When forces are transmitted with chains in the vehicle engine compartment, the correct tension must be ensured at all times. This is why chain tensioners are used, which prove themselves permanently under extreme conditions: They have to withstand high temperatures as well as the typical operating fluids. Above all, however, they must be highly resistant to abrasion. Metals are therefore out of the question: their abrasion would produce chips that promote chain wear. A temperature- and abrasion-resistant special plastic, the processing of which is one of our core competencies, has proven to be better here. The material is perfectly suited to this demanding field of application, but a great deal of expertise is required for processing: the process requires special screw geometries, and because the processing window is narrow, a very precise temperature profile must be guaranteed in the hot runner and in the machine.

Additional components such as threads and springs are assembled on robotic systems that we have developed and manufactured in-house. The assembly lines include camera and laser-supported inspection systems that check the dimensional accuracy and monitor the completeness of the system components. With the core competencies of processing sophisticated materials, automated parts handling and automated testing technology, WEISS has acquired a leading position in the development of production processes for chain tensioning systems. In addition, the thermally stabilized material is also used in the production of air and fuel lines, gear systems and connectors as well as other sophisticated plastic components.

Welcome to Weiss - your reliable partner for high-precision plastic components in the automotive industry! As a renowned supplier for Jopp Automotive, we are proud to manufacture the gearshift housing for the PDK version of the Porsche Macan. Our housing, consisting of 14 carefully manufactured plastic parts, is crucial for precise shifting, a pleasant "feel" and fast gear changes.

Our collaboration with Jopp Automotive

Jopp Automotive, a specialist in manual and automated transmission control units, focuses on maximum ease of use and first-class gearshifts. An outstanding example is the shifting of the optional seven-speed dual-clutch transmission (PDK) in the Porsche Macan. Jopp provides a comprehensive solution here - from the gear stick to the shift cable with the innovative "Shift-by-Cable" system. Our contribution? The tailor-made housing that forms the basis for perfect function..

The challenge and our solution

The development of the housing was faced with the challenge of ensuring lasting stability in order to keep actuating forces constant over the entire service life of the vehicle. Weiss developed a housing consisting of 14 precisely manufactured components, with our plastics experts actively involved in optimizing the basic design. Materials such as PA6, PA66, partly glass fibre reinforced, and POM were carefully selected and the detailed design optimized.

Our processes and quality standards

At Weiss, we place the highest value on precision. Our housing components are manufactured to very tight tolerances and then delivered to the Jopp factory. This is where the integration of metal components, sensors and controls takes place. Comprehensive mechanical and electrical end-of-line testing ensures the highest quality before the complete switch module is installed at the Porsche plant in Leipzig.

The special feature: lightweight construction and optimization

The gearshift housing of the Porsche Macan impressively demonstrates that lightweight automotive construction is also of great importance for plastic components. Our optimization work, supported by design and optimization processes such as FMEA and filling simulations, has not only improved stability, but also enabled weight savings. The visible result? The effective ribbing of the larger components.

Rely on Weiss for outstanding plastic solutions, innovative developments and a collaborative partnership. Contact us for customized components that meet the highest demands.

Alligator Ventilfabrik GmbH in Giengen an der Brenz and Heidenheim has developed an innovative safety system for commercial vehicles with the "sens.it HD" platform: sensors continuously measure the pressure and temperature of the tires of tractors and trailers and transmit the measured values to a telematics unit. This unit compares the data with customer- and vehicle-specific limit values and sends it to a cloud server via a SIM card, where it can be accessed by workshop managers and fleet operators. The system has been marketed and further developed by TireCheck GmbH - which was a development partner for sens.it HD from the outset - since the end of 2019, while Alligator is now focusing on industrial valve applications.

 

THE TASK

The task was to design and manufacture a housing for the sensor technology housed in the tire. The specifications included a service life of five years and thus permanent protection of the sensitive measurement electronics, access to the pressure sensor and integration of the antenna with which the measurement data is transmitted to the telematics unit.

 

THE SOLUTION

The production concept developed by Weiss begins not only with the plastic granulate, but also with a filigree stamped and bent part. It serves as an antenna that sends the sensor signals to the telematics unit. It is automatically separated and placed by a robot in a two-component mold equipped with a turning/turning device. The 2K injection molding system first overmolds the punched and bent part with a PBT, which is used to make the actual sensor housing, and in the second process step with a soft TPE, which closes the assembly openings and forms a seal. After an automated in-line inspection, the housings are placed - again automatically - in the transport packaging.

 

The SPECIAL FEATURE

Two automated in-line checks are part of the production process. One ensures that the hole that ensures the air flow through the sensor is present and sufficiently large. The presence of the antenna in the sensor housing is also checked. The control concept is also unconventional: as the master, the robot determines the cycle of the injection molding machine, and the control system allows both a start-up phase and continuous production in smaller quantities. The metal parts are then inserted into the molds by hand.