01 TORQUE DIRECT COVER - RAPID TD05 2024.qxp 18/01/2024 15:09 Page 1
Issue 05 / January 2024
RAPID INDUSTRIAL FASTENERS LTD
THINK FASTENERS THINK RAPID
YOUR COMPLETE
FASTENER
SUPPLIER 0121 501 3903 sales@rapidfast.co.uk www.rapidfast.co.uk
• Volume stockist of standard fasteners & fixings • In House Bespoke Manufacturing • Exclusive Far East Manufacturing Capacity • Next day Nationwide Deliveries • Vendor Managed Systems ; JIT / Kan Ban • Assembly & Kitting • Full Certification ; 3.1,3.2 & ISIR’s • Contract & Schedule orders
Head Office Unit 2, Stour Vale Road, Stourbridge, DY9 8PP
Manufacturing Hub Unit 27, Lye Valley Industrial Estate Stourbridge, DY9 8HX
No other fastener OEM knows e-vehicle assembly inside and out, like EJOT. EJOT’s pedigree as a fastening innovator goes hand in hand with automotive manufacturing’s own backstory - pretty well since day one. And given that our fastening products and systems provide application-specific solutions for all modern engineering materials, their commonality supports modern engineering goals to build lighter, build stronger, build smarter. EJOT’s Application Engineers have access to prognosis and forecasting software
No surprise then that EJOT has been working academically with design teams world-wide, to bring our fastening technology into electric vehicle assembly, and to all peripheral application developments, for some time.
that has proved pivotal for designers and can impact positively on prototype and testing budgets.
If you’re involved with any area of EV design, at any stage, at any level and you’d like a solutions-based conversation, then call or email our team: T: +44 (0) 1977 387 040 E: industrial@ejot.co.uk
Bringing it together.
Torqu Direct FP Nov 22.indd 1
Build lighter. Build stronger. Build smarter.
27/10/2022 14:40
03 CONTENTS TD05 2023_LAW.qxp 19/01/2024 12:32 Page 1
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INSIDE THIS ISSUE 04 Product news
EDITOR’S
COMMENT
TECHNICAL INSIGHTS 08 Spirol – Consider the benefits of 420 Chrome Stainless Steel Coiled Spring Pins TECHNICAL INSIGHTS 12 Bolted technology – The role of torque and tension in fastener assemblies Publisher Jerry Ramsdale Jerry@torque-direct.com Editor Hayley Everett Hayley@torque-direct.com Deputy Editor Rachel King Rachel@torque-direct.com Contributing Editor Jonathon Harker Jonathon@torque-direct.com Sales Manager – UK Claire Warman
24 Fluke – Cutting downtime while ensuring accuracy, reliability and compliance of industrial tools 26 Forward Fastener – Complex fasteners and other parts are a speciality for service-orientated Forward Fastener Manufacturing 28 Atlas Copco – Advancing aerospace assembly with a new innovative battery drill 34 TR Fastenings – Transforming the London taxi cab into a zero carbon vehicle 40 TFC – Assessing the capabilities of wave springs
Claire@torque-direct.com Sales Manager – International Harry Whyte Harry.whyte@torque-direct.com
IN-DEPTH – OFFSHORE TECH 18 Analysis – What do engineers need to consider for fastener applications in harsh offshore environments?
Circulation Tracy Howell Tracy@torque-direct.com
20 Hague Fasteners – The impact of seawater exposure and cyclic loading on bolt failure
Head of Production Luke Wikner production@torque-direct.com Designers Dan Bennett production@torque-direct.com
22 Safety – Mitigating the safety challenges of operating within offshore environments PRODUCT INNOVATIONS 14 Aggressive environment – EJOT UK & Freudenberg Sealing Technologies
Victoria Arellano production@torque-direct.com
Published by Stag Publications Ltd 18 Alban Park Hatfield Road St Albans Herts AL4 0JJ tel: +44 (0)1727 739160 fax: +44 (0)1727 739169 Email: info@torque-direct.com Web: www.torque-direct.com Disclaimer
Although the utmost care is taken to ensure that information contained herein is accurate and up to date, 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. 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 of Stag Publications Ltd.
30 Adhesives & tapes – Henkel, Tesa & DELO INDUSTRY EVENTS
ALL AT SEA Offshore rigs and structures are exposed to some of the harshest conditions on earth, from unpredictable weather and constant seawater exposure, to safety concerns around working at height and in explosive atmospheres. In addition to posing considerable safety challenges for engineers and workers, these environments also demand a lot from the fasteners, tools and equipment that build and maintain the structures within them. This issue’s In-depth focus dives deep into the challenges imposed upon fasteners by corrosion and cyclic loading, and also highlights some of the innovative technical equipment helping to keep oil and gas and construction engineers safe while doing their jobs. Not all aggressive environments are offshore, though. In this issue, we also look at reducing building envelope failure risk in coastal locations (page 14) and how novel sealing solutions are helping to protect cobots in industrial environments (page 16). Also featured are the latest developments in bolted technology (page 12) and the most recent advances in adhesives and tapes (page 30). Readers can also take advantage of a wide array of technical articles contributed by leaders in the fastener, tool and coating industries, covering topics from tool care and maintenance to advancing aerospace assemblies, and from enhancing zero carbon vehicles to the capabilities of wave springs. For those looking to educate themselves on fastener and tool trends beyond these pages, then upcoming events such as Southern Manufacturing and Electronics and MACH 2024 will be of interest. Find out what to expect in our full show previews on page 32, 33, 36 and 42.
32 DACH + HOLZ – Check out all the roofing and timber industry have on offer in Stuttgart 33 ESEF Manufacturing Industry – The Netherlands event has a focus on sustainable and innovative manufacturing solutions 36 Southern Manufacturing & Electronics – Farnborough welcomes the engineering sector once again
Hayley Everett Editor Hayley@torque-direct.com
42 MACH 2024 – Inspiring, innovating and connecting engineering-based manufacturing
Copyright Entire contents copyright © 2024 Stag Publications. 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.
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04 06 PRODUCT NEWS TD05 2024_LAW.qxp 19/01/2024 12:32 Page 1
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LATEST PRODUCTS > THE FASTENER & TOOL INDUSTRIES
REINVENTED PORTABLE SPOTLIGHT resistant plastic, the spotlight is perfect for portable use in STAHLWILLE has released its new rechargeable spotlight workshops and service vehicles. which has a ChiponBoard (COB) LED. This technology, in As you would expect from STAHLWILLE, the LED recharge which several LEDs are mounted on a circuit board, produces able spotlight offers even more details. The integrated 3.7V a particularly bright light thanks to higher luminous flux. A 30 rechargeable battery with 6600 mAh, provides power for up watt COB LED provides 2,800 lumens, more than enough to to 13 operating hours. The spotlight can be charged via a stan illuminate any workspace, whether for tradespeople or in dard TypeC cable, can be used as an ‘XXL’ power bank and industrial settings. The spotlights can do more than just turn comes with an LED capacity indicator. ‘on’ and ‘off’ as they have three different brightness levels. Another highlight is the 360° swivel Depending on the work environ ling handle which can be used as a ment, users can choose to use 25, stand or to hang the light. Once the opti 50 or 100% of the power to mal position has been found, the handle ensure uniform and shadowfree can be fixed in place with a single move illumination. ment so that the spotlight stays reliably The LED rechargeable spotlight in position. There is also a strong measures just 13 x 44cm and is magnet built into the handle. With this only 4.4cm deep. At just 700 magnet, the LED rechargeable spotlight grammes, the spotlight is also can be easily attached to the nearest more than portable. The IP64 metal surface – it couldn't be simpler! housing is splashproof, light and impactresistant. Together with its edge protection made of impact //////////////////////////////////////////////////// www.stahlwille.com/en_gb
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TOP TOOL FOR FASTENING RIVET NUTS Rivit’s bestselling RIV938 is equipped with technical features designed to speed up installation times while maintaining the highest standards of precision fastening. Rivit has been active in the fastening systems busi ness for industry, construction, and distribution for 50 years, offering an extensive catalogue of riveting tools, blind rivets and rivet nuts. This experience has supported the design of a riveting tool capable of reduc ing the margin of error during fastening: with direct adjustment of the deformation force, damage to the rivet nuts during installation is avoided. For any defec tive rivet nut, the automatic unscrewing function avoids compromising the installation work and prevents unnecessary expenses and loss of efficiency. Designed for the application and fastening of Rivsert female rivet nuts M3 to M10 and Rivbolt male rivet nuts M4 to M10, the RIV938 enables placings to be made quickly and securely. It is the ideal tool for major automotive fastening applications, such as the assem bly of battery pack housings. The maximum stroke reaches 6.5mm while the motor speed varies from 1600 rpm to 2000rpm during screwing and unscrew ing. While the clamping force reaches 20,000 Newtons. The tool comes in a strong plastic carrying case, ideal for transporting and storing the riveter and accessory kit.
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www.rivit.it
The Insert Company (UK) Limited Specialists in Threaded Inserts for Wood, Plastic and Metal
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Tel: +44 (0)121 4397329
Fax: +44 (0)121 4397346
Unit 4, Alma Industrial Estate, Stafford Road, Wednesbury, WS10 8SX, United Kingdon
04 06 PRODUCT NEWS TD05 2024_LAW.qxp 19/01/2024 12:32 Page 2
////////// PRODUCT NEWS ///////////////////////////////////////////////////////////////////////////////////////////////////////////////// LATEST PRODUCTS > THE FASTENER & TOOL INDUSTRIES
BRINGING DATA TOGETHER Test and measurement specialist HBK has launched an upgrade for its software platform, BK Connect®, providing greater scope within many of the tools, such as Indoor Pass by, which helps automotive manufacturers ensure their vehicles comply with strict, passby noise regulations. Improvements to indoor passby include imports where users can define the applicable standard for each test and the ability to export import tyre noise correction data according to the ISO3623 standard. The SPC Validation subtask now helps engineers finetune condition number thresholds before performing full passby SPC calculation. A new Team Search File Import With Mapping task has also been added, providing users with more streamlined access to search the repository for data using metadata, then map the metadata from the indexed file to metadata used in BK Connect according to BK Connect’s data model objects: Project, DUT, Test, Test Condition, Setup and Result. Other additions to BK Connect Structural Dynamics include the possibility to save residuals calculated during the modal parameter estimation in mode tables and use them for FRF synthesis. Updates in BK Connect Array Analysis enable users to calculate particle velocity for SONAH measurements and –
in playback mode – export the results from all mesh points to a UFF file or Microsoft Excel in a single operation, making it simpler to correlate measurements and analyse the results. And the rpm profile from a tacho probe or CAN bus can now be shown together with the spectrogram. BK Connect is a fully integrated usercentric software solution for multichannel data acquisition, data processing, data management and reporting. Its structure is based on userconfigurable workflows that provide users exactly what they need when they need it. This reduces the risk of error and the need for customerspecific development – while maintaining the full feature richness of a modern analysis platform. www.hbkworld.com
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CUSTOM TOOLS & SOLUTIONS If you have a specific task that requires a specialised, custom tool then you need the Custom Tools & Solutions from Snap-on Industrial. The Custom Tools & Solutions program works closely with customers to develop oneofakind tools for critical tasks that enhance safety and reliability. Often endusers modify tools to
handle an exact task which is not recommended, as modifying any tool can compromise its form, fit or function, posing a danger to the technician. The smarter way is to utilise the expertise of the Custom Tools & Solutions team. When a request arises, Snapon observes the task with your team and develops the ideal solution to address your unique application. The Custom Tools & Solu tions team designs and engineers your new tool, and when approved, begins the manufacturing process to build it to exact specifications. The Custom Tools & Solutions team designs thousands of tools each year for customers in aviation, transporta tion, natural resources, power gener ation and many other industries. No ”THE CUSTOM TOOLS & request is too big or too small; Snap on Industrial relies on more than 100 SOLUTIONS TEAM DESIGNS years of design expertise to satisfy customers’ custom tooling needs. THOUSANDS OF TOOLS EACH Custom Tools & Solutions increases productivity and safety, while reduc YEAR FOR CUSTOMERS.“ ing tool replacement costs.
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08-10 Technical Insight - Spirol TD05 2024_LAW.qxp 19/01/2024 12:33 Page 1
////////// TECHNICAL INSIGHTS ////////////////////////////////////////////////////////////////////////////////////////////////////////// SPIROL
CHROME STAINLESS STEEL COILED SPRING PINS BENEFITS Michael Pasko, Applications Engineer SPIROL Connecticut looks at the benefits of 420 Chrome Stainless Steel Coiled Spring Pins where high strength, moderate corrosion protection and superior fatigue life are critical.
S
PIROL invented the Coiled Spring Pin in 1948. Coiled Pins are used in many industries including automo tive, medical, heavy equipment, military, aerospace, and consumer products. In applications requiring a combination of high strength, superior fatigue life, and corrosion resistance, 420 martensitic chrome stainless steel offers a host of tech nical benefits and provides an overall robust costeffective solution. STRENGTH SPIROL’s 420 stainless steel Coiled Spring Pins are hardened to values approximat ing their high carbon steel equivalents and share the same minimum rated shear strength. This process also develops desired spring properties and fatigue resistance. Chrome stainless steel Coiled Pins also offer good corrosion protection against most common atmospheric and environmental conditions without the risk of rapid work hardening associated with 302/304 austenitic stainless steel. In most cases, 420 chrome stainless steel Coiled Spring Pins may be used as dropin replacements for high carbon steel pins assuming galvanic potential has been considered relative to the host material.
”SPIROL’S 420 STAINLESS STEEL COILED SPRING PINS ARE HARDENED TO VALUES APPROXIMATING THEIR HIGH CARBON STEEL EQUIVALENTS AND SHARE THE SAME MINIMUM RATED SHEAR STRENGTH.“ 08
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Coiled Spring Pins are offered in light, standard and heavy duty to meet application-specific requirements
08-10 Technical Insight - Spirol TD05 2024_LAW.qxp 19/01/2024 12:33 Page 2
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Time impacts the corrosion resistance of coated steel compared with stainless steel
Corrosion progress
Exposure time Stainless steel CORROSION RESISTANCE When corrosion resistant Spring Pins are required, there are two common options: • Carbon steel with a sacrificial protective plating or coating • Stainless steel alloys which are inherently corrosion resistant Platings and coatings provide excellent performance though they are consumed over time, whereas stainless steel provides a lifetime of protection providing free oxygen is available in the environment (free oxygen allows the fastener’s protective chromium oxide layer to reform if damaged). For plated and coated parts, once the plating or coating is depleted, the carbon steel is left unprotected and rapidly corrodes.
”STAINLESS STEEL PROVIDES A LIFETIME OF PROTECTION PROVIDING FREE OXYGEN IS AVAILABLE IN THE ENVIRONMENT (FREE OXYGEN ALLOWS THE FASTENER’S PROTECTIVE CHROMIUM OXIDE LAYER TO REFORM IF DAMAGED).“
Coated steel 420 martensitic chrome stainless steel provides good corro sion resistance in environments, including but not limited to: • Normal atmosphere and humidity • Steam • Fresh water • Alcohol • Ammonia • Alkalis • Mild acids (ex. carbonic) • Petroleum products such as gasoline, oil, crude, etc. • Mild detergents and sterilising solutions While 302/304 austenitic stainless steel Coiled Pins provide excellent corrosion protection, this material is not an appropriate solution when the pin will be subject to dynamic loads, or where strength and fatigue resistance must equal or exceed that of high carbon steel. Alternatively, 420 martensitic chrome stainless steel provides an exceptional combination of strength and fatigue resistance – in addition to its inherent corrosion resistance.
HEAVY DUTY
STANDARD DUTY
LIGHT DUTY
torque-direct.com
09
08-10 Technical Insight - Spirol TD05 2024_LAW.qxp 19/01/2024 12:33 Page 3
% of Maximum Shear Force
////////// TECHNICAL INSIGHTS SPIROL
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50
0
Estimated Number of Cycles MCK
MBK
1,000,000
MDK
Data for comparative purposes only – Conditions in this test do not infer performance benchmarks in any application as varied load, host materials, hole size, and shear plane quality/clearance will impact performance FATIGUE LIFE 420 chrome stainless steel provides enhanced fatigue life – an important consideration given that Coiled Spring Pins are often intended to function as dynamic elements within many applications. A unique characteristic of Coiled Spring Pins is that their flexibility after installation protects host holes and assemblies by dampening vibration and shock loading. For comparison, Coiled Pins of the same duty (i.e. material thick ness) produced from material of equal dimensions, were tested in the three standard materials: MBK – Standard duty, high carbon steel, plain finish MCK – Standard duty, 420 chrome stainless steel, plain finish MDK – Standard duty, 300 series austenitic stainless steel, plain finish Resultant trend lines demonstrate 420 chrome stainless steels superiority in fatigue when tested at increasing percentages of assigned minimum double shear strength
”420 CHROME STAINLESS STEEL PROVIDES ENHANCED FATIGUE LIFE – AN IMPORTANT CONSIDERATION GIVEN THAT COILED SPRING PINS ARE OFTEN INTENDED TO FUNCTION AS DYNAMIC ELEMENTS WITHIN MANY APPLICATIONS.“ 10
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THE FINAL WORD Coiled Spring Pins manufactured from 420 chrome stainless steel are an excellent material choice where high strength, moderate corrosion protection, and superior fatigue life are critical. Additional benefits to consider include: • Excellent cost/benefit relationship in performance applications • High wear resistance • Good tensile and creep strength at moderately elevated temperatures • Oxidation and erosion resistant • Improved component cleanliness as compared to high carbon steel • Reduced potential for mixed product & debris as compared to plated and coated carbon steel product www.spirol.com
COMPLIMENTARY APPLICATION ENGINEERING SUPPORT Need help choosing the most appropriate fastening solution for your application? SPIROL’s Application Engineers will review your specific requirements, and help you select the most cost-effective Spacer to meet your technical and commercial needs. Contact us today!
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12 TECH INSIGHT - Bolted Tech - Applied Bolting Technology TD05 2024_LAW.qxp 19/01/2024 12:34 Page 1
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BOLTING TECHNOLOGY
TORQUE &
TENSION
Exploring the critical roles torque, tension and DTIs play in fastener assemblies
he relationship between torque, tension and the chal lenges associated with achieving reliable tension through torque application forms a critical aspect of fastener assemblies. Torque, defined as the applied effort to rotate threaded elements within a fastener assembly, serves as a means to achieve tension, where the nut is spun down the threads of the bolt. However, establishing a consistent rela tionship between the applied torque and the resulting tension proves elusive due to a range of variables. Lubrication, bearing surface conditions, thread fit, and the use of flat washers introduce variability in the torquetension relationship. Notably, approximately 60% of the torque required for tightening a bolt is consumed by overcoming fric tion between the nut and flat washer, with additional percent ages allocated to other factors such as thread friction and bolt elongation. Tests indicate that torquetension relationships can vary significantly, up to 40%, especially for structural bolts. Pretension – denoting the existence, action or amount of clamp load or tension within a fastener assembly – is achieved by applying torque to stetch a bolt beyond its original length. Despite torque being a means to achieve tension, establishing a reliable correlation between applied torque and developed tension remains a challenge.
T
Direct Tension Indicators (DTIs) offer an innovative solution to overcome these challenges. Manufactured by Applied Bolt ing Technology, these types of washers provide a mechanism to ensure proper tension independently of specified torque values. Traditional DTIs feature bumps around the washer that flatten upon achieving proper tension, a verification process that requires the use of a feeler gage. Applied’s Squirter DTIs provide a visual confirmation of proper tension by emitting an orange coloured media when properly tensioned. This not only ensures the bolts are installed correctly but also facilitates effi cient inspection, saving valuable time on the jobsite.
”APPLIED’S SQUIRTER DTIS PROVIDE A VISUAL CONFIRMATION OF PROPER TENSION BY EMITTING AN ORANGE COLOURED MEDIA WHEN PROPERLY TENSIONED.“ The introduction of Squirter DTIs represents a significant advancement in enhancing the reliability and accuracy of tensioning within fastener assemblies, offering a valuable alternative to the conventional torquetension relationship. www.appliedbolting.com
Galvanised flange plate with DuraSquirt
Squirter DTI washers
12
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13 TECH INSIGHT - Bolted Tech TD05 2024_LAW.qxp 19/01/2024 12:35 Page 1
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BOLTING TECHNOLOGY
CALIBRATION & CERTIFICATION Our round-up includes a new torque calibration device for ensuring accurate bolted connections and CE certification for locking washers… caliTEST-B: Cost-effective torque calibration Kistler has unveiled the caliTESTB, a smaller, more costeffec tive alternative to the established caliTEST calibration device for torque wrenches, it says. The caliTESTB enables the calibration of torque wrenches or tools with an effective length of up to 1,320 mm according to DIN EN ISO 6789. In developing the caliTESTB, the measurement technology expert paid particular attention to userfriendliness and flexibility, so that screwdrivershaped torque tools can also be calibrated quickly and easily. To ensure the safety of bolted connections, specific standards cover both the testing of fasteners and the associated tools. These include DIN EN ISO 6789, which describes the regular calibration of torque wrenches. For years now, Kistler has offered the caliTEST, a special cali bration device for torque wrenches, to minimise the impact of calibration on ongoing operations. It is a popular option, particularly for larger companies with many torque tools and their own calibration laboratory. However, for medium sized companies or those using a smaller number of tools, such a calibration device is usually not worth the investment. This means they have to send the torque wrenches to specialised laboratories in order to have the calibration carried out there. Kistler now offers an alternative for this customer group, the caliTESTB. The small, costeffective brother of the large
Nord-Lock achieves CE marking for securing washers NordLock has achieved CE marking for its wedgelocking washers, a feat – it says – no other global supplier offers for securing washers. The CE marking is a requirement for anyone supplying prod ucts to the building and construction industry within the Euro pean Union (EU), ensuring that products comply with the EU’s rigorous safety and quality regulations. The milestone of attaining the CE mark reinforces NordLock’s raison d’etre –
laboratory test bench enables reliable calibrations in the range from 2.5 to 500 N·m. If required, the calibration range can also be extended to 0.2 to 1,000 N·m. Alongside the calibration in accordance with DIN EN ISO 6789, toolrelated machine capability testing in accordance with VDI/VDE 2645 is also possible. The display deviation of the calibration device is less than or equal to 0.5% for the measured value. www.kistler.com
protecting customer investments and keeping people safe. “We are thrilled to introduce CE marking for our wedge locking washers, reinforcing our commitment to delivering excellence in engineering and design. This achievement demonstrates our dedication to compliance and safety, provid ing our customers with a competitive edge in their operations,” says Graham Souter, Vice President and head of the NordLock Business Unit. The biggest upside of these washers now carrying the CE mark ing is that any building and construction business, in any EU market, can reap the benefits of these washers when compliance with regulations is assured throughout the assembly process. With a locking mechanism that uses tension instead of friction, NordLock washers keep bolted connections tight and secure. Even when subjected to severe vibrations or dynamic loads, oper ators can rest assured that their bolts will stay in place. NordLock said: “With CEmarked washers now a reality, it will be easier for anyone involved in the EU’s building and construction industry to get up to speed with the safest and most reliable bolting solution available.” www.nord-lock.com
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14 PRODUCT INNOVATIONS - Aggressive Environments - EJOT TD05 2024_LAW.qxp 19/01/2024 12:35 Page 1
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AGGRESSIVE ENVIRONMENTS
REDUCING BUILDING ENVELOPE FAILURE RISK EJOT UK’s Technical Business Development Manager Brian Mack highlights why building envelope fasteners can be put to the test in aggressive environments resulting from both external and internal conditions
A
building’s location, and the purpose for which it is used, are two of the most important considerations when deciding which type of fasteners to specify for the building envelope. The envelope design must comply with minimum perfor mance standards in areas such as thermal, acoustic and fire insulation, but it must also offer a high level of air and water tightness, as well as meet aesthetic goals. Choosing an inappro priate type of fastener to install the envelope panels may, however, impact on all of these objectives if it is not suitable for the environmental conditions. Whilst external factors such as a coastal location usually drive the requirement for building envelope panels and fasten ers capable of withstanding aggressive environments, condi tions inside the building may actually be the catalyst. One refurbishment project that EJOT UK was involved in back in 2018 at the site of IAE – a manufacturer of livestock handling equipment, equestrian stabling, steel fencing and shelters – illustrates this perfectly. The technically challenging roof refurbishment for IAE’s galvanizing plant was required after it had reached the end of its design life, but the harsh environmental conditions resulting from the industrial process within the factory were actually visi ble on surrounding roofs. Filon’s Citadel profiled sheeting was selected as the replacement panel, which needed to be attached to hot rolled steel purlins and rails in 20,000 predrilled fastener locations using fixings known to offer a resistance
to the hazardous environmental conditions resulting from the galvanising processes. EJOT Corremaks JZ1 and JA1 fasteners were specified. Manu factured from stainless steel with the highest anticorrosion class, 1.4529 (A5), these fasteners are commonly used in atmospheres such as swimming pools and industrial processing plants. In comparison to this localised environmental issue, external conditions will often have a broader impact on buildings across a larger area. But that does not mean the fastener specification cannot be tailored to deal with particularly aggressive conditions. A good example of this is a project in Antarctica that EJOT UK’s technical team recently advised on. They provided an evaluation of how EJOT Colorfast selfdrilling fasteners would perform in an area of the world subject to extremely low temperatures and very high levels of UV due to the thinness of the region’s ozone layer. Drawing on data from previous Colorfast installations in Australia where UV levels are significantly higher than in Antarctica, EJOT UK was able to confirm that the colourfastness of the overmoulded nylon heads would be retained longterm, and that a 316grade stainless steel version would match the life expectancy for resistance to corrosion. Accurate forecasting also provided how the EPDM washers of the Colorfast screws would perform at a range of very low temperatures, helping to inform specification decisions. www.ejot.co.uk EJOT Corremaks JZ1 and JA1 fasteners were specified for the project
The IAE roof refurbishment
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Range of Stainless Steel Material Grades High Mechanical Strengths (eqv. 8.8 - 15.9) High Corrosion Resistance Excellent Fatigue Resistance Diameter Range M3 – M42 Extensive Stock Product Range Full 3.1 Product Test Certification Specials & Technical Project Solutions Exclusively European Material & Manufacture
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16 PRODUCT INNOVATIONS - Aggressive Environments - FST TD05 2024_LAW.qxp 19/01/2024 12:36 Page 1
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AGGRESSIVE ENVIRONMENTS
COATING COBOTS How this novel sealing solution is helping to protect cobots in industrial environments
obots are integral to the factory floors of today. Working hand in hand with operators and engineers for a myriad of activities, cobots must be adaptable enough for use in different work environments and to handle a wide range of different tasks. As such, this requirement puts signif icant demands on the application profile for such machines. However, for a cobot to continue to handle these multiple tasks and situations over the long haul they must be properly shielded from the aggressive environments within which they work, where they can encounter dust, spraying water and other contaminants. This is why one manufacturer sought out Freudenberg Sealing Technologies (FST) to provide a reliable, flexible and wearresistant sealing solution that delivered minimal frictional losses in order to protect its cobots while on the factory floor.
C
SELECTING THE RIGHT SEAL Up to this point, simple PTFE rings had been used in order to not overly compromise the efficiency, energy consumption and speed of motion of the robotic arms. However, the rings were not able to guarantee the required IP54 protection class. High travel speeds and the forces generated in the robot arm also create an environment with temperatures at high as 60°C. A seal not only has to withstand these temperatures longterm – extremely low material elongation is important as well in order to guarantee functionality in each operating mode and at all temperatures. As a first step to overcoming these challenges, FST proposed a uring made of polyurethane (PU), however practical tests revealed the ring’s frictional forces were too great due to its relatively large surface area. To ensure the forces did not exceed 1Nm, FST needed to significantly reduce the radial forces and contact stresses on the dynamic seal lip. CHANGING GEOMETRY For the next step, FST altered the overall geometry to a zprofile and integrated a second groove. This greatly reduced the contact pressure and met the requirement for a moment of 16
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friction of less than 1Nm. In the practical test, however, the level of wear was still far too high, mainly due to the cobot’s lightweight, largely aluminium construction. The surface of the material is relatively rough due to the methods used during its processing and its basic characteristics. To solve this problem FST developed a threecomponent solid firm lubricant coating with high carbon content which made it possible to further reduce the amount of wear. With a Shore hardness of 92, the 92 AU 21101 material is very soft and flexible, however it possesses a high tensile strength of 59MPa. At minimal elongation, components made of this material can be relied on in temperatures ranging from 50°C to 110°C. EXPRESS SERVICE In response to changes in the cobot’s design, the seal geometry had to be completely reworked once again. For the final version, FST selected a zgeometry with a further optimised dynamic lip seal. A static area with a groove was constructed internally. Thanks to the systematic use of FEA calculations for the lip thick ness and a later simulation, it was possible to achieve significant savings as unnecessary process steps were eliminated. FST’s Xpress service offered fast responses and short development times throughout the process, enabling the design, simulation and delivery of sealing solutions within two weeks. “We can react and deliver the product quickly, that is a real advantage that our customers appreciate during periods of global bottlenecks,” says Alexander May, Product Developer at FST. “We arrive personally on site in short order and work directly on the specific challenges worldwide, which always results in positive feedback. In a world of highly automated mass production, we are active in an area that many other manufacturers do not find attractive: onoff products and short production runs. When this is combined with our knowhow and the same quality standards as with largescale series production in the millions of units, it’s a dooropener.” www.fst.com
RAPID INDUSTRIAL FASTENERS LTD
THINK FASTENERS THINK RAPID
YOUR COMPLETE FASTENER SUPPLIER • Volume stockist of standard fasteners & fixings • In House Bespoke Manufacturing • Exclusive Far East Manufacturing Capacity • Next day Nationwide Deliveries • Vendor Managed Systems ; JIT / Kan Ban • Assembly & Kitting • Full Certification ; 3.1,3.2 & ISIR’s • Contract & Schedule orders 0121 501 3903 sales@rapidfast.co.uk www.rapidfast.co.uk
Head Office Unit 2, Stour Vale Road, Stourbridge, DY9 8PP
Manufacturing Hub Unit 27, Lye Valley Industrial Estate Stourbridge, DY9 8HX
18-19 IN-DEPTH Offshore Technology - Analysis TD05 2024_LAW.qxp 19/01/2024 12:37 Page 1
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OFFSHORE TECHNOLOGY | ANALYSIS
HARSH AND HAZARDOUS Offshore environments are some of the harshest in the world – what considerations do engineers need to take on board to ensure the fasteners used in these applications are up to the task?
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he term “offshore” generally refers to anything that is off the coast. In oil and gas extraction, “offshore” refers to the development of oil fields and natural gas deposits under the ocean, involving oil rigs or platforms used to identify these reservoirs and extract crude oil and natural gas from the earth’s surface. Oil rig numbers have been declining globally since 2014, when the oil boom led to a spike in rig deployment not seen since 1985. In 2022, the average number of active oil rigs was 1,747 units, according to market research firm Statista. Asia Pacific is home to the greatest number of these rigs. In early 2022, concerns over tightening oil supplies following sanc tions placed on Russia led to greater exploration activity. As a result, the number of marketed and contracted oil rigs rose, despite rig supply stating relatively stable, leading to most regions seeing a higher offshore rig utilisation rate. Offshore rigs and structures are exposed to some of the harshest conditions on earth, from bad weather and constant seawater exposure to the explosive atmosphere of oil and gas handling. As a result, the fasteners, adhesives and coatings used to construct and maintain these platforms must be incredibly reliable and resistant to corrosion. FASTENER REQUIREMENTS FOR OFFSHORE Fasteners are an essential component of the maritime industry, where they are used in a variety of applications, including ship yards, merchant vessels, offshore energy systems and oil and gas pipelines. One of the main considerations when choosing fasten ers for the marine and offshore industry is corrosion resistance. This is because salt water is highly corrosive due to the high concentration of dissociated ions. As any fasteners chosen for offshore applications will be constantly exposed to sea water, it is essential to focus on corrosionresistant materials. Austenitic stainless steels are often recommended because they have a strong passive film, however in critical situations where even higher corrosion resistance is needed, certain
surface finishing treatments such as passivation, electropol ishing or special galvanic coatings can be considered. In appli cations where high mechanical properties are required in addition to corrosion resistance, engineers could benefit from using super austenitic or austeniticferritic duplex or super duplex steels. In addition to corrosion resistance, the mechanical proper ties of fasteners are also crucial in the design and construction of offshore and maritime equipment. Fasteners must be able to withstand the various pressures, impacts and potential leaks they may be subjected to in such environments. Later in this indepth focus on offshore technology, we examine the impact of seawater exposure and cyclic loading on bolt failure in offshore platforms, as well as some of the preventative measures that can be taken to mitigate this risk. SAFETY AT SEA When working in offshore environments, addressing potential safety concerns is paramount to protecting not only the lives of the workers on board, but also the vital and expensive equipment they are working with. Unpredictable weather conditions, occupational hazards such as working at height and exposure to hazardous materials, operating complex machinery and equipment, and the remoteness of many of these locations, can make offshore rigs and platforms a dangerous place to be. Carrying out regular, comprehensive risk assessments and undertaking continuous safety training and education is essential for all workers involved in offshore construction projects. Instill ing a robust safety culture and harnessing innovative technologies like realtime monitoring systems and remoteoperated vehicles can significantly enhance safety in offshore environments. Over the next few pages, we dive deep into the safety chal lenges of operating within offshore environments, and the specific considerations, tools and equipment that can help to keep engineers and workers safe.
”OFFSHORE RIGS AND STRUCTURES ARE EXPOSED TO SOME OF THE HARSHEST CONDITIONS ON EARTH, FROM BAD WEATHER AND CONSTANT SEAWATER EXPOSURE TO THE EXPLOSIVE ATMOSPHERE OF OIL AND GAS HANDLING.“ Corrosion is one of the major challenges for fasteners used in offshore and subsea applications
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20-21 IN-DEPTH Offshore Technology - Hague Fastener TD05 2024_LAW.qxp 19/01/2024 12:44 Page 1
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OFFSHORE TECHNOLOGY
Seawater exposure and cyclic loading can significantly impact bolt failure
FATIGUE & FAILURE ANALYSIS Jon Hague examines the impact of seawater exposure and cyclic loading on bolt failure in offshore platforms
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he offshore oil industry operates in some of the harshest environments on earth, with subsea equipment and pipelines subjected to extreme conditions such as high pressure, temperature, and corrosive seawater. Fasteners used in these environments are critical components that hold every thing together, and their failure can have serious consequences such as leaks, spills, and equipment damage. Here, we take a look at the impact of seawater exposure and cyclic loading on bolt failure in offshore environments, and examine some preventative measures that can be taken to mitigate this risk. FASTENER FATIGUE LIFE Fastener fatigue is a common mode of failure in offshore platforms, where equipment and pipelines are subjected to cyclic loading over long periods of time. This loading can cause microscopic cracks to form in the fastener material, which can grow and even tually lead to catastrophic failure. Fastener fatigue life is influenced by several factors, including the material properties, the design of the joint, the loading conditions and the operating environment.
”FASTENER FATIGUE IS A COMMON MODE OF FAILURE IN OFFSHORE PLATFORMS, WHERE EQUIPMENT AND PIPELINES ARE SUBJECTED TO CYCLIC LOADING OVER LONG PERIODS OF TIME.“ 20
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MATERIAL PROPERTIES The choice of material for fasteners is critical in harsh offshore environments, where seawater exposure and corrosive gases can cause rapid degradation of certain materials. Common materials used for fasteners in offshore platforms include carbon steel, alloy steel, and stainless steel. Carbon steel is the most common material due to its high strength and low cost, but it is also susceptible to corrosion in seawater. Alloy steel and stainless steel are more resistant to corrosion, but they are also more expensive and may not be suitable for all applications. JOINT DESIGN The design of the joint can also have a significant impact on fastener fatigue life. Factors such as the size and shape of the fastener, the number of fasteners, and the preload applied to the joint can all affect the fatigue behaviour. For example, joints with too few fasteners of insufficient preload may experience higher stress concentrations and be more prone to fatigue failure. LOADING CONDITIONS The loading conditions that fasteners are subjected to can also impact fatigue life. In offshore platforms, cyclic loading is common due to the continuous movement of the platform caused by waves and wind. The frequency and magnitude of the cyclic loading can vary depending on the location and weather conditions, and can significantly affect the fatigue behaviour of the fasteners. OPERATING ENVIRONMENT The operating environment in offshore platforms can also affect fastener fatigue life. Seawater exposure is a major concern, as it can cause corrosion and stress corrosion cracking
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Material choice is critical for offshore applications
Offshore oil and gas engineers operate in some of the harshest environments on earth
Further analysis also revealed that the seawater exposure had accelerated the corrosion of the bolts, reducing their strength and contributing to the fatigue failure. The combina tion of cyclic loading and seawater exposure had therefore significantly reduced the fatigue life of the bolts, leading to premature failure. PREVENTATIVE MEASURES To prevent fastener failure in offshore platforms, several preven tative measures can be implemented. These measures include: Material selection: Choosing the right material for fasteners is critical in offshore platforms. Corrosionresistant materials such as alloy steel and stainless steel are preferred for appli cations where seawater exposure is a concern. in certain materials. The presence of corrosive gases such as hydrogen sulphide can also accelerate degradation and increase the risk of failure. SEAWATER EXPOSURE AND CYCLIC LOADING IMPACTS To illustrate the impact of seawater exposure and cyclic load ing on bolt failure in offshore platforms, Hague Fasteners has presented a case study that focuses on a subsea pipeline connection in the North Sea, where several bolts failed after only a few years of service. The pipeline connection consisted of two flanges, each with 12 bolts, that were connected using a bolt tensioning system. The bolts were made of carbon steel and had a diameter of one inch. The pipeline was exposed to seawater and subjected to cyclic loading due to the continuous movement of the platform caused by waves and wind. After a few years of service, several bolts in the connection failed due to fatigue. Failure analysis revealed that the bolts had developed fatigue cracks at the root of the threads, which had grown and eventually led to complete fracture. The cracks were caused by the cyclic loading of the pipeline, which had exceeded the fatigue limit of the bolts.
Seawater exposure can accelerate the corrosion of bolts
Coatings: Applying coatings such as zinc, cadmium, or other anticorrosion coatings can help protect fasteners from the corrosive effects of seawater. However, the coating must be carefully selected based on the specific application and envi ronmental conditions. Preload: Properly tightening fasteners to the recommended preload can help distribute the load evenly and reduce stress concentrations. This can help prevent fatigue cracks from forming and improve the fatigue life of the joint. Inspection: Regular inspection of fasteners can help detect early signs of corrosion, cracking, or other defects. This can help identify potential problems before they become serious and allow for preventative measures to be implemented. Maintenance: Proper maintenance of offshore equipment and pipelines is critical to preventing fastener failure. Regular cleaning and inspection can help reduce the impact of seawater exposure and ensure that fasteners are functioning properly. Fastener fatigue life and failure analysis are critical issues in offshore platforms, where equipment and pipelines are subjected to extreme conditions such as seawater exposure and cyclic loading. The case study presented here illustrates the impact of these factors on bolt failure and highlights the importance of preventative measures to mitigate the risk. Proper material selection, coatings, preload, inspection and maintenance can all help improve the fatigue life of fasteners and prevent premature failure. By implementing these measures, offshore operators can reduce the risk of equipment damage, spills, and environmental damage, and ensure the safe and reliable operation of their assets. www.haguefasteners.co.uk
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22-23 IN-DEPTH Offshore Technology - Safety TD05 2024_LAW.qxp 19/01/2024 12:53 Page 1
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OFFSHORE TECHNOLOGY
SURE ON
SAFETY
Offshore construction projects present unique safety challenges that require specific considerations, tools and equipment
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ithin offshore environments, addressing safety concerns is paramount to protecting the lives of workers, minimising environmental risks, and ensur ing project success. Infrastructure solutions provider Utilities One handles a multitude of projects nationwide within the engi neering, construction, communication, energy and technology deployment fields. On its website, the firm outlines some of the primary safety concerns faced by oil and gas, power, and construction engineers operating in offshore environments. UNPREDICTABLE WEATHER CONDITIONS Offshore environments are prone to extreme weather events, including storms, high winds and rough seas, which can pose risks to workers and equipment. Proper planning, monitoring and execution are essential to ensuring work is conducted safely during favourable weather conditions.
”WORKERS IN OFFSHORE CONSTRUCTION FACE A WIDE RANGE OF OCCUPATIONAL HAZARDS, SUCH AS WORKING AT HEIGHTS, EXPOSURE TO HAZARDOUS MATERIALS, HEAVY LIFTING, AND WORKING IN CONFINED SPACES.“
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OCCUPATIONAL HAZARDS Workers in offshore construction face a wide range of occupa tional hazards, such as working at heights, exposure to hazardous materials, heavy lifting, and working in confined spaces. Implementing comprehensive safety training programmes and providing appropriate personal protective equipment (PPE) are crucial in mitigating these risks. COMPLEX MACHINERY AND EQUIPMENT Offshore construction often involves the use of complex machinery, such as cranes, winches and drilling equipment, which require skilled operators and meticulous maintenance. Regular inspections, preventative maintenance and proper training contribute to equipment reliability and worker safety. COMMUNICATION AND REMOTE LOCATIONS Offshore construction sites are often situated in remote loca tions, making communication and emergency response chal lenging. Establishing robust communication systems, using advanced technology and conducting regular drills are vital for quick and effective responses in case of emergencies. STRATEGIES TO ADDRESS SAFETY CONCERNS To address these safety concerns, Utilities One suggests several strategies that should be implemented on any offshore site. First, a rigorous risk assessment should be carried out to iden tify potential hazards, followed by putting in place appropriate risk control measures. Regular safety inspections, job hazard analyses and emergency response drills should also be conducted. Secondly, continuous safety training and education is essential for all workers involved in offshore construction projects, including comprehensive training on operating
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Tethering tools prevents them being dropped from heights
machinery, understanding safety protocols and raising aware ness of potential hazards. A robust safety culture and accountability should also be implemented in order to foster a strong safety culture within any organisation or team. Additionally, harnessing innovative technologies can significantly enhance safety in offshore construction. Examples include realtime monitoring systems to assess weather conditions, remoteoperated vehicles for underwater inspections, and wearable devices to monitor worker health. Finally, industry collaboration is crucial to addressing safety concerns effectively. Sharing best practices and lessons learned among different companies and projects can lead to continuous improvement in safety standard, as can participat ing in industry forums and conferences where knowledge sharing takes place. IMPROVING SAFETY WITH INNOVATIVE EQUIPMENT In addition to the considerations listed above, the tools and equipment used on offshore construction projects can also help to not only ensure worker safety, but also minimise work disruptions caused by accidents, inspections or emergencies. In turn, this can lead to improved project timelines and overall efficiency, which naturally can then have cost benefits. TOOLS@HEIGHT Oil and gas engineers required to work at height, often in chal lenging offshore locations and bad weather, are well aware of the risk of hand tools or equipment falling or being dropped, and of the potential consequences. As well as posing a major threat to anyone working below, falling tools can also cause serious damage to vital systems and machinery.
The safetyfocused Tools@Height programme introduced by Snapon Industrial mitigates this risk by leveraging tethered tools to prevent them inadvertently falling or being dropped. All tools are designed with strong, integrated fixing points to enhance safety and functionality when used at height or near critical assemblies. Snapon first pioneered its antidrop solu tions to benefit construction workers building skyscrapers in the USA, and today it is used in a wide variety of atheight applications, such as offshore construction projects. Today, the programme encompasses a wide range of tools which incorporate fixings to enable hand and power tools to be securely tethered to Snapon lanyards, bags, pouches and belts. The Tool@Height sockets, adapters and extensions all have a locking hole on four sides, while drive tools and ratchets have a locking pin which fits into the side locking hole to ensure positive locking. According to Snapon, using tools designed and manufactured to be tethered is a lot safer than adapting existing tools for working at height, as engineered attachment points do not interfere with the functionality or efficiency of tools designed to be tethered.
”SNAP-ON FIRST PIONEERED ITS ANTI-DROP SOLUTIONS TO BENEFIT CONSTRUCTION WORKERS BUILDING SKYSCRAPERS IN THE USA.“ Snapon supplies individual tethered tools or customer specific kits, with components delivered assembled and ready for immediate use. The retractable Snapon lanyards, mean while, are certified against international standards and quality tested in both static and dynamic tests in conditions more rigorous and demanding than any likely to be encountered in reality. The lanyards are capable of holding up to 12kg and feature universal attachments for tool which to not have any integrated attachment points. Several types of lanyard are available, including carabiner, fixed loop, exchangeable loop, retractable and wrist lanyards. Separate power drill and hammer holders are also available. www.snapon-industrial.co.uk
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24-25 Technical Insight - Fluke TD05 2024_LAW.qxp 19/01/2024 12:53 Page 1
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Fluke’s ii910 precision acoustic imager
SHORED-UP SUPPORT Fluke customers can now cut downtime while ensuring accuracy, reliability and compliance of their industrial tools thanks to expanded Premium Care support
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outine maintenance and care are vital to ensuring tools and equipment remain in safe and effective working order. Not only is this important from a safety and effi ciency perspective, but it can also deliver significant cost savings as properly maintained equipment lasts longer and requires fewer costly repairs. If you’re a Fluke customer, then this process has just become easier. The professional electronic test and measurement tools and software manufacturer has expanded its Premium Care support packages to include a wider range of its industrial and electrical tools. Fluke Premium care covers the routine cali bration and performance checks of tools to ensure compliance with the latest standards, as well as the repair and replace ment of damaged accessories. Top priority technical support is also offered to enable customers to solve critical equipment challenges faster. With the expansion, selected tools from the company’s range of acoustic imagers, power quality analysers and loggers, multifunction PV testers and performance analysers, ScopeMeters, motor drive analysers and process calibrations tools can now be covered by the support package. “Fluke Premium Care is a means of ensuring any gaps in 24
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production and performance are kept to an absolute minimum by maintaining the continuity of our customers’ work,” says Chris Ulfig, Technical Sales Manager at Fluke. “Less downtime means greater productivity, increased efficiency, higher profits, and more satisfied endusers. Additionally, equipment that is
”FLUKE PREMIUM CARE IS A MEANS OF ENSURING ANY GAPS IN PRODUCTION AND PERFORMANCE ARE KEPT TO AN ABSOLUTE MINIMUM.” fully calibrated is not just reliable, it is safe – and the safety of personnel is nonnegotiable. Fluke Premium Care takes away the headache of accidental damage or worrying about compli ance, calibration and performance testing to make the most out of your tools. It’s a nobrainer.”
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TESTING, CALIBRATION AND COMPLIANCE Fluke Premium Care provides coverage above and beyond a tool’s original product warranty, helping users to avoid unex pected downtime caused by damaged test equipment, acces sories, or tools that need calibration or repair. In fact, annual cost comparisons show that upgrading to a Fluke Premium Care plan can save thousands on equipment maintenance and repair. At the same time, the package supports customers who need their industrial tools to be calibrated or performance tested on an annual basis. Fluke Premium Care’s calibration and performance mainte nance service ensures test tools always provide accurate results and comply with the latest standards. With the offer of expedited calibration, repair and freight, Fluke customers can also save time and get back to work faster while maximising efficiency, safety, and productivity in the workplace. ACCURACY AND RELIABILITY INCREASES ROI Fluke’s ii900 Industrial Acoustic Imager and ii910 Precision Acoustic Imager can now come bundled with a one or three year Fluke Premium Care plan. Fluke’s acoustic cameras are a quick way for maintenance teams to accurately locate air, gas, and vacuum leaks in compressed gas systems. Those seem ingly small issues can have a significant impact on a company’s operational costs with a single 3mm leak in a compressed air line costing more than USD $2,500 a year, according to the US
Department of Energy for Industrial Technologies. Additionally, a 100 hp air compressor consumes around $50,000 in electricity every year and can waste as much as 30% of that power on pressurising leaking air lines. It is a major benefit to use equipment that is annually performance tested to ensure accuracy, reliability and safety when scanning large areas or hazardous environments from up to 50m away. For measurement tools that are used to generate safety and performance reports, such as power quality analysers or multifunction testers, regular calibration is a must to ensure compliance and to guarantee precise and conclusive measure ments. With Fluke Premium Care, the return on investment from Fluke’s marketleading industrial and electrical tools is substantially increased, the company says. “Fluke’s industrial and electrical tools are renowned for their rugged design and safety features, but accidental damage to tools and accessories can happen, especially where equip ment is used by new recruits or operators with minimal train ing,” adds Ulfig. “At the same time, calibration and performance tests are essential to guarantee the accuracy and reliability of equipment. Fluke Premium Care ensures customers have direct access to industrial and electrical tool experts who can help them to cut downtime, boost performance, control budget spend and save money in the process.” www.fluke.com
”FLUKE’S INDUSTRIAL AND ELECTRICAL TOOLS ARE RENOWNED FOR THEIR RUGGED DESIGN AND SAFETY FEATURES.”
Premium Care has now been expanded to include a wider range of test and measurement tools
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26-27 Technical Insight - Forward Fasteners TD05 2024_LAW.qxp 19/01/2024 12:54 Page 1
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FORWARD INDUSTRIAL PRODUCTS: SERVICE & ENGINEERING ORIENTATED Martyn Cleaver, Managing Director of Forward Industrial Products Group Ltd, tells Torque Direct that his company embraces the challenges of creating complex parts and providing a high quality service to customers too…
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Based in the heart of Birmingham, in Tyseley, Forward Industrial is an engineering and serviceoriented Company serving the automotive, white goods, yellow goods and construction sectors. Welcoming complex parts and committed to going the extra mile for customers, the business has been steadily increasing its turnover and scope. “We started with fasteners, but it's moved on to different parts; stampings, pressings, fabrications, plastic parts… our portfolio of parts has grown and grown,” explains Managing Director Martyn Cleaver. “After making a couple of parts to a customers’ design they’d turn around and ask if we can make the part in the middle that joins them up... So, we did and new manufacturing processes developed from there.”
”WE’RE VERY, VERY TECHNICALLY BIASED. WE’VE ALWAYS BEEN ENGINEERING BACKGROUND HEAVY.“ 26
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The method of delivery has also grown with Forward offer ing all types of VMI as a norm, JIT, Kan Ban, Direct line feed, consignment stock etc. That product range evolution has developed under the watchful eye of a team blessed with plenty of expertise, he adds: “We've got business development management and engi neers who are degree trained in design and manufacturing. We're very, very technically biased. We've always been engi neering background heavy. Most of our staff are longtermers and came from the engineering industry to start with.” Service The background of Forward Industrial’s founders and many employees has helped embed a serviceoriented culture. Draw ing on experience as former engineers and engineering buyers, the need for swift and reliable service is high on the agenda. Cleaver explains: “We’re very service orientated. There’s that old adage that ‘the customer is king’. Here, we genuinely mean that. We have to have the customer trust us, that's what it's all about. It’s a symbiotic relationship. Without them, we can't survive. And we like to think that they think the same about us.
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“We will go the extra mile. They can ring us anytime, day or night. That's the territory we're in. In many ways, our USP is the service aspect. Different companies can do it, but who could do it consistently and quick enough? It is service, service, service.” He adds: “It's easy to say to a customer: ‘Trust me, we won't let you down.’ And then they go: ‘Yeah, I've heard that before.’ But I think that you could talk to any of my customers and they would say that we are trusted to deliver to their expectations in all aspects.” That emphasis on customer support has led to investments in people too. Since the pandemic, Zoom, Teams or your video call ing software of choice have become ubiquitous, making everyone more accessible and available for meetings at shorter notice, requiring depth in staff to meet those newer customer needs. Quality and complexity Whichever sector Forward Industrial is supplying – be it the automotive market, white goods, yellow goods, specialist construction or another – quality remains King. Cleaver takes up the topic: “It's really important that we supply parts that never have a problem. We all know we can never stop the production line. We can't have any quality issues. “We’ve invested lots in our quality department. We've spent on specialist measuring equipment and we've increased our staff to take on more specialist PPAP engineers. With any customer now they're expecting more on the quality side.” And when it comes to special parts, Forward Fastener does not shy away from complexity: “The majority of parts are produced to a customer's design. And more often than not, there'll be something a bit special about it. “We do some complex parts, adhering to critical safety standards for a broad range of customers and a broad range of countries.” Exports Forward Industrials export efforts used to focus solely on Europe, but recently have expanded across the Atlantic with a sizeable warehouse established in the US: “It’s been very good, we have a large stockholding in the US and we send product all over for automotive and construction customers. We also now export to Argentina, South Africa, Thailand, Spain, China, Mexico. It’s got to the point where we will be opening more warehouses around the world to supply our customer base. That's the plan and it will be sooner rather than later.” It’s a positive message that, despite the volatile global econ omy, Forward Industrial is thriving: “Our exports are growing. We've had the best year ever in our history. We're really buoyant and confident about the future.” Forward Industrial turns over around £24 million, its MD explains: “We're at a size now where people are saying, ‘maybe they're now big enough to look after us’. So, we're getting lots and lots of opportunities. “But we have to be mindful. The fastener industry business model means you’re carrying a lot of stock. Every time you win a new customer, working capital goes up by 75% of increased turnover so an additional £1 million in sales requires £750K in stock and debtors and so it carries on.”
“Customers are looking more critically now about geopolit ical tensions. We talk to our suppliers all the time and ask if they are worried about a particular situation, what their plan is… So there are those conversations taking place. “And I think that the customer is so well informed and aware than they used to be in supply chain management. They’re asking a lot more questions – if this happens again, what will you do? If you're importing, which most of the UK is, there is no new way of doing it – it's still coming on a boat. So, it doesn't matter how that supply chain works, you're still going to have to schedule it to come in on the boat for so many weeks and have somewhere to stock it. So, the actual basis of the business hasn't changed. I think people are just a lot, a lot more thor ough now. Who they're dealing with and who and where the actual manufacturer is.” That applies to ESG too, he adds: “Everybody's also looking at how green things are. How you are shipping, are you consol idating shipments? What are you doing to reduce your carbon footprint? Customers are delving deeper. People want robust supply chains and everything else that goes with it, including ethics, awareness of modern day slavery, etc. “As a company we recently planted 2,000 trees recently to help offset our carbon footprint.” Investments Forward Industrial has invested in two clever storage systems called Agilon, from Konecranes in Finland: “It uses a robot and artificial intelligence in a big self contained storage unit. What it means for us is that when you have lots of critical parts – for instance, we use it for shim washers, with different items vary ing by fractions of a millimetre increments. They are very simi lar but you cannot afford to have them mixed up. These items go into the Agilon, kept in their separate containers and they are all scanned, barcoded and cuts out errors. “So, for the very similar parts, the high value and the small parts, can all go in the Agilon. They're constantly counted, the stock gets fed into the system. It’s a very, very clever bit of kit and we have invested in two of those. Aside from hints about increased presence overseas in the future, Forward Industrial sees growth opportunities ahead in the EV field: “We are heavily involved in electric vehicles, with various customers in various fields for EVs and in various places around the world. It’s exciting – fasteners for EVs are in everything from the battery pack to the drive train. Then there’s the infrastructure too. It’s going to become a bigger part of our business and I think it will for most people going forward.” There are broader opportunities ahead too, he adds: “I think each country has a different culture on the supply of fasteners. And the UK has a good reputation, so something for us is to say, how can we offer customers in other countries the same things we can for the UK? But for us to be able to go to our customers and say, okay, we can offer you this, because now we've opened the warehouse just down the road.” forwardindustrial.co.uk
ESG and supply chains With the supply chain woes of Covid still fresh in the mind and awareness of political tensions worldwide, customers are getting more supply savvy, says the Forward boss.
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28-29 Technical Insight - Atlas Copco TD05 2024_LAW.qxp 19/01/2024 12:57 Page 1
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ADVANCING AEROSPACE ASSEMBLY Take a look at the new innovative battery drill which replaces the need for 10 different airframe tools to better support aerospace manufacturing
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ccording to industry research carried out by sustainable productivity solutions provider Atlas Copco, 35% of holes required in airframe construction are drilled using handheld tools, which account for up to 65% of the assembly cost. Additionally, the drilling process has been found to be the cause of around 85% of quality issues and 80% of lost operator time, due to injuries sustained from legacy tooling. Having identified the need to further improve productivity and quality on the aircraft assembly line, Atlas Copco Tools and Industrial Assembly Solutions has introduced a new electric drill for the aerospace sector. The EBB16 cordless drill has been specifically designed to counter the issues highlighted by the company’s industry research, with its ergonomics, safety and usability enabling users to drill more identical holes, more accurately and more safely.
”DRILLING ERRORS CAN CAUSE MAJOR PROCESS DELAYS AND INCUR SIGNIFICANT COSTS TO RECTIFY.” “The human factor is decisive in airframe assembly,” says James McAllister, General Manager at Atlas Copco Tools and Industrial Assembly Solutions. “Drilling errors can cause major process delays and incur significant costs to rectify. The intro duction of Atlas Copco’s latest battery drill that’s specifically 28
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designed for use in aerospace manufacturing, aims to address these challenges within an increasingly competitive and quality critical sector. The innovation and development behind EBB16 reflects Atlas Copco’s focus on forging strategic partnerships with aerospace customers on their journey to the Smart Factory.” THE DETAILS Weighing just over 1kg, the compactsize cordless EBB16 is powered by a lithiumion battery and features a double battery position that enables operators to access tighter loca tions within the airframe, as well as working with less restric tion. The drill features 10 drilling programmes, ranging from 5005,500rpm and selected via a userfriendly interface (HMI), which replaces the need for 10 tools with just one. As a result, this delivers a leaner and more costefficient assembly line for aerospace manufacturers. Selectable programmes ensure the correct cutter speed for specific materials in order to reduce the risk of drilling over sized holes, while a reversible option enables the backout of drill bits in the event of a jam. Operator feedback includes a cutter usage indicator and service information via the HMI, whilst WiFibased tethering can also be provided to prevent tool usage outside a specific assembly area. The EBB16 is available in two models – Standard and Plus – for specific airframe tasks. The drill is managed with Atlas Copco’s bespoke ToolsTalkService2 software for torque programming and traceability analysis. Carried out by certified technicians, the company’s EasyStart installation and user training service is provided, as well as maintenance plans to ensure consistent and accurate drilling performance.
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The smart integrated assembly line
SMARTER FACTORIES At the centre of Atlas Copco’s Smart Factory philosophy is its Smart Integrated Assembly, which aims to eliminate costly rework and material wastage in pursuit of more sustainable manufacturing. The assembly is designed to wirelessly connect all digital tools throughout the factory, harnessing the latest 5G connectivity on selected tool models in order to optimise produc tion, improve quality, reduce costs and energy consumption. At the recent Advanced Engineering in Birmingham, the company showcased its latest generation errorproofing soft ware, Avantguard. The webbased solution provides ultimate flexibility, with the software able to run on any device with any operating system, that integrates with existing customer IT infrastructure. The Smart Integrated Assembly also features the company’s customisable ToolsControl system, which removes the need for separate controllers for each tool
Eliminating costly rework and material wastage
on the production line. The software creates a single envi ronment for connecting every tool in the factory to the client’s manufacturing execution system (MES), which deliv ers significant reductions in hardware costs and floor space. “As a strategic partner to manufacturers, Atlas Copco is fully committed to improving production efficiency by harnessing realtime data insights and hyper flexibility, as part of a smart manufacturing ecosystem,” says McAllister. “We are looking forward to demonstrating Smart Integrated Assembly with the ToolsControl ‘controller anywhere’ concept, as well as a comprehensive range of Smart connected solutions, including 5G and realtime software, to enable factbased decision making that will revolutionise production line design into a full Smart Factory.” www.atlascopcogroup.com
”THE SMART INTEGRATED ASSEMBLY ALSO FEATURES THE COMPANY’S CUSTOMISABLE TOOLSCONTROL SYSTEM, WHICH REMOVES THE NEED FOR SEPARATE CONTROLLERS FOR EACH TOOL ON THE PRODUCTION LINE.”
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ADHESIVES & TAPES
SUSTAINABILITY STICKS Torque Direct rounds up the latest product news from the adhesives sector
SOLVENT-BASED SUSTAINABILITY Global chemicals company Henkel has added what it claims is a revolutionary product to its complete range of preapplied thread locker coatings that ensure rapid passage of flowing product with the durability advantages of a waterbased mate rial. Loctite DRI 2250W is a medium to high strength pre installed threadlocker designed to meet the demands of the automotive industry. Featuring excellent chemical resistance, the solventbased, moisturecuring adhesive offers exceptional bonding strength and durability, and is capable of withstanding temperatures in excess of 200ºC. “Traditional products can lose up to 50% of their initial room temperature strength – and in some cases even more – at 150ºC,” says Scott Simmons, North American Business Development Manager at Henkel. “In contrast, DRI 2250W retains its room temperature strength above 150ºC, and in some cases up to 200ºC.” Other advantages of Loctite 2250W are its low coefficient of friction. Tested on multiple plating surfaces, the material maintains a coefficient of friction between 0.10 and 0.16. It also shows excellent performance on all types of coatings, including the newer zincflake coating, with added lubricity. As a ready applied film, the twist lock is dry to the touch and remains an inert coating until configuration. During assembly, the microcapsules inside the lid are crushed and releases the active ingredient that initiates the anaerobic healing process. When cured, Loctite DRI 2250W also works as a thread sealer and thread filler. This eliminates the need to apply liquid sealants, adhesives or other mechanical locking or sealing devices in threaded parts during manual or automatic instal lation and is current for higher output speeds.
”OTHER ADVANTAGES OF LOCTITE 2250-W ARE ITS LOW COEFFICIENT OF FRICTION.“
A SUSTAINABLE CHOICE As with the rest of Henkel’s threadlocker coating range, Loctite DRI 2250W is a waterbased product that ensures that manu facturing, application, drying, and assembly processes are environmentally sustainable. Its waterbased chemistry contains no solvents or halogen. By coating components such as screws or fasteners with Loctite preapplied threadlockers, they can be reused after disassembly by applying the appro priate liquid Loctite threadlocking or thread sealing product. 30
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CASE STUDY A major seat manufacturer needed a preapplied threadlocker to help overcome inconsistent fastener performance – and one that would work on contaminated zincflake plated fasteners. Loctite DRI 2250W demonstrated high performance equally well on all fastener types, includ ing stainless steel and zincflake plated fasten ers – working effectively on both clean and contaminated fasteners. The solution demonstrated consistent bolt clamp load across a broad service temperature range and high vibra tion loading, while offering excellent performance with good serviceability across different fastener types. Loctite DRI 2250W finds application across a wide range of industries due to its versatility and superior bonding perfor mance. Some notable applications include gearbox and trans mission fasteners, oil pans, side cover fasteners, case and cover fasteners, and engine critical fastener applications. www.henkel.co.uk
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Test have shown that Tesa 51345 performs similarly to standard film based tapes
ADHESIVE ALIGNMENT FOR AUTO Meanwhile, commercial adhesives manufacturer DELO has introduced a new active alignment adhesive for highresolution automotive cameras. The adhesive is launched under the company’s optimised portfolio geared to the high optical requirements of modern advanced driver assistance systems (ADAS). With it, DELO is helping to set process speed and align ment accuracy standards for automotive cameras. ADAS such as lane departure and emergency braking systems are becom ing increasingly capable and are steadily improving vehicle safety. Lidar and radar sensors, as well as highresolution cameras, are essential to these systems.
MORE SUSTAINABLE PACKAGING Adhesive tapes manufacturer Tesa has introduced a paperbased reinforcement adhesive tape that offers a more sustainable option for packaging. Named Tesa 51345, the tape can be used to reinforce packaging or cartons at sensitive points such as side hole handles, flap handles, and tophole handles, and is pitched primarily at manufacturers of corrugated boards. Tests have reportedly shown that the Tesa 51345 performs similarly to standard filmbased tapes. The tape’s novel strong paper backing material is coated with a solventfree adhesive that ensures reliable adhesion even on cardboard with a high proportion of recycled material. After packaging disposal, the adhesive tape can be recycled along with the packaging material. Tesa 51345 can be applied inline during the corrugated board manufacturing process or offline during box processing using common applicator systems. “Packaging and shipment of items continues to rise – with a growing preference for light and more sustainable packaging,” says Frank Domann, Corporate Marketing director Industrial Markets at Tesa. “Achieving optimal balance between the reduc tion of material thickness and adequate strength and protection for packaged goods is paramount. This is precisely where our new Tesa 51345 comes in: reinforcement adhesive tapes provide added strength to lighter packaging and cartons, partic ularly in critical stress areas. Our adhesive tape solution also contributes to achieve more sustainability in the packaging industry, as the tape has been produced using a solventfree coating process with a paper backing from sustainably managed sources and a 100% recycled paper core. And the best part: it can be disposed of together with the cardboard material with out affecting the recycling process.” By 2023, Tesa is aiming to increase the share of recycled and biobased materials in all products to 70%, and to reduce the use of nonrecycled fossilbased plastic by half.
”THE ADHESIVE’S RAPID LIGHT FIXATION ENABLES ALIGNED COMPONENTS TO BE PRECISELY FIXED IN SECONDS.“ DELO Dualbond OB6799 is specifically designed for the bond ing and active alignment of ADAS cameras. The epoxy adhesive has a linear curing shrinkage that is reproducibly below 1% and exhibits extremely low swelling behaviour, even under changing temperature and humidity conditions. This means that camera focus remains optimally adjusted and can permanently fulfil its safety functions. Since highresolution cameras are primarily made of aluminium, the coefficient of thermal expansion (CTE) is specially adapted to this material. Applicationrelevant aging tests (e.g. +85°C/85%rh, 2000h) confirm the adhesive’s high bonding strength to aluminium substrates. Particularly optimised for active alignment processes, the adhesive’s rapid light fixation enables the aligned components to be precisely fixed within a few seconds and, from that point onwards, reliably maintain their position. This makes the adhe sive ideal for manufacturing processes designed for high volumes with demanding efficiency as well as alignment accu racy requirements. www.delo-adhesives.com
Dualbond OB6799 enables high throughput and maximum reliability in the active alignment process
www.tesa.com
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DACH+HOLZ INTERNATIONAL
ALL ROADS LEAD TO STUTTGART Whether it’s exploring innovations, testing products, exchanging ideas or something else, there’s a plethora of great reasons to visit DACH+HOLZ International in Stuttgart in March 2024. tuttgart will be the roofing and timber industry’s focal point from 5 to 8 March 2024, with DACH+HOLZ Interna tional taking place. In six halls and on 75,000 square metres of gross exhibition space, more than 500 exhibitors will provide information, show products and present systems on what the future holds for roofers, carpenters and building plumbers. From digitalisation to human resources and sustain ability – the focus topics at DACH+HOLZ International cover the industry’s most vital issues.
S
Plenty of space for dialogue These focus topics and more issues will be reflected in the newly installed Workspaces, areas focusing on “Sustainability & Future” (Hall 4), “Digitalisation & Social Media” (Hall 6), “Plumbing” (Hall 7), “Startups & Innovations” (Hall 8), “Human Resources and Occupational Safety” (Hall 9) as well as all current topics relating to wood (Hall 10). Product presentations invite visitors to test and try out products. In addition, discussion rounds, pitches and networking in chillout areas ensure a varied programme in every hall. Numerous other networking events and opportu nities for an international exchange of experiences complete the trade fair’s programme. Explore innovations Many companies exhibit new products in the exhibition halls and get direct feedback from the trade fair visitors. However, it is often smaller, unknown enterprises that present and provide clever solutions for the everyday life of tradespeople. About 20 of them are concentrated in the startup area in Hall 8, where they display their innovations and solutions. This year, again, the startups will have plenty of opportunities to impress the public with their products in short pitches. Whichever of them convinces the expert jury will be presented with the “StartUp Award” on Thursday, 7 March at 11 a.m.
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Limbering up in social media Another novelty on the trade fair programme are the social media consultation sessions with influencer professionals from the industry. How do I present my company on social networks? How do I draw attention to my business? What makes good content and how do I ensure reach? Renowned influencers from the building trade will be present at the fair and available for help and advice. Anyone seeking advice in social media matters may consult Remo Klinger (@zimmerer_auf_insta, 34,300 followers), Hannah Scheurer (@holzbau_tussis, 47,100 followers), Selim Fritz (@DACHPRO, 56,500 followers) or Sina Klein (@dachdeck erin_sina, 40,500 followers). Interested parties can book online a free of charge 20minute slot (on https://www.dach holz.com/en/homepage/ from January 2024). Valuable input and customised solutions will be provided. New networking platform The brand new installed digital platform “DACH+HOLZ CONNECT” offers personalised and interactive functions to inten sify exchange between exhibitors and visitors. Categories and topics can be selected and filtered to quickly retrieve the desired exhibitor content. Users can use the search function to find suit able exhibitors, contributions and programme items, for which they can also register with just one click. In addition, the watch list and interactive hall layouts make it easy to plan a visit to the trade fair, allowing users to create customised tours of the trade fair. The contact function also gives users the opportunity to write to other people, network and then meet up in person on site. To use the “DACH+HOLZ CONNECT” platform, trade fair visitors can register free of charge at https://connect.dachholz.com/en. DACH+HOLZ International – the trade fair for green building: building envelope and timber construction – will take place from 5 to 8 March 2024 at Stuttgart Exhibition Centre. www.dach-holz.com/en/homepage
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ESEF MANUFACTURING INDUSTRY
DISCOVER SUSTAINABLE MANUFACTURING SOLUTIONS ESEF Manufacturing Industry 2024 will have a focus on sustainable and innovative manufacturing solutions when it opens its doors in Utrecht, Netherlands, from March 12 to 15. rom March 12 to 15, Koninklijke Jaarbeurs will open its doors to ESEF Maakindustrie (ESEF Manufacturing Indus try). With the theme 'The manufacturability of tomorrow', more than 175 exhibitors will show how the manufacturing industry deals with topics such as digitalisation, robotisation and sustainability. Ricardo Vivas, ESEF Exhibition Manager, explains, “This edition we offer a packed program, from presentations about the latest technologies and innovations to knowledge sessions about the challenges in the labour market. Tens of thou sands of professionals and other interested parties within the manufacturing industry can prepare for an inspiring fair.” ESEF takes place simultaneously with the TechniShow trade fair.
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Focus on a sustainable future The feasibility of tomorrow is central during ESEF. Ricardo adds, “While the labour market faces major challenges due to automation, digitalisation is transforming the entire manufac turing industry with LoT and AI. In addition, sustainability becomes crucial with a focus on green production and recy cling. All kinds of important themes that we reflect in the vari ous activities of the fair. For example, we are setting up the socalled Future Arena for knowledge sessions on energy consumption, robotisation and chain integration and more. In addition, we are setting up a 'career street' on the exhibition floor where visitors can gain inspiration about the advance ment and development of staff.”
Deep dive into the latest technologies and innovations At the trade fair, experts from Teqnow Koninklijke Metaalunie provide themed tours for visitors. Professionals gain insights into improving business processes through data. In addition, visitors receive an explanation of how to achieve a manage able, reproducible and errorfree production process. ‘Make’ and ‘buy’ under one roof ESEF takes place at the same time as the TechniShow trade fair. The power of this combination is that it brings 'make' and 'buy' under one roof. ESEF Maakindustrie and TechniShow together form the largest platform in the Benelux in the field of industrial production technology, processing and machining of metals, plas tics, accessories and tools. This is the stage where business, research, education and government meet for demonstrations, innovations and networking moments. “Visitors are therefore very welcome to visit both trade fairs in order to achieve a perfect combination of 'make and buy' solutions,” explains Ricardo Vivas. ESEF Manufacturing is the largest and most important event in the Benelux in the field of supply, outsourcing, product development and engineering. Register via event.maakindustrie.nl. With the ticket for ESEF Maakindustrie, visitors also have free access to the TechniShow trade fair. event.maakindustrie.nl/
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TIME-CRITICAL TAXIS One of the world’s most instantly recognisable vehicles, the trusted London black taxi cab, has been on an exciting journey to transition to zero carbon mobility. Here’s how TR Fastenings has helped this icon of London heritage evolve its production for a greener future…
LEVC needed to enhance and secure its automotive component supply chain
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he demand for electric vehicles (EVs) has been rapidly growing across the world, putting pressures on the tradi tional automotive supply chain. This has driven providers to find new ways of working and be more committed than ever to the changing needs of their customers – a trend that was brought into sharp focus when TR was approached by the London EV Company (LEVC) with a timecritical problem. LEVC is part of the Geely Holding Group and is on a challeng ing but ambitious journey with its innovative electric TX taxi. Working in a justintime environment, it needed a reliable automotive components provider that was able to supply a consistent and seamless service. When that was suddenly no longer possible, LEVC had to find a new provider that could
step in and help keep production moving. The company needed to enhance and secure its supply chain, embrace oper ational changes and focus on technical and engineering support coupled with a robust logistics service. Over the course of an intense transition period, TR Fasten ings and LEVC reviewed each part of these requirements, from the rationalisation of the number of parts and the types of fasteners to eliminating bespoke special parts where feasible. TR was selected as LEVC’s new supplier due to its years of expe rience in designing and manufacturing fasteners for automotive applications. The company also supplies other firms within the Geely Holding Group, including Proton in Malaysia, Lotus cars in the UK and the major Tier 1’s supplying into Volvo.
”TR WAS SELECTED AS LEVC’S NEW SUPPLIER DUE TO ITS YEARS OF EXPERIENCE IN DESIGNING AND MANUFACTURING FASTENERS FOR AUTOMOTIVE APPLICATIONS.” 34
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THE SOLUTION TR’s design and engineering teams were involved from the outset, conducting an internal review to understand LEVC’s exact needs and assigning projects teams from the TR and LEVC to work together. It was critical that there was a constant onsite presence at LEVC during this time working across the different disciplines to make sure everything was kept to a tight deadline. “We worked as part of the LEVC engineering team, which involved working onsite,” says Sven Brehler, Director of Engi neering at TR Fastenings. “This helped us to really understand the exacting requirements of the application and to create solutions fit for purpose. We covered all aspects of the vehicle build, from drivetrain, body in white, to the time and interior.” TR was quickly able to establish a stable fullservice provision for LEVC, which was especially important for a new product launch. The company now provides some 350 components used in the vehicles, and to the Tier 1’s that supple the drivetrain, brakes, lighting clusters, car seats, IP console and battery pack. “This was a challenging project where time was a critical factor,” adds Dan Pereira, Engineering Manager UK and Ireland at TR Fastenings. “We needed to act fast to understand the customer’s exact needs and put in place a system that worked. Thankfully, we understand the pressures automotive manu facturers are under and this project was a great example of how TR Fastenings can step up to any situation, working with the client to be that safe pair of hands they need. It showcases our commitment to fulfilling the needs of our customers, no matter the size or complexity of operation.”
TR’s design and engineering teams were involved from the start
TR now provides some 350 components used in the TX taxi
OVERCOMING CHALLENGES LEVC needed support quickly to meet demand, and TR was able to step in, providing additional onsite customer support. The company set about reviewing stock quantities to understand any gaps in the system, it established working relationships, collaborated with the engineers on the ground to understand their needs and ensure a seamless transition. As the supplier, TR shared data sheets with engineers and purchasing, agreeing specifications, and this sped up the process of producing prod uct and gaining PPAP approvals. Additionally, TR was asked to manage other bespoke parts on LEVC’s behalf and these too were added to the bill of materials. The supply of critical stock was resumed, and production suffered no disruption. From a personal point of view, Periera adds: “I was made very welcome on site and given access to production lines and key personnel. Within weeks I felt I was an integral part of the transition plan. The made my role as the UK Engineering Manager so much easier and enabled us to be more effective as timelines were very tight.” A SUCCESSFUL TRANSITION TR’s complete, fullservice approach prevented manufacturing disruption and enabled a lasting relationship with a new customer. This could not have been done without the close collaboration with LEVC and its key managed suppliers. To celebrate a successful transition, TR showcased the electric TX taxi on its stand at Automechanika Birmingham, with much interest shown by attendees across the threeday event. “The TX was a great talking point which opened up conver sations about our capabilities and vast product range,” concludes Brehler. “As the EV market continues to expand, TR is well placed to lead on fastening solutions for this sector.” www.trfastenings.com
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SOUTHERN MANUFACTURING AND ELECTRONICS
HEADING
SOUTH
Southern Manufacturing and Electronics opens its doors once again to the engineering sector
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ndustry personnel involved in design, engineering, production and procurement will once again return to the Farnborough International Exhibition Centre between 68 February 2024. Attendees will be able to see the latest in production hardware, components, consumables and technology from a wide range of industries, including aero space and defence, automotive, electronics assembly and production, industrial machinery, packaging, handling and logistics, energy, marine, medical, mechanical engineering and metal processing.
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”LAST YEAR’S EVENT MARKED THE SHOW’S 25TH ANNIVERSARY.“
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Last year’s event marked the show’s 25th anniversary, welcoming over 9,000 attendees through the doors over the course of three days. 460 exhibitors representing more than 600 companies showcased their products and technologies during the event, delivering numerous product launches and demonstrations to attendees.
COMPREHENSIVE SEMINAR PROGRAMME This year’s event will offer attendees a comprehensive seminar programme that covers a plethora of technical and business topics. The seminar programme will run across the three days in separate theatres, addressing some of the technical, mana gerial and environmental issues facing engineering and manu facturing today. Last year’s seminar programme was split into two tracks, one focusing of electronics and the other on engineering. On the electronics side, sessions covered an array of topics, from the future of aerospace and additive manufacturing to product testing considerations and optimising production. The engi neeringfocused seminars, meanwhile, covered CE and UKCA marking, the challenging IP landscape, digital factories, and how to take a product from concept to commercialisation. This year, more industryleading experts from across the engineering and electronics sectors will once again deliver timely and relevant educational sessions, aiming to inform attendees on the current developments and challenges within their respective fields.
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SOUTHERN MANUFACTURING AND ELECTRONICS
AUTOAERO Southern Manufacturing & Electronics is colocated alongside AutoAero, devoted to aerospace and automotive engineering. The show provides the ideal opportunity for aerospace profes sionals to source suppliers across precision engineering, elec tronics, testing and certification, and working with advanced materials such as composites. Known for its links to the aviation industry, Farnborough was chosen as the show’s location largely due to the fact that 22% of the UK’s £30 billion aerospace industry is located within the show’s catchment area.
”FARNBOROUGH WAS CHOSEN AS THE SHOW’S LOCATION LARGELY DUE TO THE FACT THAT 22% OF THE UK’S £30 BILLION AEROSPACE INDUSTRY IS LOCATED WITHIN THE SHOW’S CATCHMENT AREA.“ OFFERING OPPORTUNITIES Having grown into a fullyfledged national show over the past few years, Southern Manufacturing and Electronics provides an accessible show for the ecosystem of engineering SMEs operating across the UK and Europe. The event aims to provide the opportunity for automotive and aerospace buyers to source suppliers with the necessary skills and experience to assist with their projects across a wide range of engineering disciplines, such as precision engineering, electronics, testing and certification, and advanced materials. Visitor registration is open, and attendees are encouraged to register in advance of the show prior to its kick off on 6 February. www.industrysouth.co.uk
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39 FEATURES LIST 2024 Ad INDEX TD05 2024_LAW.qxp 19/01/2024 13:46 Page 1
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EDITORIAL FEATURES 2024
ADVERTISER INDEX ISSUE 05
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Bumax
15
• In-depth: Offshore technology • Technical Insight: Bolted Technology • Product Innovations: - Aggressive Environments - Adhesives & Tapes • Event preview: Southern Manufacturing
Ejot
02
Forward Fasteners
07
HEICO
41
Metalmate Fasteners
44
Optimas O E Solutions Ltd
11
• Editorial copy: Thursday 11th Jan • Ad copy: Thursday 18th Jan • Published: Thursday 25th Jan
ISSUE 06 MAY
Rapid Industrial Fasteners Ltd
01, 17
Spirol UK
43
The Insert Company (UK) Ltd
05
• In-depth: EVs & electrification • Technical Insight: Automotive fasteners & tools • Product Innovations: - Plastic fixings & fasteners - Coatings & platings • Event preview: Subcon / Automechanika • Editorial copy: Thursday 1st May • Ad copy: Thursday 8th May • Published: Thursday 16th May
ISSUE 07 OCTOBER • In-depth: Lightweighting • Technical Insight: Smart tools • Product Innovations: - Rivets & riveting technology - Electronic components • Event preview: Advanced Engineering / EUROBLECH • Editorial copy: Thursday 26th September • Ad copy: Thursday 3rd October • Published: Thursday 10th October
ISSUE 05 JANUARY 2024
////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////// SUBMIT AN ARTICLE OR IDEA FOR A FUTURE ISSUE OF TORQUE-DIRECT – CONTACT THE EDITORIAL TEAM: Hayley Everett > Hayley@torque-direct.com Rachel King > Rachel@torque-direct.com Jonathon Harker > Jonathon@torque-direct.com
TO ADVERTISE IN A FUTURE ISSUE OF TORQUE-DIRECT MAGAZINE – CONTACT THE SALES TEAM: Claire Warman > Claire@torque-direct.com Harry Whyte > Harry.Whyte@torque-direct.com
Designed for OEMs, Tier 1 and Tier 2 buyers, Torque Direct is produced by a team within Stag Publications with decades of experience in the fastener, fixings and related industries, including our sister publication Torque Magazine which targets distribution.
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////////// TECHNICAL INSIGHTS ////////////////////////////////////////////////////////////////////////////////////////////////////////// TFC
COMPACT COMPONENTS TFC’s Simon Ward the capabilities of wave springs in medical applications and the importance of designing with size in mind edical device engineers strive for compact designs for a variety of reasons, such as portability, enhanced patient comfort and increased efficiency. In many cases, a compact design requires compact components, and wave springs could provide an answer for designers looking to optimise the size of their devices. Springs are commonly used in a variety of medical products, such as surgical instruments, medical devices, wearable medi cal technology and orthopaedic equipment. They are commonly used as return springs for function buttons, where they can provide the necessary force to restore a button to its original position. Springs are also used to maintain electrical contact or compensate for assembly tolerances. While coil springs have conventionally served these purposes, there has been a shift in preferences and wave springs are gaining traction as an alternative. One key reason for this is their spacesaving advantage, as wave springs
M
require less than half the space of a coil spring – delivering the same spring force with a smaller operating height. The compact design of a wave spring is particularly valuable in situations with tight space constraints. They are a great choice for handheld instruments, tools, and wearable devices, in situ ations where designers are seeking to create lightweight, compact and wellbalanced products. For example, wave springs have been used in the design of insulin pens, and in surgical and dental tools that use high speed precision bearings. CHOOSING A WAVE SPRING When selecting a wave spring for medical applications, there are a few factors to consider. One option is the CresttoCrest wave spring, which is suitable for applications requiring lower spring rates. For applications involving short deflections and low to medium forces, a singleturn wave spring can provide precise and reliable performance. Linear springs may be a suit
”SPRINGS ARE COMMONLY USED IN A VARIETY OF MEDICAL PRODUCTS, SUCH AS SURGICAL INSTRUMENTS, MEDICAL DEVICES, WEARABLE MEDICAL TECHNOLOGY AND ORTHOPAEDIC EQUIPMENT.” TFC offers a wide range of wave springs
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Simon Ward is the Technical Manager at TFC
able choice if a straight load bearing system is required. However, it's important to note that engineers cannot simply interchange coil springs with wave springs without consider ing their distinct characteristics. When a load is applied, wave springs flatten to provide upward force, whereas coil springs twist during compression, causing the force to deviate from the axis. Consulting with a wave spring expert can provide valuable guidance when integrating the appropriate spring into your medical device. CUSTOM OPTIONS Wave springs are manufactured in several different forms, and with a range of spring characteristics. If offtheshelf options do not fit the size and environmental resistance requirements needed, spring specialists can design custom wave springs. This involves tailoring the number of turns or waves, material and size to meet the specific product needs. There are a range of materials available that are ISO 13485:2016 certified, suit able for different environmental conditions. Popular materials for wave springs in medical applications include 302 and 316 stainless steel, which can withstand the higher temperatures applied during cleaning and sterilisation processes, without any compromise to spring properties. It can be challenging to know where to start with wave spring specification, especially for design engineers used to working with coil springs. Working with a wave spring special ist can help achieve the best outcome, enabling medical device designers to benefit from valuable advice on which wave spring is best suited.
”CONSULTING WITH A WAVE SPRING EXPERT CAN PROVIDE VALUABLE GUIDANCE WHEN INTEGRATING THE APPROPRIATE SPRING INTO YOUR MEDICAL DEVICE.”
HEICO-LOCK®
Combi-Washers
Flexible. Fast. Innovative.
Discover our entire portfolio of Fastening Systems here!
www.tfc.eu.com
WWW.HEICO-GROUP.COM
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MACH 2024
MACH IS BACK MACH 2024 returns in April promising to inspire, innovate and connect engineering-based manufacturing
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itching itself as ‘one of the most important shows of its kind ever staged in the UK’, MACH 2024 will return to the NEC in Birmingham between 1519th April. Promising to deliver an array of new technologies, engineering services and machinery demonstrated under power, this edition of MACH will be colocated with The Engineering Supply Chain Show. Attendees to this year’s edition will discover how their busi ness can sustainably adopt new technology and techniques to improve productivity, efficiency and reduce waste. The MACH knowledge hubs will cover a wide range of processes and tech nologies, from automation to additive manufacturing, artificial intelligence (AI) and data to sustainable manufacturing. As always, visitors will be able to observe displays of live, working machines and manufacturing processes that are meeting the engineering challenges of today, as well as meet new suppliers and likeminded professionals looking to share ideas to solve business issues and improve competitiveness. IN THE ZONE Across the halls of MACH 2024, focused zones and pavilions will help visitors navigate the event and find the technologies and services they are interested in. The show floor will be sectioned off into 3D printing and additive manufacturing, automation for manufacturing, digital solutions for manufac turing, grinding and abrasives, lasers for manufacturing, logis tics for manufacturing, measurement and inspection, surface finishing, and welding. KNOWLEDGE HUB INITIATIVE Reversing the UK manufacturing sector’s poor record for adopting new technology will be tackled head on at MACH 2024. The show organiser, the Manufacturing Technologies Association (MTA) is using its flagship event to launch its new knowledge hub initiative. The programme will showcase the latest technology to exhibitors, helping manufacturers to learn more about the potential offered by such technology, as well as when to adopt it and how to implement it to best effect.
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The knowledge hubs will have dedicated stands within the various exhibition zones, and will each focus on a particular type of technology: Automation and Robotics, Data and AI, Energy Efficiency, Additive Manufacturing, and Tooling. Each of these hubs will be managed by one of the specialist centres from the High Value Manufacturing Catapult, such as the Manufacturing Technology Centre (MTC) and the Advanced Manufacturing Research Centre (AMRC). The Catapult network is recognised for the cuttingedge research and devel opment work being conducted at its various centres, collabo rating with businesses in a wide range of sectors including manufacturing, space, health, energy, transport and others.
”VISITORS WILL BE ABLE TO OBSERVE DISPLAYS OF LIVE, WORKING MACHINES AND MANUFACTURING PROCESSES.“ “The MTA is part of a united front of UK manufacturing organ isations, along with the MTC and MACH 2024 headline sponsor Lloyds Bank, to increase the uptake of technologies such as automation and robotics,” says James Selka, CEO of the MTA. “Only by embracing what the hubs are trying to achieve will the UK restore its position as a sovereign manufacturer, reestab lishing itself as a major player on the global stage. To have the High Value Manufacturing Catapult Centre running our Knowl edge Hubs is an indication of the importance these organisa tions place on our initiative, and with MACH 2024 providing the showcase and the opportunity to see the latest technology live and in action, we couldn’t ask for anything better.” www.machexhibition.com
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