Previously Kabe used to build their caravans using a technology where the dwelling part was joined with the help of cast glass fibre elements. ”But we wanted to have a solution that was more flexible, simpler, cheaper and had a lower weight”, says Daniel Blom, production manager at Kabe Caravans.
– With the old construction method we had locked ourselves in a corner. We wanted to develop a solution which would let us change lengths easily and thus enable us to build new models much faster and simpler, continues Daniel Blom.
The solution was supposed to incorporate a transition structure between the walls and the roof. Apart from this, Kabe wanted to develop new solutions for the skirting and furnishings of the caravans. And it was supposed to go fast.
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| Kabe and Sapa have together developed a solution for the transition between the walls and the roof. Even the skirting and the furnishings of the caravans have been subject to changes. |
Kabe and Sapa established a special working team. Both parties were able to take advantage of Kabe’s experience in the production of caravans. Kabe prepared base drawings and the process could start. What problems and opportunities were there? Sapa designed the solutions and ideas were exchanged in both directions. And it went really fast. It took just over a half year to go from ideas to deliveries.
– We had ambitious plans and high requirements. Many other suppliers would have simply said no, we will not manage this. But I like Sapa’s technicians and I have never heard them say that something is impossible. So far, they have been able to solve all the problems we faced. And it is very stimulating to have such a co-operation, says Daniel Blom and he continues:
– You simply feel that the Sapa people think it is fun when we come up with a problem to which there seems to be no solution.
Roof solution
The solution consists of three profiles where the inside profile is the most important part of the structure. The whole ”box” consisting of the walls and the roof made of glass fibre laminate must be able to move together with the vehicle’s chassis. This requires a flexible joint. The profile is glued and screwed with high precision and therefore it has built-in screw ports and gluing surfaces.
The solution also contains two outside profiles which cover the inside profile and contribute to the vehicle’s appearance. Both these profiles are installed using a clip fitting and can be dismantled.
– Building a new vehicle model, longer or shorter, when the solution is based on cast glass fibre elements is time-consuming and extremely expensive. The cost of tooling is expressed in millions of kronas. Now we just cut the profiles to a new length when we build a new model, says Daniel Blom. And the principle is exactly the same when it comes to the skirting solution and the furnishings.
Skirting solution
The skirting, which also consists of three profiles, is fastened with tape and clip fittings. Previously, Kabe made its skirtings of glass fibre. Now the skirting comes with integrated storage box functions. Moreover, the solution has become easier to install and the precision has improved significantly.
And now it is suddenly easy to make model changes: Longer vehicle, longer profile. It is not more complicated than that.
Tailor-made furnishings
The appearance of the profiles is an important aspect for Kabe. The aluminium look feels modern and exclusive, and it is also used for the furnishings. New profiles have been used, among other things, for the upper closets and the door frames. The construction method is the same as for the roof and the skirting solutions. If you want to have a four metre long closet, you just cut the profiles accordingly. Daniel Blom says:
– This means that the customers can get tailor-made furnishings, which are now as rational to install as a standard solution. The assembly work has also become much simpler. The profiles are prepared for fast assembly with screw ports, groves for installation fittings, etc.
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Aluminium profiles used for the upper closets and the door frames have a modern and exclusive feel. At the same time, the assembly work has become much simpler. |
Weight reduction: approx. 10%
– Environmental aspects have also become more important in the design work. Here I can see several important properties of aluminium. The corrosion resistance results in minimum maintenance needs and when the vehicle ends its life, the aluminium will be recycled. Aluminium scrap is a valuable raw material. Our new solutions have been possible thanks to the formability of aluminium and the profile extrusion technology. On top of this, aluminium is low weight. In total, if you compare the old construction method with the new one, there is a weight reduction of approximately 10%. This results in a reduced environmental impact, concludes Daniel Blom.