Grote 101 Module 8 Grommets Brackets Flanges Reflectors

Grote 101 Module 8 Grommets, Brackets, Flanges, Reflectors, Lenses, Mirrors and Flashers

Mastery Statement • In this module you will learn the different ways to secure lamps to vehicles, what requirements and options are available for reflective products, lenses and mirrors, and advances in flasher technology.

Background Knowledge • • Grote Product History Regulatory Issues How the Product Works Product Categories

Grommets • Grote History – Grommets have been an integral part of lamp mounting for over 30 years, first appearing in a Grote catalog in 1980 – Grommet manufacturing often seems a “nobrainer”, who cares proposition • There is engineering involved and exacting tolerances

Grommets • How the Product Works – Grommets are used as mounting devices for two main purposes • Absorb vibration • Expedite lamp repair/replacement – The future for grommets continues to be strong as long as incandescent lamps continue to be used, maintained and retrofit to LED lamps

Grommets • How the Product Works – Grommets are not “same as” products as you might naturally assume • Grote makes them an integral part of the overall system • Many variations are molded here at our manufacturing facility in Madison, IN and others are sourced to Grote’s exact specification

Grommets • How the Product Works – One of key selling points of the Grote grommet is our use of the Durometer Scale • Durometer is the measure of hardness of a wide variety of rubbers, plastics, elastomers and foams • Durometer is important for many reasons – Lamp interface – Push Out force

Grommets • How the Product Works – Durometer Scale • Grote selects different rated material for different products • Examples – – – Inner tube is 55 4” round grommet is 60 Rubber tire is 65 Rubber shoe heel is 70 2” round grommet is 75

Grommets • Extensive testing is done to measure – Our grommets and our lamps – Our grommets with competitors’ lamps – Competitor grommets and our lamps – Competitors’ grommets with their lamps • Keep in mind that it is friction and grip of the grommet/lamp interface and how it mates to the buck plate that holds the lamp into place

Grommets • Extensive testing is done to measure – Testing has shown that Grote lamps and grommets when used together average over 5 pounds of push-out force. That is almost twice that of our competitors

Grommets • Product Configuration – Open Back • Most prevalent • Easy access for maintenance or replacement of lamps and increased visibility – Closed Back • Protects the back of the lamp from exposure to the elements to improve lamp/pigtail interface

Brackets • Serve a similar function as grommets – Mount a lamp to the vehicle – More than a decorative accessory • Protect the lamp from knock-off – Branches, debris, buildings, forklifts

Brackets • Two types – Plastic • Polycarbonate – For use on rear, side or front of equipment • ABS • PVC

Brackets • Two types – Metal • Steel (Painted or Powder Coated) – Gray, Black – Yellow Zinc or Stainless Steel • Aluminum

Flanges • The predominant mounting option at the OEM level – With increased use of LEDs at the OEM level flanges add a level of theft protection – When using LEDs at the OEM, maintenance and removal of the lamps is lessened and permanent mounts are acceptable

Flanges • Available in two types – Plastic • Polycarbonate – Gray, Black, White and Chrome Plated • ABS – Metal • Stainless Steel

Flanges • Different Mounting Configurations – Rivet – Screw – Snap-in • Stainless Steel or Polycarbonate – Tabs that hold tight to different thicknesses of buck plate

Flanges • Grote vs. Competition Our lamps and flanges have been engineered to fit together Our lamps will fit into competitors’ flanges and vice versa It is not a given that our lamps/flanges will be compatible with competitors products

Reflectors

Reflectors • Grote History – Reflectors are the very basis of our long and successful history • There would be no Grote Industries today without that pioneering product back in 1922 • We were the sole supplier of optical reflectors to the automotive industry from 1930 -1940 • We still offer the widest variety of reflectors in our industry

Reflectors • How the Product Works – Today the process of making reflectors has changed but the function remains the same • Reflect light through a series of prisms to increase conspicuity – Reflectors are primarily red or amber – Mounted by screws, “sticky back” or other adhesive

Reflectors • FMVSS (Federal Motor Vehicle Safety Standards) – There are multiple elements of reflectors in the FMVSS 108 statutes (Trucks and Trailers) – Area 1 - Rear Reflex Reflectors • Indicates a vehicles presence and width – Area 2 - Front Side Reflex Reflectors • Can be in combination with the marker lamps • Indicates a vehicles presence and length – Area 3 - Intermediate Side Reflex Reflectors (Trailers 30 ft or longer) • Indicates presence of a long vehicle

Reflectors • FMVSS – Trailers over 80” width • In 2001 Federal regulations mandated that all trailers on the road must utilize conspicuity Tape – Conspicuity Tape • Alternate red and white (or silver) tape on side and rear of trailer • White tape in upper rear corners • Red and white tape on horizontal bar of rear I. C. C. bumper, a minimum of 1 ½” width • Colors must be placed in alternating sequences with no more than 2/3 of the sheeting in one color. Use strips of 6” to 12” per color

Reflectors • FMVSS - Conspicuity Tape • Cover a minimum of 50% of trailer length. The use of broken strips are acceptable, as the tape need not be applied to such surfaces as outside ribs, stake post pickets on platform trailers and external protruding beams. The distribution of space and material must be as uniform as practical and must identify the full length of the trailer at a height between 15” and 60” • The edge of the white tape shall not be located closer than 3” to the edge of the lens area of any lamp required

Reflectors • FMVSS – Conspicuity Tape • The edge of the red tape shall not be located closer than 3” to the edge of the luminous area of any required amber lamp but may be adjacent to any red lamp • The horizontal stripe of red/white tape across the full width of the trailer shall be as close to the extreme edges as practical, between 15” and 60” above the road surface • DOT C-2 (2” width) reflective tape, is used, may be separated into 1” strips of the same length, and placed no more than 1” apart to avoid rivet heads or similar obstructions

Reflectors • Grote Conspicuity Tape – Best warranty in the business - 7 years against fading and adhesion breakdown – Exceeds the FMVSS 108 and DOT C-2 requirements – Only reflective tape with daytime reflectivity – 12 different micro-prism patterns to reflect more light, day or night, resulting in the best visibility of any tape

Reflectors • Grote Conspicuity Tape – Maintains reflectivity regardless of the amount of exposure to UV radiation – Colors are internally pigmented (not dyed) to prevent fading and protected with an additional acrylic layer – Available in 150’ rolls, 18” strips or by trailer kits for tailored installation

Replacement Lenses • Lens History – Until the 1970’s all lamps were serviceable • Meaning that replacement lenses on standard lighting was a viable and necessary element of the business – With the introduction of sealed “throwaway” lighting standard replacement lenses became unnecessary

Replacement Lenses • Lens History – There are still many versions of lighting products use replaceable lenses – – Cab and clearance markers S/T/T lamps Work lights Hazard & warning lights

Mirrors • Grote History – We have been selling mirrors for more than half of our company's existence – There was a time in our history that we were a major OEM supplier of mirrors – Mirror styles have changed • New vehicles want customs mirrors solutions • Aerodynamic housings • Smart mirrors with cameras, heaters and sensors

Mirrors • Grote History – In 2007 we decided that we were no longer going to manufacture mirrors – A long process of testing, specifying, competitive analysis and sourcing took place – In 2009 we completed the process of moving our mirror production to mirror sourcing

Mirrors • Grote History – Grote still offers basic coverage of conventional assemblies and mirrors for Class 6, 7 & 8 vehicles. – We are very competitive against other similar lighting and mirror suppliers with our offering of convex and west coast mirrors

Mirrors • The Grote Product Line – We are not actively looking to expand our mirror product line • We are testing some new LED integrated products in Canada and they will likely be offered via drop ship to the U. S.

Mirrors • The Grote Product Line – Two typical materials • Plastic Backed – DURAMOLD – Nylon • Metal – Stainless Steel – Aluminum

Mirrors • The Grote Product Line – Significant difference when comparing our convex mirror line to competitors • Their mirrors typically do not include any J or L brackets • Our mirrors almost always include the J or L brackets (sometimes both)

Mirrors • FMVSS 111 – The NHTSA (National Highway Traffic Safety Administration) standard regulating mirror positioning and reflectivity for School Buses • TP-111 V – The section of FMVSS 111 for all vehicles that are not School Buses

Flashers • Flasher History – First made their appearance in the 30’s • Significant technology of the time was magneticoperated flasher – Not much different than today’s relay flashers – Thermal flasher was introduced in 1962 • Quickly dominated the market for two decades

Flashers • Flasher History – Electro-Mechanical developed in the late 70’s • Pre-dominantly used in the heavy duty market – Hybrid flashers were introduced in the 80’s – Solid State flashers were introduced in the 90’s – Flasher technology will remain unchanged as most flashing functions have moved to the ECM unit

Flashers • How do they work? – Thermal flashers • Two types – Fixed Load – Variable Load • Both operate on a thermalmechanical principle

Flashers • How do they work? • Heated ribbon – During the flash cycle, heat is introduced to the ribbon via a heater wire wrapped around the ribbon – The ribbon expands and based on timing snaps the bimetal blade closing the contact – When the contact closes the power that heated up the ribbon is interrupted and the ribbon cools and contracts snap back open creating the flash cycle – The entire assembly is adjusted to proper flash rate, duty cycle, and load condition

Flashers • How do they work? Thermal Flashers • Advantages Product maturity Low cost • Disadvantages Load current passing through timing mechanisms (blade/ribbon) causes product stress Battery voltage is used to time the flashers, so as load or voltage varies, the flash rate changes too

Flashers • How do they work? – Electro-Mechanical • Capacitor – The flashers time the flash rate and duty cycle by charging and discharging a capacitor – The battery voltage drives the timing mechanism • Advantages – The current is not passing through an integral part of the timing mechanism, so it creates less stress on the flasher • Disadvantages – Mechanical contacts and higher unit cost

Flashers • How do they work? – Hybrid • Integrated Circuit Technology – Requires a ground terminal • Advantages – ICT allow new features within the flashers – Monitors and controls flashers with lamp outage indication and over voltage protection • Disadvantages – Mechanical contacts and higher unit cost

Flashers • How do they work? – Solid State Flashers • Transistor All solid-state flashers use a transistor to pass the current which eliminates mechanical contacts • Advantages Accurate flash rate, accurate duty cycle, lamp outage indication, added load indication, and overload protection • Disadvantages Heat build-up and voltage drop

Flashers • The Evolution Continues – Solid-State-Relay Flashers • Through the use of custom IC technology, solidstate switching and electro-mechanical relays these new flashers have been able to take full advantage of each technology to provide the most reliable and accurate flashers on the market today!

Flashers • Current State of the Flasher Market – Most flasher manufacturers have left the business – Those that remain are typically buy/sell with the primary flasher manufacturers – Most aftermarket flashers are sourced overseas – Grote still makes most of their own flashers – Flasher market is flat or declining based on current vehicle electronics, longer lasting flashers and custom designed technology for the OEM

Customer 101 Module 8 Grommets, Brackets, Flanges, Reflectors, Lenses, Mirrors and Flashers Please consult your Grote Technical Specialist if you have any additional questions Thank-you for your valued time