Multifunction fastener saves Ford 50 cents per car
A
Profil UK product story
Edited by the Engineeringtalk editorial team
Nov 27, 2003
The extreme versatility of Profil UK's newest multifunction sheet metal fastener is being put to good use by Ford in the assembly of its Fiesta, Ka and new generation Focus models.
The extreme versatility of Profil UK's newest multifunction sheet metal fastener is being put to good use by Ford in the assembly of its Fiesta, Ka and new generation Focus models.
Up to six Profil RSN "top hat" nuts are installed in each vehicle, providing high-strength, water-tight mountings for after-market roof racks - as well as significant build quality benefits and cost savings of up to $0.50 per car.
The new Profil nuts have a completely sealed end and are mounted in the vehicle's roof cant rails at the body-in-white stage.
Their ability to provide flush-mounted class 8 EN20898 steel threads with exceptionally high torque and pull out resistance is backed by installation rates that are at least ten times faster than those of welded fasteners.
A further benefit of the Profil system is that each nut is consistently positioned to an accuracy of +/-0.2mm - approximately three times superior to that of welded equivalents.
Indeed, this inherent precision is a central factor in the vehicles' overall assembly process.
Each of the new fasteners incorporates a press fit nylon 6,6 plug, which in turn, has a Posidriv screw head form moulded into its exposed end.
The centres of these crosshead profiles are used as primary location points by the laser guided robots employed to weld the body panels together.
A 2mm thickness of sealant is subsequently applied to the spot welded roof seams - and the installed "top hat" nuts - to ensure water proofing of the body assembly prior to painting.
Throughout both these operations, the fastener's plastic plug acts as a highly effective thread protector.
During final assembly the complete installation is hidden by a plastic finisher strip, which is only removed when the roof rack is fitted.
A further novel feature of the multi-function fastener is that the heat of the paint oven softens the nylon plug sufficiently for it to take up the form of the bore's internal threads.
As a result, it can be easily unscrewed from the installed steel nut, ready to accept the roof rack's mounting bolts.
According to Profil UK's Adrian Ellis: "The simplicity of new RSN 'top hat' nut belies the painstaking effort that has gone into developing the product to fulfil all of Ford's requirements.
The installed fasteners provide high strength, precisely positioned, waterproof, steel threaded anchorage points as part of the normal assembly process.
They not only eliminate the risk of bodywork or paint damage caused by the installation of alternative products such as rivet nuts, but also the costs of separate offline manual or welding operations".
Available in M6, M8 and M10 variants, the new Profil RSN "top hat" nuts are also being evaluated by other leading automotive manufacturers for further "wet area" fastening applications, including the provision of bonnet, boot lid and tailgate mounting anchorage points.
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Other Profil UK stories
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Profil launches RSD series anchor nuts
Profil UK will be showcasing its RSD series of self-piercing nuts for sheet-metal applications at the Fastening and Assembly Solutions Exhibition on 29 October. -
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The latest additions to Profil UK's range of pierce and rivet fastening systems will form part of a presentation of advanced sheet metal assembly technology. -
Profil to showcase latest technology
Profil UK's latest pierce fastening technology will be demonstrated as part of the company's presentation of advanced sheet metal assembly solutions at the Northern Manufacturing Show. -
Profil RSN and RND rivet nuts utilised by Audi
Profil has announced that its RSN and RND rivet nuts have been specified by Audi for use in a safety-critical bonnet latch mounting application on its A4 and A5 vehicles. -
Studs chosen for BMW Mini construction
Profil UK's M8 x 25mm steel EBF studs are being uesd to retain rear light clusters on BMW Mini Clubman models.
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