FEATURE MECHANICAL COMPONENTS


Getting a grip on fasteners and their coatings within the transport sector


A focus on the automotive and EV market, by Sven Brehler,


engineering project manager at TR Fastenings


provide super high strength internal drive. One of the heaviest components in an EV is the


electric battery, which runs the risk of negating the idea of carbon emission reductions if the vehicle’s weight increases energy consumption. As a result, fastener companies such as TR and their supply chains are constantly looking to innovate and are inspired by other transport industries such as aerospace. Batteries, motors, transmissions and all their


associated electronics are the leading technology areas of EV R&D, and the fastenings and their coatings play an essential role. Innovative engineering techniques are now being applied throughout design and manufacturing.


A


s a full service provider with a worldwide reach from the USA to Asia, and Europe


to the UK, TR Fastenings works closely with automotive Tier 1 companies to respond to their needs and global developments. Supplying a wide variety of fasteners annually into the automotive sector, TR is playing a central role in shaping the future of the fastener industry. The global electric-vehicle (EV) industry is


expanding rapidly with a 60% year on year increase and sales growing to 2.1 million units in 2018. As a result, advanced technology is now a top priority for competing OEM’s and the role of fasteners is significant. Transport technology companies around the


world are under pressure to innovate as a result of rising cost pressures, and trends such as lightweighting, autonomous driving and electro mobility growing apace. Suppliers such as TR Fastenings are increasingly


required to come up with technical innovations for fasteners that work harder and ‘smarter’, that can be produced quickly and cost-effectively. The key fastening applications within


automotive include sub tier manufacturers; seating; power trains; thermal management; HVAC; high-end performance cars and the EV market – the latter being the fastest growing sector for TR Fastenings, to which they supply automotive grade fasteners to OEM specification. It’s an evolving application that is leading the fastener industry to greater sophistication.


LIGHTWEIGHTING TECHNOLOGY Achieving fastener weight reduction whilst maintaining high torque demands have become important in automotive applications. Industrial drive systems such as the Mortorq screw require up to 25% less material in the head yet still


12 JULY/AUGUST 2020 | DESIGN SOLUTIONS


WHY ARE FASTENING INNOVATIONS CRUCIAL FOR EV BATTERY MANUFACTURERS? There are a number of components which are particularly relevant for EVB assembly – fasteners with electrically isolating coatings; lightweight, non-magnetic fasteners; battery retention bolts; cable management hardware and compression limiters. All these require fasteners to provide robust and secure settings for the costly battery. Fasteners are essential, not only in the electric vehicles themselves but also in supporting technology and applications including charging units, EV battery casings, and general infrastructure equipment. An EV’s battery module can be secured with


inserts for plastics that are used to maintain either good connectivity or avoid unwanted short-circuits due to corrosion or product failure. Fasteners for the EV batteries are designed to incorporate coatings to suit the functionality of the joint – such as silver plating to improve connectivity or a high temperature resistant organic top coat to provide an electrical barrier. Component suppliers are beginning to work


closely with battery module manufacturers to develop and apply functional coatings to fasteners, including protection from corrosion. These help to either maintain good electrical connectivity or retain isolation where needed to avoid unwanted electrical resistance or potential short circuits. Highly conductive coatings can be applied


to certain materials such as plastic fasteners or fasteners prone to corrosion so they can act as electrical conductors. An increase in electrical resistance causes generation of heat together with loss of energy. EV batteries can generate high levels of heat,


so it’s essential that it is distributed over the assembly to provide general cooling and avoid localized overheating. Busbars can support the distribution of heat from local hotspots to heat sinks, but only when correctly tightened to optimise heat transfer between the various


elements. Using fasteners in thermally and electrically conductive coatings will aid an effective service life. Barrier coatings avoid electricity from going


where it shouldn’t and causing interference or a risk to safety through electrocution or fire. Specific coatings used include PTFE because it


is highly heat resistant with the ability to retain its properties across a temperature range, from -200˚C to +260˚C. It also has low predictable friction, which can help to create secure joints through torque control.


ONE SOLUTION DOES NOT FIT ALL Depending on the material and the function of a particular component and the task it performs, different solutions are necessary. TR Fastenings supplies from its own


IATF 16949 as well as from a select range of external suppliers. The International Standard for Automotive Quality Management Systems is applicable to organisations that manufacture components, assemblies and parts for the supply into the automotive industry. Only manufacturers passing strict audits and


reviews by TR’s fully VDA 6.3 certified auditors, and able to deliver to the highest OEM quality standards are used to provide the necessary high quality products into the battery market. This helps to ensure a stable and sustainable supply chain in addition to the engineering and logistics TR can deliver. Manufacturers and sub-contractors must work


together from the start to ensure the correct Design for Manufacturing (DfM) considerations. As an emerging transport sector, the fasteners


needed in EV charging units and their associated structures, requires manufacturers and their supply chain to have technical knowledge and experience. There are increasing pressures and opportunities involved working within intricate global supply chain networks, and manufacturers servicing the automotive, electronics and technology sectors will be best placed to work with emerging EV related businesses.


LOOKING TO THE FUTURE The EV sector is a fascinating one to watch as it develops and gains momentum. As the requirement for robust EV charging points grows, the automotive industry continues to innovate with fasteners playing a major role in the electric vehicle revolution. It is a rapidly accelerating market with huge


potential for manufacturers and suppliers. It is therefore essential the supply chain has the infrastructure, technology and solutions in place to meet future demand for electric car use.


TR Fastenings www.trfastenings.com


/ DESIGNSOLUTIONS


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