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Tag Archive: automotive

1. Metal Stamping in the Automotive Sector

   February 26, 2018 6 years ago Leave a Comment

   Automobiles rely on a wide range of components to operate safely and efficiently. Most of these components — which are found in every part of a vehicle, from its frame to its electrical systems — are manufactured using metal stamping and precision machining methods.

   Metal stamping, also referred to as pressing, involves placing a sheet or coil of metal into a press and forming it into the desired shape over a die or mold. This can be done in one stage or over several stages, depending on the complexity of the required end product.

   Automotive stamping allows for the manufacture of many different functioning parts, which are used in automotive bodies and frames, as well as electrical, steering, alternator, and fuel systems. These components play a crucial role in ensuring optimal safety and functionality.

   Terminals and Electrical Connectors

   The auto industry produces thousands of vehicles a year, and hundreds of terminals and electrical connectors are installed in each vehicle.

   Automotive manufacturers typically employ connectors with a two-piece socket and tab design. Using flexible materials, the male and female component ends can easily attach and disconnect, allowing for great durability and flexibility. This is crucial, given the amount of abuse these components take from weather, general wear and tear, chemical exposure, and other harsh elements cars encounter on the road.

   As the auto industry depends more and more on electrical systems, demand will rise for highly protected, durable terminals and connectors. These components can be made from a variety of different materials — including copper, brass, phosphor bronze, and various grades of steel — using four/multi-slide forming and progressive die and metal stamping techniques.

   Automotive Wire Forms

   The wire forming process involves pulling a strip of metal through a series of lubricated metal dies or molds so it can take the desired shape. Allowing for many wire sizes and shapes, this simple, versatile process can even be applied to glass. Commonly worked materials include titanium and copper, but the ideal material choice will depend on the specific application at hand.

   Wire formed products are used in a wide range of applications, including construction, which makes use of rebar, as well as heating elements and even mattresses, which make use of springs and coils. In the auto industry, wire formed products are found in tires and under chassis.

   Automotive Brackets and Hangers

   Metal brackets are also found in many different automotive applications — door panels, instrument panels, fender assemblies, and airbags, to name just a few. Primarily used to fasten one component to another, brackets can be manufactured from metals such as steel, as well as various other high-strength, oxidation-resistant alloys. Since automotive brackets may be exposed to the elements, these properties are particularly important.

   Learn More about Automotive Stamping

   Metal stamping and precision machining techniques are essential for ensuring optimal safety, reliability, and comfort in all types of vehicles. These processes, whether complex or simple, require experienced and dedicated technicians; companies should be sure to partner with knowledgeable industry leaders who can provide reliable solutions tailored to the specific application at hand. Components must be durable enough to withstand years of use in varying road and weather conditions, so quality is of utmost importance.

   At Keats Manufacturing Co., we’re proud to offer industry-leading wire form design and manufacturing services. Committed to quality in everything we do, our facilities are ISO 9001, ISO 14001 and TS 16949 compliant, and we make use of the latest technological innovations, including CAD/CAM. Our operations are overseen by 25 of the industry’s most experienced die makers.

   For more information on our custom metal stamping services for the automotive industry and discuss automotive component manufacturing options for your unique application, reach out to the team today.

2. Keats Manufacturing Achieves IATF 16949:2016 Certification

   February 8, 2018 6 years ago Leave a Comment

   Keats Manufacturing is pleased to announce that we have achieved certification under IATF 16949:2016, a technical specification for quality management systems in the automotive sector as set forth by the International Automotive Task Force (IATF).

   

   What is IATF 16949:2016 certification?

   A Quality Management System (QMS) is a set of processes, policies, records, and documented procedures that lay out the internal rules under which a company produces and delivers its products and services to customers. Within the automotive industry, one of the most ubiquitous international standards for quality management is the ISO/TS 16949. This standard harmonizes the various certification systems and assessments in the world’s automotive supply chain.

   What is the significance of the certification?

   This IATF certification demonstrates a consistent commitment to customer satisfaction and quality of products and services. Both internal and external audits of our QMS documentation show that Keats Manufacturing has a high-standard Quality Management System in place and that we operate accordingly.

   What requirements must a company meet to be certified?

   IATF16949 consists of 11 sections, seven of which detail the requirements for an organization’s QMS in order to qualify for certification:

   • Section 4: Context of the organization – The organization must determine its context in terms of the QMS, including the needs and expectations of interested parties.
   • Section 5: Leadership – Top management must show leadership and commitment to implementation of the QMS as well as assign process owners and other roles and responsibilities.
   • Section 7: Support – This section details the QMS requirements for infrastructure, people, organizational knowledge, competence, communication, awareness, work environment, monitoring and measuring of resources, and documentation of information.
   • Section 8: Operation – The organization must meet product requirements in all aspects of planning and creating their product or service. This section addresses planning, review of product requirements, design, purchasing, creation of products or services, and control of the equipment for monitoring and measuring the product or service.
   • Section 9: Performance evaluation – The organization must effectively monitor the functionality of the QMS. They must assess customer satisfaction, perform internal audits, monitor products and processes, and review management.
   • Section 10: Improvement – An organization must continually improve the QMS, meeting requirements for nonconformities and corrective actions, error-proofing processes, and problem solving.

   Once the processes and procedures have been designed and implemented for a period of time, the records collected during the operation of the QMS serve as the basis for audits, reviews of the system, and, ultimately, certification.

   How is this newer version of the certification different?

   The updated version of ISO/TS 16949, IATF 16949:2016 was published on October 3rd, 2016. It replaces the previous ISO/TS 16949 and sets forth the requirements for a QMS used by an organization within the automotive industry. Meant to be used with ISO 9001:2015, it supplements the requirements for a stand-alone QMS, customizing the standard to the specifics of the automotive industry.

   IATF 16949:2016 blends various standards from across the United States and Europe. It outlines best practices for the design, development, manufacture, installation, and service of automotive products. This international measure of quality is the gold standard for any company to develop a system for ensuring improvement and customer satisfaction.

   What does the certification mean for Keats’ customers?

   We take automotive quality very seriously. The purpose of the IATF certification is to ensure that our customers can rely on faithful delivery of high-quality products. Keats Manufacturing has long been committed to customer satisfaction and ongoing improvements, and this certification is evidence of that commitment.

   To download our IATF 16949:2016 certification and our other quality certifications, click here.

3. Metal Stamped Parts for the Automotive Industry

   June 28, 2017 6 years ago Leave a Comment

   Throughout our more than 50 years of business, the engineers at Keats Manufacturing have been producing the highest quality custom metal stampings, wire forms, and assemblies for a wide range of industries. Listed below are several examples of custom metal stamped parts for automotive that Keats has manufactured.

   Positioning Sensor for Steering Wheel

   

   Keats was sent a 0.0238” thick phosphor bronze material and our engineering team was tasked with turning that raw material into terminals to be used in numerous automotive steering wheel sensors.

   Using our precision custom stamping services, Keats was able to design, build, and package one million of these terminals and ship them to the client’s location in Europe. In addition, these terminals were also plated with bright tin to increase their corrosion resistance. The reel-to-reel plating process that we performed ensured uniform deposition of the coating and significantly helped to decrease overall cost.

   Fuel Injection Steel Shield for Engines

   An automotive manufacturer provided Keats with a print and a .DWG AutoCAD file that contained specifications of a fuel injection steel shield that was required for use in automotive engines.

   Using DCC programmable CMMs, our precision stamping process allowed us to manufacture one million parts from 1008/1010 cold rolled steel with tight tolerances of 0.003”. Zinc phosphate coating was then applied because of their paint bonding characteristics. We were able to complete and deliver this order with a turnaround time of 15 days.

   Terminal Wire Forms for Sensors

   One client came to Keats with a need for terminals to be used in sensors for various automotive parts. Starting with copper alloy wires with a thickness of 0.082”, the Keats engineering team leveraged our in-house AutoCAD and tooling machinery to achieve tolerances of 0.001” to manufacture 25,000 terminal wire forms with chamfered ends. The entire process, including delivery, took 30 days from start-to-finish.

   More Products for Automotive Applications

   To see where else Keats’ metal stamped products are used throughout the automotive industry, check out our interactive infographic.

4. How Electrical Terminals Are Used in the Auto Industry

   March 9, 2017 7 years ago Leave a Comment

   In today’s vehicles, almost all internal systems are controlled by an array of electrical terminals and connectors. These increasingly complex devices govern dozens of onboard functions, engine controls, safety features, and infotainment platforms — all while delivering critical feedback to the driver in real-time.

   What are electrical contacts and terminals?

   A network of electrical contacts must be implemented to appropriately wire an increasing number of electrical systems within the vehicle. Most electrical connectors for the auto industry are comprised of a two-piece socket and tab design. The male and female component ends, made of conductive and flexible materials respectively, allow the connectors to easily attach and disconnect from other pieces within the vehicle.

   Connectors provide cars with electrical conductivity to power its systems, as well as electrical and thermal resistance to withstand vibrations, harmful chemicals, and outside elements. As more vehicle functionality depends on the proper operation of these electronic devices, it is crucial that each automotive wire terminal and connector is durable and protected.

   What are some commonly used materials?

   Engineers can accomplish a variety of design goals by modifying their choices for core and plating materials. Different considerations such as cost, conductivity, reliability, and thermal stability all have a hand in determining which material is the right fit for the application.

   Commonly used materials for auto industry electric terminals include:

   • Various grades of steel
   • Copper
   • Brass
   • Phosphor bronze
   • Various silver oxides
   • Various metal plating such as tin to enhance fretting and corrosion resistance

   Keats provides major automotive manufacturers with pre-post, selective, and precious plating, and secondary custom wire forming with selecting plating for their electrical terminals. We combine technological innovation including four/multi slide forming, progressive die & metal stamping, CAD/CAM, and five EDM and CNC machines — managed by some of the industry’s most experienced die makers — to deliver superior custom-made products.

   To learn more about important considerations for electrical terminals in the auto industry, download our eBook, “Design Tips for Automotive Electrical Contacts & Terminals.”

5. Product Highlight: Reel to Reel Terminals and Contacts

   June 16, 2016 7 years ago Leave a Comment

   At Keats Manufacturing Company, we specialize in building high-precision terminals and contacts for electrical transmission. Essential for the automotive industry and a wealth of other applications, reel to reel custom parts maximize convenience and cost effectiveness.

   Reel to reel terminals are valuable for high volume orders of precision parts and are often used in customers’ automated assembly systems. Keats Manufacturing fulfills our customers’ most complex reel to reel requirements with technologically advanced equipment, providing contacts and terminals on lead frames, tape and reels, custom reel to reel terminals, and returnable/disposable reels.

   How We Do It

   Creating reels of close tolerance terminals and contacts requires advanced stamping techniques. We employ progressive die and four-slide/multi-slide stamping to manufacture enormous volumes of high-precision components (sometimes 20 million or more parts) with the industry’s closest tolerances, including down to ± .001”.

   This process starts with the latest AutoCAD software to design custom tooling and ends with complete manufacturing, inspection, and delivery to the customer. With the use of quality materials such as copper, brass, phosphor bronze, various silver oxides, and grades of steel, our stamping processes fulfill virtually any requirement for volume and accuracy.

   Progressive Die Stamping

   No matter how complex or precise the final product needs to be, progressive die stamping is an efficient and accurate solution. The process itself is fairly simple: materials are fed through a series of progressive stamping stations until the final part is complete.

   Though the process is fairly simple, our equipment is impressive, offering quick die change and 5 to 150 tons of die pressure to achieve tight tolerances on parts with multiple critical dimensions. The process combines premium accuracy with high volume capabilities, easily producing orders up to 20 million parts or more.

   Progressive stamping is accomplished using multiple forming and cutting stations, with quality assured by high-tech digital part inspections. Fully automated and hand packaging are both available, as well as careful tape and reel packing, which ensures that all of our customers’ parts are delivered in the best possible condition.

   Four-Slide Stamping

   Highly efficient and cost effective, four-slide stamping employs die pressure ranging from 1 to 40 tons of raw materials in flat sheet metal form. These machines combine multiple processes into one piece of equipment, forming and shaping high volumes of parts with the utmost accuracy. Though this involves a more complex process, it is preferable for use in many types of projects.

   There are numerous advantages to part production using a four slide machine. The first is lower costs: these units require less labor, less material handling, and less expensive equipment than progressive die stamping systems. Four-slide stamping machines also require no die set and are generally more productive.

   Multiple Machines for Complex Requirements

   Depending on the complexity and material requirements of our customers’ projects, multiple machining processes may be necessary. A full array of high-tech equipment is available in our facility in addition to our stamping machines — all of which are operated and overseen by the most experienced machinists and die-makers in the industry. These include multiple EDM, CNC machines, and more.

   At Keats, our quality is unsurpassed. We ensure that every step of the design and manufacturing process is completed to meet the industry’s most stringent requirements, with final inspections performed before every delivery.

   For us, efficiency is just as important as quality. We maintain fully up-to-date Kanban software to ensure our customers receive Just-In-Time (JIT) delivery whenever required — even for the highest volume orders. Whenever a question or issue arises, our highly responsive customer service team is there to help.

   With our high volume capabilities and precision machinery, we are a perfect match for all customers who need reel to reel terminals and contacts.

   For more information about these products and their industrial applications, check out our eBook, Design Considerations for Automotive Electrical Contacts & Terminals.

   Contact us today to find out more about our precision metal stampings or to request a custom quote.