The causes of quality issues in industrial bolting assembly, disruptions in the production process, or component damage are diverse and complex. Every employee can contribute—through theoretical expertise or practical skills—to identifying errors at an early stage or avoiding them altogether.

An experienced trainer and instructor will explain in an engaging and practical manner the potential sources of error in the design process, in the selection of bolting tools, and in defining assembly procedures and monitoring parameters. In addition, numerous real-life examples will highlight critical sources of error in the day-to-day handling of fasteners, components, and bolting equipment.

But how can this urgently needed, proper, and standards-compliant knowledge development be achieved within a company? This interactive presentation introduces an exciting and holistic concept: from qualification analysis to the implementation of traditional training methods and the integration of modern digital learning modules, all the way to individual competency certification.

Needs-based qualification in both theory and practice, efficiency of training measures, effectiveness in knowledge transfer in line with the current state of the art, and compliance with VDI/VDE-MT 2637—these goals can all be achieved simultaneously and do not have to be mutually exclusive.

Especially in the high-voltage sector, it becomes clear that optimizing individual products or components alone is not sufficient. What is required is a systematic approach. With the iFast Competence Center, ARNOLD UMFORMTECHNIK has created a framework in which all relevant dimensions of electrical contact fasteners are brought together. At the core are three pillars: Conductivity: consistently low contact resistance achieved through optimized contact geometries, contact pressure, and surface finishes. Cleanliness: particle-free connections in accordance with VDA 19.1, validated assembly processes, and testing methods capable of detecting even the smallest disturbances.

Sealing: protection against moisture and media through sealing concepts verified according to IP standards and helium leak testing. Beneath these pillars lies consolidated engineering expertise – ranging from simulation-based design

according to VDI 2230, FEM analyses, and ultrasonic preload force measurements to electrical resistance testing in the micro-ohm range. This is complemented by system technology for assembly and process monitoring, ensuring reliable

implementation in series production. The focus of the presentation could be on Electrical Contact Fasteners (ECF); please also see the attached abstract. However, this is still under discussion, and both the presentation and the detailed content will need to be further developed.

Information to follow

At bolting electrical contacts especially at high voltage application, the contact resistance at the connection points plays a crucial role. There is a significant relationship between this resistance and the connection's preload force. This presentation highlights the influence of materials, surface characteristics, and standard assembly conditions and demonstrat how important it is to do a optimization during the validation prozess. A process-reliable assembly strategies can be developed through the simultaneous measurement of torque, preload, and contact resistance during lab testing as well as during the assembly in line.

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A brief insight into the world of accidents and incidents involving screws and the lessons learned from them.

Recalls and accidents in all industrial segments show us time and again that we have a great responsibility in field of assembly technology.

We try to find out why this keeps happening, even though we have all the tools of Industry 4.0 at our disposal.

We discuss together what we can do to avoid such cases in the future.