EuroFasteners March 2020

Contents March 2020

Diary of Events

2020

EF 2/84 Corporate News

20-24 April: MACH – trade exhibition – Birmingham, UK Organisers : MTA (Manufacturing

EF 6/88 Products

Technologies Association) Email : mach@mta.org.uk Website : www.machexhibition.com

EF 12/94 Manufacturing Technology

2–4 June: Wire Expo – trade exhibition and conference – Uncasville, Connecticut, USA Organisers : Wire Association International Fax : +1 203 453 8384 Email : sales@wirenet.org Website : www.wirenet.org trade exhibition – Seoul, South Korea Organisers : KT Fairs Fax : +82 02 784 6810 Email : master1@ktfairs.com Website : www.korea-metal.com 23–26 September: wire China – trade exhibition – Shanghai, China Organisers : SECRI and Messe Düsseldorf (Shanghai) Co Ltd Fax : +86 216 169 8301 Email : shanghai@mdc.com.cn Website : www.wirechina.net 11–14 October: IWCS – technical symposium – Providence, Rhode Island, USA Organisers : IWCS Tel : +1 717 993 9500 Website : www.iwcs.org 17–20 June: Korea Metal Week –

bigstockphoto.com/czdistagon

Debut for niche industry at wire 2020 Düsseldorf is synonymous with wire and when the doors open on wire 2020 at the end of March, there will also be a world premiere in the world of fasteners and springs. The largest and most important trade show in the industry will celebrate an expansion of its portfolio with the complete value chain for fasteners and springs being staged for the first time in Germany’s seventh-largest city. Manufacturers, dealers and buyers will all be catered for as halls 16 and 17 are set aside for this niche part of the industry. More than 1,400 exhibitors from throughout the industry will be on hand to present new technologies, meet old and new friends and make new contacts as 70,000 visitors from 80 countries are expected during the five-day exhibition at the city’s Fairgrounds.

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EF 1/83

Corporate News

▲ The groundbreaking ceremony at the site in Künzelsau, Germany

Würth builds innovation centre

The Stuttgart-based Obermeyer Planen + Beraten GmbH engineering o ce was entrusted with the general planning. “We have set our sights high. We are delighted that we can actively contri- bute to underpinning the particularly pronounced culture of cooperation, pro- motion, research and ultimately also the innovative strength of Adolf Würth GmbH & Co KG with the architecture of the innovation centre,” said Christoph Blessing, head of Obermeyer Planen + Beraten’s Stuttgart branch. The ground oor features laboratories and workshops as well as a light- ooded, roofed inner courtyard, from which public and non-public areas can be accessed. The o ce space on the rst and second oor contains open workspaces. Further workshops, laboratories and logistics areas are planned in the basement. A second building will house a two- oor anchor laboratory, among others. Completion of the innovation centre is scheduled for late 2021. Adolf Würth GmbH & Co KG www.wuerth.de

This is precisely the special feature of the innovation centre: “These university cooperations allow us to take a scienti c approach, thus opening up entirely new opportunities. We want to develop even more from a trading company to a manufacturer,” said Thomas Klenk, managing director for product, purchasing and export at Adolf Würth GmbH & Co KG, explaining the motivation behind the large-scale project. “We aim to signi cantly shorten our innovation cycles in order to bring our new and further developments to the market even faster and to be able to o er our customers solutions with genuine added value.” Würth focuses its research and develop- ment activities on fastening technology, screws, anchors, chemicals, power tools and systems. The construction of the technology and innovation centre aims at exploiting these opportunities even more e ectively. The polygonal and expressive shape of the building is intended to promote and express innovative power.

Adolf Würth GmbH & Co KG, parent company of the globally operating Würth Group, is building a research and development centre in Künzelsau, Germany. The investment volume amounts to €70 million. Modern laboratories and workshops will be built on an area of around 15,000 square metres. A climate chamber, the latest 3D printers and seismic test rigs for anchor technology o er a wide range of options to strengthen and advance internal research in the long run. Approximately 250 people will be working in the innovation centre to implement ideas and make them t for the future: employees from the research and development department of Adolf Würth GmbH & Co KG and from group companies active in the manufacturing sector, as well as external researchers. The cooperation with Karlsruhe Institute of Technology (KIT) and the universities of Innsbruck and Stuttgart will create a cluster of knowledge and know-how.

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March 2020

Corporate News

Korea Metal Week review

Korea Metal Week was held at Kintex, Seoul, South Korea, and staged 14 types of exhibits on show, namely, fastener and wire, foundry and die casting, automobile and machine parts, press and forging, tube and pipe, metal surface treatment and painting, 3D technology, aluminium, laser and welding, fundamental manufacturing industry, pump technology industry, tools, composite, control, measurement and automation. Exhibitors were mainly from Korea, mainland China, Japan, Germany, Italy and Malaysia. Chinese exhibitors included Zhejiang GEM-Year Industrial Co Ltd, Shanghai BSC Corporation Ltd, Hebei Fuao Fastener Manufacturing Co Ltd, Zhejiang Huantai Precision Machinery Co Ltd, and Dong Tai City Huawei Standard Component Co Ltd.

Korea Metal Week seminar

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▲ 14 types of exhibits will be showing at Korea Metal Week in 2020

Exhibition oor

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Manufacturing is a pillar of Korean economy. In order to maintain competitiveness in the face of erce international competition, the Korean government announced in June that it will strive to increase the additional value of manufacturing from 25 per cent to 30 per cent, and increase the proportion of new industries and new projects from 16 per cent to 30 per cent. The aim is to make Korean exports rank fourth in the world – at present, Korean exports rank sixth. Korea Metal Week 2020 will run from 17 to 20 June 2020.

Korea Metal Week is a professional industry exhibition that deals with all aspects of production in industries of automobiles, shipbuilding, machinery and construction. KMW 2020 will showcase thousands of new technology items for the metal industry in Korea, o ering the best platform for metal manufacturing companies and buyers. Korea Metal Week www.korea-metal.com

Taiwan Fastener Trading Association (TFTA) held a directors and super- visors assembly at Queena Plaza Hotel in Tainan City, Taiwan. The assembly coincided with a special ceremony where the incumbent chairman presented an award to each respected former founder of the association. Taiwan Fastener Trading Association www.tftatw.org TFTA holds directors and supervisors assembly

▲ Members of the Taiwan Fastener Trading Association at the assembly in Tainan

EF 3/85

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March 2020

Corporate News

IAPMO’s evaluation service reports on construction fasteners

Fasco America has announced that IAPMO’s Uniform Evaluation Service has issued evaluation report 344 (ER-344) to its parent company, Beck Fastener Group, for its construction fastener, SubLoc ® Pro Scrail ® – a substitute for 8D and now 10D fasteners in seismic areas, such as the US West Coast, for vertical and horizontal diaphragms. The report certi es SubLoc Pro Scrail fasteners to be compliant with 2018, 2015, 2012, 2009 International Building Code ® (IBC) and International Residential Code ® (IRC), as well as the 2017 Florida Building Code (building and residential). IAPMO R&T marks of conformity are widely recognised, representing a high degree of integrity with regard to determining that building products are in compliance with established codes and standards. SubLoc Pro Scrails have been tested by IAPMO and are listed on building code report ER-344 as permitted to be used as a substitute for 8D and 10D common nails in OSB and plywood WSP horizontal diaphragms for resisting wind and seismic forces. The fasteners are also permitted to be used as a substitute for 8D or 10D common nails in prescriptive construction of WSP diaphragms in accordance with the IRC for maximum 15/32" inch and 19/32" thick diaphragms, respectively. Brett McCutcheon, general manager for Fasco America, said: “It is our mission to increase productivity with fasteners, tools, and systems that outperform the competition, so our customers know they are using the best solution in the market for their speci c needs. This independent report, based on rigorous testing, shows our customers just that. We make quality products like collated SubLoc Pro Scrail sub oor fasteners that increase production e ciency with the speed of pneumatic tool installation, while reducing callbacks due to squeaks. These fasteners can be used wherever you need them, now including seismic areas.” Typical building codes specify only the most basic fasteners. If a builder wants to use more advanced methods and materials, they must show proof that the alternative product performs the same, or better, than the one speci ed in the code. The evaluation report from IAPMO’s uniform evaluation service is the ultimate in independent assurance that SubLoc Pro Scrail is in full compliance with applicable code criteria.

▲ The Scrail – half screw, half nail from Fasco America

• Thread design eliminates micro-movement that can lead to squeaks • Veri ed squeak-free fastener from independent third party testing • Installed pneumatically using any common framing nailer, three times faster than collated screws • High talc collation for strips ensures the highest possible holding values by breaking independent of shank, which reduces agging of the plastic • Homogenised break points on wire coil reduce agging and ensure highest possible holding values • Utilisation of patented diamond coating maximises holding power • Thread design in conjunction with head design creates clamping force, which helps to pull material tight to the substrate • Head design maximises pull through Christian Beck, CEO of Beck Fastener Group, said: “Our family-owned company has over 110 years of experience with innovation in the fastener industry. We’re of course delighted with the publication of ER-344 for one of our newest items. We don’t measure quality, though, just by the type of materials we use, their certi cations, or conformity to industry standards. We believe quality is something even more, something engrained in our corporate culture, the fundamental way in which we do business day-in and day-out. It’s a holistic concept that permeates our entire corporation and all our processes, continually evolving them to a higher and higher level with every action we collectively take as an organisation.” Beck Fastener Group www.beck-fastener.com

Features of the fasteners include: •

Full 8D and 10D compliance to AC120

JB Springs nds extra space UK spring manufacturer JB Springs recently moved into a neighbouring production unit, adding an extra 5,500 square feet of manufacturing space to the Skipton, Yorkshire site. JB Springs will continue to employ a lean manufacturing ethos across its production facilities. JB Springs www.jbsprings.co.uk

JB Springs’ new production unit

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EF 4/86

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March 2020

Corporate News

Fastener vending milestone

Kuduma Fasteners A story on page FA EF5/71 in the January issue of EuroFasteners incorrectly stated that Paragon Fasteners had acquired Kadimi Fasteners. This is not the case. India-based Paragon Fasteners has, in the past, purchased machines from Kadimi Fasteners, not the company. It has since been an upward trajectory, passing 55,000 active devices at the close of 2015, and 96,000 as of 31 December, 2018. Meanwhile, the company’s With the recent installation of three additional devices at the Pierce Manufacturing facility in Appleton, Wisconsin, USA, Fastenal’s industrial vending programme hit a major milestone: 100,000-plus active devices driving results at customer sites worldwide. Vending is a relatively recent chapter in the Fastenal story, but it was also the prologue. When Bob Kierlin started the company in 1967, the idea was to dispense fasteners, nuts, bolts and screws from franchised vending machines lining the walls of unmanned retail stores. It quickly became apparent that the machine design could not support the sizes and volumes required by potential customers, forcing a pivot to a branch-based service model. What seemed like a setback proved to be an evolutionary step. When Fastenal revisited vending, 40 years later, the company was able to leverage a nationwide branch network, a captive last-mile distribution system, and deep inventory management expertise – critical aspects of the current programme’s success. It took a few years for the programme to gain traction, but it reached a turning point in 2011/2012, when Fastenal’s active device count increased from just over 9,000 (year-end 2011) to nearly 27,000 (year-end 2012).

▲ 100,000-plus active devices driving results at customer sites

However, the most important measure is the impact those devices are providing for businesses. That includes improved productivity, increased visibility into product usage and spend, and a meaningful reduction in consumption, often in the range of 20 to 30 per cent. With roughly $4 billion in vended sales since 2008, that is an estimated $1bn to $1.7bn in consumption savings alone for Fastenal’s vending customers. These bene ts are what motivated Pierce Manufacturing to install its rst Fastenal vending device back in 2011 and to gradually implement an additional 38 units throughout the plant, including, as it turned out, the milestone 100,000 th device. “Fastenal vending services are extremely helpful in streamlining our business strategies,” said Lorien Hegner, operations manager at Pierce Manufacturing. “Bene ts realised from these solutions include increased e ciencies, more inclusive product availability, and improved visibility and traceability of our expenses. Fastenal vending has truly changed the way we do business in the 21 st century.”

technology has expanded from a single model (the FAST 5000) to 23 specialised devices, bringing automation, visibility and control to an ever-expanding range of products. “Thanks to the willingness of our customers to try a new idea, the last ten years have seen vending become an important element within industrial and construction supply chains,” said Dan Florness, president and CEO of Fastenal. “We’re pleased to recognise this milestone with Pierce Manufacturing (an Oshkosh Corporation company) because they were one of our rst vending partners nearly a decade ago.” Fastenal’s 100,000 active devices can be measured in a variety of ways: by height (about 120 miles if stacked); by geography (they are currently installed at over 20,000 customer sites spanning 25 countries); by the number of vended transactions (roughly 17,000 per hour); by the impact on other areas of the business (safety products, the most commonly vended items, went from just under 6 per cent of total company sales in 2008 to more than 17 per cent today); or by total vended sales ($927 million in 2018 with a pace to surpass $1 billion this year – a revenue milestone that took 37 years for Fastenal as a company to achieve).

We apologise for this error.

Kuduma Fasteners Pvt Ltd www.kudumafasteners.com

Fastenal www.fastenal.com

EF 5/87

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March 2020

Products

▲ Condat’s lubricant experts will be at wire Düsseldorf, on stand B59 in Hall 16.

Committed to responsibility in the cold heading market

The Extrudex range also includes extreme pressure neat cold heading oils that are formulated to supply heavy-duty lubrication. Their chlorine-free complete additives package is active from low to high temperatures, to o er lubri cation for a broad range of operations. Using a minimum and accurate quantity of Extrudex is claimed to provide similar performance to standard cold heading oils, at lower cost. Extrudex oils are stand-alone lubricants that can be used only for the die side of the process. The product range is designed to improve tool life and usage on special deformation such as aerospace alloys and exotic alloys. They also allow homogeneous coating on the parts, which contributes to an optimum surface nish and no deposit on dies and punches. With high ash points, they are safe lubricants as they reduce the risk of re. Condat www.condat.fr

characteristics to both the machinery and the cold heading process. They eliminate cross-contamination problems often encountered during cold heading operations. In typical cold heading applications, approximately 80 per cent of oil consumption occurs when oil is dragged out of the machine on the surfaces of formed parts. Extrugliss oils are formulated to run at lower viscosity to limit oil drag out, and so decrease consumption. They are also formulated to limit soap swelling. With most heading lubricants, wire drawing soaps swell in suspension in the oil, negatively a ecting oil performance, and requiring more frequent oil replacement. With Extrugliss, drawing soaps and other contaminants are allowed to settle out of the oil, carrying with them abrasive metallic particles. As a result, the lubricant remains clean and provides optimum performance; time between oil change out is increased; and die life is improved.

People are increasingly concerned about their impact on the environment, and this includes the cold heading industry. Reducing total costs by using highly performing lubricants is important, but the responsible use of such products is also a major topic. Condat’s aim is not only to guarantee the high level of performance of lubricating solutions, but also to provide support towards responsible performance that takes into account social and environmental issues. To achieve this, the company provides solutions that allow increased productivity and reduced oil consumption, while respecting personnel and the environment. One example of increasing productivity responsibly is the use of Extrugliss dual-purpose oils. Applied for the lubrication of slides and cold heading operations, Extrugliss products can double the life of baths in service, reducing drain intervals by 50 per cent. The dual-purpose oils are formulated to provide superior lubrication

Graphics bigstockphoto.com/Artistnd 3000

EF 6/88

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March 2020

Products

Belleville spring washers in 300 series stainless steel

• Adjust the load and de ection of a washer stack by adding or removing individual washers and/or the sequence in which they are used, whether in series or parallel Stacks of washers can thereby provide a signi cant damping action in parallel stack con guration by reason of friction induced hysteresis, which dissipates unwanted energy, for example in architectural systems. They o er the ability to provide further adjustment by swapping out varying thicknesses in a stack to tune the force or compression range – also by mixing and matching of parallel/series spring discs. Belleville spring washers are similar in operation to wave washers as an anti-vibration device when installed with machine screws – but o ering higher load capability. They can be useful for o ering a visual indication of relaxation in a joint, over time or under adverse conditions. Lee Spring www.leespring.com

•

Single: One washer

Lee Spring is o ering Belleville spring washers in a wide range of di erent sizes and loading capacities. Manufactured in 300 series stainless steel, they enable engineers to quickly source these compact and cost-saving components on an urgent or a programmed supply basis. The high-performance spring washers found early application in rearms and now are widely found in aerospace, automation, building industry and elsewhere because of their ability to support very large loads with minimal use of space and to provide variable performance characteristics by varying their assembly format. Belleville washers are a type of spring shaped like a washer – named after Julien Belleville who in 1867 patented the design on which these modern versions are based. They are also commonly referred to as a coned-disc spring, conical spring washers, disc spring, Belleville spring or cupped spring washers. By stacking Belleville Washers in various con gurations, additional load exibility can be achieved in four di erent ways:

• Parallel: All washers stacked the same way • Series: All washers stacked opposite each other • Series-parallel: A combination of the two A single Belleville spring washer has a speci c load for a given de ection. Two washers stacked in parallel will yield double the load of a single washer for the same de ection; three washers will yield triple the load; four washers will yield four times the load, and so on. Alternatively, two washers stacked in series will yield double the de ection of a single washer for the same load; three washers will yield triple the de ection; four washers will yield four times the de ection, etc. combinations therefore can provide a wide variety of combined results of load versus de ection for the stack. Consequently, depending upon the application, the designer can: • Stack in ‘parallel’ to increase load • Stack in ‘series’ to increase de ection Various series-parallel

▼ Belleville spring washers are available in a wide range of sizes and loading capacities from Lee Spring

EF 7/89

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March 2020

Products

Cable management

two-piece locknut to x it in place; and sealing elements with a range of inlays. Assembly is quick and requires no tools: cables are simply fed through the enclosure opening and cable entry frame. Slit, tapered, nned sealing elements are tted around individual cables on the inside. Cables with sealing elements are then pushed back to t tight in the cable entry frame. The special shape of the sealing elements ensures high IP66 ingress protection, and a wide range of sealing elements for various diameters, shapes and multiple holes are available.

The new KDS-R system from ContaClip

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Unused entry positions in the frame can be sealed with blanking plugs, which can be easily removed at any time for additional cables to be inserted. ContaClip www.conta-clip.com

Conta-Clip has expanded its cable entry range, launching the KDS-R system for M20 to M63 round openings with or without plugs. The new cable management system consists of a few basic components: the cable entry frame with an integrated gasket; a two-piece thread and locking adapter, with a

Tiny, tangless inserts

Advanex has developed smaller, lighter, free-running 0-80 tangless inserts that can be used in a range of markets, including electronics, aerospace and automotive applications. Advanex is the UK-based developer of the industry-accredited KATO CoilThread. The development of the new Tangless 0-80 inserts involved working with new wire, tooling and processes. The new 0-80, 1-64 and M2 Tangless CoilThread inserts are available to order and have a wide range of applications, including electronic equipment and components. KATO CoilThread Tangless inserts are said to reduce installation time by up to 40 per cent, when compared to conventional inserts.

The inserts are designed to o er the following bene ts: • Size/weight – Smaller than similar fastening solutions, the inserts can save space and weight for an application • Debris free – No tang to break o , retrieve, lose or count. The Tangless design saves time and reduces risk of foreign objects remaining within a critical application • Time saving – Bi-directional design eliminates the need to orientate the inserts for installation, reducing installation and inspection time • Reusable – Quick and easy removal means no damaged threads, and this non-destructive removal prevents damage to expensive machined parts or castings Advanex www.advanex.co.uk ▲ 0-80 tangless inserts from Advanex

EF 8/90

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Products

Fasteners all at sea Bumax, a Swedish manufacturer of stainless steel fasteners, has received a major order for corrosion-resistant and maintenance-free studs to be used for a wind farm o the Belgian coast. The order will supply stainless studs, nuts and washers for the 219MW Northwester 2 o shore wind power plant, where the ability to withstand the challenging North Sea conditions is essential.

BACS screw monitoring system

for wind turbines

Checking for and replacing ruptured and deteriorated screws are among the most critical tasks of wind turbine maintenance. has developed a system for monitoring the screws used on wind turbines. The smart maintenance system collects data through sensors installed on the screws, and is expected to be in service by 2021. The system’s co-developers are the University of Tokyo, a screw manufacturer from Fukushima prefecture, and a wind power maintenance company. Japanese company BACS

▲ Corrosion-resistant and maintenance-free studs from Bumax

The order was placed by Danish steel contractor Bladt Industries, a company that specialises in large-scale and highly complex steel structures including o shore substations and o shore foundations. The wind farm is owned and operated by Belgian company Parkwind. Development of Northwester 2 is ongoing, and the wind farm is expected to be in operation in the rst half of 2020. The selected product for the project is Bumax SDX 109, a high-strength super-duplex fastener with resistance to general crevice, pitting and stress corrosion in aggressive environments. Bumax www.bumax-fasteners.com

The system is expected to make substantial savings in maintenance costs for wind turbines deployed for 20 years. The system uses sensors, embedded into the screws, and wireless transmission devices installed on the outside of the screws; these form a structure of mother and child devices. In phase one, 64 child devices, which connect wirelessly to two mother devices, are installed on a wind turbine to execute simultaneous detection. If a sensor exceeds a certain amount of numeric values it will shift to the non-simultaneous state, while other child devices continue transmission to the other devices, thereby indicating the condition of screws in advance. BACS

Ellis’s cable clamps have been used in Bahrain to secure electrical cables laid as part of a $4bn project to enhance the kingdom’s water and electricity networks. to accommodate its growing population and support its economic progress, the project involves the upgrade of the main backbone transmission network to 400 kV and the construction of three main transmission substations. Ellis’s 2A aluminium cable clamps and special compression springs were speci ed through Bahrain-based distributor Amad Baeed Electrical WLL by the Korean cable specialist LS Cable & System. Tony Conroy, Ellis’s sales director, said, “The scale of our export operation Clamps to the kingdom Aimed at enabling Bahrain

really does di erentiate us from the majority of our competitors. At present we have distributors in 39 countries and actively export to more than 40.” Ellis’s 2A aluminium cable clamps are manufactured from LM6 aluminium in sizes between 38 and 168mm. Primarily used in transmission and distribution projects in unpolluted environments, they can also be supplied with an epoxy coating for use in harsher environments, or with neoprene liners for additional cable protection. Ellis Patents Ltd

www.ellispatents.co.uk LS Cable & System Ltd www.lscns.com

EF 9/91

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March 2020

Products

Broad range fromVolt

Canoe clips, dart clips and arrow clips from Volt

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Like rivets, push-in fasteners are also simple to use and many do not require tools in order to install or remove. Depending on the material you are using or wanting to secure, simply push-in the fastener in order to hold two materials together. These economical fasteners are designed with a hollow body, which allows them to compress going into a pre-drilled or punched hole and decompress to create a secure t. These types of fasteners are also bene cial because most of them can be used repeatedly. Most people use them to secure materials such as wood, sheet metal, plastic and lightweight panels. They are also popular in stores for merchandising purposes and for places that use a lot of displays and signage, because they are simple to use and require no tools. Most can be inserted using the force of your hand.

Ratchet rivets are commonly used to hold together panels of rigid or compressed materials. The simple design allows you to achieve a secure and tamper-proof t by simply pulling the two identical pieces together. They are most commonly used in appliances, vehicles and furniture. Choosing to go with nylon or other plastic materials is always a plus because it is corrosion resistant. Volt also produces ratchet rivet extenders. These allow you to use ratchet rivets in panels with a larger thickness. Snap rivets are used in a variety of applications because they can be used in both rigid and exible materials. Snap rivets are usually small in size and have a male and female component. As the name suggests, these rivets simply snap together. They are also suitable for those who want a nished look to be seen on both sides of the assembly. Like many of the fasteners produced by Volt, snap rivets come in di erent sizes and dimensions in order to fasten materials of various thickness.

Plastic fasteners are used in almost every type of industry including automotive, appliance, electronics, furniture and more. The popularity of these types of fasteners grows each year because they have been proven to be cost-e ective, versatile and easy to use in an assortment of applications. Some of the most popular and most used fasteners are rivets and push-in clips. Both have a wide array of applications and uses. Here is a small breakdown of these fasteners and how rivets and push-in clips can make daily jobs easier. A rivet is used to simply hold together or connect two or more pieces. In fact, most rivets can secure almost any material. You would think that a fastener that is so versatile would be complicated or technical. However, most rivets have a simple design that includes a head on one end and a tail on the other end. Like most of the fasteners created by Volt Industrial Plastics, they come in many di erent sizes, shapes and materials.

Volt Industrial Plastics www.voltplastics.com

EF 10/92

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March 2020

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Manufacturing Technology

The FUL-175 fromWAFIOS

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High-end spring coiling machines The FUL series from WAFIOS stands for high-end spring coiling machines.

rollers. However, the full number is only required for wires from 14mm. For thinner wires, the setter equips the machine with fewer rolls. “There are two options when it comes to the number and design of feed rollers,” explained Andreas Sigg, construction at WAFIOS. “Either fewer pairs with a large diameter or more with a smaller diameter. Large rollers are heavy. To make handling as easy as possible, we decided on smaller roller diameters and six pairs.” In addition to the new FUL 166, WAFIOS o ers the models FUL 175 (up to 17mm), FUL 183 (up to 18mm) and – as the largest spring machine up to 20mm oil-annealed wire – the FUL 203. WAFIOS www.wa os.com

place via feed rollers with pneumatic tension – only with the FUL-16 does the operator assist and tension with the help of spring packs. The larger the machine or the wire diameter, the more feed rollers are used (FUL-16 to FUL-46: two pairs, FUL-56 to FUL-86: four pairs). The pneumatic contact pressure can be set on the screen for each pair of rollers. With this concept, feed speeds of up to 220 m/min are possible. The absence of hydraulic systems at this point has one major advantage: pneumatic components require con- siderably less maintenance. Cutting and winch equipment were therefore also designed without hydraulics. The FUL-166 is the rst WAFIOS spring coiling machine with six pairs of feed

The machines are designed for maximum productivity and quality, in conjunction with a high level of user friendliness. The types that end in 6, such as the new FUL-166, represent the latest stage of development: mechanics and control technology represent the current status. So far, seven models have been available that cover the spring wire range 0.12 to 8mm: FUL- 16 to FUL-86. With the addition of the FUL-166 for wires from 6.1 to 16mm, WAFIOS extends the spectrum upwards. The features are largely the same as for the smaller sister models.

The wire transport of all machines takes

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March 2020

Manufacturing Technology

Copper-based alloy for fasteners

In addition to ultra- ne wires, cables and stranded wires made from ISA-CON 414, Isabellenhuette produces preliminary materials for fasteners made of ISA-CON 450, another version of the copper-based alloy. The alloy reduces electrical resistance and dissipates excess heat. Both types of material, ISA-CON 414 and ISA-CON 450, are characterised by a high strength (similar to that of stainless steel) and high conductivity (similar to that of copper). With ISA-CON 450, the tensile strength is between 450 and 550 megapascal and the conductivity is 80 per cent ACS, the international Annealed Copper Standard. This combination makes the material suitable as a conductive fastener, for example as a bolt, screw, spring contact, plug connector or bus bar.

The requirements for the bolt application were a signi cantly reduced electrical resistance and thus a signi cantly reduced heat development of the bolt itself. Direct use here means that the entire current is conducted directly via the ISA-CON 450 bolt, which connects a shunt resistor with a plug. Thanks to the high conductivity of the alloy, there is only low electrical resistance with correspondingly reduced heat development in the contact bolt. In addition, heat development, which usually occurs in the shunt resistor, is dissipated better and is reduced by 50 per cent compared to a component with a steel contact. Another plus: ISA-CON 450 – like ISA-CON 414 – is also heat-resistant, which means the bolt retains its mechanical strength in applications with higher ambient temperatures. Current-carrying steel components that are di cult to cool, or that have to be signi cantly oversized to ensure su cient conductivity, can be replaced with ISA-CON 450. Mechanically supportive fasteners made of copper are also often oversized to comply with mechanical loads. The increased strength of ISA-CON means cross-sections can be reduced while maintaining the same level of safety. This allows for a reduction in weight and space, highly relevant for the automotive sector. An indirect connection replaces a previously non-current- carrying component, such as a steel screw, which presses a contact onto a bus bar. The pressed contact surface here and thus the component surface can be reduced, since part of the current can ow through the screw. The screw o ers additional safety due to its high conductivity. The direct use of ISA-CON 450 bolts in particular has a good cost-bene t ratio. Mr Brockhaus, business development manager at Isabellenhuette, said: “If heat development, electric conductivity and contact resistances are insigni cant in application, steel or simple copper alloys, such as bronze or brass, may be su cient. However, if the aforementioned problems occur, ISA-CON 450 is an ideal problem-solving alloy.” The alloy is of interest for all types of mechanically stressed plug connectors, which require high conductivity and reliability. Isabellenhuette Website: www.isabellenhuette.de

▲ The alloy reduces electrical resistance and dissipates excess heat

The ENKOnail+ series of high-capacity nail manufacturing machines incorporates the Enkotec rotary forming principle and a user-friendly machine design. This makes its nail manufacturing machines e cient, while o ering the possibility of automated production and in-line manufacturing. A key factor in the e ciency of Enkotec rotary nail machines is the durable tooling integrated in the process line and guaranteeing smooth, non-stop operations. The ENKOnail+ machines feature a user-friendly PLC control system and touchscreen operator interface, which displays current status, time and nail count. The operator interface is easy to navigate and allows for quick setup of nail parameters. It can be password protected to prevent unauthorised personnel from accessing the setup screens. Enkotec A/S www.enkotec.com When problems occur by using fasteners made of steel, for example, due to excessively high performance loss and heat development, or due to space problems or too much weight, using the ISA-CON 450 alloy is an alternative. With current-carrying components, the electrical resistance, both in the material as well as at the contact transition, is reduced compared to steel. This reduces the loss in performance, and the weight and diameter of components can be reduced too. The direct connection, for example as a bridging of a distance between two bus bars with a supporting function instead of a steel bolt or pin for a plug contact, is a promising application. High cost-e ciency

The ENKOnail+ series from Enkotec

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EF 13/95

www.read-eurofasteners.com

March 2020

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Manufacturing Technology

Error proo ng hand tools Tohnichi produces a wide selection of torque wrenches, screwdrivers and test equipment. The company is known for its selection of error proo ng hand tools that assist with avoiding possible missed or incorrect hand tightening in the assembly process. These error proo ng techniques include limit switches - once the torque setting has been achieved, it will send a signal to a PLC or counter to verify the manual tightening by tracking the number of completion “clicks” from the torque wrench. Evolving from limit switches that are cabled to wireless connectivity, Tohnichi’s latest version wireless module now has double tightening detection. This will alert the user if they try to tighten the same fastener more than once, making it a higher level of error proo ng. Tohnici America www.tohnichi.com Interactive seminar in fastener coatings with MacDermid

Following this, Lammert de Boer – global director ZinKlad, DecoKlad and XMAPP – gave an in-depth presentation on achieving global consistency in high performance coatings using the ZinKlad programme. Mr de Boer then discussed the challenges that applicators and fastener manufacturers face regarding quality performance and rising environmental challenges. The delegation understood the bene ts associated with ZinKlad and its supporting sustainable technology programmes. During the questions and answers session, delegates posed questions on hydrogen embrittlement, pre-treatment prior to plating, understanding the correct levels of ZinKlad performance and OEM transplants. Answering, Mr de Boer explained: “Our approved applicators meet the hydrogen embrittlement speci cations by closely controlling the parameters as speci ed in the ZinKlad auditing process.” Additionally, there was a discussion about lowering the risk by using alkaline zinc-nickel. “Our Enviralloy alkaline zinc-nickel technology is already extensively used within the ZinKlad programme.” In answering the speci c question on the importance of pre-treatment, Mr de Boer went on to say: “A study has shown that the majority of rejects emanated from incorrect application of pre-treatment processes. “Regarding the selection of the best performance level, white and red rust corrosion resistance is generally the most important factor.” Mr de Boer demonstrated this by showing the ZinKlad performance levels located on the MacDermid Enthone Chinese website. Mr Gardner nished the session by explaining the importance of supporting global OEMs transplanting into emerging markets: “We show the value of ZinKlad by listing our applicators on our websites for fastener engineers to select the most suitable applicators around the world.” The meeting was a success and the sessions well received, with continuing interaction during all the presentations. In particular, the in-depth level of technical discussions demonstrated the value of the seminar.

MacDermid Enthone Industrial Solutions held a ZinKlad seminar for a Chinese fastener delegation, consisting of some 30 leaders of Chinese fastener manufacturers. While visiting the Fastener Fair in Stuttgart, the delegation took a tour of best-practice technologies throughout the region. Driven by the rising regulations in the Chinese manufacturing industry, the delegates were keen to learn about the quality performance system ZinKlad. Of particular interest was how high performance, sustainable fastener coatings are carried out in Europe today. During the seminar, the delegates had the opportunity to hear about the global success of the ZinKlad programme, its bene ts for the fastener supply chain and its compliance with global environmental regulations. This is particularly important for the Chinese fastener supply chain as local OEMs increase their speci cation requirements and the applicator base looks for new technology to meet environmental directives.

Attendees at the seminar

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After a welcome speech and an introduction to MacDermid Enthone by Jasmin Baker, who highlighted the importance of the seminar for building strong working relationships within the fastener supply chain, Alan Gardner embraced the opportunity to introduce MacDermid Enthone’s OEM and sustainable excellence programmes.

MacDermid Enthone Industrial Solutions www.industrial.macdermidenthone.com

EF 15/97

www.read-eurofasteners.com

March 2020

Manufacturing Technology

Schuler press shapes parts for Italian sports cars Meeting the needs of car manufacturers in record time: that is the motto of Lasim SpA, based in Lecce in southern Italy. Transfer plants with a press force of 800, 1,600 and 2,000 tons form up to 324,000 small and medium-sized parts per day. Lasim has now ordered a press from Schuler for the rst time: a 2,000-ton machine with TwinServo technology. “We chose Schuler because of the technology and quality of the presses,” says Lasim managing director Giampiero Fedele. “We analysed the output and performance of the plant in advance, and Schuler o ers clear advantages over the competition. The short delivery and commissioning times also spoke for the investment.”

The Schuler press with TwinServo technology

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In Schuler’s TwinServo systems, two separate and only electronically synchronised torque motors work in the press table. As a result, the machines not only build signi cantly lower, but the spring de ection is also reduced by 30 per cent, while both noise protection and energy e ciency are improved. The two decentralised drives are arranged so that die cushions and scrap shafts nd enough space. In addition to two production sites in Lecce, one of which Lasim acquired from Fiat in 1992, there is a development centre in the Italian automotive capital of Turin. Mr Fedele also came from the north of the country, having moved to the southeastern tip of Puglia in 1980 to join the company as a 25-year-old. It was founded eight years earlier and today, with around 350 people, achieves a turnover of €85 million a year. The press for Lasim o ers a tool clamping area of 6.25 to 2.5 metres and is automated with a transfer that, thanks to its active vibration damping, ensures safe transport of the parts produced. They include brackets for fenders, airbags or dashboards as well as cross braces and beams, some of which are welded onto 18 interconnected robot islands. In addition to the three transfer presses, the Lasim machine park has seven further individual presses and two press lines. An order from an Italian sports car manufacturer to produce a 60-part aluminum chassis made it clear that another transfer press was needed. Mr Fedele played it safe and, in terms of production speed, opted for the sports car under the presses – the TwinServo machine from Schuler. Schuler www.schulergroup.com

EF 16/98

www.read-eurofasteners.com

March 2020