Rydahls Friction Solutions - Introduction

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Friction solutions

We deliver unique products and optimised friction solutions.

Innovated by Rydahls

www.rydahls.se

We are experts at brake and friction solutions in the manufacturing industry.

There are very few standard solutions available in industrial friction. A brake and friction solution for a lift differs, for example, significantly from one that will work in a winch or a crane.

That's why we prefer to get onboard in the design stage. If we can get to know at an early stage in the process which requirements are set for braking times, braking power and braking torque, then we can always deliver a completely unique and optimised solution – Innovated by Rydahls. The process will also be quicker and more cost-efficient, both for you and for us.

Try us! We can promise you friction solutions and fully committed service.

We want to do more, it's as simple as that!

Innovated by Rydahls

Top class experience and materials When you bring us into a project you bring in competence that has been built up since 1916. We are a company that has our roots in brake and friction solutions and how you combine and apply different materials to achieve the required effect. There is a wide range of friction materials intended for use in industrial applications, such as brake linings, clutch linings and brake bands, and we are somewhat of a world champion in this field. You will find our solutions in large and small products from manufacturers all over the world.

Innovated by Rydahls In almost every new project we face the development of a unique product solution. We don't need to invent the wheel every time, but in general innovations are the rule rather than the exception. Throughout the years we have produced friction solutions, brakes and brake linings for trucks, lifts, cranes, anchor winches, washing machines, lawn mowers and other mechanical devices.

We could make the list much longer. There are still lots of un­explored areas where friction solutions signed Innovated by Rydahls would make torque and braking torque more flexible, more user-friendly, and more reliable than existing solutions.

Friction materials that make a difference It's basically about an extensive knowlege of different friction materials and their properties. Today we have access to several hundred different material qualities, both woven and moulded, in several dimensions. We know which materials we should use, in which combination with others, so that the solution you are looking for will have precisely the right function.

Long-term sustainability We aim to run our business so that we can achieve maximum sustainability. Primarily this means what we can actually control – the consumption of energy, recycling, and modes of transport etc. But we also take the policies of our suppliers into consideration and as far as possible choose partners who share our view of long-term sustainability.

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• Extensive competence • Unique knowledge of materials • Optimised product solutions • Efficient work processes

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Unique solutions are our benchmark.

You may be in need of brake linings for generators for water turbines. Or a solution that gives variable lifting and lowering functions for a desktop lamp. Or a brake that stops the blade in a circular saw immediately. Your project is just as interesting to us, regardless of the size of the product or scope of production. If we can come in early on in the design process, we will solve the problem. Unique solutions are quite simply our benchmark.

The sooner you start the sooner you get there When you get in touch with us we can as a rule give you an immediate picture of which type of solution would suit your project. But it's only when we get the facts on the case that we can give you a specified recommendation. That's why we prefer to start off with a review, where together with you we establish which requirements are set for braking times, braking power and braking torque. It's just as important to define the environment in which the application is to operate. The sooner in the process we get to know these criteria, the sooner we can work out the right solution. Both parties save both time and money, and we can easily agree on a timetable for delivery.

Design of friction solutions With the prerequisites in place, our development department can start to do its job. With the help of CAD drawings we model the design and put it in its context.

Producing a good friction solution is partly about developing solutions that fit in with the design, and partly about selecting optimal friction materials to achieve the required braking effect. We calculate the friction coefficients and decide which materials are most suitable.

Bonding that's guaranteed to stick The bonding of friction materials such as brake and clutch linings is a special process. Throughout the years we have made it very effective and reliable. Most often we use a hot bonding method. This means in simple terms that the adhesive sets under the influence of heat and pressure. What makes bonding so special is that it is only through destructive testing that you can confirm whether the required result has been achieved. That's why we very carefully control all the parameters such as pressure, temperature and exposure times. And in this way we guarantee that we have an approved bond.

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Cost-efficient processing We have developed our own methods of processing different types of friction materials at Rydahls. We often start with plates or strips and mechanically process them to the dimensions you need. We also started using water to process materials several years ago. Waterjet cutting gives us many advantages in comparison with conventional processing. We can easily manufacture complicated shapes and achieve close tolerances. In particular we reduce material wastage, which makes the method costeffective for you as the purchaser.

Continual improvements When we have finished a project this does not mean that we let it go. After delivery we always continue our work and try to find new developments and improvements. We always endevour to find better solutions – in the choice of materials, improvement of the efficiency of our processes, and improvements of the products – which in turn can benefit you. In other words we stay with you and your business for a long time.

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Three examples from operations:

Brake lining in a gigantic forging press.

The Swedish subsidiary to one of the world's largest manufacturers of forged engine and chassis components had a problem with a brake/clutch lining in one of their forge presses.

The material wore out too quickly.

Throttle lever with simulated resistance.

A subcontractor to a boat manufacturer got in touch with us with a slightly different question – How can we get a throttle lever with electronic signal transfer to the engine to feel like a classical throttle lever with a wire coupling?

The company's forge press is one of the most powerful in the world, fully computerised presses for manufacturing front axle beams for trucks and buses. It has a press power of 16,000 tonnes and the materials in the moving parts of the machine are exposed to severe stress.

When the company contacted Rydahls they had a problem with friction linings that cracked and wore out too quickly, which affected production and service economics.

Following specifications of the braking power and braking torque we drafted and produced a dimensioned solution – a clutch and brake lining with a core of mechanically strong material and wear surfaces coated with friction material with the right properties.

Both the initial and succeeding tests went well. The machine moved with the required smoothness and linings from Rydahls demonstrated a significantly better lifespan than the previous solution.

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The boat manufacturer had installed a solution on one of their yacht models where all the electronics were connected to a network onboard. All the key functions, such as steering, acceleration and gear changing were connected to the same system.

With electronic signal transfer between the throttle lever and the engine there was none of the inertia in the lever that most people are used to, and which contributes to the experience of running the boat. There was quite simply no resistance, and some of that "boat feeling" disappeared.

The subcontractor was given the task of manufacturing a throttle lever with the right feeling. They in turn contacted us.

Our recommendation: Hot glue a friction material with a high friction coefficient to a plastic carrier and you will get an excellent product with the intertia and feeling you are looking for.

With the right materials and processing, in a costefficient and automated production process, we helped the customer towards a very good component at the right price.

Effective friction solution for a sliding clutch.

A Canadian company registered in Toronto, and with several of the world's most famous car brands on its list of customers, experienced problems with the material in a sliding clutch – just when they were about to start their series production. The friction material in the clutch did not last.

The Canadian company already had a subcontractor that had produced prototypes. They had been tested and approved in both short and long field tests. The problem was that the subcontractor could not produce the correct quality when the series manufacturing was to start.

With the overhanging threat of having to close down all of the planned product launch, the company scanned the market for a new subcontractor. We were consulted and replied that in all probability we could help them with a solution.

The product manager flew to Sweden with test plates in his hand baggage. He put these metal carriers on the table and said: "I want to have a prototype with me on the way home. Now on Sunday".

The requirements we had to work on were that the friction lining could be punched out, and be thin, bendable and flexible. It should also withstand a specified speed and degree of heat. After careful calculation and design proposals from our technicians, the choice fell on friction material RY277. It was processed, glued, fitted and delivered in time for the product manager's trip home.

The short time tests that followed produced good results. The same applied to the long duration tests, and it was possible to start production in series. In the course

of time we have followed up the development of the process for the customer, for example we have switched from punching to waterjet cutting of the material, which has reduced material wastage and given the customer an advantageous business value.

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rydahls.com

The brake experts2 After almost one hundred years in the industry we have built up unique experience and competence. We are experts at both individual products and customised brake systems and friction solutions, and offer a very comprehensive range of spare parts, products and materials.

Our customers are primarily active in the engineering, machinery and vehicle industry and in the manufacturing industry. With the needs of customers in full focus, we supply innovative solutions, top class quality, and fully committed service.

Try us! We want to do more, it's as simple as that!

Brisgatan 19, Box 12, SE-651 02 Karlstad, Sweden Tel. +46(0)10-550 94 00, Fax. +46(0)54 - 85 10 58 servicegruppen@rydahls.se

www.rydahls.com

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