System Solutions for Conductivity and Mechanical Functionality of Grounding Connections

Traditional Methods vs. New Approaches

Traditional methods often failed to meet the high reliability demands of the railway industry, frequently resulting in installation failures and poorly optimized connections. Based on the requirements of several OEM manufacturers in the railway industry, Howmet Fastening Systems (HFS), based in Kelkheim, Germany, conducted extensive research and developed a system that addresses the shortcomings of traditional systems available on the market.

Objectives of the New System

The objective of the new system is to mitigate risks for OEM manufacturers in the railway and other industrial sectors where concerns related to electrical short circuits arise. The system should provide the following:

1. The required level of conductivity corresponding to the risk of short circuit.
2. The mechanical properties necessary to ensure long-term functionality.

The system must ensure proper installation of all these combinations, as well as quality feedback and the ability for comprehensive documentation.

How the System Works

The resulting system consists of intelligent automated installation equipment, barcode scanning and documentation functions, specially designed grounding pins and nuts, and a repair system for faulty installations. The Cam-Safe system reduces the risk of grounding failures in the following ways:

1. Improving installation quality
2. Supporting quality control
3. Documenting installation success (traceability)
4. Increasing installation speed and improving ergonomics 

Improving Installation Quality

The Cam-Safe system brings significant improvements in the quality of grounding connection installations. Its intelligent automated installation equipment minimizes the possibility of faulty installation and ensures consistent results.

Intelligent Automated Equipment

One of the key features of the Cam-Safe system is its intelligent automated equipment. This equipment is designed to ensure the correct installation of all connection combinations. This means that regardless of the specific connection requirements, the Cam-Safe system is capable of ensuring its proper and efficient installation.

Minimizing Errors

Thanks to its intelligent design and automated installation equipment, the Cam-Safe system is able to minimize the possibility of faulty installation. This process is less dependent on human factors, reducing the risk of misalignment and increasing the overall quality of the installation.

Consistent Results

The Cam-Safe system not only minimizes the possibility of errors but also ensures consistent results. This means that manufacturers can expect the same high quality of installation every time the system is used. This is particularly important in industries where quality is key, such as the railway industry.

Installation Tool

The Cam-Safe installation tool is equipped with a high-resolution force sensor that measures force and stroke during each installation. The software compares the measured values with predefined target values and provides immediate feedback to the operator on whether the values are met.

The combination of stroke and force provides a specific set of parameters based on hundreds of real installation cases, taking into account various installation configurations and environments.

All values can be customized to tailor the process to specific needs and requirements.

Examples of display configurations available in various languages.

Supporting Quality Control

The Cam-Safe system also offers support for quality control. With barcode scanning and documentation functions, it is possible to track and record the installation process. This system enables quick and efficient quality checks, which is crucial for manufacturers who must meet strict quality standards.

Documenting Installation Success (Traceability)

The Cam-Safe system also offers the possibility to document installation success. Each installation is recorded, and the data is stored for future reference. This allows manufacturers to track and analyze the performance of their connections and adjust their processes to achieve optimal results.

inst. -#	time stamp	ID1	Fact: [kN]	Sact. [mm]	program-#	result	event	NOK event
xxx	21.09.21	M8AL-F	xxx	xxx	5	IO	xxx	xxx

Force control graph (left) and stroke control graph (right).

Supporting Quality Control

To support a reliable installation process enabled by the Cam-Safe system, a fully functional barcode system is also available, which can be assigned to various types of sheet materials and grounding pin configurations. After scanning the barcode on the packaging of the fastening component, the corresponding installation parameters (stroke, force, and time) are loaded into the tool ready for installation.

Each installation can also be customized for the user (if unions are accepted) or for the respective work order or production batch.

If a faulty installation occurs, the system offers an optional tool lock feature, which activates until a supervisor scans a second barcode after the root cause of the problem is identified. This means that every failure indication must be understood and corrected before continuing the operational process.

Increasing Installation Speed and Improving Ergonomics

In addition to improving the quality and reliability of connections, the Cam-Safe system also increases installation speed and improves the ergonomics of the process. Its intelligent tools and automated equipment allow for quick and easy installation, enhancing efficiency and reducing physical strain on workers.

Conclusion

The Cam-Safe system represents a revolution in the installation of grounding connections. Its innovative approach to installation and quality control ensures that manufacturers can achieve optimal results while minimizing the risk of failures. The Cam-Safe system is therefore an ideal solution for all manufacturers seeking reliable, efficient, and easily traceable solutions for the installation of grounding connections.