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FEATURE


SPRINGS, SHOCK ABSORBERS & WIRE FORMS


(rpm) or more. When high rpm is crucial to a product’s function, this can pose design challenges. Traditional retaining rings fitted on rotating shafts are limited by centrifugal forces and can yield during installation due to the component’s heavy cross-section. Higher rpm risks the centrifugal forces becoming great enough to expand and lift the retaining ring from the groove, causing assembly failure at high speed. Solutions to try and reduce this risk include adding wire ties through the holes of the circlip, or using an additional component to captivate the outside diameter and thus prevent ring expansion. However, these


approaches often increase assembly time, weight and add significant additional costs. An effective solution EV manufacturers can


opt for are Smalley Revolox Self-Locking Retaining Rings. These offer a ‘dimple and slot’ design that means that, after installation, the dimple is trapped in the slot and the ring locks into place. As the ring rotates it expands, engaging the dimple and slot mechanism and preventing any further expansion. Compared with non-locking alternatives, this offers a much higher rpm capacity.


MAKING THE RIGHT CHOICE When selecting the right wave spring or retaining ring for EVs, working with a trusted partner can help to optimise the product’s design. TFC’s engineers can, for example, develop bespoke wave springs that meet the required load characteristics and can operate in even the harshest environments.


TFC Revolox self-locking retaining ring


T: 01435 860349 www.tfc.eu.com


ANTI-VIBRATION LATCHES


Where the hardware priority for a cabinet installation is to do with the effect of the seal on the door – for instance, to ensure the gasket pulls down to a tight seal in order to maintain the correct IP rating (up to IP69K) – then anti- vibration compression latches are an easy choice, according to EMKA. This type of latch also offers a close-and-


pull design which protects the gasket from the swiping action of the cam, which can otherwise damage the gasket as it latches. These are available in many different designs, from quarter turns including L and T handles to recessed flap or chest handles, and in stainless steel, zinc die and chrome, zinc die and black powder coat, aluminium hard anodised and stainless steel, and polyamide. Compression latches can also prevent


nuisance opening thanks to their screw or lever type mechanism which is inherently resistant to vibration, a benefit for specialist road and rail vehicles as well as off-road mobile vehicles and for power generating equipment.


EMKA (UK) T: 024 7661 6505 www.emka.com


DEVELOPING AN OVER-MOULDED CARRIER PLATE AND WIRE FRAME FOR VEHICLE SEAT BACKRESTS


William Hughes has been helping a prominent European car manufacturer develop an over- moulded carrier plate and wire frame for use as the backrest on the driver and passenger seats in


its range of saloon cars and SUVs. Ten years ago this began as a reasonably


simple wire assembly project involving only wires with a plastic backplate pressed into them. But,


with William Hughes’s expert guidance, this has evolved into a much more sophisticated over- moulded assembly with a pressed bracket. This achieves a number of benefits including cost savings and reduced assembly time. Production has now moved to Bulgaria where William Hughes has created an additional fully automated robotic cell dedicated to this assembly at its factory in Plovdiv. In operation, the robot takes the wire after bending and presents it to the press which then assembles the bracket. The lumbar structure, which is


made from 5mm galvanised spring steel over-moulded in polypropylene, supports various holes for wires and a fan vent along with clips to position wires and tubes which hold a plastic air bag in place while facilitating controls for a massage function. In the beginning, the production run amounted to 70,000 parts but such has been the efficacy of the overall operation that William Hughes is now producing 700,000 units per annum.


William Hughes T: 01963 363377 www.wmhughes.co.uk


46 DESIGN SOLUTIONS APRIL 2023 45


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