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T H E E X PER T SWhat is the differencebetween a straight pivot pinand the Expander System?Jonny WibergE NGINE E R, NORD-LOCK GROUPEmail your questions about bolting technologies to experts@nord-lock.comExpander SystemPivot pins are located on cylinderrod ends and between movingmechanical parts. They provideapplications with the flexibilitythey need to operate efficiently.Damage-prone straight pinsA straight pin cannot fit into the lugs of amachine unless the lug holes are slightly bigger than the pin itself. This means that there isalways a gap between a straight pin and the lugs.Although this gap is necessary to mount thepin in the lugs, it is also problematic as it affectsthe precision of the machine. Moreover, it allowsthe axle to hit the lugs with full speed and forcewhen the direction of the machine changes. It iscommon to forget that flag washers, locking ringsand other fasteners do not actually fix the pin inthe lugs – they only prevent it from rotating andfalling out.When a machine is exposed to heavy loads andvibration, the pin slowly wears down the lug holes.This leads to the loss of precision and control ofthe machine and makes it necessary for the lugsto undergo repairs. These usually take place every3,000 to 5,000 hours, depending on the load intensity on the machine.The play between the lugs and the pin is not theonly reason why straight pins make lugs moreprone to damage. When a pin is loaded, all thepressure is forced onto a small area, deforming itpermanently. Lugs are also typically made fromsofter material than the pin, and easily lose theirshape after repeatedly coming into contact witha hard pin.Traditional straight pinwith locking ringTraditional straight pinwith flag washerA simple method to prevent lug wearAn Expander System consists of a pivot pintapered at both ends, two expansion sleeves, twotension washers and two fasteners. The pin isinstalled directly into the existing mounting. Upon tightening the fasteners, the washerpresses the slotted expansion sleeve up thetapered ends of the pin. The sleeves then expand,conform to the pattern in the lugs and lock thesystem in place. Once retorqued, the system locksfrom both sides.The pressure from an Expander System pivotpin is well distributed over the whole contactarea in the direction of the force, so the lugsdo not become damaged from the pressure.This system permanently prevents lug wearand eliminates the need for repairs.E XPANDER SYSTEMDistribution of externalforce on lugDays of downtime vs short repairsTraditional straight pins and Expander Systemalso have different repair procedures. Weldingand line boring are used to repair worn lugs whenusing straight pins. This not only takes time butalso necessitates an experienced mechanic withspecialized equipment. Since complex repairs likethese are difficult to make in the field, the machineis usually moved to a workshop causing costly andtime consuming downtime.TR ADITIONALSTR AIGHT PINDistribution of externalforce on lugSince the Expander System can be mounteddirectly into the worn lugs, there is no need forwelding and line boring. In many applications itcan actually be installed on site and operationscan resume after a few of hours.BOLTED 1 - 20197

Since the launch of the SuperboltMulti-Jackbolt Tensioner (MJT) in 1984,efforts have been made to constantlyimprove efficiency. One suggestioncame up regularly - to tighten multiplejackbolts simultaneously.The consensus was that this idea was technically and costeffectively extremely difficult to develop, until an inventorfrom Australia inadvertently built the technology thatwould change the course of jackbolt tightening forever.Little did they know that this was exactly whatNord-Lock Group had been waiting for – a compactdrive mechanism that could generate enough torquerequired to tighten multiple jackbolts simultaneously.At this time, a very conceptual model was unveiledto show how the drive, powered by what they werecalling ‘scroll drive technology,’ could be utilized. Soon,McPhee and Armstrong were officially developing thenew Superbolt Tool for Nord-Lock Group.Overcoming technical challengesAlthough McPhee and Armstrong were on the right track,there were still challenges on the horizon. Indeed, howdo you develop something that is potentially impossibleto create? “It’s sort of been a holy grail to see if someonecould figure out how to tighten multiple jackboltssimultaneously,” explains Steve Greenwell, Director ofTensioning Division at Nord-Lock Group. “Not only is ittechnically challenging, the forces and torque requirementsinvolved are also very high.”One of the biggest challenges they encountered whendeveloping the Superbolt Tool was optimizing the ‘scrolldrive technology’ — now known as UniForce — which neededefficient torque delivery to drive the Superbolt jackbolts.The technology was derived from a worm drive, whichincorporates standard balls and a scroll. Rather than havingone point of contact, the inventors decided to distribute it overseveral teeth in order to increase efficiency.“It took me many hours to calculate the helicalpath of the scroll because it’s forever changing itsdiameter as it constantly engages the balls in theball gear when it rotates around,” says McPhee.SuperboltMulti-Jackbolt Tensioner (MJT)Tightens joints with high accuracy withoutrequiring specialized skills or heavy tooling.Ln2HBOLTED 1 - 2019SComponents1 Nut body8SWDSThe idea was exactly what the industrial sector neededand it was not long before outside interest started to grow.In January 2015, as the pair were finalizing the drivetechnology for a potential investor, they got a call from anold contact who worked for Nord-Lock Group and invitedhim to take a look.DxP“I used to have my own company, which supported crazymad inventions,” explains McPhee. “We helped peoplewith wonderful ideas bring them to the market. I’ve alsoinvented many things, I get real pleasure out of creatingthings and seeing them come to life.”THE HOLY GRAILOF JACKBOLTTENSIONINGD1In 2014, Andy McPhee visited his friend and fellowinventor, Peter Armstrong. He found Armstrong hunchedover the kitchen table working on a design for a continualmotion tool that could replace a traditional hydraulictorque wrench. McPhee looked over his friend’s shoulderand, always full of ideas, made a few suggestions. SinceArmstrong did not have the CAD capabilities to implementthem, McPhee offered to help.2 Jackbolts3 Hardened washer

ScrollHOW DOES THESUPERBOLT TOOL WORK?The key principle behind the Superbolt Tool is poweredby UniForce Technology – invented by Nord-LockGroup. The patented technology consists of a uniquescroll and ball drive mechanism for uniform andhigh transfer of torque. In operation, effective torqueamplification is achieved in a very compact design –with input torque kept to a minimum. Tailored cassettes,which attach to the main drive unit, are used to transferthe necessary torque equally to each of the Superbolttensioner jackbolts.Ball gearMcPhee and Armstrong also had to decide on the best way toalign all the jackbolts and get them to the same starting position. Indeed, the jackbolts on Superbolt MJTs do not have a consistent starting point, which makes tightening them simultaneously complicated. If the jackbolts are not in the same startingposition, once one has been tightened, they all stop moving.This was solved with the use of a highly ingenious ratchetingdrive cassette, which only needs a simple battery drill for operation. Now the main tightening can be performed using theSuperbolt Tool with a power cassette attachment. “There’s stillchallenges out there,” explains McPhee. “But it’s all about servicing the customer and doing the best possible job for them.”Putting customers firstIndeed, customers have been at the heart of the development process, something that is part of McPhee’s philosophy. “I studied industrial design and whilst there was heavyemphasis on engineering, it was also critical to think about thehuman side of things as well,” he explains. “That’s very important in terms of how I look at functionality.” McPhee wanted theSuperbolt Tool to be quick, simple and easy to handle — and hesucceeded.NameAndy McPheeTitleResearch & Development Engineer at Nord-Lock GroupAge49EducationPostgraduate degree in Applied Science– Industrial Design from Queensland Universityof Technology“The Superbolt Tool is unique,” says Steve Greenwell.“Customers with many MJTs or those that haveto undertake frequent maintenance will achieveimpressive gains in efficiency and timing”.Professional backgroundAutomotive design, hovercraft manufacturing,irrigation, software designAlthough the Superbolt Tool has just been released, McPhee’smind is already racing with potential developments. “The sky’sthe limit with the Superbolt Tool,” he says. “There’s a lot ofscope out there for future development and I’m really excited.One of these days it could end up on a space station – whoknows where we go with this.”InventionsInflatable tent, carbon fiber bicycle, mobilesolar powered lights, bicycle rear-view mirrorText Ariane OsmanPassionSolving problems that enhance people’s livesPhotos Jörgen LindströmBOLTED 1 - 20199

get smartConnected machines, components,and systems are creating intelligentnetworks that can control eachother autonomously. Industry 4.0is happening now but how will itaffect the manufacturing industrywhen data is the new oil?10BOLTED 1 - 2019

This revolution, known as Industry 4.0, was conceivedthrough a high-tech project launched by the Germangovernment, which promotes the computerization ofmanufacturing. Like all innovative concepts, Industry 4.0 is full of buzzwords such as cyber-physical systems, the Internet of things (IOT), cloud computing, andsmart factories.In a smart plant, machines can predict failures and trigger maintenance processes autonomously with self-organized logistics, which react to unexpected changesin production. Who can deny the allure of automationtechnology that is improved by methods of self-optimization, self-configuration, self-diagnosis, cognition andintelligent support of workers in their increasingly complex work?Whether the manufacturing sector is prepared or not,this revolution is gathering force. Businesses will haveto carefully monitor the coming changes and developstrategies to take advantage of the new opportunities,while also facing its challenges.BOLTED 1 - 201911

LINKING GLOBAL PRODUCTIONManagement consulting firm McKinseyreports that it is highly likely the worldof production will become increasinglynetworked until everything is interlinked.This is the driving force behind theInternet of Things and also means thecomplexity of production and suppliernetworks will grow enormously.So far, networks and processes havebeen limited to one factory. But the newindustrial step will lift the boundaries ofindividual factories, and even individualcountries, in order to connect multiple factories all over the globe.In addition to condition monitoring andfault diagnosis, components and systemsin these factories are able to gain selfawareness and self-predictivity, which willprovide management with more insightinto the status of the factory.REAL-TIME TRACKINGH&D Wireless is a company that haspositioned itself on the fast-growingmarket for industrial IoT solutions andwireless real-time tracking (RTLS). Thecompany’s solutions support multiplewireless technologies, which are combinedwith security protocols, data analysisand artificial intelligence (AI).World-renowned truck manufacturerScania has chosen H&D Wireless as asupplier for the indoor positioning system GEPS for Industry (Griffin EnterprisePositioning Services).According to Pär Bergsten, CEO of H&DWireless, by using GEPS, Scania canconstantly monitor and manage its fleetof robot tugs and material handlingcarts across their factories in real time.Scania can use this data to optimize theutilization of expensive assets and improveefficiency, while ensuring the safety andsecurity of its employees.“The system digitizes and visualizesphysical processes and identifies — amongother handling of material — productionbottlenecks, uneven production flow, andunexpected machine interruptions,” saysBergsten. “Less time is wasted in thefactory and throughput increases. It iseasy to quickly locate the necessary toolsfor proper assembly using the GEPSequipment dashboard.”12BOLTED 1 - 2019MONITORING BOLTSTracked items are visualized on easy-touse software on PCs, tablets and smartphones. Besides position, Scania canmonitor the condition of the tracked assetin order to know if it has been damaged orexposed to temperature extremes.SECURITY CHALLENGESHowever, this new revolution does not onlysignal bright opportunities on the horizon. According to a survey by McKinsey,executives estimate that 40 to 50 percent oftoday’s machines will need upgrading orreplacing to meet the new demands.Security is also an issue as online integration will allow room for data leaks andsecurity breaches. This will cost manufacturers money and might even hurt theirreputation. Consequently, research intosecurity is crucial.Establishing who owns the data accumulated from networks of connected machines and components may also prove difficult — especially with the value of dataconstantly increasing.DATA IS THE NEW OILThe Internet of Things is viewed as amajor component in this transition, andfor good reason. It involves the use of bigdata, connected sensors, autonomousmachines and artificial intelligence. Byfitting sensors onto industrial components, launching connectivity to systems, collecting data and using advancedcomputer processing, companies hopeto boost productivity and efficiency.Pierre Kellner, Business Developer, SmartProducts & Services at Nord-Lock Group,says that in the past, data was gathered from surveys, research, and otherexternal sources. Now, sources of dataare being supplemented by the product itself, and its value increases exponentiallywhen it is integrated with other data. “It iscrucial to start collecting and owning bigdata, although we do not know the value ofthe data today. Data is the new oil,”says Kellner.When it comes to bolted joints, thereare several fields that will benefit fromconnected sensors and AI, such as aircrafts and airports, trains and railways,mining equipment, bridges, oil platforms,nuclear power plants and wind parks.In the case of wind parks, the offshorevariety are preferred since they can bebuilt on a large scale, enjoy better efficiency due to higher wind speeds and have lessnoise considerations than their onshorecounterparts.However, these turbines have hundredsof bolts each — a number that will likely increase into the thousands as theyget bigger and which could cause manyproblems.“Since access is hard and insome cases dangerous thismakes services difficult andthereby expensive,”says Kellner.Several sources estimate that the operation and maintenance cost will contributeto between 20 and 25 percent of the cost ofoffshore energy, compared to 10 to 15 percent onshore.The remote analysis, monitoring andreporting capabilities offered by Industry4.0 would make this more efficient andaffordable — advantages that are set torevolutionize not only the bolting sectorbut the manufacturing industry as a whole.Text Martin NeanderPierre KellnerBUSINESS DE VE LOPE R,SMART PRODUCTS& SE RVICES ATNORD-LOCK GROUPPär BergstenCEO OF H&D WIRE LESS

FOURINDUSTRIALSTEPSINDUSTRY 1.0: BETWEEN 1760-1840Going from manual production to the use ofsteam-powered engines and water as a source of power.INDUSTRY 2.0: BETWEEN 1870-1914The defining characteristic was the introduction of massproduction as a primary means of production in general.INDUSTRY 3.0: BETWEEN 1950-1970Often referred to as the digital revolution, it involved thechange from analog and mechanical systems to digital ones.INDUSTRY 4.0: FROM 2010-PRESENTThe machine is becoming an independent entity that is able to collect data,analyze it, advise upon it, and constantly work on maintaining itself.BOLTED 1 - 201913

ALSTOM AND NORD-LOCK GROUP:A SECURE COUPLINGFrench multinational Alstom is aglobal player in the rail transportindustry. The company has a raft ofinternational customers seeking themost comprehensive range of productsand services on the rail market —from trains and integrated systemsto signalling and services. To ensurethat Alstom maintains its position asthe preferred partner for clients likeSNCF and Eurostar, the group looks toa broad range of suppliers to providethe solutions and services it needs.Nord-Lock Group hasworked with Alstomsince 2014, providingsolutions for their toughengineering challenges.Alstom first started using Superbolttechnology from Nord-Lock Group almost by chance. “I’m in a rail transportation working group along withrepresentatives from some of the bigrail customers like French railwayoperator SNCF, and manufacturers likeBombardier Transport. Three years ago,we were invited to a two-day workshopat the Nord-Lock Group premises inLyon, France,” says Luc Moyart, FastenersExpert and Right First Time Manager at Alstom. “Among the products theyshowed us was their Superbolt tensionerrange, and I thought they might be per-fect for a certain type of coupler assemblythat we were using on trains for the LosTéquès project for the Caracas subway,”he says.These couplers require very largediameter bolts, which present certainissues when it comes to tightening.Although Alstom hadn’t actually beenlooking for a solution, the new Nord-LockGroup Superbolt technology they’d seenoffered some clear advantages. “I thoughtthey might be suited to train bars andcouplers because these require big 30mmbolts that were proving tricky to tighten,”says Moyart.Luc MoyartFASTE NE RS E XPE RT, ALSTOM, FR ANCE14BOLTED 1 - 2019

THE PERFECTSOLUTION TOSECURE TRAINCOUPLERSMoyart was right, and since then,Alstom has used Superbolt tensioners for two more projects. After theiradoption in 2014, they were used atAlstom’s Lapa site in Brazil and ontrains for a South African network. Thethird project involved trains producedin Katowice, Poland, for the Riyadh subway system in Saudi Arabia.“Superbolt tensioners limit the torsion in the screws used for fixingthe couplers because they use puretension. The fusible screws are machined and calibrated so that in theevent of an impact – a crash for example – they will snap at a certain pressure, leaving the coupler to slip beneaththe train, thus avoiding derailment,”Moyart explains. “Superbolt tensionerscan also be used in places that are trickyto access, and they aren’t sensitive to thedifferent temperatures we might experience in different locations over the year,unlike with hydraulic tightening solutions,” he adds.Using Superbolt technology has allowedAlstom to reduce manufacturing timethanks to coupler installation as well assimplify assembly. “The tensioners areeasier to access, which has saved usmoney in terms of industrial capacityand handling. We need less storage forthe tools because we can now tightenthese M30 screws with a simple torquewrench, and they don’t require thesame hydraulic benches to managethe tightening process like before,”says Moyart.Furthermore, Alstom has found thatSuperbolt tensioners are not justintegrated into an assembly moreeasily, but they can be assembled anddismantled with greater ease too.“One major advantage is that Superbolt tensioners can be reused, unlikeour previous bolts. which had to be discarded once they were removed froman assembly. Superbolt tensioners havea lifetime guarantee, which representssignificant savings,” says Moyart.Another key benefit is that fewer Alstomemployees are suffering from repetitivestrain injury and other problems relatedto bolt tightening since the group started using Superbolt tensioners. “Peoplehandling the heavy equipment used forhydraulic tightening are prone to healthissues, and our employees have literallyfelt the benefits of this technology, andthey’re very happy about that,” explainsMoyart.INNOVATINGA TRADITIONALINDUSTRY“The railway industry is a fairly traditional world and employees can sometimes be a little sensitive to change,making it tricky to introduce new waysof doing things, but we’ve had excellentfeedback,” says Moyart. “They can seethe benefits, not just in terms of theirhealth, but also in terms of the working environment and how these tensioners have made their lives easier. Theyhave been trained by Nord-Lock Groupteams to use Superbolt tensioners, andit’s been a very smooth transition,”he adds.Naturally, it is important for a grouplike Alstom to cultivate positive relationships with its suppliers, something that has been very easy to do withNord-Lock Group. “Our relationshipwith Nord-Lock Group has always beenexcellent – we have worked closely withthem throughout the experience. Whenw

the Nord-Lock X-series bolt securing system. There are two main reasons why Nord-Lock prod-ucts were a perfect fit for this project. Severe vibra-tion from rattling carriages on a high-speed train can lead to bolt loosening, but not when used with Nord-Lock X-series washers. The wedge-effec