No. 26/2014

InPractice

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ContentsEditorial

32 Interview with Blum on the topic of design 36 Multi-functional internal door mechanisms

04 Referenceprojects Achieved through close cooperation with SFS intec

12 Productpresentations New ideas from SFS intec

18 Morethanjusthotair Thanks to comprehensive technological know-how

20 Ball-screwdrive For reliable electrical parking brakes

24 Invisibleandinvincible The new window fittings for SIEGENIA

28 isoweld™ Zonal flat roof installation

32 Anone-too-commondesignforcommonuse Interview with Blum on the topic of design

36 Multi-functionalinternaldoormechanisms For Volkswagen

40 Relaysforalternativedriveconcepts Using special components from SFS intec

44 Prettytough Fasteners featuring PVD coatings

46 Readytocleanup The new cleaning equipment in Medina USA

48 Varietycontrolinaction At Schmitz Cargobull

DearReader,

Multi-faceted changes in the global marketplace and the resulting competitive pressures call for strong collaboration between expert partners. The real chal-lenges lie in enhancing the competitive edge whilst increasing quality. The success of today's projects depends on close co-operation between partners pooling high levels of process and technological capability.

Rapid, secure development of new products and their subsequent zero-defect mass production are the criteria against which the SFS Group measures itself day-by-day. The article on page twenty is a good example of the positive benefits deriving from col- laborative development work. Working hand-in-glove with Continental, we successfully developed the ball-screw drive for use in electrical parking brakes.

Heinz SaguerHead of Marketing and Development, Div. Construction

28 The new isoweld™ system

Read how the sterling performance of the SFS Group generated tangible customer benefits. We invite you also to present us with the challenges surrounding your products and place your faith in the expertise of the dedicated employees of the SFS Group.

I do hope you both enjoy and gain valuable insights from reading this year's InPractice.

Sincerely,

20 Ball-screw drive for reliable electrical parking brakes

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Place: HongKongProject: AirportPlan: RenovationProduct: BS-Sstainlessfasteners

n The stainless steel BS-S fastener proved ideal for this demanding application.

Back in 2012 the operators of Hong Kong Airport decided it was time to expand. In addition, major commis-sions were placed for renovation work on the existing terminal roof. The two million square foot surface was to be completely renewed over a period of three years; with no impact on air traffic.

Due to its close proximity to the sea, the lightweight construction building had to withstand enormous wind forces. What's more, the high concentration of salt in the atmosphere meant accelerated corrosion. Therefore the fasteners to be used had to be both extremely strong and corrosion-resistant.

SFS intec supplied the fasteners when the original building work commenced in the mid-Nineties. The fact that these were still in excel-lent condition convinced the airport operators of their longevity. Reason enough to make SFS intec the chosen supplier on the current project. After discussions with developers and site users alike, the choice fell to type BS-S fasteners. They are an extremely robust, high quality fastener that is simple to install.

HongKongInternationalAirport

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Place: Heidelberg,GermanyProject: OfficeandtradecenterPlan: NewbuildProduct: JB-D®

Kurfürsten-Hof

n The JB-D® system is simple to adjust, enabling secure and speedy installation.

The former Department of Justice site in Heidelberg is now the loca-tion of the Kurfürsten-Hof. The 86'000 square foot building offers space for offices, business premises and trade outlets. The front façade features a total of 480 triple-glazed windows, combining a high level of energy efficiency with economical construction methods.

In planning the window installation, the objective was to marry architec-tural directives to maximum energy efficiency. The windows were thus set back into the insulating zone of the sandwich panels. Due to the triple glazing, each one weighs up to 352 lbs.

Working with specialists from SFS intec, the choice fell to the JB-D® system. This enabled simple, secure and speedy installation of the window units to the timber support framework. This assembly system is tailor-made for the enormous forces present. The result was a state-of-the-art, energy-efficient façade construction.

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Place: Nashville,USAProject: CongressCenterPlan: NewbuildProduct: TWH-S/KCPthread formingscrews

NashvilleMusicCityCenter

The Spring of 2013 saw the Nashville Congress Center opened. The town, situated in the state of Tennessee, is surrounded by the Appalachian moun-tains and is, of course, also known as the home of country music. The planners wanted to ensure that these two special characteristics featured in the architecture of the building.

The "green" planted undulating roof blends discreetly into the surrounding mountain panorama. Meanwhile the roof-top ballroom is guitar-shaped. The narrow windows and timber cladding are reminiscent of cylinders from a music box or sheet music scores. These features make the building unique.

The construction company, Kovach Building Enclosures, finished one 680,000 square foot façade surface with 6 mm thick padded panels. The fasteners used had to be corro-sion-proof, watertight and aesthet-ically pleasing. The TWH-S / KCP thread forming screw ticked all boxes; these fasteners have been specially developed for just this application.

n The TWH-S / KCP features a particularly deeply-recessed internal TORX® drive with a neoprene sealing washer.

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Place: Vancouver,CanadaProject: BusstopPlan: NewbuildProduct: WSdowels

UniversityofBritishColumbia

Administrators at the University of British Columbia in Vancouver commissioned the architectural prac-tice Fast & Epp Structural Engineers to roof a bus stop they were installing. The objective was to generate a discreet design with totally invisible joints.

The roof material itself consists of a timber honeycomb retained at four points. In sunny weather this casts myriad crisscross shadows onto the pavement, intended to be reminiscent of the Katsura trees which grow all along the street in front of the univer-sity. The bus stop thus blends harmo-niously into the overall street scene.

The structure consists of multiple individual timber segments fastened together with metal strips let into the timber segments. This is fastened together with WS dowel pins from SFS intec. They are fastened through the timber segments and metal strips in a single stroke with no pre-drilling. The company doing the work, Dancin Timber Works Inc., certainly benefited from a simple, time-saving assembly process.

n WS dowel pins are robust and, once installed, hardly visible.

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TheintelligentreactivesleeveEnvironmentalism and the drive for efficient energy usage mean ever-increasing insulation panel thicknesses on flat roofing. More-over, the latest building regulations place extreme demands on the attachment requirements for roof seals and thermal insulation.

For these reasons, SFS intec has extended the tried-and-trusted isotak® system with a new fastening solution – the RH45/TIF-N. It meets all the requirements for fastening to concrete and consists of three separate components: the RH45 sleeve, the TIF fastener and the N nut.

Thanks to the scope for adjust-ment, different insulation thick-

nesses of up to 3.15 inches can be installed using one and the same combination. With a total of just nine different combinations, roof insulation panels of anything from 6.5 to 32 inches can be attached. The new sleeve solution is supplied pre-assembled, increasing produc-tivity on site considerably.

Another advantage is the so-called telescopic effect: under compres-sive force (e.g. caused by walking on the roof), the sleeve is forced downwards, returning to its original position when the load is removed again. This telescopic effect is already a requirement in several northern European countries and contributes immensely to the secu-rity of the roof insulation set-up.

RapidandsecureoverlappingfastenerDrill tip fasteners are convention-ally used for fastening overlapping sandwich panels and trapezium profiles to façades and roofs. These generate metal swarf which can lead to rusty patches. That not only looks bad but has an adverse effect on the strength of the connection too. In the past a thorough clean-up operation has always been unavoidable.

The new SLG-S overlapping fastener, however, has a revolu-tionary thread forming tip which does not tap into the material but rather forms its own thread – eliminating swarf and subsequent rust spots and prevents the need for time-consuming cleaning procedures .

These new tips also enable safe installation free from skid-ding, thanks mainly to the thick hexagon head drive. This ensures safe installation even when the fasteners are not set squarely. This new fastener has an improved double thread to support faster insertion and there is a thread stop to inhibit spontaneous post-instal-lation loosening. The generous thread-free zone under the head aids optimum component attach-ment, supporting secure fastener installation.

n The new SLG-S fastener provides rapid, economical fixing.

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Rivetinginseconds

The speed rivet system is rapidly increasing in popularity in industrial circles. It is particularly prevalent in the manufacture of metal casings and in many automotive applications. The system creates reliable connections extremely rapidly. Speed rivets can be set at a rate of under two seconds per cycle.

GESIPA® recently presented a riveting tool specially developed for this appli-cation: the TAURUS® 1 Speed Rivet. The rivet gun has a magazine feed containing up to 45 punch-through rivets. The hollow rivets are held on a 19.6 inch carrier pin. The system thus enables very rapid production throughputs.

The new device is an update based on the tried-and-trusted TAURUS® system body. But thanks to its intelligent design it is around 30% lighter than similar current models. In fact, with a weight of just 4 lbs and a noticeably ergonomic design, it is setting new standards in the industry.

ThenewcordlesssystemfromtheBirdfamilyGESIPA® has further extended their range of cordless blind riveting tools. The new Power-Bird® Pro offers enhanced ergo-nomics and several technical improvements to enable the system to cope with the huge numbers called for in industrial riveting.

Until now, cordless tools have found limited application on production lines. The reason has always been the high rate of wear and tear on the contact brushes in the rotor of the electric motor. The limited battery life has also been a central issue. For these reasons, pneumatic tools have been used almost exclusively on production lines.

The pipework to support such tools severely limits the operator's mobility in tight situations, where battery-powered tools are often more suitable. They are free from piped air-lines and much more flex-ible. GESIPA® carefully matched the new PowerBird® Pro to the require-ments of industrial customers.

This cordless packs a two ton punch suitable for the most demanding of riveting situations. It is driven by a brushless and hence low-wear DC motor. Lastly, the latest generation of power cells enables considerably longer operating times between charges. The latest PowerBird® Pro is now the perfect choice for continuous riveting on production lines.

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HiddenhingesfordesignerdoorsThe new W-Tec 3D+ door hinge meets the highest aesthetic demands thanks to its invisible mounting system. It is also extremely robust and solidly built. Thanks to its special design, the weight is distributed evenly across the supporting struc-ture. The high tensile knuckles see to that, making this hinge a long-term stable solution.

After assembly the hinge can be easily adjusted. The settings are indepen-dent of one another, and can be done by one person. And because of the robust build quality, no further re-ad-justments are ever necessary.

This new W-Tec 3D+ hinge fulfills the highest levels of quality, guaran-teed by stringent control, procedures

and tests on the hinge itself. Where required, SFS intec offers custom-er-specific variants too.

Made-to-measurematerialdisplacementThe latest REMFORM® II™ is designed for fastening into plastics. The fasteners are inserted directly into cored holes, with the fastener forming its own thread. This means neither nuts nor threaded inserts are required.

The key characteristic of the new screw is the optimized thread form, enabling increased productivity and process capability in assembly operations. Excellent fastening results are achieved even in thin wall and low insertion depth situations. This translates into shorter cycle times for plastic assembly operations and consider able savings over applications using threaded metal inserts.

There are three variants available covering different application areas.

In contrast to the conventional REMFORM® II™, the "HS" (High Strength) variant is particularly suitable for tougher glass or carbon fiber reinforced polymer applications. The REMFORM® II™ "F" (Fine thread) variant is used typically in light alloy applications and where the insertion depth is particularly shallow.

n The new thread geometry of the REMFORM® II™ offers enormous savings over traditional fastening techniques.

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MorethanjusthotairLeisterhasrecentlylaunchedanewhotairweldingunitcalledtheTRIACATontothemarket.Aswellasrobustbuildquality,thesystemoffersmodularfeaturesandisveryreasonablypriced.

Long-standingclosepartnership

The long-established Swiss man ufac-turer Leister Technologies has been in partnership with SFS intec for many years. In developing the TRIAC AT, the market-leading manufacturer of hot air welders turned again to their trusted partner. Our comprehensive know-how in the field of plastics contributed significantly to making the new project a reality.

In order for the new equipment to feel right and maintain shock resistance against being dropped, SFS intec polymer specialists recommended the use of duplex injection molding. This technique utilises two different thermoplastics combined in a single product. First the more robust hard

plastic is injected, followed by the softer material.

Modularandrobust

The TRIAC AT is the first piece of equipment to feature a temperature gauge, enabling welding temperatures to be set to the optimum level. As displays are so fragile, a robust protec-tion was always going to be vital. SFS intec came up with a viewing window capable of withstanding extreme loads.

Another unique feature of the TRIAC AT is its modular construction: SFS intec already had a tool for the connection head thanks to their long-standing collaboration with Leister.

Alternative welding sets can be readily produced to meet the specific needs of the market.

Designexcellence

The TRIAC AT is a truly innovative piece of equipment which cannot fail to impress with its modular build and robust design. Winning the "Red Dot Design Award" was the affirmation of successful design collaboration and the incentive for us to engage in further project initiatives together.

Simon Hug, Division Industrial, simon.hug@sfs.biz

From A to Z, everything from one partner. From initial consultation... ...to manufacture: a perfect one-stop shop.

AninterviewwithLeisterTech-nologiesdevelopmentengineers

What was the driver behind the development of the TRIAC AT?This eighth generation model was to set new standards, reflected in its design, ergonomics and functionality.

So what particular features does this unit offer over previous models?The TRIAC AT is the first of its kind in the world, where all critical param-eters like temperature and air flow can be carefully controlled; offering suitability for extreme conditions.

How have customers responded; how has the market reacted to the new handle?

The rubberized parts not only improve safe handling, they also provide the equipment with extra stability during work breaks. In contrast to competitive tools with conventional grips, this equipment is just right for professional users, offering a wider application range and much more flexible handling.

What made you choose SFS intec for this demanding project?SFS intec designs and develops high-quality, precision tooling for complex duplex components with a range of requirements. The plastic components are developed in unison with the customer: starting with the tooling concept right through to the component geometry. Both companies engage in a long-term

partnership. That's the best way to address exacting demands for design and functionality.

How do you choose suppliers, and which points are particularly critical?Critical issues include reliability and maximum care, creativity and commitment in addressing none-too-common requirements. Chosen suppliers have to be in tune with the latest processes, enabling them to think outside the box and offer us innovative solutions and the associated added-value.

The "RedDotDesignAward" is an internationally recognized symbol of distinction. It has been awarded since 1955 by the North Rhine-Westphalia Design Center. A jury of specialists awards the "Red Dot" to products exhibiting outstanding design quality. Current evaluation criteria are the degree of innovation, functionality and minimal ecological impact.

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Aball-screwdriveforanelectricalparkingsystemonthebrakecalliper

Theball-screwdriveforanelectricalparkingsystemisajointdevelop-mentbyContinentalandSFSintec.Thisrevolutionarybrakingsystemiscompactandeasytomaintain.Thekeytothissuccessfulprojectwasthelong-standingmutualtrustbetweenthecompanies.

Comfortandsafetycombined

The automotive industry is subject to continuously escalating demands on safety, comfort, efficiency and environmental impact. This translates into ever-increasing space require-ments for the components concerned. This must, however, be strictly limited because of the counter-drive towards compactness.

Space constraints are most crucial in the underbody area, because of

the number of systems located there: wheel mounts, shock absorbers, catalyser and for all- or rear-wheel drive vehicles the cardan shaft. These all call for compact thinking.

Drivingforwardsviaco-development

The first tier automotive specialist Continental came up with a space- optimizing concept, targeting the replacement of the rather cumbersome conventional, mechanical hand brake

Hanspeter Kuster, Division Automotive, hanspeter.kuster@sfs.biz with an electrical system. This would eliminate the current complicated cabling and servomotors.

Continental turned to their long-term development partner SFS intec early on. The company was able to offer its expertise in cold forming, machining, heat treatment and assembly tech-niques. The ensuing collaboration rapidly progressed the idea into a working solution for mass production. The target budget was also achieved.

Theball-screwfunction

The ball-screw is a critical compo- nent in the electrical parking system. It transfers enormous loads very efficiently. SFS intec produces three

cold formed parts for the device with extensive secondary machining operations. These are married to various further components and out- sourced parts to produce a complete assembly.

This is integrated into the brake calliper and driven by a combined motor-transmission unit. Eliminat- ing the driver's hand brake lever also opens up more space in the passenger area. Developers thus have more possibilities to increase the aesthetics and comfort of the interior.

Trust-basedpartnership

Continental and SFS intec have already co-developed a considerable number

of projects. The basis has always been direct, open communication. It is the garnering of the two companies' extensive know-how which generates such refined, innovative and econom-ical solutions. In the final analysis, it is the end-customer who benefits.

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Dr.SörenKirchner,DirectorofElectricBrakingatContinental

"At Continental we successfully merge local customer support and global know-how management into safety-critical components. A key reason for our choosing SFS intec was likewise their worldwide reach, their willingness and indeed ability to localize production of complex components in the important NAFTA regions and China.

We value SFS intec as a capable partner when it comes to component development with expertise in manufacturing processes. The high quality demanded by SFS intec is also in tune with our zero defect culture."

BernhardSchmittner,HeadofCoreDevelopmentHydrau-licBrakingSystemsatContinental

"We particularly value the customer focus and high degree of co-respon-sibility for the product concerned at SFS intec, coupled with broadly- based technical expertise. These are important requirements when it comes to producing such high-tech vehicle components.

We have been very happy with the collaboration. SFS intec has been a very agile partner when it comes to design change ideas; any necessary adjustments were quickly and fault-lessly realized. This is a key require-ment for new technologies in every vehicle and market sector throughout the world."

Investinginasharedfuture

SFS intec is a company offering complete solutions. Numerous customers draw on our range and depth of development and manufac-turing know-how. In the case of the electrical parking brake, development input was not required merely to manufacture the component: life tests were designed to prove out its long-term function.

The ball-screw drive developed in close collaboration with Conti-nental consists of over eighty individual components. Three cold formed parts make up the heart of this complex system. The drive is completed using outsourced ball bearings, springs and axial bearings. The reliable functioning of the whole demands precise assembly of the numerous individual parts.

The first task was designing suitable processes for efficient manufacture. Investments were then made in a special purpose assembly machine. This had to ensure all the require-ments of the complex assembly operation were met in full – with an integrated 100% inspection station to ensure that each and every assembly functioned perfectly.

From the initial development to the supply of ready-to-fit components, SFS intec is there with constant help and support.

n SFS intec manufactures several cold formed components for the ball screw, among other parts.

n Heat treatment enhances the strength of the key components.

n The individual components are assembled into the ready-to-fit system in a purpose-built machine.

With a turnover of over thirty-three billion euros, Continental is amongst the leading automotive suppliers in the world. The company contributes massively to vehicle safety and global environmental protection, offering braking systems, drive-train and chassis assemblies, instrumentation, infotainment, vehicle electronics, tires and other technical rubber components. Continental is moreover a leader in networked vehicle communication systems. The company employs some 178,000 people in forty-nine countries.

The automotive group with its three divisions Chassis and Safety, Powertrain and Interiors, turned over twenty billion euros in 2013. The group has one hundred and seventy global locations. As a valued partner to both the car and truck industry, the group develops and supplies future-focused innovative products and systems for modern vehicle builders, harmonizing individual mobility and the joy of driving with safety, economy and environmental considerations.

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Invisibleandinvincible–newwindowfastenersSIEGENIAhasdevelopedaninnovativewindowsystemmeetingallthedesignrequirementsofmodernarchi-tecture.Itissimultaneouslyreliableandfunctional.SFSintecsupportedtheproduct'sdevelopmentwiththeirbroadly-basedtechnicalexpertise.

Lessismore

The main architectural driver for windows appears to be narrower frames and larger panes. Such modern designs call for concealed fasteners, which have very demanding design constraints. They also have to meet stringent reliability and functionality requirements in their daily use.

Rising to these needs, SIEGENIA extended its existing range of fasteners with the creation of the "TITAN axxent 34". The system is characterized by maximum load transfer against minimal wear. Other features include the extensive vari-ability and ease of adjustment. This greatly simplifies window installation.

Comprehensivecapabilitiesatthecore

Once again on this project, it was a question of wide-ranging capabilities from SFS intec coming to the fore. Expertise in cold forming, machining, heat treatment, surface treatments and inspection techniques were all called upon. All the parts were subject to extensive quality tests.

SFS intec carried out every operation in house. This ensured that the high level of product quality was met for each component and that the func-tionality of the individual components was harmonized to each other. All of this meant that SIEGENIA could rely on a development and production partner capable of taking on complete responsibility for product quality.

Comprehensivetechnologyfromasinglesource

For high-tech fasteners like the "TITAN axxent 34" to function perfectly, all the components must operate in total harmony. For this reason, SIEGENIA needed a skilled component develop-ment partner. SFS intec has the necessary know-how to meet that need, and develop and produce all the required cold formed parts.

Working closely together, eighteen separate cold formed parts were developed, each and every compo-nent the subject of continuous opti-mization work, resulting in stimulating discussions between the two compa-nies. Every decision on the project's progress was made jointly.

Daniel Schmid, Division Industrial, daniel.schmid@sfs.biz

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Athoroughlysuccessfulproject

The excellent collaborative develop-ment work between SIEGENIA and SFS intec contributed significantly to reducing the overall development time to the absolute minimum. The "TITAN axxent 34" really is a great example of successful co-develop-ment work. An attractive design capable of standing up to the rigours of daily use, it once again demon-strates that as is so often the case, less is more.

AninterviewwithElenaSeidelB.Sc.,designengineeratSIEGENIA

How did the collaboration with SFS intec come to fruition?SIEGENIA has been working success-fully with SFS intec for over thirty years now. A very real partnership has been born of the genuine belief in one another's capabilities and the excellent contacts engineered between the two firms. We particularly value the extent of the technology spectrum at SFS intec.

Which products were developed jointly?For the current project it ranges from highly demanding to relatively simple cold formed components. Every individual part was carefully examined. As the "TITAN axxent 34" featured hidden fasteners, precision was the

key consideration. Numerous addi-tional requirements were addressed by SFS intec via their extensive know-how in heat treatment and surface finishing.

How would you rate the collaboration?Close and productive partnerships are the key to bringing demanding proj-ects like the "TITAN axxent 34" to life. Throughout the development period we were continuously confronted with changing requirements and parameters. Our contacts at SFS intec came to the fore at such times through their commitment. Thanks to their flexibility, they responded very rapidly to our emerging wishes and requirements.

n The component spectrum for the new SIEGENIA window fasteners covers multiple cold formed parts, several of which feature a special coating.

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isoweld™:fieldfasteningforflatroofs

With isoweld™ SFS intec has created a revolutionary system based on the concept of field fastening. In contrast to seam fastening, the attachment points are arranged independently of the roof membrane. The fastening points can thus be arranged in a regular pattern.

Long-lastingbondingviainduction

The new system is specifically aimed at installing insulation panels and roof membrane on flat roofing. The insulation is attached to the substructure using metal plates and fasteners. The roof membrane is then rolled out on the top and the overlaps are sealed by welding.

The metal plates have a special coating activated by induction, enabling a permanent fastening of the plates to the seal. This attaches the membrane to the flat roof, sealing the roof.

Anintelligentsystemthathasbeenimpressingourcustomers

Heating the plates is done with an induction unit developed in-house, the isoweld™ 3000. The system can be used in an upright position, and is also equipped with a search and control function. This ensures the correct positioning of the inductor over the metal plates. In addition the equipment automat-ically adapts to the power supply

and ambient temperature. These safety functions ensure a perfect weld.

This new system is ideal for both PVC and TPO membranes. It has already been tested successfully on numerous sites and has been very well received. Users value the simplicity, economy and safety offered by the system.

Sonja Oesch, Division Construction, sonja.oesch@sfs.biz

Stepone: measure out and estab-lish the fastening points

Steptwo: install the fastening components

Stepthree: roll out the membrane and weld the overlaps

Stepfour: mark the fastening points Stepfive: get the induction tool ready

Stepsix: weld the metal plates to the membrane

Theinstallationprocedureusingtheisoweld™systemisoweld™isarevolutionarysystemforattachmentofinsulationpanelsandsingleplymembranesystems.Thekeyconceptisusinginductionforfieldfastening,makingforasimple,safe,economicalsystem.

n The designers of a new office and archive for the Fondation Jérôme Seydoux-Pathé in Paris used the isoweld™ system. Photo from the Michel Denancé – collection Fondation Jérôme Seydoux-Pathé © 2014 – RPBW.

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Place: Cormons,ItalyProject: ILCAMlogisticscenterPlan: Renovation

The logistics center of the ILCAM furniture company was in need of renovation. The contractors using isoweld™ for the first time found the project to be an ideal application for the system because the roof was built from pre-fabricated concrete elements. The optimum fastening location was along the wider concrete sections.

Thanks to the isoweld™ system, the membrane did not have to be cut manually to fit the concrete section sizes. This meant enormous savings in time and materials. The installer was very pleased with the new system.

Place: Paris,FranceProject: Officesandarchivesfor theFondationJérôme Seydoux-PathéPlan: Extensionandnewbuild

A new office and archive was to be created for the Fondation Jérôme Seydoux-Pathé, and the renowned architectural practice of Renzo Piano was commissioned to carry out the work. The result is a quite spectacular building reminiscent of a snail shell.

The freeform construction called for enormously precise installation work due to the curved elements. What's more, operators had to work in confined spaces and at height. The hand inductor of the isoweld™ system proved ideal for this applica-tion. It made for ergonomic instal-lation work, despite the difficult working environment.

Place: Bühl,GermanyProject: WerbaPrintandDisplayPlan: Newbuild

The flat roof of the Werba Print and Display printing company in Bühl, Germany features numerous roof-lights, making it almost predestined for the isoweld™ system. It is both easy to install, and blends in well with the surrounding roof area.

The technology represented new territory for the chosen installer. Nevertheless, after a brief training session, they became fully adept with the procedures involved. Among the features particularly well received were the upright ergonomic working posture and the user-friend-liness of the induction equipment. Meanwhile, the installer concerned has used the isoweld™ system on other projects.

Place: Medina,USAProject: ProductionareaPlan: Newbuild

The existing building complex of SFS intec at Medina in the United States was extended in 2013. This addition doubled the space. The new isoweld™ system was used for the flat roof installation.

Though the system was new to the chosen contractor Meade Construc-tion, the installers rapidly came to grips with the technique. The user-friendly handling was so well received, that they intend to continue using the isoweld™ system on future projects.

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Anone-too-commondesignforcommonuse

Thesedays,productsusedinourdailylivesareoftenchosenfortheirdesign.Thistrendinfluencesthecomponentsused.Whethertheyarevisibleornot,theyhavetoblendintotheoverallconcept.ComponentsusedinfurniturefastenersmadebythecompanyBlumareagoodexample.WetalkedtotheengineerGerhardKleinsasser,HeadofDesignandDevelopmentatBlum,aboutthissubject[pictureontheright].

How has technology developed in the field of furniture fasteners over the last twenty to thirty years?

Design has become increasingly important. An installed kitchen has to be as attractive inside as out. This applies particularly to large surface area hardware such as our box systems. Thought has been given to material combinations. The choice of colors, especially for covers, has become particularly important. Along-side design stands user benefit, so all the requirements pertaining to the value analysis chain have to be consid-ered: things like ease of installation and ergonomic adjustments.

Design has increased in significance for many items from our daily lives. Has this been the case with furniture hardware and what are the foreseeable trends?

Functional elements should be hidden – not visible. This leads to miniatur-

isation of the components. Also more functionality has to be built into less space. Plastic strengths are approaching their limits. This is leading to the increased use of cold formed steel parts like those offered by SFS intec. The trend away from add-on parts towards integrated design will continue into the future. This is particularly evident in the product lines TANDEMBOX intivo and LEGRABOX [see the info box on page 34].

What are the design requirements for furniture hardware now?

Design has to be in touch with emotion and oriented towards the human scale. If a product does not exhibit the right proportions this will be subconsciously recognized. That's why functional components should not be visible. This extends by the way into acoustics: it is so easy for unpleasant noise to be generated by opening and closing

cupboard doors and drawers. This has a negative effect on people's perceptions and overall impressions. So noise reduction is an important criterion in the development of new products. Another important issue is the recognizability of a product. Our products have to be recognizable across the range through specific design features.

What effect does design have on the choice of materials and build?

The general trend towards minia-turization is a particular challenge. Numerous products, including our hardware, are getting smaller. Simultaneously, increased functions are being asked for. Quality and good design must never be ignored, so product finishing is increasing in importance. Heat and surface treat-ments can improve both the appear-ance and longevity of a product. Alongside general design consider-ations such as strength character-

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for universal application across the platform. This concept is reproduced at the interfaces with our suppliers. Existing systems should be capable of being used on any program. These factors have a major influence on variety control. Because of the demanding requirements only high quality application-optimized parts can be considered.

What can a supplier like SFS intec do to help meet the design require-ments of a product?

Blum wants to position itself as the technological market leader. We expect that from our suppliers too. They have to have a basic

understanding of our products. That requires a fundamental knowledge of applications and the associated requirements. A clear under-standing of the interplay between function and assembly is also vital. That's why we strive for long-term partnerships throughout the value-added chain. This includes the ongoing development of technol-ogies and functions. We enjoy just such a partnership with SFS intec. Their specialists are capable of combining multiple functions into very compact spaces. Though most components provided by SFS intec are not visible, they play a vital role to the function and design of our hardware. Both installers and the end customers in their kitchens profit from that input.

istics, ecological considerations are coming to the fore: things like energy efficiency and recycling options. That's why higher value materials like stainless steel with smudge-proof or matte finishes are being increasingly used.

Are fasteners and other compo-nents taken into consideration during the design phase?

With every development we consider very carefully the requirements of the market place. Intelligent platform concepts enable us to offer the public an economical wide range of compo-nent types. We utilize a limited number of individual components

JuliusBlum is a global corporation specializing in the manufacture and marketing of furniture hardware. The main products are lifting mech-anisms, hinges and drawer systems; particularly for kitchens. Furniture manufacturers and component distributors around the world are customers of the company. The group employs 6,100 people with 4,650 in Vorarlberg, Austria, where the company has seven plants. There are also manufacturing plants in Poland, the USA and Brazil and twenty-seven sister companies and affiliates.

The company supplies over one hundred markets around the world. Focused research and development has enabled Blum to maintain its position as an innovative market leader and reliable supply partner to furniture manufacturers every-where. Central to this is the contin-uous attention to customer needs throughout the entire value-added chain from kitchen manufacturer, seller and installer to the final purchaser!

n In the past we embraced the maxim "design follows function." Meanwhile this principle has more or less been turned on its head. Though the function still remains more significant than the design, the latter is becoming increasingly important. In creating new products today, both parameters have to be fully addressed and satisfied. This is particularly evident in the trend towards increased functional integration. To date additional functions such as soft

closing have been integrated into one existing product. [picture on the left]. This simplified production, but increased the size of the product overall. With the increasing value placed on design, additional functions are having to be integrated into a product concept [picture above].

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Anappealingassembly

There's nothing new about a door release mechanism – they have been around for as long as cars have. Previously they were some-what simpler and had just one job, which was to open and close car doors. In modern cars they are considerably more complex, have diverse shapes and forms and are more attractive to look at. They also now incorporate multiple additional functions.

Multi-functionalinternaldoormechanismsforVolkswagen

Productdesign,occupantsafetyandusercomfort–includinganintegratedhi-fioutput.Theseweretheimportantconsiderationsforahigh-end,multi-functionaldoormechanism.

Roman Bergler, Division Automotive, roman.bergler@sfs.biz SFS intec has been a direct supplier to Volkswagen for decades. Previously the range of supply covered loudspeaker grilles, switch covers and assemblies. In 2012 we won the contract for a further assembly; namely the door release mech-anism for the new VW Golf Sportsvan, to be launched in the Spring of 2014. This was another milestone in the collaboration between Volkswagen AG and SFS intec.

Secureevenintheeventofanaccident

This new, sophisticated assembly presented a range of challenges to the developers at SFS intec. The timeframe, technical aspects and project management requirements from Volkswagen AG all had to be met. These included stringent requirements in regard to safety and functioning in crash conditions. The doors must be capable of opening even under extreme loads.

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To demonstrate the requisite functionality following an accident, numerous tests had to be carried out prior to the start of produc-tion. To this end prototypes very similar to the end product were generated. SFS intec produced a series of injection molding tools and assembly jigs within just eight weeks in order to be able to produce the assemblies in question.

Extensiveteststoestablishtherightresults

The prototypes had to withstand heavy test loads. For instance, they were subjected to a range of climatic tests (–40 °F to +194 °F)

and life tests including 100,000 lever operations. These tests provided the developers with the information they needed to man- ufacture the final product. The data collected was analysed via several feedback loops, before being adjusted, and tested once more.

For this project, very precise develop- ment procedures with simulations and prototype builds were the key to success. This enabled SFS intec to meet the technical and safety-critical specifications of Volks- wagen AG in full. The timeframe also had to be strictly adhered to. The tight seventeen week schedule allotted from project start to series readiness was also completely maintained.

Smoothoperator

Following completion of the develop- ment phase, the next task was organizing logistical arrangements. No mean feat for thirty-eight indi- vidual components: plastic injec- tion moldings, galvanized levers, decorative frames, loudspeaker grilles in plastic and metal – the speakers themselves and diverse switches from suppliers across Europe and Asia. Everything had to be co-ordinated to produce the resulting thirty different assemblies.

The next job was automating the assembly, including process monitoring and tests. The plastic injection moldings are made

at SFS intec's Hungarian plant, where assembly using the various purchased parts like switches and speakers also takes place. After manufacture the lever-strength of every assembly is checked. A final 100% automated inspection follows including laser marking of test designation. Following visual examination, the completed assemblies are placed in specially developed trays ready for dispatch to the Volkswagen plant.

Challengingprojectco-ordinatesaddressedinfull

This development, particularly the very tight timeframe required, represented a considerable chal-

lenge. Nothing, however, remains to potentially hinder production and series supply over the coming years. More than 100,000 vehicles a year, each with four door mech-anisms, will be equipped, so up to 3,000 assemblies per day will be required.

There are also different models: left- and right-hand versions, black and chrome finishes, standard and hi-fi sound systems – all to be planned, produced, inspected, packed and delivered on time, every time. That Volkswagen chose SFS intec for this work is at once a heavy responsibility and a very satisfying recognition.

n Assemblies are 100% inspected for completeness, correctness and proper functioning and the lever strength. Each assembly then receives a laser test-certification mark.

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Widerangeofelectricvehicles

Research and development engineers have been working for years on reducing the dependency on fossil fuels. The automotive industry is very much involved in this trend. Electrically-powered vehicles require a complete elec-trical drive-train.

The automotive industry continues to offer vehicles with alternative drive concepts. It is possible to differentiate between hybrid electric vehicles (HEV), fuel cell vehicles (FCV) and battery electric vehicles (BEV) drives. Numerous vehicles in these categories are already available in the market.

Increaseddemandsonrelays

In these vehicles some form of rechargeable energy store, such as high voltage batteries, must be integrated into the wiring loom. Other auxiliary systems such as braking are also increasingly being electrified. This requires a significantly higher operating voltage. This, in turn, increases the demands on the relays.

Tyco Electronics rose to this chal-lenge. With the help and support of SFS intec they devised an inno-vative generation of high voltage relays. These can control voltages of up to 1,000 volts and currents in excess of 100 amps.

Anewconceptwithoutgasfillingincreasestheworkinglife

Previous high voltage relays required a compressed gas filling; generally using Hydrogen or Nitrogen. For this reason a sound hermetic seal was imperative for these devices.

Tyco Electronics offers a very intelligent solution to the needs of electric vehicles and charging stations. In developing the new product generation EVC 250, the focus was very much on product longevity as well as overall power rating. There is no pressurized gas in the contact chamber, removing the necessity for a hermetic seal.

Relaysforalternativedriveconcepts

Theautomotiveindustryisincreasinglyturningtoelectricaldrivesystems.Theserequireever-increasingcurrentsandvoltages.TycoElectronicshasdevelopedanewrangeofrelaystomeettheseneeds.Thisinno-vativefunctionissupportedbyprecisioncoldformedpartsfromSFSintec.

Heribert Grabherr, Division Industrial, heribert.grabherr@sfs.biz

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This means that the relays are not only longer lasting, but also simpler and less expensive to produce.

Closecollaborationcallsforefficientcommunication

This new generation of relays presented Tyco Electronics with a range of techno-economic chal- lenges. Specialists at SFS intec developed application-optimized

components early on in the project development. Cold forming tech-niques enabled the component requirements to be met in full from the outset.

This development served to reinforce the long-standing part-nership between the two compa-nies, which had already proven its worth during the development of the existing 12 volt relay family. Tyco Electronics and SFS intec are driving their collaboration

forward with the development of next generation relays. In this way, both companies are playing their part in supporting the development of elec-tric vehicles. nArmaturein

magneticsoftironWhen the spool is conducting, the armature moves the shaft and the working contact to the contact supports. As soon as the spool voltage is removed, the natural spring force returns the armature to its starting position.

nCoreinmagneticsoftironThe core draws the armature on when current is flowing in the spool, closing the gap between the core and the armature.

nBearinginmagneticsoftironThe armature is held in this sleeve, but is free to rotate. A special coating ensures life-long efficient functioning.

nContactcarrierincopperThe twin copper contacts carry the working current and secure against arcing during emergency switching situations due to their particular geometry.

nShaftinnon-magneticA2-70The shaft is attached to the armature, so it moves upwards with the armature and the conducting spool, closing the load current loop via the attached contact.

Coldformedcomponentsoffersomanyadvantages:n material savingsn high mechanical strengthn high repeatabilityn economic advantages

When did the collaboration between Tyco Electronics and SFS intec begin?The two companies have been working in close partnership for almost twenty years now. Previously, the work extended only to relays in the 12 volt range. Since 2011 however, the emphasis has been moving towards high voltage relays.

What were the challenges surrounding the development of this new range?The new EVC 250 models differen-tiate themselves from previous high voltage relays in terms of the contact chamber which has an intelligent response eliminating the need for pressurized gas filling. This makes it easier and therefore less expensive to produce. The anticipated life also increases significantly.

What contribution did SFS intec make?SFS intec specialists were there from the early development phase. They recommended the use of cold formed

components for the man ufacture of several specific parts. This offered us both technical and economic advantages. We now have a total of six cold formed parts in the system.

How will the development progress?We are already working with SFS intec on the next generation of high voltage relays. These will offer the same sort of characteristics in an even more compact and efficient form. We will be using precision cold formed components from SFS intec on these parts too.

AninterviewwiththedevelopmentteamatTycoElectronics

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es ©

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Inconsumerelectronics,productshavetobefunctionalandeasyontheeye.UnisteelproducesPVDcoatedfastenersformanysuchapplications.Thisinnovativecoatingmeetstheneedsofappearance,feelandfunctionallinone.

Aestheticfastenersforday-to-dayequipment

Major manufacturers of domestic appliances place a good deal of emphasis on the appearance of their products. This has to be taken on board as well as the actual functionality. Whereas fasteners were formerly purely functional components, they now have to meet aesthetic considerations too, particularly when they are visible to the final customer.

This development is particularly evident with mobile phones. A black phone calls for matching coated fasteners. They also have to be resistant to corrosion and friction in order to ensure long-lasting functionality. The trend soon began to extend to other mobile devices like tablets, note-books and more.

PVDcoatingsaretheidealsolution

High value consumer elec-tronic products demand high-tech finishes. This means that surface coatings have to meet exacting requirements. Conventional finishing technol-ogies such as polyurethane PU coating processes simply do not completely fulfill the current requirements. They are in any event too viscous to be effective used for miniature components with fine surface structures.

In contrast, finishes using Physical Vapor Deposition PVD offer a blend of optimum functionality and aesthetics. The coatings are applied under vacuum, enabling a smooth, even surface with a metallic feel to be produced. PVD also sets new standards for friction-, corrosion- and scratch-re-sistance for mass production components.

Meetingthechallengeheadon

As with every application of a new technology, Unisteel was initially confronted with a host of new challenges. These were all successfully addressed prior to mass production. A reliable process for coating miniature parts under vacuum was soon developed. A highly constructive and collaborative effort between the employees involved and the experienced end users addressed the following critical issues:

n guaranteeing a complete surface coverage n strong adhesive coating to ensure assembly tests would be met n coating thousands of fasteners reliably in a single process to achieve a homogeneous coating thickness n developing internal tests and specifications for fasteners using this new coating

Thecustomeristheonewhobenefits

Unisteel now produces fasteners with a PVD coating in black, silver, grey and gold. Other colors can be developed as and when needed by customers. Surface structures can also be applied, offering a further dimension to the final appearance.

All fasteners are tested internally for coating adhesion strength, resistance to friction damage, corrosion proof and scratch resis-tance. PVD coating meets all spec-ified requirements. Customers have attested this. They are, quite simply, delighted with these products.

Prettytough

Cao Jin Da, Division Electronics, cao_jd@unisteeltech.cnn Miniature screws with PVD coatings are now used on numerous mobile phones. They are offered in different colors and surface finishes.

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Readytocleanup

Edward Campbell, Division Automotive, edward.campbell@sfs.biz

Foryearsnow,asaresultoflegalrequirements,thedemandforABSsystemsinNorthAmericahasbeenincreasingsteadily.ThiswasthebackgroundtothedevelopmentofcorrespondingmanufacturingexpertiseatSFSintecMedina,USA.

Thesamequalitywhereverthemanufacturingsite

Long delivery routes are expen-sive and inevitably endanger the security of supply. For this reason automotive suppliers in particular are tending to relocate added-value activities close to the end user markets. This both optimizes the logistics and eliminates currency risks. But such projects require the development of specialist technical capabilities as well as the obvious investment in machinery and infrastructure.

For over twenty years SFS intec has been working on fasteners for the manufacture of ABS systems. The mechanical components of the magnetic valves are particularly demanding in terms of their man-ufacture. The main challenge lies in producing these components in massive quantities, burr-free and extremely clean.

ExtendingtheproductionintheUnitedStates

Once the decision was made to produce ABS parts at the North American plant in Medina, exten-

sive planning and project work was needed on both sides of the Atlantic. One of the core manu-facturing investment would be a multi-chamber dipping system to ensure that the cleanliness specifi-cations were met in full.

The cleaning process was specif-ically developed to eliminate particle contamination and ensure the removal of both organic and inorganic contaminants. Particular attention needed to be given to ease of use, the ability to pre-set all process parameters and the protection of the components against damage during the cleansing operations.

Technologytransferandmachineinstallation

Before the machines concerned could be approved for transpor-tation to America, extensive test cycles were carried out in Switzer-land, alongside intensive training procedures for the American operators. As soon as the equip-ment arrived in Medina, the entire team got to work on assembly and commissioning of the system. Fourteen months after the initial

n The cleansing station in Medina handles the cleaning, inspection and air-tight packaging of fasteners and cold formed parts.

project launch, the first customer approval provided the green light for the start of production proper. Up to eight employees at a time from Heerbrugg were stationed in America for six months to ensure a fault-free production process!

Alongside the impressive cleansing system, the complete manufac-turing technology surrounding it had to be developed. One key issue was the control of waste water via recycling procedures. A laboratory infrastructure was also needed to meet the needs of cleansing bath analysis and measurements on the purity levels of the final cleansed parts. Thanks to packing in a clean room environ-ment, the last process step was satisfactorily implemented.

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Varietycontrolinaction

Schmitz Cargobull is one of the largest global manufacturers of semi-trailers, trailers and truck bodies. Customers can build their own vehicle from the numerous modular systems on offer. Even special systems can be produced very quickly. Alongside the high quality on offer, the short response times is one of the key strengths of the company from Altenberge, Germany.

Fasterproduction

Schmitz Cargobull is determined to continuously optimize their production response to the continuously increasing demand for their products. A process analysis was carried out in collaboration with SFS intec and the rivet specialist GESIPA®. This indicated optimization potential in streamlining of the components used as well as in the assembly process itself.

SchmitzCargobull,SFSintecandGESIPA®haveenjoyedapartnershipformanyyears.Workingtogether,theywereabletostreamlinetherangeoffastenersinuse,savingconsiderablecosts.Thebasiswasacompleteanalysisofthenumerousfastenersusedinbuildingtrailers.

Othmar Koch, Division Industrial, othmar.koch@sfs.biz, and Kay Brenning, GESIPA®, kay.brenning@gesipa.com G-BULB® type. These rivets are excellent at balancing out toler-ances in material thicknesses and hole geometries. These properties are particularly significant in safety- critical applications. The extent and costs of handling, of course, fell quite dramatically.

Using the GESIPA® TAURUS® 4 riveting tool helped to optimize assembly operations. What's more after changing over to this kit, installation faults were effectively eliminated. A power head drive enables working with high tensile rivets. In response to the excellent results obtained, Schmitz Cargobull has changed over completely to using these machines.

A multitude of different fasteners and rivets were being used. These in turn required specific installation tools, matched to the component in question. Frequent material and tool changes were causing un- necessary production down-time. SFS intec carried out an analysis of the parts being used. This resulted in a significant reduction in the article range and the number of tool changes involved. Productivity was improved enormously.

Optimizingtherivetsusedandtheirinstallation

Among other developments, several existing rivets were changed over to rivets of the

Optimizedlogistics

Thanks to the reduction in the range of parts used, the material management costs have been reduced. In addition a just-in-time approach has been adopted. Speci-fied delivery dates must, invariably, be met exactly. However, storage costs are minimized.

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MarkHengst,Strategic Purchasing at Schmitz Cargobull

The GESIPA® processes and docu-mentation so impressed us that we invited them to take part in a workshop on riveting techniques at the Altenberge plant in the Summer of 2012.

After two sessions, GESIPA® had replaced five competitors' products with two GESIPA® G-BULB® rivets. It meant that work stations could be reduced in scale, process times reduced and a significant economic benefit could be generated.

RalfBorgschulte,Strategic Purchasing at Schmitz Cargobull

At Schmitz Cargobull we have always maintained a close working partnership with SFS intec. For us it is important that we have a direct partner for both threaded fasteners and rivets. Everything we ask for is provided competently and reliably.

For years now we have had the same reliable contact personnel at SFS intec and GESIPA®. That simpli-fies the collaboration in many ways. People from SFS intec do not just know our names, they understand our trailer business.

ImprintPublisherSFS Group

EditorialteamStaff of SFS intec, GESIPA® and Unisteel

ChiefeditorArthur Lenart, arthur.lenart@sfs.bizTel. +41 71 727 50 38

FrequencyofpublicationAnnual

Printinggalledia ag, Berneck CH

CoverVisionstudios, Balgach CH

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Increasedcustomerbenefitsvia:

nReducedmaterialmanage-mentandlogisticscostsA narrower range of fasteners means larger, more economical production runs and delivery lots.

nOnepointofcontactformultipletechnologiesIn SFS intec, Schmitz Cargobull has found one specialist they can talk to about any fastening issue.

nOptimizedassemblyAssembly operations honed by the use of TAURUS® 4 from GESIPA®

n The TAURUS® 4 from GESIPA® can handle Monel rivets at Schmitz Cargobull…

...This material is resistant to contact and electrolytic corrosion, making it ideal for connections to aluminium.

Threebrands-onespirit

www.unisteeltech.com www.gesipa.comwww.sfsintec.biz

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