Developed to keep pace with the new materials mixes now prevalent in advanced vehicle manufacturing – especially on premium brands – the quality of the new KSB earthing stud from Profil has already allowed several automotive OEMs to reduce the number of earthing points on top-selling vehicles from thirty down to twenty-two. But this 25% saving on parts (and associated installation costs) is only the tip of the story behind the success of the new earthing stud.
Because the stud is self-piercing, manufacturers are also seeing significant cost savings by doing away with the need for the expensive additional processes involved in either welding studs into place or having to drill holes and then bolt them on. Also, with material thicknesses being continually reduced in the quest for weight saving, an added advantage cited by those now enjoying all the benefits of the Profil earthing stud is that the risk of deformation in the parent material – always high with welded studs – has also been eliminated through the use of a cleaner, better mounting and installation method.
Specified worldwide by some of the biggest brands, including Porsche, Mercedes-Benz, BMW and Jaguar Land Rover, Profil’s earthing stud has proven to be ideal for fitting at the body-in-white stage, because it is installed complete. Its unique flanged construction also provides a total seal against paint or other material ingress or bleed through. When the vehicle then progresses from BIW to the electrical installation process, it is a quick and simple task to remove the integral nut on each Profil earthing stud, offer up the required cable shoes to the pair of completely clean faces and then torque it down for a guaranteed earth across the lifetime of the vehicle.
Commenting on the success of its KSB earthing stud range, Profil’s Glenn Williams says: “By working closely with our customers, we are almost always present when new design or production challenges begin to emerge. This involvement at the earliest stages in both arenas has proven to be of great value to our customers, and thus to our business. The origination, design and development of our unique KSB earthing stud range is a good example of what this relationship can result in. As more customers began working with new material types and mixes, including ‘sandwiches’ using multiple materials, it became clear that previously used methods of achieving sound, reliable, practical and cost-efficient grounding or earthing were no longer viable. So, we developed a solution with the new KSB stud. It has proved hugely popular with applications on so many of todays’ top-end vehicles.”
KSB earthing studs are available in two versions, and can be used in both steel and aluminium construction, with material thicknesses ranging from just 0.7mm right up to 4mm. Profil recommends that OEMs embrace a galvanic coating on the studs where possible. All KSB earthing studs can be installed either manually for short-run or prototyping purposes, or by bespoke, fully automated installation equipment designed and installed by skilled Profil engineers direct into production lines.