Collaboration for the successful development of the OMEGA V cabin
CWA Constructions SA/Corp. produces state-of-the-art cable car cabins and vehicles that impress both passengers and cable car operators alike. We at Bossard were also able to contribute and support the IMPACT project, which revolves around the new OMEGA V cabin. This cabin accommodates ten people and will be used in mountain regions as well as urban areas, from winter to summer. The first cabin was produced in the fall of 2018.
The first discussions about the development of the Omega V took place in 2016. The engineers of CWA AG and the Bossard Engineering Team worked closely together from the beginning. The timing was perfect as the cabin was in its early development stage. Efficient and safe solutions were sought for the new lightweight cabin.
Designing and implementing efficient and safe solutions
The right product for every application
Multi-functionality is a key word in the Omega V project. Many connections have to meet multiple requirements such as vibration safety, corrosion resistance, and an appealing appearance, as well as being suitable for automated assembly. One of the most important connections in the cabin are the corner connections. The screws required for this are subjected to dynamic loads and are screwed into aluminum. In addition, there are high requirements for corrosion resistance. Since a high level of safety is required here, we defined TAPTITE 2000® screws for the connections. 28 M10x70 of these thread-forming screws ensure the connection of the corner columns to the roof and floor frame. A special zinc layer coating meets the requirements for corrosion resistance and lubrication. By using these multifunctional screws, combined with optimal design, the upstream thread cutting and additional screw security are eliminated. Another feature of these screws is that they comply with standard DIN 267-30 and thus meet all requirements of ISO 898-1 for strength class 10.9. In addition to the TAPTITE 2000® screws, thread-forming screws according to standard DIN 7500 from the Bossard catalog group 9 and 11 are also used.
Design of the connection
The question arose of how to design a thread-forming screw for safety-relevant connections. Bossard's Engineering Service "Expert Design" was used to calculate and determine the dimension based on the operating forces. The data of the tightening torque and preload force obtained were checked with Bossard's various tests in the testing laboratory. In addition, the thread engagement depth was verified by over-torquing tests. The combination of the results yielded the dimensions for the design and the parameters for assembly.
The assortment smartly considered
In the course of development, a variety of surfaces, screw drives and materials accumulated. Together with CWA engineers, the focus points of drives, surfaces and locking systems were examined and an assortment analysis was carried out using the "Expert Assortment Analysis". Among numerous improvements, DIN 7500 bolts, for example, can often eliminate additional locking elements. Blackened INOX fasteners meet the requirements for elegant design and hexagon socket drives (Torx) create the ideal conditions for partially or fully automated assembly.
Support through to assembly
To assemble TAPTITE 2000® thread-forming screws, an electrically driven screwdriver with torque and angle sensors is required. It should be noted that the screwdriver is additionally loaded with the so-called forming torque when using thread-forming screws. The screwing-in is carried out at high speed, whereby the tool switches to a slower speed before the head of the screw comes into contact, thus ensuring a process-safe tightening process. The Bossard engineering team accompanied the CWA assembly team during the assembly of the first cabins with the necessary tools and expertise.
Customer benefits
The combination of the engineering services and the multi-functional fasteners results in the following advantages for CWA:
- Cutting threads is not necessary
- Higher carrying capacity of the nut thread due to thread forming
- No additional lubrication of screws is necessary
- Fast assembly with electric tools
- No additional locking or adhesives are necessary
- Shorter lead time
- Fewer individual parts
- Streamlined assortment
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