First place awards for two SiEVA’s innovations
1. Definition of the fold shape on the tubes made of HSS with increased static and dynamic load capacity of the car seat linking shaft
SiEVA Development Centre, Business Unit Novo mesto, has developed within the framework of R&D project MEVES on behalf of and in cooperation with company TPV from Novo mesto, an innovative definition of key features of the fold shape on linking shafts carrying and supporting the seating part of the car seat. They researched legality and requirements related to fold shaping on the thin wall tubes made of high-strength steel. The purpose of these research actions was both to reduce the weight of the seat and increase the static bending and continuous dynamic load capacity of the linking shaft.
The linking shaft function is to provide comfort and safety. Shaft is the key element of the seating height adjuster enabling vertical adjustment of the car seat and so providing better comfort for the driver and passenger. In addition, it absorbs the collision energy in case of a lateral crash decreasing pelvic and leg injuries of the driver or front-seat passenger. In a regular use the fold on the linking shaft is subject to dynamic bending loading while in case of collision it has to bear enormous quasi-static loading, owing to which it can be deformed only to the extent that its functions are still maintained.
Within the framework of these research actions we found out that it is not possible to reduce weight only by using thin wall tubes made of high-stength steel. Moreover, it is necessary to develop a new shape of fold and new technological processes for serial production. Therefore, the innovation is a result of systematic research actions performed on the areas of design, manufacture, and measurement of carrying capacity of the folds on thin wall tubes made of high-strength steeel. The research also included study of different impacts made by material parameters, different fold shapes, different technologies and control procedures used in serial mass production of linking shafts.
TPV has used the aquired knowledge to design new shapes of the folds within the IBK fi18 and fi35 project which has made possible to meet the customer’s key requirements relating to function and weight of the product.
2. Integrated resistance welding in the forming tool
In cooperation with technologists and experts in the field of mechanical engineering from TPV Novo mesto, SiEVA Development Centre, Business Unit Novo mesto has developed an apparatus for electric resistance welding of small metallic items onto a surface of a continuous metallic banc.
The initial technological process comprised two production stages: the first one consisting of cutting and forming the plate in the forming tool and the second one of nut welding on the plate in the welding tool. The innovative approach resulted in developing a tool allowing integrated welding already at the stage of plate forming in the forming tool.
This innovation appears to be one of the minor and simple ones, however these very ones usually turn out to be the most successful. The reasons why this innovation is relatively inexpensive yet advanced and profound are the following:
- in the new tool, the manufacturing time of the product is 70 % shorter than in the usual process;
- operating costs and maintenance costs for tools and machines have decreased;
- internal logistics costs and intermediate stocks have been reduced;
- as this technology represents a new design, a patent application for protection of innovative technological process has been filed;
- products made out of this innovative tool are successfully sold to a European OEM through the partner company TPV.
