Automotive

In vehicle technology, plastic solutions impress with their many advantages such as low weight, durability and outstanding functionality. Thanks to technological developments and substitutions, new automotive applications are emerging day by day – also for your special needs.

  • Industries
  • Save weight with automotive components made of plastic injection molding.
Facts

Based on your requirements, we work out customized solutions together with you.

Your advantage:

  • Process optimization on the component
  • Improved assembly processes
  • Weight reduction
  • Cost savings
Contact
Contact details for more information:

vertrieb@konzelmann.com
+49 7143 40 80 - 0

Engines
Radial Axial Bearings (Friction Bearings)
Radial Axial Bearings (RaAx Bearings)
Transmissions
Thrust Washer
ID Sealing (REDI)
Fly Discs (FLY DISC)
REDI hook (REDI HOOK)
REDI EVO
Lightweight Design – Metal Substitution
ELC Case
POS Case
Locking Bracket
Actuators
Thrust Segments
Gearwheel
Insulators

Radial Axial Bearings (Friction Bearings)

Task

Due to engine downsizing, more and more energy is released in the form of vibrations at the crankshaft. A system is required which can absorb these huge vibrations and torsional oscillations. 

Solution

Friction bearings made of tribologically-optimized polyamides from KKI for viscous torsional vibration dampers fulfill the requirements. Viscous torsional vibration damper systems can effectively minimize vibrations and torsional oscillation in low-consumption and emission-reduced engines for the automotive industry. Such systems are fully production-ready.

Viscous torsional vibration damper systems minimize vibrations and torsional oscillations. Effective, low-consumption and emission-reduced engines for the automotive industry are fully production-ready.

Your Benefits

  • Consumption-optimized engines are suitable for series production.
  • Through the use of tribologically-optimized polyamides in the bearings, the torsional vibration dampers are more powerful and absorb the vibrations.
  • Installation space is thereby reduced and the required damping characteristics are adjusted to the respective engine.

Contact Us

Do you have similar requirements? Get in contact.

vertrieb@konzelmann.com
+49 7143 40 80 - 0

Plastics Applications

Tribologically Modified and Optimized Polyamides

Expertise

Tribology

Activities

Radial Axial Bearings (RaAx Bearings)

Task

Simultaneously acting radial and axial loads usually require the combination of two bearing types. This means increased installation space, since each bearing must be designed according to the requirements.

Solution

Here too, it took a bright mind to come up with the solution. A clever engineer devised a combined axial-radial bearing that is essentially an entirely new machine element. The combination of radial and axial bearing in a single component significantly reduces space requirements. Forces in both radial and axial direction are absorbed by the build-up of a lubricating film between the bearing halves. The effect is reinforced due to the tilting of the bearing, thus enabling extremely high bearing forces. The assembly is almost identical to the installation of a deep groove ball bearing. Minimum lubrication by any medium (except air) is required.

Your Benefits

  • Space reduction due to 2-in-1 design
  • Tilting of the bearing reinforces bearing effect
  • Saves a conventional bearing
  • Weight reduction, because completely made of plastic
  • Easy mounting

Contact Us

Do you have similar requirements? Get in contact.

vertrieb@konzelmann.com
+49 7143 40 80 - 0

Thrust Washer

Task

The individual rotating elements in the drive train must be mounted against each other or against the case. A needle bearing or bronze bearing is often used for this purpose. These require a complex installation or a large axial installation space.

Solution

KKI's thrust washers replace typical axial bearing elements, e.g. needle bearings, and are already available in series. Thanks to the polymer solutions, the axial installation space can be reduced or used for other components. Through special material-surface combinations, both friction moments and heat input can be reduced. If required, the bearing can be secured against twisting and/or equipped with snap-in lugs for overhead mounting. By using TriboKon, the weight can be reduced considerably. Minimum lubrication through a medium is recommended.

Your Benefits

  • Reduction of the axial space
  • Reduction of frictional torque
  • Significant weight savings
  • Emergency lubrication available
  • Overhead installation possible

Contact Us

Do you have similar requirements? Get in contact.

vertrieb@konzelmann.com
+49 7143 40 80 - 0

Picture Gallery

Expertise

Tribology

Activities

ID Sealing (REDI)

Task

In addition to traditional rectangular sealing rings, which seal on the outer surface, there are some applications where the seal is applied to the inner diameter. These rectangular sealing rings (REDI) are used when a groove cannot be inserted into the shaft due to cross-bores in the shaft or the cross-sections are too small.

Solution

Due to the special material surface combination and KKI's tried-and-tested REDI design, both leakage and frictional torque can be significantly reduced compared to conventional solutions from iron castings. An expansion by centrifugal forces is effectively prevented by special geometries and materials.

Your Benefits

  • Substitution of GG-rings
  • Reduction of leakage
  • Minimizing the frictional torque
  • Simplified installation also in deep enclosures

Contact Us

Do you have similar requirements? Get in contact.

vertrieb@konzelmann.com
+49 7143 40 80 - 0

Picture Gallery

Expertise

Tribology

Activities

Fly Discs (FLY DISC)

Task

Due to the numerous rotating components in the drive train, they have to be separated from one another, not only to reduce frictional torque but also to prevent the wear of two elements.

Solution

The KKI axial discs reliably separate two rotating elements. These discs are installed as a flying disc, since in these applications no space is available for anti-rotation devices. In order to reduce the resulting frictional torques, the disks are equipped with a special material-surface combination. This technology also delivers higher durability under extreme stress conditions compared to bronze discs, for example. The use of TriboKon can be used to cover different wall thicknesses and applications. Through the use of polymeric materials and reduced wall thicknesses, considerable weight reduction and space savings can be achieved.

Your Benefits

  • Ease of manufacturing
  • Fast and easy assembly
  • Special contrast/color adjustments possible for better identification after assembly
  • Increased resiliency
  • Weight savings
  • Reduction in wall thickness enables space savings

Contact Us

Do you have similar requirements? Get in contact.

vertrieb@konzelmann.com
+49 7143 40 80 - 0

Picture Gallery

Expertise

Tribology

Activities

REDI hook (REDI HOOK)

Task

Applications with difficult assembly procedures (e.g. blind mounting in large gears) require a consistent mounting diameter. Otherwise, damage to the rectangular sealing ring (REDI) cannot be excluded, leading to costly replacements. Typically, cast iron sealing rings are used here, which lead to material-specific disadvantages during assembly and use.

Solution

With the HOOK method developed by KKI, the REDI is assembled as usual and hooks itself to a defined diameter. This technology can be implemented in almost all materials, dimensions and variants. In contrast to cast iron rings, mounting is carried out within the groove. The REDI therefore lies cleanly inside the groove during the assembly of surrounding components, ensuring easy, error-free installation. What's more, a reduced lead-in chamfer is required as the HOOK technology almost completely compensates the expansion.

Benefits

  • Reduction of frictional torque from 25 to 60% as compared to cast iron rings
  • Leak values from 20 to 50 ml/min (or within a predefined range)
  • Reduction of the lead-in chamfer
  • Compensation of the expansion
  • Better price performance ratio, because a process step is eliminated

Contact Us

Do you have similar requirements? Get in contact.

vertrieb@konzelmann.com
+49 7143 40 80 - 0

Picture Gallery

Expertise

Tribology

Activities

REDI EVO

Task

Three trends currently determine the rectangular sealing ring (REDI) market. Firstly, stricter exhaust gas regulations demand a noticeable reduction in frictional torque and leakage losses in commercially available REDI materials. Secondly, the technologies required for this purpose should only have minimal effects, or the material selection should generally be customized to the application. Thirdly, due to increasingly complex transmissions, error-free assembly is crucial.

Solution

With the EVO-REDI, KKI has proved that these challenges can be met. The EVO-REDI reduces friction and leakage to a minimum. The leakage can therefore be used where it is most effective. What's more, the special design of EVO-REDI facilitates error-free assembly. These modifications do not affect the available installation space, which is why the customer does not need to adapt the surrounding components, and existing sealing rings can be replaced 1:1. Through the use of TriboKon polymers further commercial potential savings can be achieved.

Benefits

  • Reduction of friction moments by up to 50%
  • Leakage values from almost 0 to 50 ml/min (or within a predefined range)
  • Savings potential – fast (<<1 sec) assembly is possible
  • Suitable for manual or automated assembly lines
  • Error-free installation of the body
  • No adjustment required, 1:1 replacement
  • Special contrast/color adjustments possible for better identification after assembly

Contact Us

Do you have similar requirements? Get in contact.

vertrieb@konzelmann.com
+49 7143 40 80 - 0

Picture Gallery

Expertise

Tribology

Activities

ELC Case

Task

The level of a truck trailer is to be controlled by air springs, for example when the trailer is unevenly loaded or takes a curve. The system is designed to compensate for the "misalignment".

Solution

KKI pneumatic valve bodies made of plastic replace the currently used aluminum valve bodies. The valve bodies regulate actively and dynamically the air supply of the air springs. The trailer height is constantly monitored and maintained at the desired position and level.
No mechanical rework is needed on the valve body.

Your Benefits

  • No corrosion
  • Reduction of system weight
  • Reduction of costs
  • Active increase of road safety (by centering the vehicle's balance point)
  • KKI mounts all additional components such as silencers, screw sleeves, ultrasonic-welded covers and checks component leakage.

Contact Us

Do you have similar requirements? Get in contact.

vertrieb@konzelmann.com
+49 7143 40 80 - 0

Picture Gallery

ELC

Plastics Applications

Glass fiber reinforced polyamides

Expertise

Fluid Power

Activities

POS Case

Task

For parking and maneuvering a truck trailer, a system is required which opens, closes and controls the compressed-air brakes.

Solution

KKI pneumatic valve bodies made of plastic replace the currently used aluminum valve bodies. The valve bodies control the air supply to the compressed-air brakes.
The trailer can be parked and maneuvered with the highest degree of safety and precision.
No mechanical rework is required on the valve bodies.

Your Benefits

  • No corrosion
  • Reduction of system weight
  • Reduction of costs
  • KKI ultrasonically welds the covers to the valve body and checks the component for leakage.

Contact Us

Do you have similar requirements? Get in contact.

vertrieb@konzelmann.com
+49 7143 40 80 - 0

Locking Bracket

Task

A bracket with corresponding locking contour is inserted into the transmission to prevent the axial movement of non-activated shift forks. This comes into play when the shift fork lock fails. For this purpose, a sheet metal bending component is used, which is very costly to manufacture and requires several processing steps.

Solution

The KKI locking bracket replaces the previously used sheet metal bending component. To manufacture the component by injection molding, the existing component was re-engineered to adopt a design compatible with injection molding. This polymer solution not only reduces the weight but also enables single-process production. The sheet metal bending part, in contrast, had to be produced in several steps.

In addition, the polymer solution has the advantage that the component can be used in several transmission types through appropriate optimization.

Your Benefits

  • Dimensionally stable construction material
  • Resistant to oils
  • Thermal expansion coefficient close to aluminum
  • Significant weight savings

Contact Us

Do you have similar requirements? Get in contact.

vertrieb@konzelmann.com
+49 7143 40 80 - 0

Picture Gallery

Expertise

Equipment Technology

Activities

Thrust Segments

Task

Manufacture of a large thrust washer that can easily be exchanged in workshops as a repair solution

Solution

Instead of a complex thrust washer, several small thrust segments are implemented and inserted.

Your Benefits

  • Simple and robust production of components
  • Easy change of the segments in case of repair

Contact Us

Do you have similar requirements? Get in contact.

vertrieb@konzelmann.com
+49 7143 40 80 - 0

Picture Gallery

Plastics Applications

  • High-performance polymer, tribologically modified

Expertise

Tribology

Activities

Gearwheel

Task

  • Reduction of NVH (Noise Vibration Harshness) in torque transmission

Solution

Replacement of a metal gear rim by a polymer component

Your Benefits

Alongside the originally requested noise reduction, costs savings were also achieved.

Contact Us

Do you have similar requirements? Get in contact.

vertrieb@konzelmann.com
+49 7143 40 80 - 0

Plastics Applications

Tribologically modified high-performance polymer

Expertise

Tribology

Activities

Insulators

Task

Manufacture of high precision components with minimum wall thickness

Solution

Mold concept for serial production taking into account the best injection point location and placing the parting lines correctly for best ventilation results

Your Benefits

Best compromise between manufacturability and market competitiveness.

Contact Us

Do you have similar requirements? Get in contact.

vertrieb@konzelmann.com
+49 7143 40 80 - 0