In PracticeNo. 23/2011

Photo: Getty Images

Contents

12 SFS intec launches an innovative fastening system for photovoltaic installations.

14 The first-tier automotive systems supplier, Scherdel, supplies an advanced camshaft angle variator for luxury cars. Each unit is fitted with a deep drawn cap from SFS intec.

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

08 The culture of sustainable construction An interview with the renowned architect Daniel Libeskind

10 Fastening technologies for the energy sources of the future A dedicated fastener system for photovoltaic installations

12 Window installation in heat insulated walling A secure, tested fitting system for top-end windows

14 Deep drawn parts of superb quality SFS intec components in luxury V6 and V8 drive trains

16 Manufacturing expertise for safer driving Maximum functionality in the minimum space in a new ABS system

from TRW

18 Combining top quality with maximum productivity with the new GAV HF blind rivet insertion tool from GESIPA

The ideal system for automotive light assembly

20 Technical seminars: showing you how to save money How Wincor Nixdorf optimised their manufacturing processes

22 Dynamic 3D: a hinge for all seasons Dramatic increases in window installation flexibility offered

by the Dynamic 3D hinge system

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ImprintEditorial teamStaff of SFS intec

Frequency of publicationAnnual

Graphics and editingMarketing Services SFS intec

PrintRDV, Rheintaler Druckerei und Verlag AG, Berneck

PublisherSFS intec

Cover The SFS intec stand at the Munich 2011 construction exhibition: “BAU”

Editorial

20 Fewer assembly components in a system from SFS intec mean greater economy: quite fitting for Wincor Nixdorf automated teller machines.

Sustainable business pays dividends

Sustainability is about only cutting down as many trees as can grow back again. Living from profits rather than capital. For our society, it means each generation operating within its means and not burden-ing those who come after with debt. Those who invest, produce and consume control sustainability. Technical know-how, creativity and a touch of imagi-nation are what’s needed to develop models for consumption which address resource management and environmentally responsive production methods.

In this edition of our “In Practice” report, we hope to show you some genuinely impressive results of our determination with customers and partners to create truly innovative manufacturing solutions. Solutions that reduce petrol consumption, improve home energy efficiency, fit solar panels and reduce raw material usage everywhere we work.

We should be particularly delighted to think that these short reports on our work might provide you with food for thought for future projects.

Arthur BlankGeneral Manager Europe

Full-on fastener functions for farm vehicle fixingsFarm machinery is employed in demanding situations, so the fasteners and fixings used in its construction are very important to manufacturers. It is, of course, particularly intensively used during sowing and harvest-ing; sometimes under extreme conditions. One of the leading producers of fasteners for agricultural equipment is the Danish company UNIBOLT which can look back on over a hundred years of history and has been a member of the SFS intec group of companies since 2009.

Offering a wide range of powerful fastener solutions, like plough bolts, combine blade retainers, outsize wheel nuts and cotter pins, UNIBOLT covers the full spectrum of farm implement fixing requirements. Just as important as an extremely high quality level is reliable short-term availability. UNIBOLT meets this need with advanced stock control, so that all can be safely gathered in on time!

n Farm vehicles are subject to enormous mechanical loads. Powerful fasteners and fixings are essential to guarantee low wear-and-tear, making for reliable running.

n The ISO-PLUS fasteners are in fact suitable for every type of walling and diverse styles and thicknesses of insulation cladding. Whether it’s a new-build or a restoration project, the extra-long polymer plug is the secret.

Insulation installation made easyPre-fabricated insulation panel systems support sustainable building methods with low energy consumption. But exterior wall facings are exposed to enormous climatic load cycles. A study by the Swedish SP Technical Research Institute in 2007 demonstrated that thin insulation panels were frequently subject to condensation moisture, making them a particularly fertile breeding ground for algae and fungi.

Now the Swedish pre-fabricated wall cladding specialist FINJA has developed a particularly robust solution: the ISO-PLUS panel. SFS intec worked with the company to develop a perfectly matched fixing system for these extremely thick insulation panels. What was needed was know-how in both fastener and plastics engineering. The result of these combined capabilities was a super-strong combination plug and screw fixing capable of withstanding extremes of foul weather and wind pull. An easy-to-fit, extra-long plastic wall plug helps to ensure surface-tight fixing. It means both the installation speed and panel security are massively increased.

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What will life be like in the year 2015? To address this question, the United States Ministry of Energy initiated an international university competition back in 2002 called “Solar Decathlon”. Each year twenty teams from the USA, Canada, Puerto Rico, Spain and Germa-ny compete to design the most attrac-tive, energy-efficient house.

The team from the Technical University of Darmstadt won for the second time with their latest project “sur-PLUShome”. One-and-a-half years went into designing, developing and erecting the building, which features photovoltaic modules with a nominal output totalling 19 kW. That means that the building generates twice the amount of energy it consumes.

The support structure of the “sur-PLUShome” building consists of a solid timber frame, which not only offers the right eco-balance, but is extremely lightweight. Quite a significant aspect when you consider that the building had to be transported to America and back to Germany! This feature made choosing the right construction fasten-ers a decisive factor.

Those in charge chose the WT system from SFS intec, capable of withstand-ing the compressive and tensile stressoccurring during the transportation and build. The WT system also impressed with its ease-of-use: every support andcross-member installed quickly and reliably, with no pre-drilling required.

Even the German premier, Angela Merkel, was noticeably impressed by the winning building. After a guided tour, she praised the innovative energy-efficient concept; emphasising the central role of inter-disciplinary co- operation in the acceptance of new technologies.

n The “surPLUShome” of the Technical University of Darmstadt demonstrated how energy- efficient, sustainable building may look in the future. The main timber frame is retained by pairs of crossed WT fasteners. These self-tapping, double-threaded fasteners offer both optimum support strength and minimal spacing between primary and auxiliary members. Viewing the project, German Chancellor Angela Merkel was most impressed by the advanced construction concept.

Photo: Getty Images

WT fastening systemSunny times ahead for timber engineering

CO2 reductionBio-fuels open up the potential for independence from fossil fuels: what’s more, they reduce CO2 emissions. But using these alternative fuels calls for alternative technology. The leading automotive system supplier Continentaloffers this in the form of a bio-ethanol-compatible forecourt pump.

SFS intec produce the ostensibly insig-nificant contact pins for the system, which, on closer examination, reveal a most interesting design solution. In contrast to the former flat plugs, these perfectly formed, rounded components offer a reliable seal; eliminating fuel seepage.

A word in your earFor more than fifty years, PHONAK has been the byword for technologically advanced listening and transmission systems. These high-tech marvels from the Swiss special-ists are so compact that they can be either hidden within the ear or located inconspicuously behind it. The demands on the screws and fasteners used are, understandably, also extreme.

PHONAK have clearly set out their priorities: corrosion-proof fasteners with optimum holding strength and ease of insertion – oh, and not too expensive either... Meeting these objectives called for a world premiere: the first 0.7 mm diameter REMFORM® thread-forming screw.

It proved possible to smoothly integrate the REMFORM® into the PHONAK assembly process without further adapta-tion. The direct insertion technique offered an extremely efficient assembly procedure. The REMFORM® forms its own thread in the pre-moulded holes in the plastic housing. This translates into increased productivity and process capability. It means SFS intec are playing their part in supporting the economical manufacture of modern, miniature hearing aids.

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Sig. Saccardo, what made you choose to work with SFS intec on this giant project?

Primarily the many years of experi-ence we had had of the products and support services offered by SFS intec. We wouldn’t have got very far with conventional fasteners on the Nola project. We needed a real system solution, which in truth SFS intec provided with the SPIKE® twister and IC 120 installation unit.

Which particular requirements did the fastener system have to meet?

The envisaged longevity of the roof system was for me one of the major challenges. The aim was to produce a roof installation capable of remaining intact for a minimum of twenty years. Safety standards represented another hurdle. Here in the Gulf of Naples, roofs have to stand up to extreme wind forces. The expert knowledge of SFS intec in this field was of particular rele-vance when it came to meeting the requirements of the building regulations.

Which other support services did SFS intec offer during the planning and installation phases?

As I said, the safety theme was central, and working with SFS intec,we were able to carry out applica-tion tests reflecting practical con-ditions during the planning phase. It meant we could get hold of statistical data which formed the basis for the engineering approval of the fasteners used.

Fasteners for Europe’s largest photovoltaic flat roof installation The Italian energy company ENEL recently commissioned Europe’s single largest photovoltaic roof installation. The system is fitted to the roof complex of the Interporto marketing centre in Nola near Naples, producing around 33 million kilowatt hours of electricity per year. The roof membrane specialist, General Membrane SpA, covered the 700.000 square metre surface. We talk to Pierantonio Saccardo, Managing Director, about why he chose SFS intec fastener technology.

What’s more, we had full technical support from SFS intec on site. Their help in demonstrating the correct insertion of the SPIKE® twisterfasteners was of particular benefit in progressing so quickly with the work.

Did the SFS intec products directly influence the productivity of your installation team?

Definitely; particularly using the IC 120 installation machine, which enabledsafe, efficient on-site installation. The dual hammer drills see to that. Onedrills through the insulation layer into the concrete, then the other drives the belted fasteners into the hole. It’s as simple as that.

So all your completion target dates were met?

Just so. We were able to meet our customer ENEL’s expectations in this regard in full. I put a lot of it down to the regular, open communication with SFS intec. The roof surface dimension-ing had to be re-adjusted regularly during the build phase. But working closely with the SFS intec engineers, I could do that without delaying the project progress at all.

Against this backdrop, the flexibility and ease-of-installation offered by the system is just about ideal. And working with a company like SFS intec, we had a partner with all the right answers to difficult fastener issues.

n The 25 megawatt installation in Nola is the largest amorphous solar panel system in Europe. Fasteners from SFS intec served to support the roof membrane fitting from General Membrane. Their Managing Director, Pierantonio Saccardo, looks back on comple-tion of a perfect project.

The culture of sustainable construction –An interview with the renowned architect Daniel Libeskind

The beautifully concise term “green architecture” defines a movement which is growing rapidly all over the world. In discussion with our editorial team, Daniel Libeskind talks about the interplay between the imperatives of cultural creationand the drive for ecologically sound development.

Herr Libeskind, your name is synony-mous with unconventional architectural design. When and where did you discover your passion for architecture?

For most architects, the route takes them through a classic architectural training period spent in the offices of an architectural practice. They start to develop their own small projects and go on from there step by step. For me it was different. I came to architecture via music, my first love. As a young man I was an accordion virtuoso and very into classical music. I received a stipend from the America-Israel Cultural Foundation. But I was unable to blot out other influences. Even as a young child, I loved drawing and mathematics was already starting to fascinate me. The world of architecture was the perfect melting pot for all this, where all those influences and interests could be richly combined. So I opted for architectural studies.

Which of your many works are you most proud of and why?

It is impossible to answer that ques-tion. It’s like asking someone what their favourite piece of music is. Each building or space has its own special mission, its own special quality and its own special background, all serving as sources of inspiration for me. I have an individual relationship to each building project and these vary enormously, because they are engendered by such different influences.

Supposing you were to be given a completely unlimited budget by a sponsor to enable you to realise an architectural dream – what building would you create and what sort ofexterior features could we anticipate?

The exact opposite of what most people expect. I have never believed bigger budgets mean better buildings. It sometimes happens that a tough schedule or tight budget generate creative forces. It can truly be an inspiration. As I said, every building hides its own particular history, and the building facade serves to define that history. Whether it be coloured concrete, timber, steel or stone; it all depends on the specific mission. I try to imbue each and every design with its own individual characteristic; independent of any cost plan.

The recent trend has been towards eco building with more and more integrated into, or fastened onto, the building’s outer “skin”, such as solar panels on the roof, shades fitted to the facade, and so on. Do you see this trend con-tinuing?

These manifestations will undoubtedly continue to flourish, not simply as a trend but as an integral part of sus-tainable buildings. What is asked of the architect is to find a way to apply creativity and sensitivity to the inter-faces between the building’s core structure and the ecological fittings attached to it. I am absolutely con-vinced that today’s technologies will be merged into integral solutions which we cannot currently imagine.

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n Daniel Libeskind has become renowned for an open, critical discourse and multi- disciplinary approach. His creations range from cultural installations like museums and concert halls through to town and country planning and even stage designs, art installa-tions and exhibitions.

n Among the best known works of Daniel Libeskind are the theatre and office building in Dublin‘s Grand Canal Square (top) and the Denver Art Museum (bottom).

What influences do ecological certifica-tions like Leadership in Energy andEnvironmental Design (LEED) have on your work?

Environmental certifications are a superb tool for architects. Thanks to defined standards, questions surround-ing green credentials of buildings can be discussed in a very focused way with the client. I think the LEED certifi-cation category for innovative planning is singularly useful. These accredita-tions gain credits. It means that the certification procedure is not merely a directive for energy efficiency; but rath-er that it positively drives advanced building concepts. I think the idea that sustainability somehow detracts from aesthetics is a total myth. It’s exactly the opposite: new technologies open up new avenues for exemplary design.

Sustainable construction is the current mega trend. What might the next trend be in your view?

I don’t regard green architecture as a trend, but rather as a new paradigm for sensitive design. It is not just about using new technologies, but re- acknowledging the longevity of the building. For us sustainability means building with quality. A well designed building becomes, and above all re-mains, a lasting piece of our cultural landscape.

Fastening technologies for the energy sources of the future

Peter Sencar, FasteningSystems, senp@sfsintec.biz

Renewable energy systems will be the byword in future energy provision. Above all, photovoltaic systems, which harvest the energy of the sun, make an enormous contribution towards environmental and climatic protection. That’s why so many companies now generate their own eco-power. Huge industrial and retail park roof areas are just about ideal for installing solar panels.

The demands made on those fasteners used are not inconsiderable. Both the installation costs and the extreme forces generated by wind and snow have to be kept in check. With the new SOL-F and SOL-R systems, SFS intec have successfully addressed the significant requirements of installers of these units. Both ranges offer a convincing combi-nation of efficiency and reliability.

Show premiere at BAU Munich

These revolutionary products were first shown to the international trade at this year’s Munich BAU building exhibition. Visitors were extremely enthusiastic, particularly about the ease-of-use and exemplary flexibility, the enormous installation strength; and not least about how futuristic ideas can be converted into tangible reality using ingenious technology.

Bertrand Piccard, our honoured guest speaker

The solar symposium organised by SFS intec to coincide with the trade show served to demonstrate just what single-minded belief in a new idea can achieve. Air pioneer Bertrand Piccard shed light on sustainable interaction with the energy sources of our world, pointing out that the sheer inexhausti-ble energy of our sun is the way for-ward to guarantee sustainable energy for our future. But so far this potential has been totally under-utilised. What is needed is a pioneering spirit to research new approaches to energy, environmental management and new technologies. This is what Bertrand Piccard is trying to promote with his latest project.

SFS intec presented two world firsts to trade visitors at this year’s BAU exhibition in Munich. The SOL-F and SOL-R fastening systems have been specifically developed for the direct attachment of solar energy panels to industrial roofs. The highly innovative fastener concept requires no pre-drilling, simplifying the installation enormously. The two products and a solar seminar led by the pioneering pilot Bertrand Piccard were extremely well received by our numerous visitors.

n The undisputed stars of the show at this year‘s SFS intec stand were the SOL-R and SOL-F systems, which set new standards in the installation of photo-voltaic systems.

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Born in 1958 in Lausanne, Switzerland, Bertrand Piccard comes from a dynasty of scientists and explorers: he was perhaps predestined to carry the inheritance of his forefathers forward. Whether as psychiatrist, pilot, presi-dent of the humanitarian “Winds of Hope” charity or UNO goodwill ambas-sador, his aim is always the same: to marry the scientific legacy of his family to his love of pushing the boundaries of this adventure we call life.

With his latest project, “Solar Impulses,” Bertrand Piccard is again striving to fly around the world. In place of hot air balloons, this time it will be solar powered aircraft. The flight will serve to demonstrate the importance of modern technology to sustainable interaction with the energy sources of our world.

Innovative installation of solar converters on roof areas

SOL-R for metal profiles and sandwich panel roofing

Thanks to its geometry and its numerous different fixing options, this system offers absolute maximum flexibility.

Whatever the shape of the external geometry or substrate, SOL-R offers a perfectly flat assembly surface. Whether it be a new build or a restoration project, the totally ad-justable system smoothes out uneven roof surfaces, no problem.

SOL-F for classic flat roofs

With the SOL-F, SFS intec offers a remarkable complete package consisting of the installation fasteners themselves, a matched installation tool and software for dimensioning. Everything in one system for rapid, secure installation of support profiles for solar panels on flat roofs.

The flexible length of the separator profile makes the SOL-F the ideal solution for every insulation thickness and even for sloping insulation.

With his “Solar Impulses” project, Bertrand Piccard is setting new standards in the use of solar power.

A number of technical develop-ments have helped bring windows to a new level of quality and tech-nology over recent years. But in-creasing window sizes and triple glazing with corresponding weight increases have served to make installation considerably more difficult. However, SFS intec has matched their JB-D® system to these new demands. Window installation to RAL guidelines, with secure force transfer during window opening and closure, is just as vital as three dimensional adjustment. All of which allow build tolerances to be taken care of with ease.

Being careful over energy consumption is part and parcel of life in 2011. For-malised legal directives on the reduc-tion of energy usage and associated CO2 emissions are on the increase. Building energy efficiency is one area of increasing importance. How modern construction takes place is highlighted by 58 new residences in the Hamburg suburbs. The project planners really demonstrated a full appreciation of modern environmental considerations.

Large scale glazed areas complete the picture of extremely well insulated brick facades

Within the building an all-new gas central heating system serves to ensure highly efficient energy con-sumption with associated reductions in CO2 emissions. Meanwhile around 40% of the energy used to heat water

comes from roof-mounted solar energy modules. A high level of comfort is achieved by the controlled ventilation and heat recycling system. Thickly insulated facades, coupled with triple-glazed windows, complete the perfect picture of sustainable, energy-efficient building with low impact costs.

Window manufacture and installation on the same high level

This North German build project was fitted with 530 individual plastic win-dow units manufactured by window specialist H.O. Schlüter GmbH. Many were full height floor-to-ceiling units and all were a massive 88 mm thick; often with roller blinds factory fitted. Because of the considerable demands on heat, noise and sun screening, a triple glazed unit was chosen. The

Heinz Hutter, FasteningSystems, hhe@sfsintec.biz

Window installation in heat insulated walling

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windows were to be installed in the insulated walling.

The glass units have a total weight in the region of 560 kg; quite a challenge for the installers. Conventional installa-tion supports and fasteners were out of the question. Standard easy-to-bend retainers would be useless with such loads. Likewise, standard timber and uPVC wedges generally used in win-dow fitting were totally unsuitable for the thick, heavily insulated walls involved here.

The installers worked with SFS intec to rise to the challenge; choosing the JB-D® assembly system, which is capable of overcoming even quite considerable build tolerances. To meet the required building regulations, SFS intec provided the relevant load bearing values.

Customer benefits from the JB-D® assembly system

“Using these three-way adjustable JB-D® fixings enables us to transfer all the weight and movement loads into the load bearing framework of the walling. Even the height can be adjusted to match the isothermals; making installation considerably easier but at the same time more secure. To eliminate glass breakages and frame material deformation, the setting rails have to be fitted as indicated by the manufacturer and RAL directives to ensure that they take the load. Keeping to the exact frame gaps is actually critical,” explains site manager Jörg Peters. The project has since been completed. The most noticeable fea-ture of the build is the complex range of apartments, each with floor level windows, meeting the needs

of customers for bright, individually designed living spaces – all with views over the park.

The JB-D® window system

Fitting windows into heavily insulated wall cavities is greatly simplified using the JB-D® system. Thanks to the three dimensional adjustment feature, just a few easy steps are needed to set the window frames perfectly.

What’s more, the SFS intec system meets all the requirements of the German certification institute ift. So both manufacturers and fitters can have total confidence that these fixings both meet the thermal requirements, and can stand up to the stresses caused by high winds and daily use!

Nr. 10541805

Deep drawn parts of superb quality

Michael Düring, AutomotiveProducts, dumi@sfsintec.biz

in deep drawing techniques and heat treatment processes, were invited to become involved in the project.

Meeting the needs and the timeframe

The first discussions among Scherdel, the end-user OEM’s and SFS intec served to establish the base line appli-cation requirements. This resulted in a radical redesign of the housing geo-metry. Possible materials were also investigated for their capability to withstand the trials of the test rig. These tests took place just eight weeks after the initial contact. To the enormous satisfaction of everyone concerned, the deep drawn housing sampled by SFS intec met all the criteria. The functional optimisation by heat treatment was a critical aspect.

Manufacturers of German luxury cars have been establishing new standards of efficiency for V6 and V8 engines. Getting more power from less fuel has been supported by first tier company Scherdel with a revolutionary valve timing mecha-nism. This is fitted with a housing from SFS intec.

Future-focused companies who pay heed to environmental issues have been showing the way forward in the automotive world. Engineers and technicians alike recognised the sign of the times, and launched a hitherto unheard-of development offensive. But when it comes to marketable, future-ready vehicle concepts, the bar is set quite high; not least because the requirements are at times diametrically opposed to one another. Trying to marry the thirst for more power and lower emissions represents quite a challenge to the industry.

The German supplier Scherdel has also set the points to the future. The latest manifestation is a cam shaft angle variator for a new generation of V6 and V8 engines for the German luxury car sector. Scherdel engineers made a massive breakthrough specifically through reduced weight and more compact dimensions, functional opti-misation, greater resistance and of course, reduced costs.

Rugged housing design

Designing the housing for the cam shaft angle variator was a particular challenge. What was needed was an uncompromisingly high-tech solution. The daily punishment of stop-and-start traffic queues, cold and hot starting and long journeys at high speed calls for robust engineering components. In their search for the optimum solution, Scherdel engineers looked at a range of manufacturing alternatives. It was established that a deep drawn housing would offer the best resistance to the anticipated dynamic loading. As a result, SFS intec, with their expertise

Working in partnership

The entire project was hallmarked by the close-knit, open co-operation between the various engineering teams. As the development pro-gressed, technical changes were needed, which were immediately checked by Scherdel and then dis-cussed and approved by the OEM’s. Above all, it was this effective com-munication which helped create such a superb quality product within the established timeframe.

Photo: Getty Images

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n The system housing is produced by SFS intec by deep drawing. Special process-ing techniques enable the retention flanges on the perimeter to remain pliable, even after heat treatment.

n Perfect in every detail. Ultra-modern tech-nology lies behind V6 and V8 engines. Every aspect of bought-in sub-systems has to meet rigorous quality requirements.

Ulrich Dagostin, Global Key Account Manager at Scherdel, was closely involved in the development of the valve timing mechanism. He talks here about the co-operation with SFS intec.

“Automotive OEM’s have been placing their trust in our know-how for many years. We have to conti-nuously strive to earn that trust, and the high quality suppliers we use are an important aspect.

We got to know SFS intec as a really reliable supply partner. A partner who reacts quickly and genuinely helps us in problem-solving. The decisive factors were the application engineering support and significant-ly, having all the processes under one roof.

Their strength in depth and efficient channels of communication certainly helped us achieve the extremely tight schedule we had to face.”

n The cam shaft variator enables the best possible valve control settings. In turn, this means lower consumption and reduced emissions; with increased torque and power.

Tobias Loher, AutomotiveProducts, lto@sfsintec.biz

Manufacturing expertise for safer driving

Seemingly bigger inside than out and fitted with state-of-the-art equipment, today’s city cars are equipped with the latest safety devices. In the re-launched Volkswagen Lupo, a newly developed ABS system from the international safety specialist TRW keeps the little car on the straight and narrow even during critical braking. SFS intec played their part in getting the system on the road with a mixture of technological know-how and an international presence capable of meeting the technical and financial project targets full-on.

Road safety is one of the challenges of the moment, best addressed by combining the latest technologies and systems. The total safety concept has been a theme for American first tier giant TRW for some considerable time. Known as “cognitive safety”, it is a way of pooling the capabilities em-bodied in the occupant restraint arena, steering, braking and chassis elec - tronic systems, to take passenger safety to another level.

Increased process capability

With the launch of a new ABS system, fitted initially to the re-styled VW Lupo, TRW has reached another milestone in active vehicle safety. Not only in terms of smoothing the braking action, but also the total development and manu-facturing efficiency behind it.

As the system progressed through the development phase, turned parts were successively replaced by cold formed components. It meant a much higher process capability in series manufac-ture for TRW. This was because cold formed parts demonstrate a very high repeatability. TRW were also delighted to be able to draw on components over a range of manufacturing techniques from a single manufacturer. SFS intec produced not only the cold formed parts for the system, but also a very demanding plastic moulding.

International collaboration

Behind the new ABS generation from TRW lies a global network of skills, all carefully meshed together. Core development of the system is at the TRW American HQ, completion of the technical concept and purchasing comes via the German subsidiary, series production takes place in both Europe and the USA; soon to be extended to Asia and South America. SFS intec was established in the required markets, ready to meet the needs of an organisation with global reach.

Step-by-step to the goal

The road from concept to series manu-facture was not always easy. Achieving the proposed component geometry was a particularly difficult issue at

n Brake support systems from TRW are produced on ultra-modern assem-bly lines.

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n Vehicle technology for tomorrow: the latest VW Lupo features an ABS system from TRW. VW’s new arrival consumes just 2.44 litres of diesel per 100 kilometres. This corresponds to a CO2 emission of 65 grams, making it the most economical four-seater in the world. The picture on the left was taken at the 2007 Frankfurt IAA Show launch.

times. Different potential solutions were produced and tested out. So total co-operation among the development teams was essential right from the start.

Test series were driven successively, with the knowledge gained feeding into the next phase. One particularly useful point was the ability to carry out secondary machining operations at SFS intec directly. It meant that all the requirements of the project specifica-tion could be met.

Growth objectives taken on board

For TRW, the collaboration with SFS intec is an example of a successful international partnership. With their comprehensive capabilities from development through to mastery of mass production and support struc-tures like logistics, SFS intec was able to offer TRW the support needed to reach growth targets. One critical consideration is a global presence in the important automotive markets; a decisive requirement in facing the challenges of the future.

Sigrid Leber, Senior Product Line Manager at TRW, reflects on the work with SFS intec.

“To meet the global demands of today’s automotive world, innova-tions are essential. As a system supplier, we play our part in ensur-ing that the vehicles of tomorrow meet not only the legal demands placed on them, but also fulfil economic criteria.

To achieve this we work with production partners who have comprehensive manufacturing know-how, coupled with thorough-going production capabilities. SFS intec is just such a company. The potential to have all the parts for our new ABS produced under one roof was a decisive factor. The concentration of capabilities and the close collaboration from all sides were what brought this project to fruition.”

n Everything from the same one-stop-shop: TRW uses a range of different parts from SFS intec in their new ABS generation. This not only simplifies purchasing procedures, it makes for rationalised manufacture.

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When it comes to lightweight systems for vehicles, blind rivets are among the most versatile fas-tening solutions available. Fully automated production processes demand rigorous process capabili-ties. This was the background to the development of the latest offer-ing from the blind rivet specialist GESIPA’s production palette.

The trend towards lighter-weight systems in the automotive industry, which increasingly use modern polymer alternatives to steel, place new demands on fasten - er technology. The method of riveting as well as the rivets used is becoming ever more important. Traditional methods tend to impact rather too heavily on both technical and economic limits; particularly with hollow containers, housings and other elements accessible from one side only.

The future of lightweight super-structures

So-called engineering plastics which save on weight are increasingly re-placing the former metal components. Even door systems have seen plastics coming to the fore. It is a change which has ramifications for fasteners and fixings. These now have to be designed to achieve close bonding between a metal and plastic interface.

All this requires a considerable amount of background knowledge in order to meet the, at times, somewhat contra-dictory requirements placed on blind rivet properties. Central to all this are, of course, the reduction in surface pressure during fastening, the overall insertion behaviour and the seal achieved.

Combining top quality with maximum productivity with the new GAV HF blind rivet insertion tool from GESIPA

Kay Brenning, GESIPA, kay.brenning@gesipa.com

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As a result, various vehicle manufactur-ers have been in contact with GESIPA blind rivet specialists. The requirement was for a fully automated insertion system with integrated process moni-toring. A system was duly designed based around a blind rivet developed in-house with a 16 mm head diameter. This reduced the contact pressure so much that the plastic under the head was not deformed in the slightest.

Process security

The GESIPA team placed a great em-phasis on reducing down time; in turn increasing process capability in multi-shift scenarios. Any deviations from the reference values are immediately displayed by the integrated control unit, with the system reacting with a temporary shut-down. It means that process-secure manufacture is effec-tively guaranteed. Another revolution-ary feature introduced by GESIPA was the intelligent monitoring and control of rivet delivery to the workplace.

It means that enormous feed distances of up to 20 metres are now a reality. Nothing gets in the way of stationary working; even in extremely tight situa-tions.

All the fastener technology you need

Assembly is fast and efficient. The rivets are delivered by the tube system from the magazine to the gun. The gun is equipped with a fill level moni-tor; and can even be fitted with an extra buffer store to ensure automatic re-filling.

The gun carries out the actual riveting operation, with nothing left to chance. Sensors detect the rivet location, the position of the delivery piston and the pressure inside the gun.

n The finishing touch. When it comes to productivity, the automotive industry has been stepping on the gas lately. GESIPA kept up with this trend with the GAV HF, offering 45 blind rivet insertions per minute.

The whole is monitored by an industrial process surveillance system with an eight-inch display, supported by a GESIPA in-house operating software package. The core advantage is that the rivet, the delivery system and the monitoring software all come from the same place. What could be better when it comes to addressing individual customer requirements?

In summary: Applications for blind rivet technology are running away with us. But today’s rivet systems are more than capable of dealing with different fastener geometries and different materials to be joined. Addressing such diverse requirements does call for innovative solutions like the new GAV HF blind rivet station from GESIPA.

n Together with the blind rivet, the GAV HF offers a reliable installation system. Starting from the delivery head, the rivets are inserted efficiently at a constant quality level. The optional fully automated version can be fitted to a complete production line or strapped to an industrial robot.

Technical seminars: showing you how to save money

Lukas Schüpbach, Electrical Components Industry, slu@sfsintec.biz

Working closely with Wincor Nixdorf, SFS intec successfully developed a fastener solution to help save money producing automated teller machines.

SFS intec customer seminars are about more than just passing on technical know-how. Our specialist engineers instead try to develop real-life technical improvements for actual customer applications. It is often well worth shedding light on fastener issues. Productivity can often be massively enhanced by simply using the right fastener.

That eureka moment at the seminar

The development of the new Wincor Nixdorf fastener can be traced back to just such a seminar. Discussions be-tween presenters and delegates gave rise to a development project with the aim of simplifying a rather irksome assembly procedure; and it was not just a case of saving manufacturing time. The key point was reducing the number of individual components

used. The fewer the number of parts, the easier would be the logistics and assembly.

Innovative fastener concepts

What do you need to connect the safe of an ATM to the cash dispenser? Well for Wincor Nixdorf, the answer had been four fasteners per position. For the project team at SFS intec one thing was obvious from the start; namely, that a completely new fastener con-cept was needed, integrating the functions of these individual compo-nents into a single unit. One thing which gave rise to concern when Wincor Nixdorf produced a specifica-tion was the extraordinarily low overall length available.

n Wincor Nixdorf belongs to the world‘s leading suppliers of IT solu-tions for banks and commercial con-cerns. They supply top-of-the-range hardware systems as well as innovative software and service support packages.

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What won through was a TORX PLUS® 12EP with external thread. This part can transfer enor-mous torque values even with a very low head height, and thanks to the integral locking teeth under the head, no additional special washers are needed. Likewise redundant were the hitherto essential separator spacers and flat washers, because the new fastener has its own thread-free starter point. The developers even thought about the earthing cable. The external TORX PLUS® offered the potential to insert an additional female thread into the head by machining. This could then be used to attach an earth cable. To differentiate between the two versions of the fastener, one was coloured silver and the standard one was coloured black in the in-house plating centre.

Customer benefits writ large

This new assembly fastener is opening up all sorts of rationalisation potential for Wincor Nixdorf. The product offers a massive insertion torque, saving time in installation. Meanwhile slimming down to one single component has paid quality dividends: the chance of forgetting or mixing components during assembly or maintenance are eliminated. But that’s not all: fewer parts mean reduced logistics and administration costs. Such results, coupled with customer recognition, are what keeps SFS intec pushing on to achieve pioneering solutions, offering massive customer benefit.

Martin Asshauer, Product Development Engineer at Wincor Nixdorf, summarising the work with SFS intec:

“I expect a strong supplier to help improve our efficiencies and economics. That is exactly what SFS intec did with the new fastener.

It was impressive to see how SFS intec took the ball and ran with it; presenting a solution so quickly. Reducing from four parts to a single integrated component is, quite frankly, nothing short of a quantum leap.”

Fewer parts means increased productivity

Where previously four individual parts were needed, there is now only one doing the same job. With a thread-free insertion tip, an integrated washer function, an external TORX PLUS® power drive and locking feature, this fully integrated part does the whole job and creates savings for Wincor Nixdorf in purchasing and logistics to boot.

Sonia Malavasi, Hinge Technology, mson@sfsintec.biz

Dynamic 3D: a hinge for all seasons

n The multi-faceted Dynamic 3D does not just look the part. It offers a high level of functionality. Both installation and adjustment are a piece of cake. Height, sidewards position-ing and flush fitting adjustments are all done with one and the same tool.

SFS intec has developed the Dynamic 3D universally adaptable hinge for the Italian window manu-facturer SOTECO.

It was back in the mid eighties when SOTECO became one of the first Italian manufacturers to launch uPVC-framed windows. These were rapidly recog-nised as ideal for both new build and renovation work, thanks to their numer-ous advantages. Among these are, alongside the obvious visual appeal, the high level of thermal and sound insulation provided; and last but not least the ease of fitting.

Over recent years, SOTECO has continued to develop the possibilities available from uPVC window units, so that these days, plastic windows can be matched to a whole myriad of customer concepts. That might be the use of special plastics, construc -tion and design details or colourways. In fact, SOTECO’s more creative customers can actually design their own windows.

Made-to-measure windows

That offer covers a comprehensive range of accessories like handles, safety locks and hinges. These have to combine several significant factors: beautiful designs, universal application, ease-of-installation and ready adjust-ment.

With the development of the Dynamic 3D, SFS intec met all the criteria required by SOTECO. As well as its functionality, the hinge offers a wide range of applications; whether that be plastic, timber or aluminium frames, windows, balcony doors or full entrance doors. Installers and specifiers have a virtually universal solution in the DYNAMIC 3D.

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At SOTECO, the customers can design exactly the window they want to suit personal preference. That does demand a high degree of flexibility in production and logistics areas, which in turn requires highly reliable supply partners. In the following interview, project manager Moreno Fra-nzò discusses why he chose SFS intec for hinges.

Sig. Franzò, going back for a moment, when did the association with SFS intec take shape?

Our relationship with SFS intec is now ten years old. At that time we had been searching for better hinges and hit upon SFS intec, whose products we investigated more closely. Over time that relationship developed into a partnership, which provides enormous benefits thanks to the high quality hinge systems available to us.

One of those solutions is the new Dynamic 3D. What made you choose that particular system for your products?

I first came upon this product at the last MADE exhibition in Milan. I was immediately impressed by the powerful combination of aesthetic appeal and functionality; which, to be honest, is almost unique. Then there is the univer-sality – the system can be used on uPVC, timber and aluminium, or timber-aluminium composites. With the Dynamic 3D you know you have a suitable hinge to hand. Previously, we had to keep adapting special products to fit our particular applications. That was always a lot of trouble.

So has the Dynamic 3D affected your window build directly then?

Absolutely: to get a perfect bore and screw location, SFS intec provided us with a special template. That makes the hinge assembly much easier. At the moment we are in the process of integrating the manufacture of our aluminium and aluminium-timber composites. When the work is com-plete, the Dynamic 3D will be fitted to both profiles on a fully automated high-tech assembly line that will save us a lot of time and money.

Were you able to optimise anything else?

Most certainly: the stylish design and big range of colours meant we could address the seemingly ever-increasing demands of our customers. There is a definite trend towards personalised windows. That requires a high degree of flexi-bility. Also, working so closely with SFS intec meant that we could match and maximise various details of the production process, which provides us with the added value we want from capable suppliers.

Can you envisage any further advantages going forward?

Well, customer feedback is the key thing for us. It is impor-tant for us to know how they get on with our windows and how their installation procedures go. We will be evaluating each and every customer response and relaying these to SFS intec; but to be perfectly honest, I do not think there is an awful lot of room for improvement on the Dynamic 3D!

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