Industries

Task

How can we switch to a new system approach in less than 6 months without jeopardizing series supply?

Challenge

• Optimization of the geometry of the component
• Integration of further requirements from the area of add-on parts with a very short start-up time
• Customer requirement: Reduce assembly effort and improve flexibility

Our Solution

Through disruptive ideas and rapid exchange of experts in a team working in partnership, a new component is developed in which all previous add-on parts can still be used. Transport weights and volumes are reduced and assembly times are shortened. The series delivery capability can thus be realized five months after the first technical discussion.

Task

How can two components be combined to form a complex geometry and thus extend the technical lead of the façade profile?

Challenge

• Process stainless steel and galvanized steel with one roll forming tool
• Combine several individual profiles into one profile cross section
• Many asymmetrically distributed holes
• Partial application of an adhesive strip within the roll forming process

Our Solution

We developed a process for a roll-formed profile in which both steel and stainless steel can be formed with a roll-forming tool, in combination with partial application of an adhesive strip. The result is a ready-to-install facade profile in numerous variants. This facade solution is more stable, can be used in galvanized steel without a plastic edge, and is considerably more sustainable as a stainless steel profile. In addition, the compact profile solution reduces the variety of parts to the relevant function and simplifies storage and handling in the supply chain.

Task

Wie lassen sich Schaltschränke mit rollgeformten Profilen vor Ort schneller und flexibler montieren?

Challenge

• 4 Befestigungsvarianten in einem Profilquerschnitt
• 3 verschiedene Lochraster
• Hohe Umformgenauigkeit in der Lochsummentoleranz
• Platzersparnis durch einen kompakten Profilquerschnitt
• Flexiblere nachträgliche Gerätemontage

Our Solution

Die Entwicklung und Realisierung eines Rollformprozesses auf Basis von geclusterten Lochrastern in Verbindung mit einem Gleitmutterkanal. Anders als beim vorhergehenden Strangpressprofil ist in der Montage kein Ausmessen von Löchern und kein Bohren mehr nötig. Dadurch wird der flexible und schnelle Aufbau von Schaltschränken erleichtert und beschleunigt.

Task

How can a spring profile be connected to a plastic injection molded part in series production as economically as possible?

Challenge

• Development of a machine-falling part (without manual reworking) from two components for series production.
• Consulting and realization from prototype to technical specification to process optimization of the complete supply chain.
• Claim of the customer: Halve costs, multiply robustness.

Our Solution

By modifying and simplifying the add-on parts to the greatest possible extent, a complex injection-molded part can be replaced by a simple plastic strip. The result is a proven system component that is used in many electrified vehicle series as a standard component by German automakers.