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Customised solutions – some examples

Here you can read about a couple of cases where we have developed optimised friction solutions for our customers. For practical reasons, we maintain the anonymity of the customers. Our intention is only to relate a few interesting assignments and to give an idea of who we are and what we can do.

Effective friction solution for a sliding clutch

A Canadian company registered in Toronto, and with several of the world's most famous car brands on its list of customers, experienced problems with the material in a sliding clutch – just when they were about to start their series production. The friction material in the clutch did not last.

The Canadian company already had a subcontractor that had produced prototypes. They had been tested and approved in both short and long field tests. The problem was that the subcontractor could not produce the correct quality when the series manufacturing was to start.

Effektiv friktionslösning till slirkoppling

With the overhanging threat of having to close down all of the planned product launch, the company scanned the market for a new subcontractor. We were consulted and replied that in all probability we could help them with a solution.

The product manager flew to Sweden with test plates in his hand baggage. He put these metal carriers on the table and said: "I want to have a prototype with me on the way home. Now on Sunday".

The requirements we had to work on were that the friction lining could be punched out, and be thin, bendable and flexible. It should also withstand a specified speed and degree of heat. After careful calculation and design proposals from our technicians, the choice fell on friction material BK4200. It was processed, glued, fitted and delivered in time for the product manager's trip home.

The short time tests that followed produced good results. The same applied to the long duration tests, and it was possible to start production in series. In the course of time we have followed up the development of the process for the customer, For example we have switched from punching to waterjet cutting the material, which has reduced material wastage and gives the customer better business value.

Brake lining in a gigantic forging press

The Swedish subsidiary to one of the world's largest manufacturers of forged engine and chassis components had a problem with a brake/clutch lining in one of their forge presses. The material wore out too quickly.

The company's forge press is one of the most powerful in world, fully computerised presses for manufacturing front axle beams for trucks and buses. It has a press power of 16,000 tonnes and the materials in the moving parts of the machine are exposed to severe stress.

Bromsbelägg i gigantisk smidespress

When the company contacted Rydahls they had a problem with friction linings that cracked and wore out too quickly, which affected production and service economics.

After specification of the brake force and brake torque, we drafted and produced a dimensioned solution – a clutch and brake lining with a core of mechanically durable material and wear surfaces coated with friction material with the right properties.

Both the initial and succeeding tests went well. The machine moved with the required smoothness and linings from Rydahls demonstrated a significantly better lifespan than the previous solution.

Throttle lever with simulated resistance

A subcontractor to a boat manufacturer had a slightly different question: “How can we get a throttle lever with electronic signal transfer to the engine to feel like a classical throttle lever with a wire coupling?”

The boat manufacturer had installed a solution on one of their yachts where all the electronics were connected to a single network on-board. All the key functions, such as steering, acceleration and gear changing were connected to the same system.

Gasreglage med simulerat motstånd

With electronic signal transfer between the throttle lever and the engine there was none of the inertia in the lever that most people are used to, and which contributes to the experience of running the boat. There was quite simply no resistance, and some of that "boat feeling" disappeared.

The subcontractor was given the task of manufacturing a throttle lever with the right feeling. They in turn contacted us.

Our recommendation: Hot glue a friction material with a high friction coefficient to a plastic carrier and you will get an excellent product with the inertia and feeling you are looking for.

With the right materials and processing, in a cost-efficient and automated production process, we helped the customer towards a very good component at the right price.