GIVI Magazine - Dicembre 2020

A WORLD WITHIN TECHNICAL AND DESIGN OFFICE At the heart of every Givi-branded product is the technical office. Sixteen engineers and three designers work closely together to develop new products. The process of creating a top case can be described as “labor” in every sense of the word, as it takes an average of 9 months to reach the marketing stage. It all begins with an initial sketch on paper, drawn up by the designers. After that comes the first 3D model using CAD, a step which is necessary so that a copy of the top case can be milled from a block of wood. Aesthetic details, which are difficult to render clearly on a monitor, are then added to this scale model. Next comes the laser scan, to obtain the final form which will be fed back into the CAD process. Finally, the engineers model the other components, like the locking mechanism and gaskets, on the computer. Inside our cases is everything we need to set out on a journey. Although these accessories may seem to be made “simply”, in all reality they are the result of sophisticated technologies and incredibly precise construction. To find out more we visit Givi, one of the world’s largest manufacturers of soft luggage and hard cases. by Simone Succi - Polimi Motorcycle Factory, photography by Marco Marini This is how “model zero” of the top case is created, which is now ready to be built and tested in the R&D department. R&D DEPARTMENT Obtaining the finest materials is a vital part of guaranteeing product quality. This is the Givi “ethos”, which is put into practice first of all by conducting internal resistance tests, but also by locating the R&D department immediately below the technical office in order to improve communication between the two areas. The R&D department is responsible for testing both the materials and the finished products. The materials undergo processing by a series of machines, including one which performs the xenon test to ensure the durability of components exposed to sunlight. This involves them being subjected to constant artificial “rainfall” and powerful UV lamps in a test which lasts for 1,500 hours and is passed only if the product’s color does not fade. Then comes a salt mist machine, that tests metals for resistance to corrosion. As the name suggests, the test consists of surrounding a metallic component in a haze of atomized water mixed with salt. The test is considered to have been passed if the item shows no rusting after 240 hours. Then, for finished products, there is a whole new range of tests, one of the most important of which is the shaker for top case plates. This involves reproducing the vibrations measured on the cobbled streets of Milan, but with the strain doubled in comparison to the real route. The force of acceleration can reach as much as 50 G: in other words, the top case experiences a force 50 times greater than its real weight! Next is an oscillating machine consisting of a motorcycle rear seat cowl, where frames and bags are mounted. The machine features an eccentric mechanism which enables periodic motion, simulating the amplified movement of the shock absorber compressing and expanding. Some might think of top and side cases like mere containers made of plastic (or sometimes aluminum), items which serve to increase the carrying capacity of motorcycles. However, most people are unaware of the extraordinary industrial process that lies behind these accessories, with their deceptively simple appearance. They must be aesthetically pleasing, strong, spacious, aerodynamic, water resistant, practical, safe, lightweight and durable, all at once. To learn about all the work that goes into making the accessory which has, perhaps, the greatest impact on motorcycles than any other, we paid a visit to Givi: a global giant and the undisputed Italian leader when it comes to these accessories. We were welcomed by Giuseppe Visenzi, the ever enthusiastic President and founder of the company, who began by producing a simple engine guard in 1978 and has since transformed the business into an true enterprise, with more 800 employees and 10 branches and manufacturing units all over the world. It may be true that you shouldn’t judge a book by its cover, but we can’t deny the impression made on us by the enormous showroom where we were greeted. Laid out before us was the Brescia-based company’s full range of bags and top cases, as well as a selection among the most interesting accessories from the over 150 featured in the catalogue, including products from Kappa and Hevik, Givi’s other brands. Of the major innovations shown to us, one standout was the CAM frame for top cases designed for off-road use, with 18mm-diameter tubes and an attachment with 4 anchor points (instead of the usual 3): the result is a more solid product, able to resist all types of stress. The new Weightless range consists of top and side cases made from thermoformed ABS, for a lighter and more flexible product. As we would go on to discover, however, the showroom provides just a glimpse of the vast world that lies behind the scenes. CAPTION (p. 150-151): FROM TINY PELLETS GROW MIGHTY TOP CASES 1. In huge tanks, thousands of nylon “pellets” await their turn to be sucked into long tubes, heated up and injected into the moulds which will turn out a variety of shells, used to produce top cases and side cases. Along with the structural nylon are additives for the chosen colour palette and for protection from ultraviolet rays. MADE OF STEEL 2 and 3. The exterior and interior of a computerized milling machine: this tool is working on a block of steel. It will carve out a mould which will be used to produce plastic top cases. A mould may last for as long as 20 years. 4. The finished product, after it is removed from the moulds. The finish on the surface of these containers is practically definitive. CAPTION (p. 152): ROBOTS AND LASERS 1 and 2. The automatic press with its robotic arm to feed in sheet metal for bending. The metalworking department of the Brescia-based company contains many automated machine tools: they are used for both flat cutting (thanks to a laser) and for producing the tubes that make up the various case frames. The entire plant is highly reliant on robotic technologies, using automated welders and templates. Nonetheless, the presence of operators is essential both for setting up the welding jigs and for manual quality controls. CAPTION (p. 155): ULTRA-LIGHT 1. A robotic arm applies silicone to pre-determined points of the aluminium sheets to guarantee water-resistance. 2. Working on a metallic component used for assembly. 3. The lightweight alloy sheets are joined using rivets. These are used in conjunction with o-rings to make the assembled unit water-tight. 4. The area where the various finished pieces are stored. Every day, products from here are shipped all over Europe. 5. Givi’s main headquarters, in Flero in the Italian province of Brescia. In addition to the showroom where the products are on display, this building also houses the Research and Development department. CAPTION (p. 153): “AUTOMATIC” SHEET METAL 3. The machine for laser-cutting sheet metal parts, visible in the foreground. The material to be processed is loaded and unloaded by fully automated means. It is used for aluminium and iron items, for components connected to the attachments. It makes it possible to handle large quantities of pieces without relying on manual action. 4. There are five automatic welding lines managed by robots. In Givi, both MIG and TIG technologies are used, with the latter particularly useful for joining small pieces like the bag fixing points. CAPTION (p. 148-149) FROM DESIGNS TO REALITY 1. The wooden model (right) of the TRK35N top case and the production model: the latter is in plastic, with the lid finished in aluminium. 2 and 3. The Brescia-based company has its own Style Centre where all its products are drawn up before being transformed into three-dimensional images on the computer. MILAN CONDITIONS IN THE LAB 4. The aluminium top case in the foreground is in the laboratory, undergoing one of the most exacting tests of its components: a shaker is vibrating at its base to test the fixing plate. The simulation program replicates and amplifies the effect of riding on Milan’s cobbled streets. In the background, another top case is being shaken vertically in imitation of the strain caused by the rear suspension: the test lasts for 100 hours and includes different stages with 10 kg and 20 kg loads. 5. A laser scanner is used to take the measurements of the final models, or prototypes, to create a computerized 3D model. The test, which lasts for 100 hours, takes place in three steps: the first 50 hours use double the maximum permitted weight (20 kg); the next 25 hours use the permitted weight (10 kg); while the case is empty during the last 25 hours. This last phase may appear to be the easiest, but in reality, many components have been found to struggle considerably during the empty-case test. This cycle of tests is essential, both for the approval of a new product and for inspections. In fact, periodic testing is carried out to identify any potentially defective production batches. PROTOTYPING In addition to R&D, there is another department that has been recently relocated beside the technical office: prototyping. It consists of a mini-production line, where the components for various products are developed for testing. One example of what happens here is the creation of side-bag frames, which are specific to each motorcycle. The mounting frame is held in place by a stand, while the modelers take the measurements for the other tubes to connect it to the motorcycle. In general, there are three anchor points plus a strut connecting the two mounting frames. Following this, the tubes are manually cut and bent, and the various components are checked to ensure that they fit together properly. Finally, the welding jigs are produced, i.e. plates featuring special clamps to hold the individual pieces in place during welding. At the end of this process, the pieces are scanned by a laser which creates a 3D model with a tolerance of up to 0.1mm. One difference between the line where prototypes are made and the general production line, in addition to the welding carried out by hand, is the machine used to cut the pieces. At the production stage, where large numbers of components are needed in a short time span, a laser cutter is deployed. But here, where pieces need to be manufactured individually, the solution is to use a water jet cutter, allowing different types of materials to be processed despite making the process slower. Such a huge amount of work for the construction of a frame might seem unreasonable, particularly if you consider that many competitors make bags which attach directly to the motorcycle. Givi, however, are careful to point out to us that the presence of a frame guarantees greater strength. Their system (Monokey or Monolock, depending on the family) means that the same bag can be attached to motorcycles from different brands, thanks to bike-specific frames or the adoption of a universal mounting system. PLASTIC MOULDING The plastic moulding plant is divided into two sections: one where the moulds are produced, the other dedicated to manufacturing the shells. The moulds are cut from blocks of steel using a 3- or 5-axis milling machine. A complete mould consists of two main parts: one male and one female. These join together, leaving only a minimum amount of space for the plastic. Depending on the complexity of the piece being made, the two parts may feature moving sub-parts which make it easier to inject the plastic and remove the piece. The surfaces of each mould are treated with a process called electropolishing, which gives the plastic piece a more resistant finish, as well as a more attractive one. Moulds have an average lifespan of 20 years, but can also be repaired in the event of moderate wear and tear. A mixture consisting of 95% structural plastic, 4% colouring and 1% UV protection is fed into the machinery through a complex system of pipes which run throughout the entire workshop. The UV protection alone represents 25-30% of production costs, but guarantees a longer- lasting product. The mixture, which arrives in the form of solid pellets, is then heated up by friction and injected into the mould. The injection reaches a pressure of up to 1,800 atmospheres, the equivalent of being 18km underwater. When the plastic has completely filled the moulds, it is time for the presses to firmly clamp the two halves of the mould together. Both hydraulic and electromagnetic presses exist, and are capable of exerting pressure in the region of 600-700 tonnes/cm2. When the piece has solidified, it is removed using a suction system which places it on a conveyor belt to cool down. For certain shapes, a wooden model is placed inside the piece to prevent excessive shrinkage. The shells are then packaged and sent to the assembly department. FRAME PRODUCTION The metalworking department is where all the metallic parts are made. The most complex task is, without a doubt, producing the frames. It begins with using laser machines to cut the pieces, both for sheet metal and for the tubes. The laser cutter is able to handle sheets of 3,000 x 1,500 mm2, and uses a software which automatically arranges cutting patterns to keep material waste to a minimum (the technical term for this is “nesting”). The pieces produced by the tube-cutters feature openings on the surface, which the automatic tube-bending machines use to detect the correct positioning of the tubes to be bent. In fact, the production line has not only a manual bending station, but an automatic shaping station too, which is capable of handling up to 12 different processes at a time. An operator then assembles the individual components in a welding jig and inserts them into one of the four automated MIG (metallic arc) welding stations. Recently, a TIG station (arc welding with a non-consumable tungsten electrode) was also introduced. This addition was necessary for the bag mounting points and also enables greater quality control. When it comes to inspections, both manual and automatic templates are used. The former are frames into which welded, cooled pieces are placed to ensure that they respect tolerances; automatic templates, on the other hand, are capable of making a 3D scan of the piece and comparing it with the original model used for reference. The check takes just a few seconds, making it useful for periodic controls of individual components after cutting and bending too. In terms of the number and quality of the pieces, production is monitored by internal software. Every single batch is labelled with the station and operator that produced it, in addition to specifying the area for which it is destined. This makes it possible to tell if an operator works particularly well or poorly on a given machine, thus enabling optimum human resource management. Another aspect of technological optimization within the plant is the vertical warehouse. This completely automated tool storage system guarantees control over the quality and organization of work equipment. In fact, each operator must identify themselves when requesting their equipment; and, once they have obtained it, must scan a bar code to confirm that they have chosen the right item from the machine. This helps to prevent loss and encourages employees to take care of the equipment, as they are personally responsible for it. ALUMINIUM CASES The plant at Barbariga (BS) in Italy, with an area of 20,000 square metres, is Givi’s logistical centre. This is where all finished products are stored before being shipped to their destination, and where both national and international shipments are handled. On an intense day of work, the logistics department is able to send out multiple lorry-loads. The same building is also home to the assembly department for aluminium top cases. The shaped pieces are still covered in film when they arrive at the assembly department. Removing this film from each top case is a relatively laborious process, but it protects the product from damage during transport. On the same topic, we were also told about how top case processes have been optimized even in terms of how they are transported: in fact, the current method enables smaller carts to be used, which helps to save time. The assembly department consists of various production lines. In general, an aluminium top case is made up of fewer pieces than a plastic one, but requires greater care and control during assembly. One of the reasons why such high precision is required at this point is water-tightness: generally, plastic top cases are less permeable, while aluminium ones require an o-ring on every rivet and silicone between the different components. The application of silicon is carried out by a robot, which enables greater precision and reduces waste. Water-tightness is assessed within the plant itself: a machine with a rotating arm sprays a case with water at a rate of 25 litres/minute for 10 minutes. The test is considered passed if the case has a water resistance equivalent to that required by IPX4-IPX6 certifications. We also learned that Givi’s models are not waterproof if submerged in water, due to the presence of a small drainage opening. This valve is necessary to prevent altitude changes from creating a vacuum inside the case and making it impossible to open. In any case, it in no way compromises the functionality of the product - after all, it wasn’t designed for underwater use! ENGLISH TEXT ENGLISH TEXT 38 39 Chi parla di noi Givi Magazine December 2020 The trade press often talks about us. It dedicates news to our products, involves us in dossiers on specific topics and compares us with other brands within comparative elaborations. The article that we propose here, realized last year by Motociclismo magazine, has gone beyond our expectations. Divided into two parts, it presents a long “technical” intro, which tells in detail how our cases are created, followed by an interview with Giuseppe Visenzi, President of GIVI Spa.