1,600 Sales are increasing every year! Sales Amount(100 million yen) 1,400 1,200 1,000 800 600 400 200 0 1 3 5 7 9 1113151719212325272931333537 Contribution to safe transportation (Aviation, Space), Quality of defense management system JIS Q 9100: certification 2
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Important parts of the mechanical components Coming loose Threaded fasteners have their roots in Ancient Mesopotamia. It was introduced into Japan s island of Tanegashima with guns in the 16 th century. Various shapes. Metric, Unified, Round Thread, Trapezoidal Thread etc. External and Internal threads Breaks Detachable Various Materials 4
Potters bar rail crash, May 10, 2002. A four-car West Anglia Great Northern train travelling at 100 mph (approx. 160 kph) bound for King`s Lynn in Norfolk, England. As the train crossed over a faulty set of points, they moved, causing the bogie of the carriage to cross onto the adjacent line and ultimately derail and crash into the Potters Bar station, leaving several passengers and spectators severely injured, as well as 7 casualties. Four nuts on the set of points at which the West Anglia Great Northern train derailed was not in position, which is believed to have been the main cause for the accident. 5
The cause of loosening threaded fasteners Nonrotating Loosening Rotating Loosening 6
Why emphasize the bolts axial force?! Proper axial force Improper axial force With a proper bolt axial force, the external force is applied to all the components. Therefore, the bolt is less likely to break. With an improper bolt axial force, most of the external force is applied to the bolt. Increasing the possibility for the bolt to break. 7
Stress amplitude S (N/mm²) Bolt Preload Reduction in the axial force will cause the bolt to break within a short period of time! If the Stress Amplitude Is Large or the Axial Force Is Lower Than That of the External Load, the Bolt Will Break More Easily. Non-breaking Breaking Number of repeated stress until breaking Most of the External Load is Borne by the Bolt Bolt Breaks, Becomes Damaged. Most of the External Load is Borne by the Bolted Joint No Burden on the Bolt, No Breakage or Damage. Safe & Secure Number of repeated loads before breakage N 8
Loosening Cause and Countermeasures 1-1 Non-rotating loosening 1 Countermeasures Initial loosening(conformability) Cause :Irregularities in the contact portion Height differential Subsidence loosening Cause :Plastic deformation on the entire surface due to the excessive tightening and/or external force. Depressed volume 9
Loosening Cause and Countermeasures 1-2 Non-rotating loosening 2 Countermeasures Fretting corrosion Cause :Abrasion associated with lateral displacement of the contact portion adherence adherence Loosening due to thermal cause Cause:Coefficient of linear thermal expansion Steel Aluminium Copper Carbon steel Cast iron Unit: Stainless steel 10% nickel steel 20% nickel steel Duralumin Aluminum Bronze 10
Loosening Cause and Countermeasures 2 Loosening rotation Countermeasures Repeated load to bolts axial rotation direction Various anti-loosening components Repeated Load to bolts axis Repeated loading perpendicular to bolts axis 11
The principle of HARDLOCK Nut 1 Wedge 2 Strike the wedge with a hammer Push the wedge with the screw of nut 3 4 Integrate the wedge with the nut. Simply tighten the convex nut and Loosening effect occurs! 12
Wedge Locking structure of the HARDLOCK NUT Locking structure of the traditional Japanese Wedge principle. a 2 1 By combining the Convex Nut designed with an eccentric conical protrusion 1 and the Concave Nut with its concentric conical depression 2, due to the wedge priciple they will lock themselves onto the perpendicular axis of the bolt. Due to the strong locking force created by the Wedge of the HARDLOCK NUT, no matter if it is exposed to severe vibrations and/or impacts the HARDLOCK NUT will stay intact! 13
The HARDLOCK NUT main features 1 An Anti- Loosening locking effect recognized by the world! 2 3 Available in various materials and surface treatments tailored to the environment! Reusable without reduction in performance! 4 5 Full torque management and completely fastened even with zero (0) axial force! Maintenance-free reduces total cost! 14
The main locking components of the world Flange nut Double nut Nylon insert nut Spring washer Self-Lock nut 1 Toothed washer Self-Lock nut 2 Disc spring washer Anaerobic adhesive Special locking washer HARDLOCK NUT (upper side) HARDLOCK NUT (underside) 15
1 An Anti-loosening effect recognized by the world! - NAS test results Let`s verify the anti-loosening effect in the image Impact Stroke Test bolt Collar Frame Vibration stroke Plain washer specimen The figure above is a schematic diagram of a mounting device based on the NAS3354. The NAS (NATIONAL AEROSPACE STANDARD) 3350/3354 is an accelerated vibration test commonly referred to as the NAS test. 16
1 An Anti-loosening effect recognized by the world! - NAS test results NAS3350/3354 Test Results(M10 x 1.5/Class4/Electroplating) General Hex nut ゆるみあり Flange nut Double nut Nylon insert nut Self-Lock nut 3 Self-Lock nut 2 Pass mark Spring washer Toothed washer Disc spring washer Special locking washer Anaerobic adhesive Number of repeated stress (Cycles) 17
Bolt preload 18 1 An Anti-loosening effect recognized by the world! - Junker test results 1 Junker Vibration Test(Loosening under transverse repeated loadings) German Industrial Standard:In accordance to DIN 65151 and DIN 25201-B Junker Vibration Test. Vibrating the top plate left and right Junker Vibration Test HARDLOCK Nut Schematic diagram Flange nut General Hex nut General Hex nut with spring washer Nylon insert nut Actual test machine Number of repeated loadings
Axial clamp force[kn] Axial clamp force [kn] 1 An Anti-loosening effect recognized by the world! - Junker test results 2 Even with High, Proper or Low axial clamp force, the HARDLOCK NUT will not come loose 20 90% of the yield point 60% of the yield point 30% of the yield point 15 HARDLOCK NUT HARDLOCK NUT 10 HARDLOCK NUT 5 Single Nut Single Nut Single Nut 0 0 500 1000 1500 Number of repeated loadings (Cycles) 0 500 1000 1500 Number of repeated loadings (Cycles) 0 500 1000 1500 Number of repeated loadings (Cycles) Even with 3 different amplitude displacements the HARDLOCK NUT will not come loose 10 9 8 7 6 5 4 3 2 Single Nut HARDLOCK NUT Amplitude : 0.35mm 0.5mm 0.75mm 1 0 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 Number of repeated loadings (Cycles) 19
2 Available in various materials and surface treatments! Size M5 - M130 W1/4 - W2 UNC1/4 - UNC2 Material Low carbon steel (JIS SS400), Medium Carbon Steel (S45C) High tensile steel (Cr-Mo, Ni-Cr-Mo) Heat-resistant Steel : (Inconel, Incoloy, Monel, Hastelloy) Corrosion-resistant steel : General Stainless steel, Brass, Titanium Alloy, Aluminum Alloy Resin, New materials And Various other materials! Surface treatment Electroplating, Hot-dip galvanizing, Hot-dip aluminized galvanizing Non-chromium treatment, Nickel alloy plating High-performance antibacterial plating, Aluminum alloy plating And various other surface treatments! Shape Standard type, Thin type and Special types 20
Material Reference:Biphasic system stainless NSSC2120(Manufactured by Nippon Steel & Sumikin Stainless Steel) Twice the intensity as SUS306, similar Corrosion resistance to SUS316L NSSC2120 21
Plating reference 1: Antibacterial plating 本製品は ( 株 ) 神戸製鋼所が独自開発した高機能抗菌めっき (KENIFINE) を適用しております KENIFINE は ( 株 ) 神戸製鋼所の登録商標です その効果で ナット & ボルトのゆるみ止めと抗菌 清潔の2 重の安心 安全を演出します この抗菌めっき加工は ( 株 ) 神戸製鋼所の技術導入先で実施しています 22
Plating reference 2: High nickel alloy plating 23
Axial clamp force [kn] Axial clamp force [kn] Axial clamp force [kn] Axial clamp force [kn] 3 Reusable without reduction in performance! 25 25 20 20 15 10 5 1 st Tightening Remaining axial clamp force: 15 10 5 11 th Tightening 95% Remaining axial clamp force: 93% 25 0 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 Number of repeated loadings (Cycles) 0 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 Number of repeated loadings (Cycles) 25 20 20 15 10 5 41 st Tightening Remaining axial clamp force: 15 10 5 51 st Tightening 93% 93% Remaining axial clamp force: 0 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 Number of repeated loadings (Cycles) 0 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 Number of repeated loadings (Cycles) 24
Axial clamp force [kn] Axial clamp force [kn] Axial clamp force [kn] Axial clamp force [kn] 4. トルク軸力管理が可能軸力 0 でも完全ロック!! 4 Full torque management and completely fastened even with zero axial force! 45 40 35 30 25 20 15 10 5 0 45 40 35 30 25 20 15 10 5 0 1. HARDLOCK NUT 2. Double NUT The convex nut was tightened to 80% of the yield point, then the concave nut was tightened but still No change in the axial clamp force! MANAGEABLE 0 10 20 30 40 50 Tightening Torque [N m] No change in axial clamp force 0 10 20 30 40 50 Tightening Torque [N m] The lower nut is required to fasten with about 50% of the targeted axial force because the Axial clamp force will be increased when the second nut is tightened. 45 40 35 30 25 20 15 10 5 0 45 40 35 30 25 20 15 10 5 0 NOT MANAGEABLE 0 10 20 30 40 50 Tightening Torque [N m] 0 10 20 30 40 50 Tightening Torque [N m] Large burden on the bolt can lead to disaster! Change in axial clamp force 25
4. トルク軸力管理が可能軸力 0 でも完全ロック!! 5 Maintenance-free reduces total cost! BEFORE AFTER 1. Management at high tightening torque of 500N m 2. Since nuts comes loose due to expansion and contraction of the rail, the inspection process required 3 people, 3 times a month 3. The fishplate bolt broke frequently. 1. Easy management at low tightening torque of 250-300N m 2. The need for inspection was reduced greatly with only 1-2 people once a month! 3. Bolts breaking was drastically reduced! 26
5 Maintenance-free reduces total cost! Item Item - Example of a certain Railway company`s fishplate fastening - 項目現行ナット使用の場合 In case of other nuts ハードロックナット使用の場合 In case of HARDLOCK NUTs 項目単位 Unit Monthly 月単位年単位 Yearly Monthly 月単位年単位 Yearly Labor 人件費 costs Yen 円 // Person 人 300.00 35,000 300.00 35,000 300.00 35,000 300.00 35,000 Procedures 作業回数 Times 回 // month 月 3 36 1 12 Work 作業人数 force Person 人 // times 回 3 3 2 2 保線管理室 Location 箇所 500 500 500 500 Track maintenance Total labor cost 人件費総額 US$ 円 157,500,000 1,350,000.00 1,890,000,000 16,200,000.00 35,000,000 300,000.00 420,000,000 3,600,000.00 ナット単価 Nut price US$ 円 0.75 90 0.75 90 3.00 360 3.00 360 Quantity 数量 Pieces 個 50,000 600,000 50,000 600,000 Total nut amount ナット総額 US$ 円 4,500,000 37,500.00 54,000,000 450,000.00 18,000,000 150,000 216,000,000 1,800,000.00 トータルコスト Total cost US$ 円 162,000,000 1,387,500.00 1,944,000,000 16,650,000.00 53,000,000 350,000.00 636,000,000 5,400,000.00 Cost comparison 経費比較 1 1 0.33 0.33 27
Improvement case 1 BEFORE In high speed rail cars, repeated impact of the rail coupling causes the nut to loosen and may even risk detachment. Damage to friction ring also causes the nut to loosen. AFTER By using the HARDLOCK NUT, even under repeated impact, loosening is prevented and detachment does not occur. Breakage of the friction ring is eliminated by using the HARDLOCK NUT and has been adopted by many rail car manufacturers. By using the HARDLOCK Nut, the maintenance cost associated with inspection and re-tightening was successfully reduced. The HARDLOCK Nut 28
Improvement case 2 BEFORE To prevent loosening at steelwork equipment lines, the shafts has key grooves and is fastened with both toothed washers and nuts as well as welding in some instances. In recent years, steelwork facilities are continuing with a fire-free work environment. Therefore, welding and such other procedures has been minimalized. AFTER When using HARDLOCK Bearing nuts, it eliminates the need to use toothed washers, key grooves and welding procedures, significantly improving the workability. Eliminating the need for welding procedures, the HARDLOCK products creates a safe, fire-free work environment. 29
Improvement case 3 BEFORE When a train passes, a force of 500G is applied to the switch, and even specially shaped double nuts used on the movable parts can become loose on a daily basis. While the switch (movable part) is essential to maintain the track gauge, it is extremely difficult to maintain the gauge of the track while preventing loosening. AFTER By using the HARDLOCK NUT, the maintenance cost associated with inspection and re-tightening was successfully reduced. The HARDLOCK NUT successfully maintained the gauge of the track and prevents loosening simultaneously. As a result, the HARDLOCK Nut has been adopted by all railway companies in Japan. By using the HARDLOCK Nut, the maintenance cost associated with inspection and re-tightening was successfully reduced. The HARDLOCK Nut successf 30
Improvement case 4 BEFORE Steps to prevent loosening had been used including double nuts and the use of spring washers but vibrations during transportation and micro vibrations that occur after installation had resulted in frequent loosening. AFTER By switching to the HARDLOCK NUT, all problems related to loosening were completely solved. By using the HARDLOCK Nut, the maintenance cost associated with inspection and re-tightening was successfully reduced. The HARDLOCK Nut successf Because loosening does not occur, both the number of inspections and re-tightening work has been significantly reduced resulting in labour savings. 31
Architecture 32
Other major applications 1 Poor environmental areas Hazardous areas High-temperature areas E.g.,) Petrochemical complex, pharmaceutical chemistry plant, sewage treatment plant. E.g.,) Nuclear power plants E.g.,) Gas turbine Places where maintenance is impossible Places with continuous operations E.g.,) Great Seto Bridge, Tokyo Sky Tree, Exterior wall of skyscrapers, Water supply and sewerage systems. E.g.,) Vehicle production facilities, Injection molding machines, Industrial robots 33
Other major applications 2 Places where strong tightening is difficult Places where safety is the top-priority E.g.,) Movable parts of wheelchairs, Movable portion of rail points Places where high-durability is required. E.g.,) Shinkansen, Amusement equipment, Vehicles, F1 cars Other places where severe vibration and impact occurs E.g.,) Detached housing, Akashi strait bridge E.g.,) Screen machines, Off-Road trucks, Bulldozers 34