise points along the trailing flanks of mating threads. EFC points out that this joint tension in the body of the screw represents a better value compared to custom placed nylon patches, prevailing torque nuts, or permanent locking alternatives. The Shakeproof ® Thread functions in any standard tapped hole and can be qualified using Go/No-Go thread gauges. The Shakeproof ® Thread is reusable to allow ease of service while preserving thread integrity and still providing consistent performance with increased cycle life. EFC also offers professional engineering support and free samples in 1/4, 5 /16, 3 /8, and 1/2 inch diameters to validate the Shakeproof ® Thread as a solution for customers. www.efc-intl.com
hese polyamide (nylon) handles are resistant to corrosion, impact and common chemicals; they have good dimensional stability and high thermal resistance. The handles are suitable for applications such as gates, guards, cabinets and caravans, as well as industrial applications in general. Flat profile handles can be attached with M6 (only for PF94) or M8 hex head screws. The handles are available in two heights (36mm and 45mm) and lengths from 110mm to 201mm. The standard colour is black but other colours are available on request. A catalogue detailing Bülte Plastics’ full range of products is available for free. To request a copy visit the company’s website. www.bulte.com
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NORMA’s robust clamp NORMA Group offers among other things a full range of heavy duty bolt clamps that are endorsed by customers from multiple industries.
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he universal NORMACLAMP GBS bolt clamps are designed primarily for use in applications where hose clamps must meet stringent requirements. In particular if suction and pressure hoses - complete with plastic or steel inserts and high shore hardness values - are to be connected and attached. They are therefore particularly suitable for use on commercial and special vehicles.
Unique design for tough requirements The robust clamp according to DIN 3017 is supplied in four different materials: aluminium-zinc, stainless steel, zinc plated mild steel and clear chromate, as well as four band widths. Its distinguishing feature is the extremely high band tensile force. The clamp has a unique design that includes safety features and is characterised by a twofold improved failure torque, and threefold improved band tensile forces. The specially designed bolt is fastened to the clamp and cannot get lost. It also has an integrated spacer which improves efficiency. The reinforced loops are suitable for higher torques. A mechanical lock closure prevents corrosion because it has no welding points and thus no corrosion contacts. Above that, the lock is much stronger with regard to tension than a welded solution. The hollow trunnion has a double benefit as when extreme tensile forces are applied to the bolt, the deformation of the hollow trunnion reduces the tensile forces on the bolt and to the mechanical lock, drastically extending the time until destruction. Since neither the band nor the bolt is deformed, the clamp can be re-used which, NORMA says, is a unique characteristic on the market. For optimal hose protection NORMACLAMP GBS is equipped with a bridge that keeps the hose away from the bolt. The band’s edges are rounded, which gives protection against injuries and damage to the hose surface. The heavy duty bolt clamp can also be delivered with a quick release closure which allows a rapid assembly and disassembly of the clamp. Other available versions include a solid trunnion, a quick lock, a spring, and a rubber bracket. All components are environmentally friendly as no chromium VI is used for the surface treatment.
State-of-the art production The NORMACLAMP GBS bolt clamp is manufactured at the company’s facility in Hustopeče in the Czech Republic and is made available to the clients via the NORMA distributions services network. The factory is equipped with the latest technology and processes and is certified according to ISO 9001, TS 16949, OHSAS 18001 and ISO 14001 – a factor that NORMA Group says its customers consider as important as the quality and reliability of the clamp. www.normagroup.com
50 Fastener + Fixing Te chnology • Issue 9 Apr - Jun 2013
Advertisers index Action Can Ltd...................................................................................49 Adolf Pühl GmbH & Co. KG..................................................................7 Advance Spares Limited....................................................................25 Albert Pasvahl GmbH + Co................................................................ 31 Alloy & Stainless....................................................................................2 Ambrovit...............................................................................................9 Anochrome Group.............................................................................25 Baker & Finnemore Ltd.......................................................................38 Berdan Bolt & Nut Co.Ltd.................................................................... 27 Böllhoff GmbH....................................................................................43 Bossard Ltd......................................................................................... 37 Bralo...................................................................................................39 Bülte Plastiques SA..............................................................................45 Deepak..............................................................................................52 East Midland Coatings....................................................................... 41 EFC International................................................................................ 11 ETMA.................................................................................................. 17 Fastener Fair Hannover......................................................................35 GBK UK Ltd.......................................................................................... 31 GESIPA Blindniettechnik GmbH...........................................................45 Harald Böhl GmbH.............................................................................35 Heroslam............................................................................................ 21 Hilti Aktiengesellschaft..........................................................................5 Hugo Benzing GmbH & Co KG........................................................... 41 IBW - Ingenieurbuero Wolfgang Weiss.......................................... 21, 41 Lee Spring.......................................................................................... 11 Lesjöfors AB........................................................................................ 10 Lohmann GmbH & Co KG.................................................................. 31 NOF Metal Coatings Europe...............................................................23 Norm Civata AS.................................................................................. 15 NORMA................................................................................................1 Peter Schröder GmbH........................................................................45 Precision Technology Supplies Ltd...................................................... 51 PSM International................................................................................29 Rolevet Ltd.........................................................................................24 Rotor Clip Ltd...................................................................................... 47 Specialinsert Srl.................................................................................. 47 Spirol..................................................................................................35 Stafa Group........................................................................................33 Staytite...............................................................................................44 Top Screw Metal Corp........................................................................48 Vibration Master apS.......................................................................... 19 Vlier Products...................................................................................... 21 WPI Services B.V..................................................................................49 Wrentham Tool Group........................................................................33
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