Fastener + Fixing Technology #3

www.sundram.com Iss u e 3 O c to b e r 2011

www.fastfixtechnolo g y. co m

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Fastener + Fixing technOlOgy The aim of Fastener + Fixing Technology magazine is to present the latest fastener engineering concepts to designers, engineers and production managers in key growth industries. To help us do this we are always interested in hearing from you on what fastener related topics you would like to see highlighted in the magazine.

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o make it easier for you there are several ways you can get in touch. We have a Fastener + Fixing Technology Facebook page, where you can leave messages, you can send a tweet to @fastfixtech on twitter, or you can connect with us on LinkedIn by visiting our company page or messaging me direct. We also update these media feeds with the latest fastener related news from the magazine, meaning that you can always be connected to the latest developments in the fastener industry.

Features in this issue of Fastener + Fixing Technology include an ‘India in the spotlight’ feature which focuses on the developments and capabilities of key fastener related companies in the Indian market, as well as a feature on the latest developments in sheet metal fastening.

This issue also includes another insightful article from Dr. Bill Eccles on ‘The basics of bolted joints’. The article looks into the importance of fastener selection, based on how a threaded fastener sustains loading and the influence that tightening procedures can play.

Will Lowry Editor

Contents

Tel: +44 (0) 1727 814 400 Fax: +44 (0) 1727 831 033 www.fastfixtechnology.com Group Publishing Director Jamie Mitchell info@fastfixtechnology.com Editor Will Lowry editor@fastfixtechnology.com Executive Editor Phil Matten Senior Advertising Executive Harry Whyte sales@fastfixtechnology.com Advertising Executive Claire Lake sales@fastfixtechnology.com Production Manager Andy Clow

Disclaimer

Industry news Latest fastener industry news............................................ 6-8 India in the spotlight The supplier of choice......................................................10-11 Intelligent solutions for high productivity ..........................12 Achieving customer satisfaction .........................................14 Cost effective solutions for PV solar ...................................14 Fulfilling customer needs .....................................................14 The ideal strategic position ..................................................14 Right Tight expands manufacturing capacity ....................16 Acquiring a diverse customer base .....................................16 New hydrogen annealing facility for Samrat .....................18 Showcase India......................................................................19

10-18

The basics of bolted joints Dr. Bill Eccles focuses on the basics of bolted joints ..........20-22 Sheet metal fastening Offering a long lasting solution .......................................... 24 New clinching tool delivers ................................................. 25 Indian interest increasing .................................................... 26 Supplying a broad range ..................................................... 26

Part of the Mack Brooks Group Romeland House, Romeland Hill, St Albans, Hertfordshire, AL4 4ET, UK

24-26

Copyright Entire contents copyright © Fastener Fairs Limited 2011.

No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means without the prior permission of the publisher.

Three tips for improving productivity Geoffrey King of Saint Gobain looks into improving productivity in the PV industry ................... 28-29 Trouble free fi tting through new topcoat Dörken introduces its new Delta-Protekt ® VH 301.1 GZ topcoat ............................................................. 30 Product news Latest fastener product news ........................................ 32-34 Advertisers index ................................................................. 34

4 issue 3 October 2011 • www.fastfixtechnology.com

The Publisher cannot be held responsible or, in any way, liable for errors or omissions, during input or printing of any material supplied or contained herein although the utmost care is taken to ensure that information contained is accurate and up to date. The Publisher also cannot be held liable for any claims made by advertisers or in contributions from individuals or companies submitted for inclusion within this publication.

The opinions expressed are not necessarily those of the Editor or Fastener Fairs Limited.

28

Ambrovit is one of Europe’s largest wholesale distributors of chipboard, self-tapping, self-drilling screws and bolts.

Thanks to its new automated warehouse, Ambrovit is now able to store around 20,000 ready-to-ship pallets as well as offer a Special Service to guarantee quick delivery.

Visit us at BATIMAT in Paris November 7th/12th 2011 Hall 5.3 Stand C99

AMBROVIT S.R.L. • 27026 Garlasco (PV) Italy - Via Giulio Natta, 29 • Ph. +39 0382 810280 - Fax +39 0382 810700 • sales@ambrovit.it - www.ambrovit.it

Fastener industry news

The changing face of car design Techsil highlights that its RTV silicone adhesives deliver improved performance and increased productivity for demanding automotive headlamp design.

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s designers push the boundaries of vehicle styling, and technology drives improved performance and smaller headlamps, the demands on key materials such as adhesives has increased.

Techsil’s business development manager, Steve Morrow, has been working with a number of automotive manufacturers to provide solutions for design and productivity issues with vehicle headlights.

In one case an adhesive was required to bond the dissimilar substrates of the reflector and a polycarbonate lens. The adhesive colour needed to be black to match the reflector housing and it also needed to operate in extreme high and low ambient temperatures. The versatile nature of RTV silicones allows the bonding of many different substrates; at the same time giving a long term level of elasticity that can cope with thermal expansion differentials over a wide range of operating temperatures.

Another application was an electric car where there was a need for an adhesive to bond a glass lens to the ABS housing. The silicone selected was clear and also fast-curing which enabled leak testing to be performed straight away. This helped decrease the manufacturing time by 22 hours thereby greatly improving productivity.

“Constantly increasing demands on the performance of vehicle lighting means they need to be incorporated into more complex and compact packages. In addition to bonding solutions, we offer a broad portfolio of products for lighting including LED encapsulants, thermal interface adhesives and lens materials.”

‘Slimming down’ - with EJOT® Industrial fasteners specialist EJOT® supports lightweight design strategies in the plastic field.

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ightweight design is one of the central starting points of cross-business research and development activities of many companies. Intelligent lightweight design concepts will be of crucial importance for compliance with future CO 2 limits in the automotive area. For that reason special importance will be attached to the lightweight suitability of fasteners for direct assembly into plastics.

The EJOT DELTA PT® screw, which has been the benchmark for reliable and easy direct assembly into plastics for many years, will also have to meet these new demands.

The DELTA PT® screw supports lightweight design concepts, says EJOT, through its outstanding fastening performance and possible reduction in dimensional parameters.

Additionally a reduction of bolting points is possible for many applications. The sum of these measures is a significant contribution to weight saving. If the full utilisation of weight saving potential is requested in the customer’s product specifications, a variation in the choice of the fastener material can also have the desired effect. For example, many DELTA PT® variants can be made from aluminium instead of steel.

EJOT® sees the last evolutionary step for innovative material selection in the use of plastic material for the DELTA PT® screw. The fastening elements made of the thermoplastic Grivory HTV-5H1 with 50% fibre glass offer the same joint reliability as metal screws, but with a much higher potential for weight reduction.

A plastic screw with similar dimensions weights up to 85% less than its counterpart made of steel.

6 issue 3 October 2011 • www.fastfixtechnology.com

Expand Your Operations and Increase Profits in India’s Fastener Industry Experience the Benefits of Becoming a Licensee of ND Industries, a Leader in Fastener Thread Locking, Masking, Lubricating, and Sealing Since 1955. » ND Materials:

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Fastener industry news

NORMA Group provides innovative fluid systems NORMA Group has secured a large order from an internationally operating vehicle and engine manufacturer to develop and manufacture fluid systems for the transportation of fluids into the exhaust pipe to reduce nitrogen oxides.

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he innovative product solutions are manufactured for a series of different vehicle platforms. From beginning of the production, the annual order volume will be in the lower double digit millions of euro for a four-year time period. Production will start in 2014.

The fluid pipes are an integral part of the ‘Selective Catalytic Reduction’ (SCR) technology that reduces nitrogen oxides in exhaust gases. The components of the NORMAFLEX product group used for this major order include heated pipe systems and joining technologies of thermoplastics which convey urea into the exhaust pipes. Globally higher exhaust emission standards increase the demand for new technologies to treat exhaust gases.

Werner Deggim, CEO of NORMA Group says: “We are

excited about this significant order. NORMA Group is a pioneer in innovative joining technologies and fluid systems. Industrial clients from the engine industry such as truck manufacturers, that must comply with tighter emission regulation, are increasingly interested in our products. Going forward, we expect to provide our systems for the SCR technology also to other OEMs.” Bernd Kleinhens, member of the board and managing director business development at NORMA Group adds: “As exhaust emission standards are raised across the globe, engines for commercial vehicles and passenger cars are increasingly equipped with state-of-the-art technology to treat exhaust gases. This also applies to agricultural machines and construction vehicles.”

Pin and insert installation technology Spirol Industries offers a wide range of technology solutions for costeffective pin and insert installations. The correct application of this technology enables users to provide lower cost, more reliable assemblies which can be delivered faster.

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oth semi-automatic and fully automated installation machines are available and Spirol offers customers a full project management service to ensure specification of the correct machine to meet any specific customer requirement.

Spirol’s range of pin and insert installation machines are based on modular designs that can be customised to suit specific assembly and production needs.

To provide the most suitable solution, Spirol works closely with customers to determine their objectives. Based upon identified requirements, Spirol will then develop the most suitable assembly concept before submitting a detailed and fixed cost proposal with a performance guarantee.

On confirmation of acceptance of the proposal, the assembly concept is assigned to a Spirol project engineer and a detailed assembly layout is developed. The required Spirol pins and inserts are specified and control packages are developed. Spirol also designs fixtures to hold and align components accurately during assembly - a critical element of the assembly process.

All specified machines are then tested, installed, set up and certified whilst training is provided to operators. Only when this whole process has been completed to the satisfaction of the customer is the installation finished.

The invisible tape Lohmann GmbH & Co. KG has drawn on its decades of experience in the development of customised adhesive solutions for the building & renewable energies market segment to help develop and patent a product for fixing cells within crystalline solar modules.

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he product is a single-sided adhesive laminating tape comprising an Ethylene-Vinyl-Acetate (EVA) - compatible substrate together with a mesh-like coating of special adhesive.

Lohmann points out that this adhesive tape represents a completely new way of securing solar cells and has many advantages for the user. For example, it has a sufficiently high initial tack with respect to the EVA material and the rear of the cell. This enables the ‘strings’, a collection of solar cells connected in series within a module, to be held in place during the lamination process. As the substrate and the multi-layer films in the solar modules are made from EVA, the adhesive tape is rigid and resistant to deformation prior to lamination. This prevents the cells from ‘drifting’ and facilitates both manual and automatic application.

Another factor that Lohmann says makes its DuploCOLL adhesive tape unique is its adaptability. Owing to its compatibility with all other components, it remains invisible following lamination – no inclusions or discolouration. The adhesive tape can be supplied as a directly applicable die-cut for ease of use. Taken as a whole, the ‘invisible tape’ optimises the manufacturing process for crystalline solar modules and helps reduce cycle times.

8 Issue 3 October 2011 • www.fastfixtechnology.com

india in the spOtlight

The supplier of choice Sundram Fasteners Limited (SFL), a market leader in high tensile fasteners in India, is part of the TVS Group, an automotive component group in India which has sales of Rs 31,500 Crores (US$ 7 billion).

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stablished in 1966, SFL has business interests in high tensile fasteners, radiator caps, cold extruded parts, powder metal parts, iron powder, gear shifters, hot forged parts, automotive pumps and assemblies. SFL sales last year were approximately Rs 2,400 Crores (US$525 million), with exports from its Indian operations accounting for approximately Rs 490 Crores (US$107 million), which is around 20% of the total revenue of SFL. SFL has manufacturing facilities in India, Germany, UK and in China, and is able to manufacture an entire range of standard and special fasteners at its Indian, Chinese and German facilities. SFL’s high tensile fasteners are manufactured in four fully integrated manufacturing facilities in India, with the total installed capacity around 80,000 metric tonnes.

“ SFL manufactures an entire range of standard and special fasteners and has manufacturing facilities in India, China, and Germany.”

SFL has a large number of cold forging machines to manufacture both bolts and nuts. Hot forging facilities add to the manufacturing range of higher size nuts. A host of secondary operation machines such as copy turning, CNC turning, grinding, milling and drilling add to the capabilities of manufacturing special fasteners. Continuous state-of-the art heat treatment furnaces ensure consistent metallurgical properties and SFL can offer a wide option of surface finishes from zinc phosphating, zinc plating with various passivations, Cr+6 free zinc plating, Dacromet ®, Magni and PTFE. Application of adhesives, sealants and lubricants on threads, as well as on the other surfaces, are also offered.

SFL’s standards range includes hex screws, bolts, square

10 issue 3 October 2011 • www.fastfixtechnology.com

head bolts, hex flange bolts, heavy hex flange bolts, square neck bolts, double end studs, stud bolts, hex nuts, flange nuts, slotted nuts, castle nuts, nylon inserted self -locking nuts, all metallic lock nuts and socket products. The range of socket products includes socket head cap screws, shoulder screws, socket button head cap screws, socket set screws, flat head screws, hexagon socket keys, “T” handle keys and special socket screws.

The special fasteners range includes connecting rod bolts/ nuts, main bearing cap bolts, cylinder head bolts/studs, flywheel bolts, rocker lever adjusting screws, banjo bolts,

Category

Diameter

L

Automotive / Industrial fasteners Bolts / Screws Nuts

M6 - M36 ¼ inch - 1½ inch

10m

/8 in

3

M6 - M36 ¼ inch - 1½ inch

Windmill fasteners Structural Bolts

M30 - M64

Washers

M24 - M64

Barrel Nut Aerospace fasteners

Up to M30

Bolts / Screws

¼ inch – 7/8 inch

Up

Up

caliper bolts, wheel bolts/studs, wheel nuts, two piece wheel nuts, track shoe bolts/nuts and turbo charger shafts.

SFL has also invested in the tool rooms in all of its manufacturing facilities and makes all of its tooling (except carbides, taps and thread rolling dies) in-house. SFL’s tool rooms are equipped with CVD coating and cryogenic treatment facilities.

To add to its tool rooms SFL has laboratories which have been accredited by NVLAP and are equipped with chemical and mechanical testing equipment. Testing equipment at SFL includes SCM, metallurgical microscope with photography attachment, coating thickness checking equipment, profile projectors, contour graph, magnetic particle testing equipment, UTM’s, Torque Tension testing machine, roughness testers, fatigue testing machine and salt spray testing chambers.

A team of dedicated engineers which include mechanical engineers, metallurgical engineers, as well as specialists in tool engineering and machining, work in the engineering department at SFL. They use CAD/CAM, process designer software and FEA analysis. SFL allocates engineering resources to customers to work on new projects and the dedicated team works closely with customers’ engineering departments and offer design inputs, proto-type development, testing of samples and final launch of bulk supplies. Even in on-going projects SFL engineers undertake standardisation and variety reduction projects with customers.

SFL has also started to produce aerospace fasteners and is working with leading customers from the aerospace market. An exclusive plant which can handle fasteners to be made from titanium, Inconel ®, Waspalloy ® and aluminium is being set up in Chennai. The aerospace division has obtained AS 9100 certification and has plans to get NADCAP approval.

To tap the fastener potential of the growing wind energy segment SFL is also setting up an exclusive plant to manufacture the full range of wind energy fasteners. The facilty will have access to the technological expertise of Peiner Umformtechnik GmbH, Germany which is a 100% owned subsidiary of SFL. The exclusive wind energy fastener

Length

Grade/RM

mm - 300mm

8.8 / 10.9 / 12.9

nch - 12 inch

Gr 5 / Gr 8 / Gr 10

-

Gr 8 / Gr 10

-

p to 420mm

8.8 / 10.9

-

-

-

Gr 8 / Gr 10

p to 6 inch

Inconel®, Titanium, A286, H11, Aluminium, Waspalloy ®

“ SFL has a worldwide reputation of being a reliable source for critical/ special fasteners and has over five decades of expertise in developing and supplying these fasteners.” plant will be equipped with the latest hot forging machines, thread rolling machines, heat treatment, hot dip galvanising equipment, as well as a fully-fledged tool room and laboratory which handle Torque Tension testing up to M64 diameter bolts.

All of the various divisions of SFL are ISO/ TS 16949 and ISO 14000 certified. The fasteners division is certified for AS 9100. SFL has also won the ‘Supplier of the Year’ award six times from General Motors, North America, and has practiced TPM in all its manufacturing facilities for the past 10 years.

“SFL has a worldwide reputation of being a reliable source for critical/special fasteners and has over five decades of expertise in developing and supplying fasteners. We are able to supply standard and special fasteners to all leading OEMs of the automotive and Industrial segments in India and overseas, with the aftermarket requirements in India met through our wide network of distributors and dealers both for the automotive and industrial markets.”

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india in the spOtlight

Intelligent solutions for high productivity A current focus at LPS Bossard PVT Ltd, based in Rhotak, Haryana, is the Indian wind industry, with the company working with various customers to help reduce manufacturing costs, whilst also participating in developing technical innovations and improving the service quality. Here Mr Rajesh Jain, managing director at LPS Bossard, explains how the Bossard Group can further help wind industry companies.

What are the benefits for wind energy companies to work with LPS Bossard?

Rajesh Jain (RJ): Working with our specialists in fastening technology, especially at an early stage of the development, will help wind companies to save substantial production and assembly costs. This is because LPS Bossard engineers analyse where an optimisation of a product range can reduce the number of parts and where the use of multifunctional parts can simplify production and assembly.

What is LPS Bossard’s track record servicing this industry?

RJ: We are able to offer a complete range of wind turbine fasteners and C-part items solutions for all parts of a wind turbine. Applications where we have already provided solutions include for nacelle assembly, generator assembly, gear box assembly, the rotor hub, the rotor blades (stud and stampings), the tower fl ange, the tower internal, the foundations, as well as the control systems.

We also have a trained and dedicated wind segment sales and engineering team spread across 15 different locations in India. All of these locations have been chosen due to their proximity to wind turbine manufacturers and wind turbine sites/parks, enabling us to offer a localised service.

How does LPS Bossard support its customers?

RJ: We offer convenient and secure procurement of consistent quality products worldwide. LPS has got a state of the art, dedicated wind fasteners production setup wherein all critical operations are done in-house. As the demand grows, a capacity expansion green field project is already into its final stages. In addition to this the labs and product R&D centre are also getting further enhanced with the addition of the latest equipment, all with a special eye focused on innovation, productivity and quality. Also, our extensive service network with its many locations ensures that our customers are provided with the optimum relationship between price, availability and quality.

What else does LPS Bossard offer as a value added service?

RJ: Full integration is enabled right from the design stage to machine erection on site. LPS Bossard helps to reduce or eliminate costs along the whole procurement and value-added chain, through logistic systems which are developed to meet customer requirements. Through ABC analysis we calculate that the cost of procuring C-parts makes up around 50% of the total cost of procurement, although in terms of value they are only worth around 5% of the total. This is an area which offers an enormous potential for rationalisation.

We also have an engineering portal in place which offers 24x7 online technical assistance to our customers. Our engineers also offer customised technical support extended right up to customer remote sites.

Finally, our ‘point of use kitting’ logistic systems simplify procurement, reduce inventories and at the same time prevent bottlenecks in supply right up to machine erection, allowing the customer to spend more time on their core tasks.

12 Issue 3 October 2011 • www.fastfixtechnology.com

PREPARE FOR THE BEST PERFORMANCE Our know-how as a global fastener expert guarantees significantly better performance and a sustainable improvement of your competitive position.

Free up your resources and reduce your Total Cost of Ownership with LPS Bossard. With our high performance fastening technology and state-of-the art logistic solutions, we deliver excellent quality product solutions and service spread across 15 locations in India.

LPS Bossard Pvt Ltd NH-10, Delhi-Rohtak Road Kharawar By-pass Rohtak, Haryana 124001 – India

Phone: +91 1262 305 198 Fax: +91 1262 305 111 india@lpsboi.com www.bossard.com

We contribute to your success with our expertise in the following areas: • Productivity enhancement through proactive design and development collaboration • Efficient processes thanks to intelligent fastening solutions • Lean supply chain with point of use value added kitting solutions and on-site support Call us today for a consultation, send us a mail or visit us online.

india in the spotlight

Achieving customer satisfaction Established in 1999, Landmark Fasteners Pvt. Ltd is an ISO 9001:2008 accredited company based on the Anand Industrial Estate in Ghaziabad, Uttar Pradesh, 30km away from New Delhi.

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manufacturer of aluminium pop rivets and high tensile bolts, Landmark states that it is committed to achieving customer satisfaction by consistently meeting customers’ specific requirements in terms of quality, cost effectiveness and timely delivery. The company achieves this through continued training and the adoption of new technologies.

Landmark has two manufacturing units at Ghaziabad and Baddi (Himachal Pradesh) and currently employs around 80 people including 30 senior technicians. The factory at Anand Industrial Estate manufactures aluminium pop rivets and the manufacturing unit in Baddi manufactures nuts/bolts.

Besides manufacturing, Landmark also caters to customer requirements for galvanised/SS/ bi-metal self–drilling screws and dry walls screws, under the brand name ‘HP’ a registered trademark of the company. Landmark’s self-drilling screws have features such as xylan coating that passes 1,000hrs SST with leak proof EPDM washers. These screws come in different types and Landmark’s range comprises of screws that can also drill through 25mm thick purlins.

Landmark Fasteners is part of the Dun & Bradstreet Global Database and has been assigned the D & B D-U-N-S ® Number: 92-038-5718. The company is ISO 9001:2008 certified and is rated SME 3 by CRISIL.

Cost effective solutions for PV solar Multiple Overseas Exports and Eagle Line Fixings, both part of Multiple Group, manufacture a range of channel nuts, bracketry fixings, clamps, fasteners, and products for the building hardware sector.

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ultiple Group produces parts complying to BS, ASTM, JIS and DIN standards from steel, alloy steel and stainless steel (304/316) by pressings, hot forging and turning processes.

Apart from its regular product range, Multiple Group also has a comprehensive infrastructure backed by hi-tech dies and a tooling room which enable it to develop any kind of special part exactly to customers’ drawings, samples and specifications.

Multiple Group also highlights that its production facility is well equipped with the latest zinc, phosphate, powder coating and hot dip galvanising plants to meet customers’ desired level of satisfaction.

“We are equipped with the best infrastructure and latest technology to meet the needs of our customers. Currently we are manufacturing quality and cost effective solutions for PV solar mounting systems. Our intelligent panel support/clamping systems, brackets, accessories and fixings for PV solar can be used on sloops, insulated roofs and flat surfaces for ultimate power, bond strength, weather resistance and safety.”

Fulfilling customer needs Mitter Fasteners is an ISO/TS 16949:2009 accredited company which was established

by Mr Devinder Sahani and Mr Mukesh Sahani in 1982, with the intention to manufacture and supply high quality products, at a competitive price, on a long term basis.

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ue to an increase in demand by customers the company enlarged its activities by entering into O.E. manufacturing of cold forged components, sheet metal components and machined components for the automotive industry.

Mitter Fasteners has four units in Ludhiana, Doraha (Ludhiana), Lucknow and Rudrapur, and says that its modern facilities, coupled with its committed team and continuous customer support, enable it to meet customers’ demands.

“Our mission is to provide quality products and services to our customers across the globe and to help our customers in providing high quality precision components at competitive cost. We are committed to fulfilling customers’ needs through our quality systems and procedures.”

The ideal strategic position Rivit Srl states that its Indian branch, with offices and warehouses located in Chennai, Tamil Nadu, gives the company the ideal strategic position to help deal with the increasingly expanding Indian sheet-metal working industry, as well as the growing demand for good quality products and qualified service for traditional, mechanical, hydraulic and hydro-pneumatic fastening tools.

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he opening of the Indian branch in April 2011 coincided with Rivit exhibiting at Fastener Fair Mumbai and BLECHIndia, with the company receiving lots of visitors at both shows, all interested in learning about tools for rivets and rivet nuts.

Rivit highlights that the professionalism of Rivit Italy, derived from 40 years of practice and experience in countries around the world, is now operative in Rivit India.

The Indian branch is a stand-alone unit for all purposes, with a comprehensive range of products in stock, constantly replenished by the Italian headquarters. Rivit India offers commercial assistance and technical support to sheet metal working companies in the fields of automotive, transport (buses, trucks, trains and ships), electrical appliances and electronics.

“Rivit India technical and commercial staff of are now at the disposal not only of production and processing companies, but also of local retailers and distributors. They can offer advice and quotes, as well as shipping all over India and neighbouring countries. There is also now a fully operative after-sales and repairs services centre for riveting tools.”

14 Issue 3 October 2011 • www.fastfixtechnology.com

india in the spOtlight

Acquiring a diverse customer base Norma Group Products India Private Limited, a subsidiary of NORMA Germany GmbH, started its operation in December 2008 and has grown rapidly ever since, acquiring a diversified customer base.

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ORMA-India has a state-of-the-art production facility in Pune for hose clamps from a diameter range of 12mm - 200mm. It also serves its customers with all the product range of Norma clamps and connectors by sourcing it from its parent location to help customers in reducing tooling investments on low volume requirements.

The planned growth trajectory of NORMA-India is based upon robust investment plans in the coming years. NORMA-India explains that by working in partnership with its customers, it can ensure every product solutions is exactly matched to their needs. NORMA-India has the aim to become the preferred supplier in automotive and industrial segment with its entire leak proof, long lasting and serviceable products in all the areas of joints.

NORMA-India is a Tier-1 supplier to major OEMs such as M & M, Mahindra Navistar, Tata Motors, Ashok Leyland Nissan, Fiat and Volkswagen with a very wide range of products.

NORMA-India points out that it is also rapidly gaining recognition from industries such as aerospace, rail, marine, ship building, chemical, cement, food and beverages, power generation, petrochemical, refinery, gas installation units, building and construction, off-highway segment, infrastructure and allied industries.

Ajit Wankhede, head of business development (distribution services) of NORMA Group India, says: “With our new distribution centre we aim to establish a resilient distribution network across India in order to meet the growing requirements of our customer base. NORMA Group appointed dedicated distributors in each state shall exclusively supply local dealers and end-customers in specified areas.

Right Tight expands manufacturing capacity Established in 1979, Right Tight Fasteners Pvt. Ltd (RTF), based in Nashik, India, supplies fasteners and customised products for a wide range of critical applications for various industry sectors.

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TF is ISO/TS 16949:2009 certified and has facilities covering 25,000m2 across five locations. The company has recently undergone an expansion programme to widen its bolt manufacturing capacity to approximately 10,000 metric tonnes in the size range of M5 - M22.

RTF has also installed sophisticated facilities for heat treatment, zinc plating, zinc aluminium flake coating, bolt forming and secondary operations. RTF highlights that equal care has been taken to ensure a good quality product by way of installing a wide range of testing equipment and supporting facilities.

Naturally – your customers demand the best.

At NORMA we guarantee that as a distributor you have the widest range of products to choose from. Whether your customers are small or large companies, our products will fit every customer’s connection technology needs.

www.normagroup.com

Customer Value through Innovation.

NORMA Group’s innovation Engineered Joining Technologies and applications know-how provide cleaner, more efficient use of precious energy sources in areas such as Cooling System, Air Intake & Induction, Emission Control and Ancillary System.

Visit us at www.normagroup.com for more information about our solutions.

Cooling System

Air Intake & Induction

Emission Control

www.normagroup.com

india in the spOtlight

New hydrogen annealing facility for Samrat Established in the year 2005, Samrat Wires Pvt Ltd (SWPL) is primarily engaged in the business of manufacturing steel wires to meet demanding applications such as cold forming.

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n associate unit of Gita Group, which has an annual turnover of more than Rs. 700 Crore, SWPL is located in Khopoli, about 100km away from Mumbai off the Mumbai-Pune highway. SWPL has a state of the art facility that can currently process approximately 8,000 metric tonne per annum of wires of different sizes and grades.

Currently the plant caters to a wide variety of grades that include SAE 1541/EN8D, SAE 4140/SCM 440/SAE 4135/SCM 435, AISI 10B21/15B25, AISI 15B41, SAE 1008/1010/1015, SAE 52100/EN 31, SAE 8620, as well as electrode quality wires and MS/LC HB HHB wires. The plant can handle wire rods in the diameter range 5.5mm – 28.6mm.

SWPL highlights that the plant is fully equipped with the required testing and measuring equipments to support quality production. The list includes spectrometer with a capability to identify 16 elements, tensile testers, hardness testers, a microscope with image analyser and a magnification of 1,000X, upset testing machine, micrometers and digital micrometers, as well as vernier calipers. All these are calibrated at appropriate intervals by NABL accredited agencies.

To meet the growing demands from its users from the stand points of quality, cost and delivery, SWPL has embarked on an expansion programme to reach 14,000 metric tonnes per annum and has ordered a hydrogen annealing facility from Ebner, based in Austria. SWPL states that it is the first service provider/manufacturer in the country, to have taken such a bold and pioneering step to opt for hydrogen annealing set up, and hopes that this will enable it to reposition itself and become the preferred source for alloy steel wires.

Features of the Ebner hydrogen annealing furnace, which SWPL expects to commission before the end of the year, include: • • • • •

Zero addition to the level of decarburisation present in the input wire rod.

Minimum spherodisation of 95%.

Uniform grain size.

Bright surface for the wires.

Shorter cycle times facilitating shorter lead times for delivery to customers.

“Since 2005 we have established ourselves as a major player in the Indian wire market and with the help of our trained and motivated workforce we will continue to strive for excellence and continuous improvement.”

india in the spOtlight

Showcase India Providing engineering solutions across a range of markets, Showcase India will help you source products, find services, and answer engineering design questions.

Tel:

+91 982 103 8609 +91 982 040 4557

email: sales@fitright.co.in Tel: +91 22 6615 7219

Arrow Enterprises

D. H. Exports Pvt Ltd

We manufacture quality assured Anchor Fasteners based on International Standards and designs. Our range of Anchor Fasteners includes Mechanical Chemical,Nylon Frame & Concrete Anchors. We make Anchor Fasteners in M.S., S.S.304 & S.S.316. We are authorised dealer for ETA Approved U.K. Based Chemicals Anchors. We offer on Site Testing for Fasteners.

D. H. Exports Pvt. Ltd. is a leading manufacturer of SS cold drawn long products in Round, Hexagon, Square, Flat Bars and Wire sections. With complete in-house production facility, we specialise in manufacturing variety of Stainless Steel Grades and sizes.

email: sales@dhexports.com Tel: +91 22 6666 1750.

Fit-Right Nuts & Bolts Pvt. Ltd

Global Impex India

Fit-Right Nuts and Bolts is a leading Manufacturer of Cold Forged, Stainless Steel and HT fasteners and components as per various National/International standards or as per customers specification. Our Speciality being ASTM Fasteners, Exotic Alloy fasteners,Ex-Stock Availablity of Standard size/grade Fasteners and lowest lead time for other fasteners.

We are one of the largest importers and distributors of fasteners/ C-Parts in India. We have tied up with some of the most reputed fasteners/C-parts suppliers in the world to introduce their products in the Indian market. Since 2002, we have been supporting major OEMs and Global corporations in India with their C-Parts management requirements.

Tel: +91 11 4242 0475 email: sales@globalimpexindia.com

Raajratna Ventures Ltd

Rishi International

Our company specializes in manufacturing high quality stainless steel fasteners & threaded bars in grade A2 & A4 ranging from M4 to M16 according to various standards like DIN/ISO/ASTM/JIS. The fasteners are available in most thread forms like METRIC/UNC/BSW. We at Raajratna strive for continuous improvement through productivity gain and employee participation.

Part of RAAJRATNA GROUP

RISHI INTERNATIONAL is a leading manufacturer of Industrial Fasteners in INDIA. Since our foundation in 1974 we have been involved in production of fasteners using hot and cold forming process. Our range of fasteners starts from M8 til M64 and upto 600mm lengths.

We specialise in fasteners and fittings/brackets as per drawings.

We are ISO 9001:2000 certified company by TUV.

email: sales@raajfasteners.com email: support@raajfasteners.com

email: rishi@rishimail.com www.rishiinternational.com

Cost effective advertising in Showcase India is seen by 6,000 fastening engineers.

To promote your company here please email sales@fastfixtechnology.com or phone +44 1727 814 508

Fastener + Fixing Technology

The basics of bolted joints

By Dr. Bill Eccles, Bolt Science www.boltscience.com

Over the last sixty years great improvements have been made by the fastener industry in improving the design and reliability of their products. However, no matter how well designed and made the fastener itself is, it cannot alone make the joint more reliable. Fastener selection, based upon an understanding of the mechanics of how a threaded fastener sustains loading and the influence that tightening procedures can play, is also needed. This article provides an introduction to the basics of bolted joints and the major factors involved in the design of such joints.

I

t is not widely understood how a bolted joint carries a direct load. A fully tightened bolt can survive in an application that an untightened, or loose bolt, would fail in a matter of seconds. When a load is applied to a joint containing a tightened bolt it does not sustain the full effect of the load but usually only a small part of it. This seems, at first sight, to be somewhat contrary to common sense but hopefully this article will explain why this is the case.

Bolts are made from elastic materials such as steel. When a bolt is tightened the bolt is stretched like a spring (figure 1).

Figure 1

The joint itself is usually made of a metallic material which is also elastic. As the bolt is tightened, the joint is compressed and acts as a compressive spring (figure 2).

Figure 2

Put together, the bolt and the joint act as a combined spring system.

In a tightened joint, the tension force in the bolt is balanced by the compressive force in the joint (figure 3). A key point to understanding how Figure 3 forces are transferred in a bolted joint is to realise that the only way that the bolt can be loaded is by applying a load through the joint.

Loading the joint with an axial load will change the bolt extension and the joint compression (figure 4).

Because the stiffness of the joint is typically five times or more the stiffness of the bolt, the effect of the axial loading

Figure 4

20 Issue 3 October 2011 • www.fastfixtechnology.com

is to primarily reduce the compression in the joint rather than extending the bolt. This point can be difficult to appreciate, but this is key to understanding why bolts are tightened rather than left loose.

Figure 5

Figure 6

Figure 5 shows a bolt and nut securing a bracket to a support plate. With the nut loose on the bolt, if a weight of 1 is added to the bracket, as shown in figure 6, then the force in the bolt shank will increase by 1. However, if the nut is now tightened and the weight applied, the force in the bolt shank will not increase by 1 but usually by only a small fraction of this amount.

An understanding of why the bolt does not sustain the full effect of the applied load is fundamental to the subject.

A model can often be of help in understanding why the bolt does not sustain the full effect of the applied load. Figure 7 is an attempt to illustrate the load transfer mechanism involved in a bolted joint by the use of a special fastener. In the case of this fastener no significant load increase would be sustained by the fastener until the applied load exceeded the fastener’s preload (preload is the term used for a bolt’s clamp force).

With the special fastener shown, the bolt is free to move within its casing, a compression spring is included within the casing so that if the bolt is pulled down the spring will compress. A scale on the side of the casing indicates the force present in the spring and hence the force present in the shank of the bolt. Figure 7 illustrates this special fastener in its untightened condition.

The bolt is now inserted through a hole in a support plate and a bracket attached to the special fastener by securing a nut to the threaded shank. If the nut is now rotated so that the head of the bolt is pulled down, Figure 7 the spring will be compressed. If the nut

Fastener + Fixing Technology is rotated so that 2 force units are indicated on the casing, the compressive force acting on the spring will be 2 and the tensile force in the bolt shank will also be 2. This is illustrated in figure 8; this is like a tightened bolt without any working load applied.

If a weight is now added to the bracket (figure 9) of value 1, then the initial reaction is to think that the load in the bolt must increase, otherwise what Figure 8 happens to the additional force?

Surprisingly it will keep at its existing value of 2 - it will not ‘feel’ any of the additional force. To visualise why this is so - imagine what would happen if the load in the bolt did increase. To do this it would compress the spring more and a gap would be made between the bracket and the plate. If such a gap was to form then it would mean that there would be 2 units of force acting upwards - due to the spring, and 1 unit of force acting downwards from the applied weight. Clearly this force imbalance would not occur. What does happen is that the effect of the applied load is to decrease the clamp Figure 9 force that exists between the plate and the bracket. With no load applied, the clamp force is 2 units and with the load applied this decreases to 1 unit of force. The bolt would not actually ‘feel’ any of the applied force until it exceeded the bolts clamp force.

Figure 10 shows the condition when a load of 3 is applied.

The joint will separate and the 3 units of weight acting down will be balanced by the 3 units of force in the spring.

The point of joint separation, from a design perspective, is usually taken as the point at which the joint will have a finite length. Besides sustaining the full applied loading there are usually bending forces induced into the bolt because of eccentricity of the applied loading.

Repeatedly applied this will rapidly lead Figure 10 to fatigue failure of the bolt.

Older design procedures proposed calculation methods based upon the idea that the bolt will not ‘feel’ any of the applied load until it exceeds the bolts clamp force. That is, the bolt should be sized so that its clamp force is equal to the external load after a factor of safety has been included. Practical fasteners differ from that shown in figure 2 in that elongation of the fastener and compression of the clamped parts occurs upon tightening. This compression results in the bolt sustaining a proportion of the applied load. The actual amount of the load being sustained being dependent upon the relative stiffness of the bolt to the clamped material.

In actual practice, the bolt will sustain a proportion of the

22 Issue 3 October 2011 • www.fastfixtechnology.com

applied loading prior to the joint separating. This is due to the joint compressing, as well as the bolt extending, when tightened.

This is illustrated in figure 11. When the loading is applied, the compression of the joint is reduced. This, in turn, increases the distance between the two joint faces which, in turn, increases the loading on the bolt. The bolt and joint stiffness can be computed and, from this, the proportion of the load sustained by the bolt and the amount that the joint compression is reduced can also be computed. The key aspect of the Figure 11 success or otherwise of the majority of bolted joints is the residual loading that acts on the joint interface. That is, will joint separation or joint movement occur when loading is applied?

As the applied load acting on the joint increases, the force clamping the joint together decreases. If the clamping force decreases to zero as a result of the applied load, the bolt will have to totally sustain any subsequent increase in this load. Research has shown that bolted joints usually fail as a result of the applied forces acting on the joint decreasing the clamp force, present between the joint layers, to below a required level. Failure can include leakage from a joint (if it contains a gasket) or the bolts coming loose or failing due to fatigue. Initially it may appear that the joint failure is not due to insufficient clamp force, but a more detailed analysis often shows that this is indeed the cause rather than defective or sub-standard bolts or the bolts sustaining too much load.

Many applications require that the plates comprising the joint be clamped together tightly so that any possible movement is prevented. Effectively the plates are prevented from moving by friction increased by the bolt’s clamp force. In such applications, a level of clamp force must be maintained in order that movement is prevented. If the clamp force reduces to below this level, joint movement can be caused that dramatically increases embedding (plastic deformation under the nut/ bolt head) resulting in the bolt quickly losing preload and then loosening or failing by fatigue. If the joint contains a gasket, a minimum level of clamp force is usually required in order that leakage is prevented and the sealing function is maintained.

Maintaining a high initial bolt preload is essential to ensuring that a bolted joint will survive.

Prior to forming his company, Bolt Science in 1992, Bill’s original background was in design engineering. The company is a provider of independent technical expertise in bolted joint technology. He is a chartered engineer and has a Doctorate in Engineering on the self-loosening of threaded fasteners. Bill has delivered training courses around the world on the analysis of bolted joints and bolting technology.

Stainless Steel Fasteners If you are looking for Metric or Unified Stainless Steel Fasteners in A2 & A4 material, wide range of sizes, large stocks and competitive prices. Look no further. We offer same day despatch on all stock orders and quick turn round for non stock parts.

Precision Technology Supplies Ltd. The Birches Industrial Estate, Imberhorne Lane, East Grinstead, West Sussex, RH19 1XZ Tel +44 (0) 1342 410758 Fax +44 (0) 1342 311464 Email info@pts-uk.com www.pts-uk.com

sheet metal Fastening

Blind Rivets

A Riveting Experience ORLOCK Double locking system OR-BULB Split Tail STELOCK / STEEL-FIX Steel High Strength and Multi-Grip U-FIX High Versatile Multi-Grip T.P.R / O.R.P Superior Peel ORNILOCK / OR-BOLT Multi-Grip Structural

www.ornit.com

World Wide: +972-86610222 USA: 1-877-627-0423

Offering a long lasting solution When designing an application, an engineer is faced with a wide choice of joining techniques including; welding, gluing and screwing. Although all these techniques are worthy of consideration, the advantages of blind rivets, both standard and structural, are numerous, offering a safe, effective and reliable fastener.

O

rnit Blind Rivets, a designer and manufacturer of an extensive range of cost effective, safe, effective fasteners, explains that its customers use blind rivets because they do not change or damage the microstructure of the sheet metal and therefore do not alter its physical properties. Blind rivets are easily installed and do not require skilled labour or expensive installation equipment. Once assembled, blind rivets spread the clamp load over a large blind side area, eliminating warping and other deformations. Also, hard-to-get-to places are easily reached as blind rivets are installed from one side of the work piece.

Rivets are assembled using on-site fastening systems like pneumatic, electrical or mechanical riveters. The process is straightforward, requiring neither skilled labour nor additional specialised equipment. During assembly labourers are not exposed to possible burns, electric shocks, vision damage or inhalation of toxic gases and have no need to use cumbersome, expensive safety equipment. A single riveter is capable of installing fasteners of various thicknesses, head and material types and a rivet’s grip range is capable of joining a wide range of sheet material thicknesses, thereby simplifying inventory.

When choosing the ideal fastener, compatibility with the joint material is essential. For example there are many grades of stainless steel available and Ornit’s stainless steel structural rivets are suitable for most of the types eliminating the time consuming, costly process of matching the characteristics of the rivet to the joint material. Since aesthetics is also an important concern, Ornit’s range also includes countersunk head, providing a flush finish with the material surface.

New clinching tool delivers International fastening and assembly technology specialist Böllhoff has developed a new fastening tool which it says enables class D airtight air duct flanges to be manufactured significantly faster, cleaner and more economically than traditional drill and fix methods.

C

alled SPOT CLINCH® 0404 IP the tool is TÜV NORD certified for class D and produces cold formed airtight joints in cycle times of between 0.9 to 1.5 seconds: which Böllhoff points out is less time than it takes to drill a hole. The robust, pneumatically operated tool achieves low cost, high quality, joints in a single operation. No additional fastener components are required, there is no swarf and hence no waste.

Key to the success of SPOT CLINCH ® and the class D joint it achieves is its tooling which is designed to penetrate the top and bottom layers of each joint while leaving a middle layer in tact to prevent air leakage. The process delivers high strength, interlocking joints which do not vibrate or work loose over time.

The clinching tool is easy to use. Jaws are opened either manually or pneumatically and positioned along the profile. A trigger is pulled to deliver a clinching force of 35kN. Distances between fastening points are generally between 120mm and 160mm. Weighing in at 4.7kg the clinching tool requires 5 to 6 bar air pressure supply.

The SPOT CLINCH ® technique can be used to join steel and stainless steel sheet as well as aluminium and other non-ferrous materials. Coated and prefinished materials can also be joined together without surface damage.

“Advantages of the SPOT CLINCH ® process include no consumable items, low energy use, absence of thermal load and damage to work pieces, option to use interim layers of film or adhesives, no pre or post treatments, excellent repeatability and environmental credentials – no heat, fumes and low noise.”

Böllhoff...

... key partner for innovative industries For more than 130 years we have specialised in developing innovative and high quality advanced fastening technology, as well as the corresponding assembly systems.

Think global, act local Due to our international network of subsidiaries and own production facilities, also in India, we act globally as a familiy-run business.

We offer connecting solutions for metallic and synthetic materials: ■ Blind rivet technology ■ Thread technology ■ Plastic joining technology and quick locking technologies etc.

We are just the perfect choice to be your partner in Success!

Telefon +91 11/41 43 11 90 · E-mail jkeswani@boellhoff.com

sheet metal fastening

Indian interest increasing Rivit Srl, a European manufacturer of sheet metal fastening systems and related tools, says that since the opening of its Indian branch it has received a lot of interest from sheet metal working companies within India, all of which are interested in its range of tools. Some of the more popular products include: RIV912 - A hydro-pneumatic tool for rivet nuts, distinguished by its oneposition trigger mechanism, which allows the start of the automatic stroke with one pull. The rivet nut is automatically screwed onto the rod by a small trigger pressure, while deformation and unscrewing of the rivet nut takes place in a single cycle when the trigger is fully depressed. The stroke can be easily adjusted making work quicker and easier.

RIV912 has been designed with a plastic handle casing, while both piston and cylinder are made of aluminium, allowing a lighter and handier tool. Finally, in order to avoid the need for a special mandrel RIV912 uses a Grade 12.9 Allen screw. RIV912 is supplied without the mandrel kit and it is equipped according to the requests of the customer.

RIV916 – This hydro-pneumatic tool represents in Rivit’s view a real innovation, as it answers the need for a fixing tool with a long stroke for the application of special inserts such as Tubriv and Jackriv. Assembly of the kits is done with a toothed ring nut and keys are no longer necessary. The stroke is easily adjustable and the adjustment ring can be blocked using the counter-ring.

RIV916 is also lightweight and easy to handle.

RIV998 – A hydro-pneumatic tool for rivet nuts designed to place Rivsert threaded female rivet nuts from M3 - M12, and Rivbolt threaded male rivet nuts from M4 - M8. The RIV998 features high reliability and long life, due to its hydro-pneumatic system, the mechanical components used in the internal structure of the tool, and its reduced dimensions and light weight.

RIV998 comes in a plastic case with tie rods and heads from M3 - M10 (M12 on request).

RIV938 – This is used to place Rivsert threaded female rivet nuts from M3 - M10, and Rivbolt male rivet nuts from M4 - M8.

Supplying a broad range Shanghai Rivet Manufacture Co., Ltd (RET Global) has over 16 years experience in the sheet metal fastening industry and is able to supply a broad range of bind rivet nuts.

B

lind rivet nuts, sometimes also called insert nuts or thread inserts, can provide a simple and effective way to join materials, with the benefits of an internal thread, in a variety of applications. RET points out that its blind rivet nuts can be fitted at any stage in the production process, making their use extremely flexible, and can be used in a variety of applications including automobile, railway, elevator, electric cabinet, ventilator, air-condition, furniture, construction and equipment in electric and light industry production.

RET explains that blind rivets enable components, which are assembled later in the production cycle, to be adjusted, and are ideally suited to applications where access is only available from one side of the work piece.

“A user simply pushes the nut onto the tool mandrel, which will then automatically spin on, they then place the nut in the hole of the parent material and pull the trigger. This makes the rivet collapse and form a flange on the back side of the parent material. The tool then automatically reverses and unthreads from the nut, leaving the user to simply attach the mating part with a bolt and tighten.”

RET offers a wide range of blind rivet nuts including flat head, countersunk and reduced head, as well as round body, knurled body and hexagonal body in steel, aluminium and stainless steel. It can also offer open end rivet nuts, as well as close end rivet nuts, with the latter being mainly used where no liquid is allowed to pass between the screw and the blind rivet nut. To form a pressure-tight seal between the blind rivet nut and the work piece, RET manufactures blind rivet nuts with a seal on the body side.

“With 16 years of experience in the industry and by focusing on supplying rivet nuts to all over the world, we owe our excellent reputation to our successful distribution of the broadest range of blind rivet nuts, and by offering extremely competitive prices, as well as a reliable and continuous stock supply.”

26 Issue 3 October 2011 • www.fastfixtechnology.com

ONE OF THE BIGGEST MANUFACTURERS OF BLIND RIVET NUTS IN ASIA We have more than 1,000 styles in stock and our production capacity is 5 billion pieces.

We can produce blind rivet nuts in steel, stainless steel, aluminum and brass. We also produce lots of non-standards based on customers drawings and samples.

SHANGHAI RIVET MANUFACTURE CO.,LTD. Export Department Tel: +86 21 372 86065 / 372 86522 Fax: +86 21 372 86066 Email: chinarivet@gmail.com / cyd@chinayuanda.com

www.ret-global.com

Fastener + Fixing technOlOgy

Three tips for improving productivity in solar module manufacturing

By Geoffrey King, market manager, Renewable Energy, Saint-Gobain Solar

The photovoltaic (PV) industry is expected to grow exponentially over the next five years with market experts anticipating the global market to more than double in size by 2014.

W

hile this impressive growth rate is good news for the photovoltaic industry as a whole, module manufacturers are faced with a unique challenge – how to meet increased demand, while remaining profitable. In order to remain competitive and take advantage of industry growth, module manufacturers need to take steps to enhance overall production efficiency, reducing cost-per-unit. Automating production lines, reducing material waste, and decreasing equipment downtime are three ways module manufacturers can increase throughput, as well as their bottom line.

The speed of automation Before solar power was considered a viable source of energy, module manufacturing plants with 100 megawatts of capacity were considered large. Today, as module manufacturers strive to meet the growing market demand for solar products around the world, facilities are expanding and we are seeing manufacturing plants with annual manufacturing capacity of 300 megawatts and more. This higher level of capacity has created the need to increase production efficiency and automated processes are becoming standard.

One key area where automation can help manufacturers increase overall productivity is manufacturing speed. By maximising output for each step in the production process, automation enables increased capacity, while eliminating the need for additional investment in continuous plant expansion in order to meet everincreasing demand.

By eliminating human error, automated production lines offer an increased level of accuracy, ensuring a consistently high-quality final product.

Automation also reduces the need for manpower, further reducing manufacturing costs.

Frame tape applications are a good example of how automation can provide benefits on a PV module production

28 issue 3 October 2011 • www.fastfixtechnology.com

line. Frame tapes are used to secure the solar module into the metal frame to ensure the mechanical load requirements of the IEC standards are satisfied. The application of frame tape plays a key role in ensuring consistent adhesion and centring the module into a frame. While smaller manufacturing operations might use hand applicator tools for the framing process, larger manufacturers need advanced solutions that can provide precision at high production speeds. Semi-automated taping equipment or fully automated robotic tape and framing stations offer increased production speeds to help manufacturers expand their capacity and maximise output while also reducing manpower costs.

For manufacturers on the lookout for new technologies that provide increased production efficiencies, a new generation of foamable sealants is now available. This curable thermosetting material is applied warm to provide instant adhesion in the framing process. High bond strength is achieved immediately

after contact with the module glass, backsheet and frame, ensuring a consistent level of quality. Compared to conventional pumpable sealants, such as silicone, this new hybrid foamable frame sealant takes significantly less time to cure and eliminates clean-up time.

To further streamline the framing process, next generation

single-piece framing systems offer an advanced solution for use with automated systems. The patented single-piece frame concept features a single continuous frame profile with corner notches cut in place to allow for wrapping around the solar module using a robot. The process allows framing to be done at very high speeds - less than 30 seconds per individual module compared to traditional methods.

Making the most of valuable resources Wasted resources, be it materials, components or labour, can significantly affect a module manufacturer’s bottom line by increasing the unit cost per individual solar module. Each process within the manufacturing operation should be assessed carefully for waste reduction.

The process of framing solar modules, for example, provides significant opportunities for manufacturers to reduce production input. With conventional sealing methods, excess silicone overflows onto the module surface after the module is inserted into the frame and is wasted – an expense that could easily be avoided with a foamable sealant. This new technology allows optimum cavity fill to be achieved without any overflow, enabling the manufacturer to save on unnecessary material expenses, as well as man-hours spent cleaning.

Another way to reduce waste is by eliminating three of the four corner keys needed to frame a module. This is made possible using a single-piece framing system, reducing the material resources needed and the unit cost of each module.

Utilising existing equipment There are many ways for manufacturers to increase

efficiency without investing in expensive additions or changes to the production line. One way is to maximise the service life of consumables used in the photovoltaic module-making process. Choosing products that offer longer service lives means equipment downtime can be kept to a minimum. This, in turn, leads to reduced costs as the frequency of purchasing new consumables is lowered.

The vacuum lamination process provides a prime example.

Advances in silicone membrane formulations have led to the development of membranes that are highly resistant to EVA outgassing at high heat exposures, offering many savings for module manufacturers. Fewer membranes are required over a certain period of time, reducing the impact on purchasing logistics and lowering inventory requirements. In addition, the time required to change a membrane can vary between four to eight hours, presenting a bottleneck in the lamination process. By increasing the number of cycles per membrane, the laminator downtime can be significantly reduced. Avoiding the unnecessary costs of getting additional laminators online helps increase capacity and output from existing equipment, achieving optimal efficiency.

In order to remain competitive in the midst of the ongoing market growth, PV module manufacturers need to focus on enhanced production efficiencies, driving down overall manufacturing costs. Minor adjustments to photovoltaic module-making processes, such as utilising automation technologies, choosing advanced materials and maximising the service life of consumables, are ways for manufacturers to increase efficiency without having to invest in additional equipment.

Fastener + Fixing Technology

Trouble free fitting through new topcoat A new Dörken MKS Systems topcoat offers optimised threaded connection properties when fitting against parts made of aluminium or against KTL-coated surfaces.

I

n launching the Delta-Protekt ® VH 301.1 GZ topcoat, Dörken MKS-Systeme GmbH & Co. KG of Herdecke says it is providing an enhancement of this silica-based seal with integrated lubricant. In particularly difficult applications it prevents stick/slip effects when building chromium(VI) -free surfaces against KTL-coated parts. The new topcoat can also be assembled against aluminium without any problem and thus fulfils the specifications of VW’s new norm 1131-1/2.

Dörken explains that in the changeover from surfaces with chromium(VI) content to chromium(VI) -free surfaces, there were problems in the past when fitting against KTLcoated components. These are reflected in VDA 235-203 test specifications and the surfaces approved there. Currently the only areas where these so-called stick/slip effects are still evident are in particularly difficult applications. These include, for example, fasteners with extreme outer supports.

Another problem is presented by the increasing demands for reduced weight in vehicle construction. This is now leading to the use of appreciably more lightweight metals, such as aluminium and magnesium. The connecting surfaces below the bolt head range here from die cast parts, to milled or polished backing runs. As regards the thread, screw-in depths are required of three times diameter into the grooved thread. High coefficients of friction lead here at full load / when tightening the angle of rotation to high levels of fastening torque, which exceed the control limits and even the capacity of the power screwdrivers being used.

The new Delta-Protekt ® VH 301.1 GZ topcoat has been developed specifically for such scenarios and meets the specifications of VW’s new 1131-1/2 norm, such as, for example, double fastening into the yield point against aluminium or five times fastening into KTL. The new topcoat has been used in various build locations both in lightweight construction and in the difficult applications mentioned and successfully solved the fitting problems there.

Dörken points out that combined with the tried and tested Delta-Protekt ® KL 100 zinc flake basecoat the system features corrosion resistance times of over 720 hours in salt spray testing and also provides greater resistance to brake fluid, oils and cleaning agents. It improves mechanical properties, prevents the problematic stick/slip effects, withstands loosening under temperature of up to 180°C for 96 hours, achieves better grip results and ensures that coefficients of friction are kept constant. Depending on the layer build-up and the shape of the coated part, the coefficient of friction here, as defined by DIN EN ISO 16047, falls into a range between 0.09μges and 0.14μges (VDA – Association of the German Automotive Industry). The corrosion protection layer’s particularly high resistance to mechanical stress also enables constant coefficients of friction to be maintained even when parts are screwed in or out numerous times. The screw connection retains its friction-locking capacity even when exposed to heat. In terms of heat-induced loosening as defined by VW 1131-2, a value of > 0.06 is achieved.

“ The new Delta-Protekt® VH 301.1 GZ

topcoat can also be

assembled against

aluminium without

any problem…”

30 Issue 3 October 2011 • www.fastfixtechnology.com

Connecting with Indian fastener engineers A new technical publication for the growing Indian market Fastener + Fixing Technology presents the latest fastener engineering concepts to designers, engineers and buyers in key Indian growth industries.

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product news

New instant grab hybrid structural adhesive 3M has launched an innovative two-part hybrid technology structural adhesive which it says can save days of time when bonding bighead® and general fasteners.

3

M Scotch-Weld Epoxy-Acrylic Hybrid Structural Adhesive 7271 B/A has been designed to instantly secure bigHead and other mechanical fasteners. It is suitable for a wide variety of substrates including composites, GRP (glass reinforced plastics), epoxy-based resins, aluminium and stainless steel. Dispensed using the easy to use 3M Scotch-Weld EPX system, the adhesive can be applied with a manual or pneumatic hand-held applicator.

Imran Idrees of 3M’s industrial adhesives and tapes division commented: “3M’s vast expertise and experience in adhesives has enabled the development of this exciting new product. 7271 B/A can instantly hold mechanical fixings unlike commonly used two-part acrylic adhesives which can take anything up to three hours to hold fixtures.”

He adds: “Moreover, when compared with pungent, basic entry-level acrylic adhesives this ‘instant grab’ adhesive is odourless.

This eliminates the need for a respirator to protect against odour during use, and can be applied vertically or even upside down without the adhesive dripping.”

Taking cam latches to a higher level Southco highlights that its customer-centric approach enables it to offer products that have improved levels of quality, as well as enhanced and upgraded functionality.

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lobal product manager, Jesús Albillos, explains: “Whilst acknowledging the cam latch is fundamental to an almost infinite array of industries and applications, we believe users deserve levels of security, functionality and choice that are equal to those designed into more sophisticated and complex access hardware – and at affordable prices.”

He adds: “Therefore, in addition to providing off-the-shelf product options, we work closely with our customers to develop cam latch solutions tailored to meet individual requirements and applications.”

Notably, modifications to the Southco E5 range of fixed grip cam latches have been developed at the request of customers seeking such attributes as intuitive push-to-close convenience, material options – such as stainless steel - and a choice of T-handle and L-handle styles.

Other E5 enhancements include styling and access control options, such as hand, tool, and key-actuated models and a choice of single-point and two-point latching installations.

All E5 latches, regardless of head style, include a latched/unlatched position indicator.

bigHead extends sandwich Low thermal expansion epoxy Master Bond Inc says that its Master Bond EP30LTE-LO, panel fastener range formulated with a special blend of polymeric and As sandwich panel technology continues to extend into more applications and industries, so the problem of how to securely fasten to them grows.

inorganic materials, features unparalleled dimensional stability and sets new standards of performance for bonding, sealing, casting and coating applications.

igHead Bonding Fasteners Ltd points out that problems include inserts, which are designed for solid plastic, do not work with low density honeycomb structures and rivet technology will often place too much stress on a small area of the panel skin and consequently will be weak. bigHead highlights that its range of bigHead® fasteners require no minimum density or panel thickness and distribute the load evenly through the panel skin which is not punctured and weakened.

Also, bigHead fasteners can be surface bonded with a wide range of structural adhesives and can be used with almost any panel material, from carbon fibre and plastics to recyclable materials. bigHead is currently working with a number of leading sandwich panel manufacturers to provide fastening solutions, resulting in bigHead’s range of sandwich panel fasteners continuing to grow. bigHead’s sandwich panel fastener range currently includes the TwinDisk ® for high-load applications, where the fastener is bonded to both panel skins, as well as fasteners for bonding to one panel skin, and the new 1-Fix solid-head design which conceals the adhesive from view.

his two component epoxy combines performance with a very low thermal expansion coefficient, a significant breakthrough from the high thermal expansion that is typical of most epoxy compounds.

Serviceable over the wide temperature range of -60°F to 250°F, EP30LTE-LO cures at room temperature with 85% of its maximum strength developed within 48 hours. Faster cures are possible at elevated temperatures.

Master Bond points out that this 100% reactive epoxy features an exceptionally low coefficient of thermal expansion of 12x10-6 in/in/ °C and a low shrinkage rate of less than 0.0002 in/in. It also bonds well to metals, glass, ceramics, wood, vulcanised rubbers and most plastics, and produces bonds with a tensile strength over 5,000 psi.

EP30LTE-LO has a 10 to 1 mix ratio by weight and can be easily applied with a spatula, knife, trowel, brush or paint roller.

It can also be readily cast as thick as 1 inch without undue exotherm developing. EP30LTE-LO is available in half-pint, pint, quart, gallon and 5 gallon container kits.

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prOduct news

Continuing to develop Ornit Blind Rivets is using all of its 35 years experience and success in the rivet industry to help it look forward and develop more innovative products, as well as enhancing existing products.

O

rnit’s leading brands, Orlock, Or-Bolt, Or-Bulb, Ornilock and U-Fix, available in steel, aluminium and stainless steel, are still very much in demand in the construction and automotive, as well as electronic and solar energy industries.

However, Ornit is always looking to the future and trying to anticipate its customers’ needs. Ornit’s R&D department is presently completing the development of two new structural rivets, both are to be launched during 2011, with one being a 4.8mm structural rivet with a split tail formation, and a visible mechanical lock that creates a strong, waterproof, vibration resistant joint, and the other being a 6.4mm structural rivet with 3 locking systems, high tensile strength, an extensive grip range and a mandrel that breaks flush.

Ornit’s R&D department is working closely with ‘The office of the Chief Scientist’ (OCS) of Israel’s Ministry of Industry, Trade & Labour to develop these products. Ornit is further expanding its product line by adding another member to the Orlock family, in the form of Orlock aluminium in diameter 7.8mm.

In addition, Ornit is moving its R&D department to spacious 150m2 offices, as well as adding an additional 800m2 to the production floor.

Advertisers index Alloy & Stainless Fasteners Inc .............................. 2 Ambrovit Srl .......................................................... 5 Böllhoff GmbH .................................................... 25 Bossard Ltd ..........................................................13 Dörken MKS-Systeme GmbH & Co. KG ............... 36 DS Fasteners Ltd ................................................. 34 Fasten.it .............................................................. 33 Landmark Fasteners Pvt Ltd .................................15 Mitter Fasteners ...................................................15 Multiple Overseas Exports ....................................15 ND Industries ........................................................ 7 Norma .................................................................17 Ornit Blind Rivets ................................................. 24 Precision Technology Supplies ............................ 23 Ray Fu ................................................................ 32 Right Tight Fasteners Pvt Ltd .................................16 Rivit Srl ................................................................ 35 Samrat Wires Pvt Ltd ............................................18 Shanghai Rivet Manufacture Co Ltd ................... 27 Shei Kai Precision ................................................ 23 Sundram Fasteners Ltd ......................................... 1 Tecfi S.p.A ............................................................. 9 Top Screw Metal Corp. Ltd .................................. 29 Vlier Products ...................................................... 21 WPI Services B.V. ................................................. 21

INNOVATION

DELTAÂŽ protects surfaces.

While you are reading this, we are still working on new technologies.

The most important thing in any company is the people who work there. And that is particularly true in our case. Because it is purely down to our colleagues, their know-how, their commitment, their expertise and their passion, that we are able to offer the world what it expects of us: innovation in zinc flake technology and now in electroplating systems too. That’s what we work 365 days a year for. Even while you are reading this. More info at www.doerken-mks.com