Techforum 1 12 en

techforum
Issue 1 I 2012
ThyssenKrupp
Developing the future.
Cover picture The iwalk is an innovative product from ThyssenKrupp Elevator offering advanced technology, maximum user convenience and low environmental impact. Because the new moving walk is highly customizable, it solves many of the challenges of previous designs a key factor in the selection of four horizontal and three inclined iwalk units for installation at Atocha railway station in Madrid/Spain. A variety of new features make riding the moving walk an even safer experience; for example, the lower height of the comb segments in the entry and exit zones greatly reduces the risk of tripping, especially for passengers with luggage. The iwalk not only complies with European standard EN 115, which requires moving walks to have 400 millimeters of free space, but, due to its greater pallet width, it also permits large trolleys and shopping carts to be used. Despite this, the overall dimensions of the iwalk have been reduced, setting new standards for the sector. Two different types of balustrade are available, providing added safety while at the same time giving the new moving walk its stylish look. Both the slim variant shown here and the robust version are made from twelve millimeter shatterproof safety glass, which runs the entire length of the balustrade. Sustainability was also a key factor in the development of the iwalk. Technical features such as fewer components, the use of new energy-saving systems and LED lighting, as well as lower weight, help reduce energy consumption and environmental impact. Less shipping volume and less packaging are further aspects that help make this versatile moving walk even more sustainable. The iwalk was awarded first prize in the 2011 ThyssenKrupp Innovation Contest.
PUBLISHER ThyssenKrupp AG, Corporate Center Technology, Innovation & Quality, ThyssenKrupp Allee 1, 45143 Essen, Germany Editor: Guido Focke, Telephone: +49 201 844-536291, Fax: +49 201 8456-536291 ThyssenKrupp techforum appears once or twice a year in German and English. Reprints with the permission of the publisher only. Photomechanical reproduction of individual papers is permitted. ThyssenKrupp techforum is distributed according to an address file maintained using an automated data processing system. ISSN 1612-2771
Foreword
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Dear readers,
ThyssenKrupp has been organizing the in-house Innovation Contest since 2000. The level of participation among our subsidiaries was once again pleasingly high in 2011 and the quality of the projects outstanding. Our engineers do a great job when it comes to translating new ideas into products, processes and services in the context of active and sustainable innovation management. This plays an important part in living up to our slogan Developing the future. I would like to take this opportunity to thank them all. For us, innovations and technical progress are key factors in managing global growth and using finite resources in a sustainable way. The inescapable need to become better offers clear opportunities for our Group: With our engineering expertise in the areas of Material, Mechanical and Plant, we enable our customers to meet the rising demand for more in a better way, gain an edge in the global market and manufacture innovative products in a cost- and resource-efficient way. The development projects in the ThyssenKrupp Innovation Contest underline the successful work of our research and development departments and at the same time act as an incentive to further expand our innovation activities. The winning entry in the 2011 Innovation Contest was the iwalk moving walk developed by ThyssenKrupp Elevator which significantly reduces space requirements. It also offers major advantages in production, transportation and installation, as well as during use for example through lower power consumption. ThyssenKrupp Presta Camshafts won second prize with its project Modular concepts with integrated camshafts Presta. The Presta process makes it possible to manufacture camshaft modules using a thermal-mechanical joining process to integrate assembled camshafts inseparably into a cylinder head cover. In addition to significantly reducing emissions, this process also lowers the cost of manufacturing the cylinder head/cover system. The wear resistance of wind turbine components is key to the availability of the turbines and avoiding downtimes. Under the project awarded third prize, Rothe Erde developed a steel bearing cage with a polyamide coating to separate and guide the individual rolling elements, which significantly reduces wear. The special Energy and Environment innovation award went to a team from ThyssenKrupp Industries India for the development of an energy-efficient two roller mill to produce sugar from sugar cane. By completely redesigning the mill structure they managed to minimize friction losses and wear. This results in significantly lower energy consumption compared with conventional mills and thus to a substantial reduction in CO2 emissions. Several of the outstanding projects entered in the 2011 Innovation Contest are presented in this issue of ThyssenKrupp techforum. I am also particularly pleased that in Dr. Reinhold E. Achatz we have found a recognized expert for our research and development activities. Dr. Achatz was appointed head of Corporate Center Technology, Innovation & Quality in April 2012. You can read more about him on the next page. I wish you an enjoyable read. Yours,
Dr.- Ing. Heinrich Hiesinger Chairman of the Excecutive Board
ThyssenKrupp techforum 1 I 2012
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Dear readers,
The world is changing at ever-increasing speed. As a result, the importance of innovation bringing new ideas to market successfully is growing constantly. This is true of all regions, sectors and markets. Only innovative organizations can maintain their levels of value added efficiently and effectively and grow them by developing new markets. For this, a focus on existing and newly acquired core competencies is essential. That means understanding the needs of our current and future customers and delivering products and solutions that meet their expectations in terms of quality and functionality. In my new position as head of Corporate Center Technology, Innovation and Quality I intend to work together with colleagues from our Group companies to develop and implement a consistent, forward-looking innovation strategy for ThyssenKrupp.
Yours
Dr.-Ing. Reinhold Achatz Head of Corporate Center Technology, Innovation and Quality
Brief portrait Reinhold Achatz holds a degree in Electrical Engineering (Dipl.-Ing.) from Friedrich-Alexander University Erlangen-Nuremberg (1979) and a Ph.D. in Information Technology in Mechanical Engineering (Dr.-Ing.) from Munich University of Technology (2009). In September 2010 he was appointed Honorary Advisory Professor at Tsinghua University in Beijing. Dr. Achatz was most recently Corporate Vice President of Siemens AG. In this function he headed Corporate Research and Technologies at Siemens (from October 2006) which employs around 1,800 people in Austria, China, Denmark, Germany, India, Japan, Russia, Singapore and the USA. He was responsible for research in the areas of Electronics, Energy & Environment, Information & Automation, Materials & Hardware Design, Processes & Production, Industrial Communication Technologies, Software & Systems Engineering, SMART Innovation and Sustainable Solutions. From April 2009 he was also responsible for the Corporate Development Center with around 4,000 software developers worldwide the majority in India, Central and Eastern Europe. This organization develops software products and solutions for Siemens business units. He is also member of numerous organizations and institutions including the German Council of Science and Humanities, the German Cyber Security Council and the Boards of Trustees of the Fraunhofer Institute for Experimental Software Engineering (IESE) and the Max-Planck Institute for Computer Science (mpii). Dr. Achatz took over as head of Corporate Center Technology, Innovation & Quality at ThyssenKrupp AG in Essen on April 01, 2012.
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10 / Tailored Tempering
Customized material properties for hot-stamped parts
Dipl.- ING. SAschA SikOrA, Dipl.- ING. JANkO BANik, Dr.- ING. StephAN GrAFF, Dipl.- ING. RObert LAureNZ, Dr.- ING. FrANZ-JOseF LeNZe ThyssenKrupp Steel Europe AG
The requirements placed on vehicle crash performance and fuel consumption have increased consistently in recent years. Technologies such as the press hardening of manganese-boron steels can help reduce car body weight while optimizing service properties. ThyssenKrupp Steel Europe has developed an enhanced press hardening process called tailored tempering that makes it possible to exploit the full range of strength levels offered by steel through precise control of the cooling process in the forming die.
16 / PLADUR Antikondensat

Functional surface for dry interiors

BeAte FuGMANN, Dr. rer. NAt. BettiNA WerNer, Dipl.-ING. RAlF WittkOwski, Dipl.-ING. AXel POhl,
Dipl.-ING. ReiNhArd TGer ThyssenKrupp Steel Europe AG
Working with a paint manufacturer, ThyssenKrupp Steel Europe has become Europes first coil coater to develop a water-absorbing coil coating system for to steel surfaces: PLADUR Antikondensat is used in the construction sector as a cost-efficient alternative to conventional fleece membranes. The new two-coat system can be applied on ThyssenKrupp Steel Europes existing coil coating lines without the need for any additional investment. It comprises an anti-corrosion primer and a functional top coat and was developed for use in industrial and agricultural buildings with non-insulated roofs and walls. The anti-condensation function effectively prevents the formation of mold caused by damp conditions and thus protects employees health and avoids damage to goods and machines. Already successfully launched, the innovative coating system offers customers both cost savings and greater architectural design freedom, as PLADUR Antikondensat can be installed at any angle and is available in a variety of colors.
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22 / Solabs 2 Renewable energy generation using solar-active

facade module for industrial and commercial buildings

Dr. rer. NAt. ROMAN GlAss ThyssenKrupp Steel Europe AG Dipl.-ING. ANdreAs LitZkOw ThyssenKrupp Bausysteme GmbH Dr.-ING. LArs PFeiFFer, Dr. rer. NAt. BettiNA WerNer ThyssenKrupp Steel Europe AG
ThyssenKrupp Steel Europe and the subsidiaries of the Color/Construction business unit have jointly developed a new sandwich facade module which can be used to provide thermal energy in commercial and industrial buildings. The Solabs 2 facade module is similar in design to a standard module and comprises an insulating core bonded firmly to coil-coated carbon steel face sheets. The outer color of the facade module is selected to achieve a high degree of solar absorption and therefore a high level of energy input. Incorporated in the insulating core is a pipeline system which is connected to the facade exterior so that the solar energy can be utilized in the form of heat. Together with a customer, an architect and a system partner, ThyssenKrupp Steel Europe is currently working on constructing a reference building featuring such modules. On successful conclusion of the project, it is intended to launch the solar-active facade module on the market.
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28 / HD High-ductility, low-alloy, fine-grain structural steels A new product series for cold forming
MAtthiAs Gruss, Dipl.-ING. MAXiMiliAN NAGEL, Dipl.-ING. Peter HFel Hoesch Hohenlimburg GmbH
High-ductility (HD) steel grades extend the possibilities for structural design in lightweight automotive engineering. The new material HSM 700 HD from Hoesch Hohenlimburg sets standards with yield strength of at least 700 MPa in combination with elongation of approx. 20%. These values are made possible by an innovative micro-alloying concept based on the use of niobium. Coupled with a precisely defined process routine for hot rolling and subsequent cooling, the scatter range of the mechanical properties can be greatly reduced.
32 / Foundation of heliostats for solar power stations

Using special equipment to install thin-walled steel pipes

Dr.-ING. JOhANNes Kcher, DOris Becker-SpOhr ThyssenKrupp Tiefbautechnik GmbH
Solar thermal power stations and systems are based on the principle of using a large number of mirrors to focus sunlight onto a concentrated point of a receiver tower, thus creating a huge amount of heat for producing steam, which can be used in turn to drive turbines for generating electricity. The many thousands of mirrors which are needed for such a system must be securely founded. For this purpose, ThyssenKrupp Tiefbautechnik, a manufacturer of construction machinery and components for specialized civil engineering applications, has developed a special tool and process which enable foundations to be installed quickly, easily and economically.
38 / iwalk

A milestone in the moving walk industry

DIPL.-ING. MIGUEL GONZLEZ ALEMANY ThyssenKrupp Elevator (ES/PBB) GmbH
iwalk is the new moving walk from ThyssenKrupp Elevator. The biggest advantage of this new system is that it reduces space requirements in several dimensions. The new design allows a reduction of more than 50% in installation depth, which means the horizontal variant can be installed directly on existing floors. This reduces construction work for installation and lowers costs. The modular design permits greater flexibility and offers significant advantages in production, logistics and installation. This innovation represents a fundamental re-design of conventional moving walk technology, resulting in significantly enhanced customer value alongside all the product advantages.n of moving walk technology, resultinganced customer lue al
44 / Mini-PROven

Reduced emissions from small and medium-size coke ovens thanks to single-chamber pressure control
Dr. rer. NAt. Friedrich HuhN, Dipl.-ING. FrANk Krebber, Dr.-ING. JOANNA KhN-GAjdZik, KerstiN berschr ThyssenKrupp Uhde GmbH
For environment and occupational health reasons it is becoming increasingly important for coke plants to be operated with the lowest possible level of emissions. In the past, changing pressure conditions in each individual oven, with particularly high values at the beginning of the coking period, often resulted in considerable emissions at the oven closures. To prevent this happening on modern large-scale ovens, ThyssenKrupp Uhde developed the PROven (Pressure Regulated Oven), a single-chamber pressure control system which regulates the pressure in the individual coke chambers down to a constantly low level. In the meantime, after many years of successful service, the system has been upgraded in both its design and process engineering. The result is Mini-PROven, which in future can also be retrofitted to old small and medium-size coke oven batteries in the interest of better environmental protection.
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50 / Modern gearless drive systems for high-capacity belt conveyors

GNther KerkhOFF BSEE, Dipl.-ING. Peter Sehl, VlAdiMir Svirsky MSME ThyssenKrupp Robins Inc.
In many mining areas, ore grades are declining. New mines are being developed in ever more remote areas. Pits are getting deeper and more hard-rock mines are switching to underground operations. This means that more material must be transported over longer distances, which creates new challenges. As mining volumes increase, demands for availability are also rising. As a result, conveying systems need to be equipped with modern drive systems that guarantee a high degree of reliability.
56 / Energy-efficient two-roller mill

YAshwANt SAkhArdANde B.TECH, ArviNd KArMArkAr B.E. (Mech) ThyssenKrupp Industries India Pvt Ltd.
To meet market demand for energy-efficient equipment, ThyssenKrupp Industries India has developed a highly energy-efficient, trash plate-less two-roller mill to overcome the limitations (frictional losses, complexity and wear) of the conventional three-roller mill. The new mill reflects the pioneering role played by ThyssenKrupp Industries India in the Indian sugar industry. As mills are major power consumers in the sugar industry, there was an urgent need for an energy-efficient alternative. With its large market presence in the sugar industry, ThyssenKrupp Industries India is constantly looking to develop more energy-efficient equipment and processes for all areas of sugar production.
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64 / POLAB Shuttle The new generation of laboratory automation
Dipl.-ING. HuGO HASSMANN ThyssenKrupp Polysius AG
Fast and comprehensive quality analysis in all stages of production is essential in the cement and building materials industry. As well as representative sampling in the various stages of the process, sample preparation and sample analysis are key factors in monitoring the quality of the end product. The increasing use of alternative fuels and raw materials calls for a highly flexible and continuously available laboratory automation system to meet current and future requirements. POLAB Shuttle is a freely configurable laboratory automation system with a common human-machine workspace.
70 / MDI-Wind Machine Diagnostic Interface The online condition monitoring system thats not just for wind turbines
Dipl.-ING. ANdreAs Eicke ThyssenKrupp System Engineering GmbH
It is becoming increasingly important to be able to implement condition monitoring to protect high-grade investments such as wind turbines and other major industrial plant and installations. ThyssenKrupp System Engineering has developed a Machine Diagnostic Interface (MDI) for this purpose that is based on proven and reliable standard components in terms of the hardware used. As regards the software, the measuring and automation system used is based on mature technology, was developed in-house and has proved its worth over many years on testing and assembly lines in the automotive and supply industry. The basic concept of the Condition Monitoring System (CMS) and the essential technical elements of the MDI are introduced here. The development was funded by the German Federal Ministry of Economics and Technology (BMWi).
76 / Development of cages for slewing bearings in wind turbine systems

Dr.-ING. JrG ROllMANN, Dr.-ING. WilFried SpiNtiG, Dipl.-ING. SteFAN SchNieder, Dipl.-ING. ReiNhArd JrGeNs Rothe Erde GmbH
Slewing bearings are key components in the power-train of a wind turbine. They are used as blade adjustment bearings and as nacelle bearings. The roller bodies in these bearings are kept separate from each other preferably by steel cages. To prevent wear, a plastic coating process for cages was developed at Rothe Erde. Various tests conducted on plastic-coated cages used in heavy-duty blade bearings (dia. 2 m) revealed a considerable increase in wear resistance on these cages compared to uncoated cages. Following the integration of this coating process into the cage production line, the process is one of the standard features of Rothe Erde bearings for wind turbines today, particularly those used in the offshore sector.gesetzt werden.
80 / DampTronic select
Dipl.-ING. Ole GtZ, Dipl.-ING. KlAus SchMidt ThyssenKrupp Bilstein GmbH
The DampTronic select two-stage damping system developed by ThyssenKrupp Bilstein bridges the gap between conventional, passive shock absorbers and complex, infinitely variable electronic damper systems. When configuring his vehicle, the customer no longer needs to decide between normal or sports tuning, but can simply change between two suspension settings by pushbutton. At the heart of the innovation is the highly compact DampTronic select valve with two damping force characteristics which can be tuned largely independently of each other. Low component costs and integration work have reduced the costs of the system so much as to make it attractive even for the compact and small car segment.
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Tailored tempering: Functional part production with temperature-controlled die segments
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Tailored Tempering
Customized material properties for hot-stamped parts
Dipl.- ING. SAschA SikOrA Project Manager, R&D ThyssenKrupp Steel Europe AG Dortmund Dipl.- ING. JANkO BANik Project Engineer, R&D ThyssenKrupp Steel Europe AG Dortmund Dr.- ING. StephAN GrAFF Coordinator, R&D ThyssenKrupp Steel Europe AG Dortmund Dipl.- ING. RObert LAureNZ Coordinator, R&D ThyssenKrupp Steel Europe AG Dortmund Dr.- ING. FrANZ-JOseF LeNZe Product Manager Hot Stamping, R&D ThyssenKrupp Steel Europe AG Dortmund
The requirements placed on vehicle crash performance and fuel consumption have increased consistently in recent years. Technologies such as the press hardening of manganese-boron steels can help reduce car body weight while optimizing service properties. ThyssenKrupp Steel Europe has developed an enhanced press hardening process called tailored tempering that makes it possible to exploit the full range of strength levels offered by steel through precise control of the cooling process in the forming die.
Press hardening In the field of tension between globalization, cost-efficiency and emissions control, steel offers a range of new solutions for car body production. Press hardening of parts made of steel MBW 1500 offers new opportunities for costeffective weight reduction. The requirements placed on vehicle crash performance and fuel consumption have increased consistently in recent years. To meet the conflicting demands of increased safety and lower vehicle weight, various new lightweighting strategies have been developed and implemented. Technologies such as the press hardening of manganese-boron steels can help meet these requirements. Tensile strengths of up to 1,600 MPa in the finished part can be achieved through a suitable combination of
manufacturing technologies with the steel MBW 1500. This steel is used among other things for A and B pillars, roof frames and dash panel cross members. The very high tensile strengths achieved by hardening make it possible to reduce weight while maintaining high crash safety. Compared with high-strength cold forming steels, complex shapes can be produced with high dimensional accuracy and without significant springback. Thanks to prior austenitization and the reduced flow stresses this allows that MBW 1500 can be formed with lower press forces compared with the cold forming of high-strength steels. This is one of the main advantages of press hardening. Hot stamping or press hardening has become an established technology worldwide for the production of structural body parts.
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Tailored Tempering customized material properties for hot-stamped parts
Optimization possibilities for hardened structural parts

In parallel with the possibility of developing high strength levels through the hardening of MBW 1500, body developers are expressing interest in parts with locally reduced strength levels and improved residual elongation values. This results from the stresses and associated strains occurring when the part is under load. Deformation of a body part occurs for example as a result of the energy introduced by a crash. In order to have greater deformation reserves for the hardened part, one idea is to provide a local improvement in ductility in the form of increased residual elongation values. There are several technological ways of doing this in hot stamping. However, cost aspects also have to be considered. From a cost point of view it would make sense to shift the control of local mechanical properties to the actual press hardening process in order to eliminate production steps. ThyssenKrupp Steel Europe has taken on this challenge and developed a process for local ductility improvement taking cost aspects into account. The process was
designed for the so-called direct hot stamping route, in which the blank is austenitized homogeneously and formed in the die. Only a single forming step is needed to produce structural body parts.
Tailored tempering process

The new tailored tempering process exploits the full range of strength levels offered by the material. The properties of modern steels are determined on the one hand by their chemical composition and on the other hand by an intelligent heat treatment strategy. The possible phase transformations are represented by time-temperaturetransformation (TTT) diagrams / Fig. 1 /. In the case of hot stamping MBW 1500, microstructure control was implemented in the forming die. The use of a partially heated die makes it possible to achieve locally slower cooling of the previously austenitized material. Whereas the material in the non-heated die segment cools at a high rate, forming a martensitic structure, the reduced cooling rate in the heated die segment results in a ferritic-pearlitic or ferritic-bainitic

1,000
Ac3 Work area tailored tempering 750 Transforming temperature [C] Ac1
Sp
40* Sp 45
70* 25
70* 30*
B
500 Work area press hardening Sp 35 70
M
250
M
465 375 270 210 180 160
475
6 8
6 8
6 8
4 6 8
10-1 100 101 102 103 Cooling time t8/5 [s] Fig. 1 / TTT diagram for MBW 1500
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microstructure depending on process control. The martensitic transformation produces a strength level of 1,500 MPa, the ferritic-bainitic transformation a strength level tensile of 650 MPa. The desired mechanical properties of the material and part can thus be controlled via the chosen die temperature. The resultant microstructure is achieved via the chosen cooling rates and determined indirectly by the desired mechanical properties of the part. This coordinated process makes it possible to control material properties very specifically and also to limit them locally.
Technological implementation
As part of the ThyssenKrupp special research project InCar (see also ThyssenKrupp techforum, issue 1/2011) this process was used to manufacture MBW 1500 parts in a pre-production test die. One innovative solution from this project is a B pillar made from MBW 1500 using the tailored tempering process. B pillars are load-bearing safety-relevant parts of the passenger cell. The required strength levels in the part were determined initially on the
basis of a crash simulation. The B pillar was designed to meet the main load case in the IIHS test (Insurance Institute for Highway Safety). The simulation showed that the lower area of the B pillar required elongation values of 15% and strengths of 650 MPa to meet the crash requirements. Kinetic energy can be absorbed by a ductile bottom section, while the very strong top section offers the required resistance to buckling. A hot stamped B pillar with the same high-strength properties throughout would not have met the crash requirements for this vehicle. To validate general forming feasibility a thermomechanically coupled FEM simulation was carried out before production of the prototype die. The mechanical properties theoretically achievable with the tailored tempering process vary depending on cooling history. To allow simulation of the mechanical properties of parts produced by tailored tempering, a precise mathematical model is needed to describe phase transformations. ThyssenKrupp Steel Europe developed its own program for this.
FEM simulation
Phase transformation
Martensite share 1 = 100% 0 = 0% 2.5 mm

1.00 0.95 0.90 0.85 0.80 1.00 0.95 0.90 0.85 0.80 0.75 0.70 0.65 0.60 0.55 0.50 0.45 0.40 0.35 0.30 0.25 0.20 0.15 0.10 0.05 0.00
Bainite share 1 = 100% 0 = 0%

550 525 500 475 450 425 400 375 350 325 300 275 250 225 200 175
Hardness [HV]
Sheet thickness
0.75 0.70 0.65 0.60 0.55 0.50 0.45 0.40 0.35 0.30 0.25 0.20 0.15 0.10 0.05 0.00
Fig. 2 / FEM simulation with coupled phase transformation
Transition zone
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Temperature [C] 550
20
Fig. 3 / Thermal image of a B pillar in the Tailored Tempering process
[HV5] 500 450 400 350 300 Hardness 250 200
Transition zone
Transition zone 150 100 50 0 -80 -60 -40 -20 0 20 40 60 80 [mm]
Distance between heated and cooled tool segment
Fig. 4 / Hardness gradient of a B pillar of MBW 1500 made by Tailored Tempering
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This made it possible for the first time to predict the necessary cooling conditions and resultant phase transformations for temperature-controlled dies / Fig. 2 /. The simulation results showed that there will be a transition zone between the soft bottom section of the B pillar and the press-hardened top section. These results were used to design the die segments and as process parameters in part production.
Conclusion
The research work showed that by raising the die temperature and therefore reducing the cooling rate of a previously homogeneously austenitized MBW 1500 strength can be controlled analogously to hardness. Given the appropriate die temperature, ductility properties can therefore be increased in a controlled way. This means that different local strength properties can be achieved in hot stamped parts. This was demonstrated with reference to the example of a B pillar. Through local modifications to the microstructure and hence to strength levels, the failure behavior of crash-relevant structural parts can be favorably influenced. Based on the positive results gained in terms of material properties and cost efficiency, the tailored tempering process is soon to be used for the volume production of B pillars.
Parts with property profile

Based on the results of the crash simulation and the thermomechanically coupled FEM simulation, the positions of the cooled and heated die segments were determined. A pre-production die was then built consisting of parallel water-cooled and electrically heated segments. Monitoring of the hot stamping or press hardening process is facilitated by thermal imaging. This was also used in the production of the B pillar. It allows measurement of the heat distribution and thus of process stability within the part. The thermal image shows that the cooling rate of the material was reduced by the heated die segments / Fig. 3 /. After opening the die, the temperature in the bottom section of the B pillar is > 550 C, while the temperature in the top section is approximately 80 C. Between the two temperature zones a steady temperature increase can be observed. This is a result of the operation of the process, in which zones with high and low cooling rates are present close to one another. The subsequent part tests therefore focused on measuring the hardness transition zone and dimensional accuracy. Using the measured hardness values, a conclusion can be drawn about the size of the transition zone and a comparison drawn with the FEM simulation / Fig. 4 /. Although the different-temperature die segments are 5 mm apart, the size of the hardness transition zone is 50 mm. The increase in hardness is steady and gradual. In addition to hardness, further mechanical properties were measured in the bottom and top sections of the B pillar. The strengths measured in the ductile zone are at the level previously determined in the fundamental investigations of 650 MPa. In view of the temperature gradient present in the part after forming, tests for dimensional accuracy were carried out. The trimmed part was compared with the target geometry based on the CAD data (Computer Aided Design). As a rule the dimensional variation was less than 1 mm. This is a good result for a prototype part, so further optimization measures were dispensed with. In later production, dimensional variations can be offset by holding the part in the die.
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PLADUR Antikondensat for dry interiors
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Functional surface for dry interiors
PLADUR Antikondensat
BeAte FuGMANN Project Engineer Flat Products Dev., BU Color Constr. ThyssenKrupp Steel Europe AG Eichen Dr. rer. NAt. BettiNA WerNer Team Leader Flat Products Dev., BU Color Constr. ThyssenKrupp Steel Europe AG Eichen Dipl.-ING. RAlF WittkOwski Team Coord. Prod. Oper. Siegerland, BU Color Constr. ThyssenKrupp Steel Europe AG Eichen Dipl.-ING. AXel POhl Team Leader Flat Products Sales, BU Color Constr. ThyssenKrupp Steel Europe AG Eichen Dipl.-ING. ReiNhArd TGer Management Board, BU Color Constr. ThyssenKrupp Steel Europe AG Eichen
Working with a paint manufacturer, ThyssenKrupp Steel Europe has become Europes first coil coater to develop a water-absorbing coil coating system for steel surfaces: PLADUR Antikondensat is used in the construction sector as a cost-efficient alternative to conventional fleece membranes. The new two-coat system can be applied on ThyssenKrupp Steel Europes existing coil coating lines without the need for any additional investment. It comprises an anti-corrosion primer and a functional top coat and was developed for use in industrial and agricultural buildings with non-insulated roofs and walls. The anti-condensation function effectively prevents the formation of mold caused by damp conditions and thus protects employees health and avoids damage to goods and machines. Already successfully launched, the innovative coating system offers customers both cost savings and greater architectural design freedom, as PLADUR Antikondensat can be installed at any angle and is available in a variety of colors.
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PLADUR Antikondensat functional surface for dry interiors
Background Warehouses, factory buildings, sports halls, farm buildings, stables, indoor riding arenas and covered storage areas for machines and vehicles are frequently built using single-skin roof and wall panels with no insulation. Due to the temperature differences between the cold outside and the warm inside of the buildings (so-called thermal bridges), condensation frequently forms on inner roof and wall surfaces. Especially with the flat roofs commonly used for industrial buildings, this can result in localized or widespread dripping. To prevent water from dripping onto goods, animals or people and to stop mold forming in damp areas, the non-insulated panels can be backed with a water-absorbing fleece membrane. The fleece soaks up condensation due to capillary action, though absorption capacity is dependent on installation angle. Due to the materials used, fleece membranes are only available in gray and have a rough surface which tends to show dirt. To give architects and building owners greater freedom when designing industrial and commercial buildings, ThyssenKrupp Steel Europe collaborated closely with customers to develop a functional coating system called PLADUR Antikondensat. This coil-coating alternative to fleece solutions displays good absorption and desorption properties and has a smooth, high-quality appearance.
The coated product is attractively priced, versatile and available in different colors to meet customer wishes. Development and application of PLADUR Antikondensat PLADUR Antikondensat was developed on the basis of a ZM EcoProtect (ZM = zinc-magnesium) substrate and comprises two coats. The coating process is shown in / Fig. 1 /. Following the application of a chromium- and cobaltfree pre-treatment, a primer is applied in the first coating stage and then thermally cured. The primer protects the surface and cut edges of the end product from corrosion. It is particularly important to optimize the substrate adhesion, top coat adhesion, and water diffusion/retention properties of the primer for the intended use of the product in damp conditions. After the sheet exits the primer oven, the functional top coat is applied. The water absorption effect is achieved by incorporating functional microparticles in the coating. With the correct temperature control in the top coat oven, the particles are concentrated in the surface of the coating and firmly embedded in the system by the binder. On exiting the top coat oven, the hot, coated strip is water-cooled. A special cooling unit and an intelligent control system ensure no moisture is wound into the strip when it is recoiled.
Top coat oven Strip pre-treatment Intelligent cooling system
Primer oven
Primer coater Top coat coater PLADUR Antikondensat
Fig. 1 / Coil coating process for PLADUR Antikondensat
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Fig. 2 / Profiling plant in Eichen: Roll forming of steel sheet with a PLADUR Antikondensat coating into a trapezoidal profile
Fig. 3 / Stacked storage of the trapezoidal profiles Under side: white PLADUR Antikondensat coating for the inside of the building; Top side: coil-coated gray PLADUR coating in RAL 9002 for the outside
Processing PLADUR Antikondensat Using PLADUR Antikondensat instead of a fleece membrane can save time and money when processing coils into single-skin construction panels. Fleece membranes, which are roughly 1 mm thick, have to be applied in a separate process following coil coating. Applying the functional coating directly in the coil coating process allows this additional step to be eliminated. The organic coated coil can be sent directly to the profiler for processing into the required end products. / Figs 2 and 3 / show the production of trapezoidal profiles from two-side coated steel. The anti-condensation coating on the under side (inside) can be formed and stacked without the need for an additional protective film to prevent cracks and pressure marks. Alongside the savings on time and cost there is a further advantage: The roughly 40 m paint coating is significantly thinner than fleece solutions. That allows thicker strip materials to be profiled and smaller forming radii can be used without damaging the surface. Compared with a fleece product, the finished part has a smoother, superior appearance.
Properties of PLADUR Antikondensat

The aim of the developers was to create an anticondensation product with a functional paint coating that was equivalent to commercially available fleece membrane solutions. The graphic in / Fig. 4 / shows the absorption behavior of the coating compared with a commercial fleece product. In a so-called constant atmosphere test performed at 40 C and 100% humidity, the paint coating and the fleece membrane are loaded with moisture at an angle of 90 over a period of 168 h. In the first 24 hours, the paint and membrane solutions display similar water-absorption behavior. Thereafter, the curves move apart, with the water absorption of the fleece membrane remaining constant at around 280 g/m2 while that of PLADUR Antikondensat rises further to around 500 g/m2. The coated surface reaches its saturation plateau after 120 hours, and the quantity of water absorbed (approx. 500 g/m2 ) is almost twice as high as with the fleece solution tested.
20 /
600 500 400 [ g/m2 ] [ g/m2 ] 300 200 100 0 1 2 3 4 5 6 [h] Fig. 4 / Comparison of water absorption in a constant atmosphere test (40 C, 100% humidity) at an angle of 90 between a commercial fleece membrane and PLADUR Antikondensat over a test period of 168 h 24 48 120 144 168 Fleece PLADUR Antikondensat
300 250 200 150 100 50 0 0 1 2 3 4 5 [h] Fig. 5 / Comparison of water release after storage in standard atmosphere (20 C, 55% humidity) at an angle of 90 between a commercial fleece membrane and PLADUR Antikondensat over a test period of 5 h PLADUR Antikondensat Fleece
With regard to water release, both surfaces were roughly the same: Given adequate ventilation, both the fleece and the anti-condensation coating release the absorbed moisture within 4 hours, as shown in / Fig. 5 /. The application of an optimized two-coat system also allows the product to be used in corrosive environments, such as in agricultural operations. The steel panels retain their long-lasting protection against corrosion. In physical terms, the new PLADUR Antikondensat is superior to conventional fleece products. It is also quicker and less expensive to produce. The price advantage that can be achieved over fleece products is a key factor in the highly competitive market for single-skin construction panels. Moreover, the coated product is suitable
for universal applications. Thanks to its ability to store water in its functional micro-particles at any angle, PLADUR Antikondensat can be used for sloping roofs, flat roofs and walls. And it has more to offer than these technical and economic advantages: With its smooth white surface, the product looks good and reflects light effectively to create a bright and friendly working environment.
Summary and outlook

PLADUR Antikondensat is an innovative, attractive, universal coating system for use in non-insulated industrial buildings such as warehouses, stables etc. The coating system prevents the formation of mold effectively and sustainably and stops condensation dripping from roofs
Fig. 6 / Roofing an industrial building in Leipheim with PLADUR Antikondensat
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Fig. 7 / Colorful park deck design using Additive Floor, parking garage at Rijnstate Hospital in Arnheim/Netherlands
or running down walls. In addition to physical advantages such as higher water absorption capacity and customizable corrosion protection, the coil coating system saves time and costs in production and makes for improved formability during profiling. With a reduced total coating thickness of just 40 m, the steel product can be formed with tighter radii, which means it can also be used, for example, in structural members. Its suitability for use at any angle offers greater design latitude to architects and opens up new markets for ThyssenKrupp Steel Europe. PLADUR Antikondensat was developed to production readiness and launched on the market in a short space of time. Initial customer projects have already been carried out / Fig. 6 /.
The next step will be to further develop and extend the PLADUR Antikondensat portfolio: Incorporating pigments in the top coat or integrating a color coat between the primer and top coat will allow even greater customization of the finished surface. Standard RAL shades can be realized from translucent to opaque. This gives architects added design freedom and opens up further markets for ThyssenKrupp Steel Europe, such as use in Additive Floors for parking garages / Fig. 7 /.
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Aesthetic steel skin for industrial buildings: An industrial facade from ThyssenKrupp Steel makes use of solar energy.
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Solabs 2
Renewable energy generation using solar-active facade module for industrial and commercial buildings
Dr. rer. NAt. ROMAN GlAss Senior Expert New Surface Technologies and Pilot Production, R&D ThyssenKrupp Steel Europe AG Dortmund Dipl.-ING. ANdreAs LitZkOw Quality Management ThyssenKrupp Bausysteme GmbH Lbeck Dr.-ING. LArs PFeiFFer Team Coordinator Quality and Development, Color/Construction business unit ThyssenKrupp Steel Europe AG Kreuztal Dr. rer. NAt. BettiNA WerNer Team Leader Development Flat Products, Color/Construction business unit ThyssenKrupp Steel Europe AG Kreuztal
ThyssenKrupp Steel Europe and the subsidiaries of the Color/Construction business unit have jointly developed a new sandwich facade module which can be used to provide thermal energy in commercial and industrial buildings. The Solabs2 facade module is similar in design to a standard module and comprises an insulating core bonded firmly to coil-coated carbon steel face sheets. The outer color of the facade module is selected to achieve a high degree of solar absorption and therefore a high level of energy input. Incorporated in the insulating core is a pipeline system which is connected to the facade exterior so that the solar energy can be utilized in the form of heat. Together with a customer, an architect and a system partner, ThyssenKrupp Steel Europe is currently working on constructing a reference building featuring such modules. On successful conclusion of the project, it is intended to launch the solar-active facade module on the market.
Background
For some years now there has been a lively debate driven by the imminent effects of climate change and rising worldwide demand for energy about how to save energy and use it more efficiently. The required reduction of CO2 emissions on the one hand and the pressure to lower energy supply costs on the other are prompting potential builders of commercial and industrial buildings to look for alternative concepts and products with which they can meet these challenges now and in the future. In addition to the previously mentioned measures, such as saving energy and more efficient utilization, local renewable power generation and supply can be regarded as an additional component. Depending on the thickness of their insulating core, sandwich construction products from the Color/Construction business unit of ThyssenKrupp Steel Europe already surpass todays insulation standards, and in the future too they will play an important role in saving energy in commercial and industrial buildings. The rigorous further development of these sandwich products and their modification for energy generation purposes are a significant means of meeting the aforementioned challenges. In addition to complying with insulation standards, the building envelope will also be to supply energy. Solar thermal energy, i.e. the conversion of solar energy into thermal energy, is one possibility for generating renewable energy. A further criterion for a sandwich product of this kind is that it must meet requirements for architectural integration. The appearance of a building envelope used to supply energy should also satisfy the visual requirements of clients and architects. The current project coordinated by the Color/Construction business unit and running under the working title Solabs2 is an example of very good interdisciplinary cooperation between various internal and external partners. As a first step, the goal of the product development was to integrate solar thermal energy generation into an existing facade module. To begin with, various pre-prototypes were created by the R&D department of ThyssenKrupp Steel Europe and their efficiency measured by an independent, external institute. Then the findings were successfully channeled into a prototype which was produced in a small batch at the subsidiary Isocab N.V. in Belgium.
24 / Solabs 2 renewable energy generation using solar-active facade module for industrial and commercial buildings
This small batch of solar-active modules will become part of a building power supply system. Testing is currently underway on a reference building constructed and operated jointly with a target customer and system partner. In a final step the findings and data obtained from the test will be used to determine the optimum customer benefit in this complex scenario. Further steps will then be planned on this basis.
From facade panel to absorber

A classic sandwich facade panel comprises an external and internal face sheet, usually made from coil-coated carbon steel, and an insulating core. The outer face can be shaped according to requirements. / Fig. 1 / shows a sandwich product in the form of an exploded drawing. To optimize absorption of the solar energy on the building envelope, the paint coating of the outer face sheet must have the highest possible coefficient of absorption. Depending on the pigmentation of the paint, dark color tones normally display a high absorption value. / Fig. 2 / shows the solar spectrum as an orange curve on which the wavelength and intensity (left-hand axis) are plotted. The absorption (right-hand axis, inverse) is plotted as a function of the wavelength for the selected color tone. In general it can be said that the higher the coefficient of absorption, the better the input of solar energy into the surface. The paint system used here has a solar absorption >90 % and is anthracite gray, i.e. a color tone popular for industrial and commercial buildings. The energy introduced into the surface is now discharged into a pipeline system filled with a heat transfer medium. The pipeline system is in contact with the outer face sheet, so the heat initially acting on the outer sheet can be discharged via the connection between the face sheet and the pipe. / Fig. 3 / shows the schematic layout of the facade module in the form of an exploded drawing.
The fact that the pipeline system exits the facade module at the rear has the advantage of allowing the panel to be placed in different positions on the facade. With its dark coloring it can thus be used as a design element for the facade appearance. Furthermore, it is impossible for the human eye to distinguish between solar-active and solar-inactive panels with the same color and surface finish, which means that the facade retains its familiar appearance. In addition to design aspects, unfavorable ambient conditions, e.g. shadows cast by neighboring buildings, may make it necessary to optimize the positioning of the panels. The structure of the panels permit them to be positioned individually on the facade while also meeting the design requirements of customers and architects. The energy input from the sun can be considerable, depending on the weather conditions and geographical position. Even diffuse radiation produces a significant input, so the facade module is not solely dependent on direct sunlight. Energy is therefore even available on overcast days. / Fig. 4 / shows by way of example a thermograph of the diffuse radiation input on a solar-active facade element in the stationary condition (the element is not in operation, no energy is discharged from the surface).
Wide range of combination options

To use the energy from the facade surface, the solar-active facade modules have to be integrated into a technical system. Two application scenarios are theoretically possible: preheating of service water or support for heating systems. However, the lowness of the sun in winter months means that the facade is far better suited to supporting the heating system, also given the fact that commercial and industrial buildings usually have low pitched roofs. In addition to architectural integration in the facade as described above, another advantage is that there is no need for any additional support structures on the facade, as the module acts both as an absorber and a facade.
Inner face sheet Solar intensity
Solar spectrum Absorption Paint system outer face sheet 0 0.4 Wavelength [m] 2.5 1 ThyssenKrupp techforum 1 I 2012
Insulating core
Outer face sheet
Fig. 1 / Exploded drawing of a sandwich product
Fig. 2 / Standardized solar spectrum (orange) and wavelength-dependent absorption properties of the paint system used (blue)
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Outer face sheet
Outer face sheet
Inner face sheet Insulating core Pipes
Inner face sheet Insulating core Pipes
Fig. 3 / Exploded drawings of the solar-active facade module seen from two directions; components: inner and outer face sheets, a foam insulating core, and a pipe system which exits on the rear face (right)
To achieve the best customer value, the technical system must be customized for the planned application in accordance with geographical conditions. / Fig. 5 / shows a possible system integration scenario. The preferred system is a combination of the solar-active facade with a heat pump to support the heating system, using the facade as an energy supplier for the system.
Reference building
The customer who is constructing the reference building jointly with ThyssenKrupp Steel Europe wants a sustainable and environmentally
friendly energy supply. The building is a sales office with a logistics building. With an insulation thickness of 170 mm on the facade and 220 mm on the roof, the building has a very high insulation standard. In addition the facade will be used together with a heat pump to supply heat to the office and the logistics shop. The logistics building has a floor area of 20 x 20 m and the two-story office approx. 10 x 10 m. The west and east facades are equipped with a total of 46 solar-active facade modules. This equates to an absorber area of around 220 m2. On the north facade the pipeline system is connected to the inner face sheet of the sandwich product so that 23 modules are used here
45 C
10 C
Fig. 4 / Thermographic image of a module manufactured in a small batch (left), close-up picture of the profiled module surface (right)
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Solabs 2 renewable energy generation using solar-active facade module for industrial and commercial buildings
East facade
Pump
Heater Requirements Profile Storage Heat pump
Pipes
Geothermal probe
West facade
Sun Position Facade

South facade
Fig. 5 / Selection of possible combinations for obtaining the best performance and the best customer value: The facade is used as a source of energy (orange-colored areas). When planning a building, its geographical position and orientation must be taken into consideration. The system is customized for the energy load profile and is put together in accordance with the customers wishes.
Fig. 6 / Overview of the reference building: The east, west and south views are shown; logistics building: 20 m x 20 m, office: 10 m x 10 m (two stories). The weather data, system characteristics and use profile are recorded. The east and west facades each contain 23 solar-active facade modules. 23 elements in the north facade are used for heating purposes. The office faces south; here the rooms can receive additional energy from sunlight through the windows.
as a panel-type heating system for the logistics shop. / Fig. 6 / presents the key facts. The office building is heated by conventional radiators. Together with partners from the plumbing, control, utilities and building management fields, a system and control concept was drawn up to provide the customer with a reliable supply and enable the relevant parameters, operating conditions and settings to be tracked and modified. The reference building was constructed in close cooperation with the customer, the architect, the system partner and the plumbing company in the period from September to December 2011. / Fig. 7 / shows the interior of the sales office before the customer moved in, looking to the north east corner. Visible on the right are the black pipes and on the left the gray pipes along the wooden support structure. The elements of the north facade will heat the logistics building via the inner lying pipeline system, drawing the necessary energy from the facade (black pipes, east and west). The corresponding outer face of the building is shown in / Fig. 8 / looking to the north east corner.
and more demanding, e.g. the reduction in the consumption of primary energy by buildings specified by the German energy saving regulations (EnEV), solar thermal energy can contribute to the energy supply for future buildings.
Conclusion and outlook

To date, little use has been made of solar thermal energy in industrial and commercial buildings. Making direct use of the facade to supply energy is therefore a new option. With requirements becoming more
Fig. 7 / View of the inside of the sales building. Looking into the north east corner. On the left the sandwich facade heating system (gray pipes), on the right the solar-active modules (black pipes)
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Fig. 8 / Reference building: Outside view looking to the north east
With the idea of modifying sandwich products for energy generation purposes, ThyssenKrupp Steel Europe with the Color/Construction business unit and its subsidiaries are playing a pioneering role, while also paving the way for innovative concepts for the use of renewable energies in general and, in this case, solar thermal energy in particular. Through the successful cooperation of the teams involved the Color/Construction business unit, ThyssenKrupp Building Systems, Isocab N.V., the R&D department of ThyssenKrupp Steel Europe and external partners it has been possible to modify a small batch of sandwich products to function as solar absorbers. The small batch has been installed as part of the customers solar-active facade designed to guarantee heating for the building. New concepts for integrating the solar-active facade into the buildings supply system were drawn up jointly with the system partner. The reference building and the technical system are complete and have been put into operation, and the customer has already moved into the building. Data and experience with the new concept will be collected over the next few years. Current calculations indicate that a considerable amount of CO2 can be saved during operation (in the case of the reference building up to 15 tons per year). In addition, energy costs are expected to be very low thanks to the very thick insulation and the utilization of the facade surface.
The Solabs 2 facade module is in the pilot phase of product development, with the priority on integrating the expertise acquired in steel-based absorbers into an already existing production flow. At the same time, methods for quality assurance and to improve production flow are being developed for subsequent volume production. Thanks to the successful pilot phase and the construction of the reference building, the basis for the future marketing of Solabs2 is now in place. The system provides a possible solution for meeting todays and tomorrows challenges with regard to efficient energy supplies for buildings.
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HD High-ductility, low-alloy, fine-grain structural steels

A new product series for cold forming
MAtthiAs Gruss Process Engineering / Product Development Hoesch Hohenlimburg GmbH Hagen Dipl.-ING. MAXiMiliAN NAGEL Process Engineering / Product Development Hoesch Hohenlimburg GmbH Hagen Dipl.-ING. Peter HFel Head of Quality Management / Laboratories Hoesch Hohenlimburg GmbH Hagen
Hoesch Hohenlimburg has developed the new HD product series with greatly improved properties for cold forming. Forming operations, in particular for complex components with high strength requirements, can be performed with even greater process reliability using the new development. Image: Medium-wide strip from Hohenlimburg on the rolling mill
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High-ductility (HD) steel grades extend the possibilities for structural design in lightweight automotive engineering. The new material HSM 700 HD from Hoesch Hohenlimburg sets standards with yield strength of at least 700 MPa in combination with elongation of approx. 20%. These values are made possible by an innovative micro-alloying concept based on the use of niobium. Coupled with a precisely defined process routine for hot rolling and subsequent cooling, the scatter range of the mechanical properties can be greatly reduced.
New HD grades: highly ductile and very strong

Rising demands for strength and ductility have also taken micro-alloy fine-grain structural steels to their limits. In critical forming operations with several drawing stages and high degrees of forming, they have a tendency to form macrocracks. A new grade was needed in order to provide greater scope for development and design engineers. This was the starting point for the development of the new HD (high ductility) grades. The solution to the problem of cracking was found in the alloying and rolling concept. At high degrees of forming, conventional microalloy fine-grain structural steels form pore-shaped cracks which ultimately lead to component failure. The reason for this are crude precipitates in the microstructure at which the dislocation lines build up and grow into macroscopic cracks. / Fig. 2 / shows a comparison of images taken by SEM (scanning electronic microscope) from two heavily formed specimens. Visible in the lower picture as bright areas are several cruder and finer precipitates, which in the given forming case have already resulted in the formation of pores (the dark areas). The upper picture shows the newly developed grade in which the precipitates are in the macroscopically non-detectable nano range. There can be different types of precipitates. Cementite, i.e. iron carbide compounds, forms at the grain boundaries when the material contains sufficient carbon. Another type of precipitate are carbonitrides, i.e. compounds of carbon and nitrogen with the alloy elements titanium, niobium or vanadium. The size of the precipitates is the key factor in the formation of pores, and this size is largely affected by the process routine during hot rolling. After hot rolling, the medium-wide strip passes over the runout table and is wound into coils. Precipitate growth is already strongly influenced on the runout table by the way the temperature is controlled. Without selective cooling, the precipitate growth will continue in the finished coil.
High-strength low-alloy, fine-grain structural steels

High-strength low-alloy (HSLA) fine-grain structural steels are very much in trend among hot strip processing companies. These high-strength materials permit cost savings, primarily by dispensing with expensive heat treatment operations. Often there is no longer any need for heat treatment to guarantee component strength, because the microalloy materials come ready equipped with the required mechanical properties. Furthermore, medium-wide strip is becoming increasingly important in all areas where dimensional accuracy plays a key role. A glance at the standard reveals why: The tolerance range for mediumwide strip is far narrower than that for hot wide strip in all aspects width, thickness and flatness (see DIN EN 10048 and DIN EN 10051). Accordingly, the demand for medium-wide strip in these grades is high, as reflected in volumes over the past few years / Fig. 1 /.
500,000 450,000 400,000 Production output [t/a] 350,000 300,000 250,000 200,000 150,000 100,000 50,000 0 New Steel Grades High Strength Low Alloyed Steels Tempering Steels
Fig. 1 / Demand for medium-wide strip grades since 1999
98 /99 99 /00 00 /01 01 /02 02 /03 03 /04 04 /05 05 /06 06 /07 07 /08 08 /09 09 /10 10 /11 11 /12 12 /13 13 /14 14 /15 15 /16
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HD grade: no carbide
7 m
Conventional high-strength grade: crude carbides
cementite increases with the amount of the carbon in the material. Consequently, more carbon leads to a higher probability of cracking. However, carbon also has a strength-increasing function and cannot simply be eliminated. After all, the material should not only be easy to form but also able to withstand high loads. To make the new material suitable for as diverse a range of applications as possible, its required minimum yield strength was fixed at 700 MPa. In this strength range the material is suitable for use in safety-relevant components / Fig. 3 /. What was needed, therefore, was to find an alloy element to reduce the diffusion of the strength-enhancing carbon. It would need to inhibit the development of the precipitates in the material while simultaneously increasing its strength.
Niobium for greater strength

The concept drawn up to achieve this goal set out to permit only nanoprecipitates which would increase strength selectively and influence the precipitation kinetics by slowing down carbon diffusion. Niobium was on the shortlist of possible alloy elements and proved to be ideal for this purpose. At the atomic level, niobium is far bigger than the surrounding iron. Incorporating niobium into the Fe lattice therefore results in lattice strains which obstruct the carbon atoms in their diffusion and slow down the diffusion process. The precipitate size of the carbonitrides can thus be selectively reduced. Precipitate size, strength and carbon content of the material are directly interrelated. A high number of small nano-precipitates increases the strength even when the carbon content is reduced. A medium tensile strength of 750 MPa can thus be achieved even with small quantities of carbon.
7 m Fig. 2 / Scanning electron microscope: Comparison of heavily formed microstructure
The size of the precipitates is the key factor in the formation of pores, and this size is largely affected by the process routine during hot rolling. After hot rolling, the medium-wide strip passes over the runout table and is wound into coils. Precipitate growth is already strongly influenced on the runout table by the way the temperature is controlled. Without selective cooling, the precipitate growth will continue in the finished coil. Precipitate size is influenced not only by the process routine but also by carbon content. For example, the size of the grain boundary
Fig. 3 / Collar test, top: HD grade, bottom: conventional high-strength grade
Fig. 4 / Coil shower for fixing the obtained microstructure
HD High-ductility, low-alloy, fine-grain structural steels / 31
Normal 70 60 Complex design Total elongation [ %] Ferritic steels 50 Density [ ?] 40 30 20 10 0 200 300 400 500 600 700 800 900 1,000 1,100 Tensile strength [MPa] Lightweight design potential Fig. 5 / Parameter spectrum of the ferritic steel grades (Total elongation as factor of strength) HSLA high-strength low-alloy steels 0.005 0.000 600 640 680 720 760 800 840 800 Yield strength [MPa] Mean value Standard deviation Quantity measurement 29.20 105 Conv high-strength 753.9 HD grade 748.7 15.29 105 HD700 grade 0.020 0.015 0.010 Too soft Parts crack 0.025
Fig. 6 / Variances in yield strength from the standard value, comparison of HD grade/conventional high-strength grade
Provided a specific process routine is applied during production of the medium-wide strip, the number of niobium nano-precipitates can be increased step by step. The niobium dissolved in the material is automatically precipitated from the microstructure during the hot rolling of the material into medium-wide strip. Heating the slabs already caters for the high target temperatures and sufficiently long dwell times which are needed for the micro-alloy elements to be uniformly dissolved. Then the micro-alloy elements are precipitated out of the microstructure again through forming and cooling. Particularly finely dispersed precipitates are thus produced during the thermomechanical rolling process under controlled conditions of recrystallization. After the final rolling pass it is important to fix the microstructure in order to keep the precipitates fine. This requires the thermal energy remaining after the rolling to be removed from the medium-wide strip. The medium-wide strip is therefore cooled on a cooling line. This preserves the nano-precipitates until the coil shower, which is the final station of the thermomechanical treatment process. The coil shower fixes the microstructure once and for all, i.e. the microstructural components are frozen in place / Fig. 4 /. In the cold condition the niobium now exists in the form of tiny nano-precipitates. As an additional process engineering benefit the coil shower also permits a higher pickling capacity, as the pickling speed can be increased.
Thanks to the defined process routine, the scatter range of the material parameters is greatly reduced. / Fig. 6 / shows a comparison of the yield strength fluctuations of a conventional high-strength grade with those of the new HD grade. The HD grade displays far less fluctuation. Analytically, the material HSM 700 HD is characterized by a higher niobium content of max. 0.25% and a very low carbon content of max. 0.06%. The tensile strength is approx. 800 MPa with a mean yield strength of approx. 750 MPa / Fig. 6 /. Compared with microalloy grades, the material stands out for its higher elongation, which at approx. 20% is far higher than with conventional microalloy materials.
Conclusion
High-strength grades are now being used in all areas of automotive production. Customer demands continue to grow, however, particularly with regard to the complexity of component geometry. The HD concept taps into this sales potential by offering increases in strength and elongation compared to grades already on the market. The decisive advantage is the reliability of the HD grades. The scatter range of the mechanical properties is far smaller than that for conventional highstrength grades, which has a direct positive impact on freedom of design for components. Safer vehicle components of greater complexity can thus be developed. It is already possible to discern considerable market potential for these new grades. With a view to the future requirements of electromobility, an expansion of the HD grade spectrum into further strength ranges looks promising.
Higher process reliability and best formability HSM 700 HD

The HD grade HSM 700 HD recently introduced by Hoesch Hohenlimburg is produced by the described process routine. The HD added to the name stands for high ductility, i.e. it is a material with enhanced forming properties / Fig. 5 /.
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Thema
Foundation of heliostats for solar power stations

Using special equipment to install thin-walled steel pipes
Dr.-ING. JOhANNes Kcher CEO ThyssenKrupp Tiefbautechnik GmbH Alsfeld DOris Becker-SpOhr Head of Export Sales ThyssenKrupp Tiefbautechnik GmbH Alsfeld
Solar power station in California/USA
ThyssenKrupp ThyssenKrupp techforum techforum 1 I 2012
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Solar thermal power stations and systems are based on the principle of using a large number of mirrors to focus sunlight onto a concentrated point of a receiver tower, thus creating a huge amount of heat for producing steam, which can be used in turn to drive turbines for generating electricity. The many thousands of mirrors which are needed for such a system must be securely founded. For this purpose, ThyssenKrupp Tiefbautechnik, a manufacturer of construction machinery and components for specialized civil engineering applications, has developed a special tool and process which enable such foundations to be installed quickly, easily and economically.
Specialized civil engineering

ThyssenKrupp Tiefbautechnik has been operating for years as a manufacturer of machinery for specialized civil engineering applications. Its portfolio includes driving and extracting equipment which can be used to drive steel sheet piles such as girders, pipes or sheet pile walls into the ground. Using counter-rotating shafts with mounted eccentrics, the machines create vertical vibrations. Via a clamp, these vibrations are induced into the ground with frequencies of approx. 40 Hz. The vibrations loosen the ground within a small radius around where the pile element is to be driven, turning it into a fluid-like state. This results in such a great reduction in skin friction and toe resistance that the sheet pile ultimately sinks into the ground by virtue of its own weight. These machines are driven by a diesel-hydraulic unit, to which they are connected via hydraulic hoses / Fig. 1 /.
Fig. 1 / Vibration unit during the driving of sheet piles
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Also in the portfolio are so-called hammer drills and rotary mechanisms which mounted on suitable carrier equipment supplied by the customer are used in particular to drill holes for anchoring tasks. Smaller machines are available to drill blasting holes in quarries, tunnels or mines. Thanks to the combination of rotation and hammering action of the high-precision, hydraulic striking mechanism at variable striking frequencies of up to 60 Hz, the drilling rates achieved are several times higher than those achieved with simple rotary drills, particularly in rocky ground. / Fig. 2 / shows a hammer drill mounted on a carrier during the drilling of holes to secure a deep construction pit. For a number of years now, these machines have been used increasingly in the environmental engineering and renewable energy sectors, with their features accordingly adapted and expanded for these tasks.
Geothermal drilling
Environmentally friendly geothermal systems used to heating (or cool) residential buildings are based on the principle of drawing heat from the ground and transforming it to a higher temperature by means of a heat pump so that it can be used to heat a building. To be able to draw heat from the ground by renewable energy generation, also known as near-surface geothermics, holes must be drilled to a depth of up to 100 meters, usually in a very confined space. For this purpose, special double-head drilling systems / Fig. 4 / were developed firstly to guarantee reliable, exactly aligned drilling even in loose soil by means of two concentrically inserted drilling pipes (cased drilling), and secondly to ensure the exact installation of the so-called ground loops by supporting the hole wall with the outer pipe after the inner drilling pipe is removed on reaching the final depth of the hole. Only this way is it possible to achieve the good thermal conductivity between the ground and the loop that is essential for the systems efficiency.
Foundation of offshore wind turbines in the alpha ventus test field in the North Sea off the Lower Saxony coast
For the secure foundation of so-called tripods / Fig. 3a / as the base structure of the wind turbines, three nails are driven into the sea bed, first by vibration technology and then by hammering / Fig. 3b /. The tripods have a weight of approx. 500 tons, with each nail weighing approx. 160 tons. This work was carried out using the largest available machines, which produce vibratory forces of over 400 tons and have a power rating of more than 1,000 kW. In the future, a new generation of machines will produce vibratory forces of over 1,000 tons with drive ratings of more than 2,000 kW. These new machines will be able to pick up the piling from a horizontal position directly from the work ship or pontoon and drive it vertically into the sea bed. This will result in significantly shorter installation times and far lower foundation costs.
Mineral oil extraction: Foundation of heliostats for the worlds biggest solar power station
In a solar power station, many hundreds or thousands of mirrors, controlled to track the sun as it moves, concentrate the sunlight in a focal point of a tower so that the resulting temperatures of over a thousand degrees Celsius turn water into steam. This steam is generally used to drive a turbine which generates electricity. The individual mirrors must be set up on foundations which can absorb the forces acting on the mirrors from the tracking and the wind loads. It is customary to bolt the substructures of the mirrors onto either heavy-duty concrete foundations or concrete posts which are driven into the ground. This method is elaborate, expensive, time-consuming, and material intensive. The conventional work sequence is as follows: Construct a concrete foundation with corresponding formwork or drive a concrete post into the ground Drill holes into the foundation to secure the mirror support Bolt the support to the foundation Install electric control boxes and actuators for the mirror adjustment Mount the mirror carriers and mirrors
Fig. 2 / Drilling holes to secure a construction pit
With the new foundation method, thin-walled pipes are driven into the ground using vibration technology and a special clamping tool, with the pipe lowered only far enough for an upper section to serve directly as the mirror support. All the previously described work steps apart from installing the control boxes and actuators are thus reduced to a single step. The special feature of the clamp is that it is cylindrical in shape for insertion into the pipe, and its outer diameter is roughly the same as the inner diameter of the pipe. Clamping pistons grip the pipe at the lower end / Fig. 5 /. The clamp is connected to the vibration unit via an extension which is adapted to the pipe lengths. In this way the pipe is pulled into the ground by vibration, with the cylindrical clamping gripper supporting the pipe against buckling. This method means that even use in heavy soils with small obstacles is no problem, and the required wall thickness of the pipe can be minimized. Because the upper end of the pipe is not clamped and therefore cannot be damaged or deformed, mounting holes for the actuators and their controllers can be drilled into the pipes economically before they are sunk. This avoids damage to the galvanization, which is applied to the pipes as rust protection.
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Fig. 3a / Tripod with sleeves as the underwater base structure for an offshore wind turbine
Fig. 3b / Vibration driving of pipes as nails to found a tripod on the sea bed
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Hydraulic control block Rear rotary mechanism
Release: Clamping pistons retracted
Carrier plate
Front rotary mechanism with hollow shaft
Clamp: Clamping pistons extended
Fig. 4 / Compact double-head drilling system for geothermal holes
Fig. 5 / Rear rotary mechanism
/ Fig. 6 / shows the work sequence for this technology on a solar power station, which in this case is not used to generate electricity but to extract substantial additional quantities of crude oil from natural oil deposits in California, which had been exhausted by conventional methods. The highly pressurized hot steam is not used to drive a turbine but is directed into the depths of a mineral oil deposit. The heat reduces the viscosity of the oil so that, in conjunction with high pressure, the resulting mixture of oil and steam can be conveyed to the surface. The mix is cooled in a separator and the oil forwarded for further processing while the water is returned to the work cycle. Using this method it is possible to extract up to 100% more oil from existing oil deposits instead of developing new deposits at high expense and risk. The installed thermal rating of the system is 29 MW. This required the installation of a total of 3,822 heliostats with 7,644 mirrors which reflect the sunlight onto an approximately 100 m high receiver tower / see title picture of this report /.
Conclusion
The examples described show that further developments and innovative ideas can open up new applications in the renewable energy field for equipment from ThyssenKrupp Tiefbautechnik. In addition to the two examples outlined in the fields of offshore wind turbines and geothermics, the third example is impressive proof that by combining a simple new development with new installation methods for renewable energy generation systems, work processes can be shortened and material saved.
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a/
b/
c/
Fig. 6 a / Carrier with vibrator, extension piece and pipe clamping gripper b / Setting the pipe upright c / Threading d / Clamping, aligning and vibration driving e / Mounting the actuators and the control boxes
d/
e/
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iwalk at Atocha railway station, Madrid/Spain
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iwalk
A milestone in the moving walk industry

DIPL.-ING. MIGUEL GONZLEZ ALEMANY Chief Research Officer ThyssenKrupp Elevator (ES/PBB) GmbH Gijn -Asturias/Spain
iwalk is the new moving walk from ThyssenKrupp Elevator. The biggest advantage of this new system is that it reduces space requirements in several dimensions. The new design allows a reduction of more than 50% in installation depth, which means the horizontal variant can be installed directly on existing floors. This reduces construction work for installation and lowers costs. The modular design permits greater flexibility and offers significant advantages in production, logistics and installation. This innovation represents a fundamental re-design of conventional moving walk technology, resulting in significantly enhanced customer value alongside all the product advantages.
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iwalk a milestone in the moving walk industryin neuer Meilenstein in der Fahrsteigindustrie
Fig. 1 / Inclined variant of the iwalk at Atocha railway station, Madrid/Spain
Moving walks
The moving walk is a well-known product which has been in existence for over 100 years. Global demand is met by several competitors, whose moving walks all have very similar product architectures. The basic design of the moving walk comes from escalators, with which they share several components. Rising customer requirements call for new technologies even under difficult installation conditions. With the iwalk / see title picture of this report and Figs 1 and 2 /, ThyssenKrupp Elevator has developed a breakthrough technology with the flexibility to better meet customer requirements.
Customer value
Moving walks are installed in almost all airports around the world. They improve passenger flows within terminals and make connections easier and more comfortable. But passenger transportation systems are not always in the most appropriate locations. For example, there are long connecting corridors with no moving walk. This is due to the in part huge installation requirements of conventional solutions. The reduced dimensions of the iwalk offer customers greater flexibility. Pit depth is reduced from 1,000 millimeters to less than 400 millimeters. This even allows the iwalk to be installed on top of the finished floor, without any civil work / Fig. 3 / . Just as people change their habits with new technologies and trends, so do airports. Shopping areas become bigger or are moved to a different location. The flow of people also changes. Conventional moving walks do not have the flexibility to react to these changes. iwalk is modular, so its length and location can be modified easily. Relocating moving walks is now a real possibility for airport authorities.
Reduced dimensions and modularity are also important in metro applications. Creating large pits in connecting tunnels is either unfeasible or very expensive, and access to these tunnels is usually difficult. For this reason, iwalk is the perfect solution for installation in the long connecting tunnels found in many metro systems around the world. Moving walks and shopping carts are closely linked. That is why the shopping floors of many malls are connected to parking areas by inclined moving walks instead of escalators. iwalk is designed to give users a safe, comfortable ride even when using shopping carts. The reduced comb height (only 7 millimeters, compared with 45 millimeters in conventional solutions) allows passengers to enter and exit the moving walk safely, while the 1,100 millimeter pallet width provides more space for wider shopping carts without increasing the outer dimensions of the moving walk / Figs 4 and 5 /. Aesthetics are also a very important part of these systems. Moving walks are part of the architecture of airports and shopping malls. iwalk brings important elements into play to provide customers and users with a pleasant experience: the use of glass transmits lightness; rounded shapes, LED lighting, the new handrail entry and the fact that there are no visible screws are in line with modern architectural trends. Aesthetics steered the entire development, because design starts by defining the elegant appearance of the product. The new product has good environmental credentials, requiring around 30% less material than conventional solutions. Transportation volume is also reduced; one 45 meter conveyor requires only one container, while conventional solutions require four. Lubrication is dramatically reduced due to the special chainless design. Energy
iwalk a milestone in the moving walk industry
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Fig. 2 / Horizontal variant at Atocha railway station, Madrid/Spain
consumption is also reduced owing to the lighter moving mass, the higher drive efficiency, the more efficient LED lighting and the Energy Efficiency Controller. A life cycle analysis based on the eco indicator EI 99 HA shows that iwalks carbon footprint is up to 52% smaller than conventional moving walks. ThyssenKrupp Elevator carries out these analyses for all new products as part of its sustainable efficiency program. The aim is to improve the energy efficiency of all products over their entire life cycle.
Innovation
When designing the iwalk, the engineers deliberately started from scratch rather than trying to make incremental improvements to the existing technology. Behind this decision was the firm belief that with the technologies currently available, and with all the observations made from user interaction with the product and from customer needs and preferences, even the original inventors of conventional moving walks would have made them differently. The result is a totally new product architecture which establishes a benchmark in this industry.
Conventional moving walk
iwalk
No pit
Reduced installation depth
Pit
Fig. 3 / The horizontal variant of the iwalk can also be installed directly on the existing floor
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One of the key components is the aluminum pallet, which is the people-carrying element. On the iwalk it is also the way power is transmitted to the whole moving band. Pallets are connected by a new, lubrication-free joint, with a large diameter to reduce pin pressure and increase lifetime. This eliminates the need for the pallet chains used in conventional products. The lower pallet surface is especially designed to engage with the special polyurethane rollers that transmit power to the pallet band / Figs 6 and 7 /. The whole system is designed to increase passenger comfort by reducing vibration levels to a minimum 8 mg. The pallet length of 127 millimeters, combined with the special turnaround sections, is what allows pit depth to be reduced to 350 millimeters. The central modules are built from special rolled galvanized steel profiles with a tubular shape formed by laser welding. These profiles combine the structural function of the conveyor with the guides for the pallet band. The balustrade supports are also attached to these profiles, allowing the whole assembly process to be completed without the need for adjustments. Modularity is guaranteed / Fig. 8 /. The reduced comb height has been achieved through the reduced pallet length and the new design of the fixed plates in the return station. To date, moving walks have required a tension device at one end which is capable of compensating for different pallet band lengths caused by wear to the joints and by the different rates of thermal expansion of the steel structure and the aluminum pallet band. For these reasons, conventional moving walks feature fixed comb plates over the pallet band, with a usual comb height of more than 40 millimeters. The iwalk solution is to attach the combs to
the pallet band tension mechanism, maintaining a constant position in relation to the pallet guide in the return area. The comb plate in this innovation is made out of several slats, which move below the covering plate when the pallet band stretches. This solution allows a comb height of just 7 millimeters, which makes exiting the conveyor much safer. The technology used in the iwalk is protected by more than 15 new patent families.
New manufacturing process

The first step in most existing manufacturing processes for conventional moving walks is to produce the steel structure. This structure can only be produced when the layout with the final job site dimensions has been confirmed. Once this truss is built, changes are virtually impossible. The complete assembly process is a customized operation. The precision and experience of the specialists have a major influence on quality. The modular concept of the iwalk is based on a completely new process which allows a significant reduction in manufacturing time. Modules are assembled virtually automatically, with adjustments no longer needed. Quality is guaranteed by the manufacturing process and by the accuracy of the parts. The workshop space required to produce moving walks is also reduced. Field conditions are no longer critical. The accuracy achieved in the modules using this new manufacturing process also improves field installation quality and reduces maintenance.
Higher pallet width 1,100 mm
Fig. 4 / Lower height of comb enhances safety and convenience
Fig. 5 / Reduced outer dimensions despite higher pallet width
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Fig. 7 / Low-maintenance drive
Fig. 6 / Good for the environment: lubricant-free pallet band
Fig. 8 / Simple installation thanks to modular design and lower weight
Customer feedback
Launching new products in particular for metro and airport applications is always a major challenge. In many cases, specifications require products to have proven track records of several years. Despite this, the iwalk has already been selected for its unique features by several customers. The Sao Paulo metro in Brazil is a very demanding application with high traffic flows. The iwalk pitless configuration (i.e. installation directly on the existing floor without any civil works) was the most efficient solution due to the existing installations in the tunnel. The alternative using conventional technology would have been either unfeasible or incredibly expensive. This configuration was also preferred by Metro Madrid and Mlaga Airport in Spain. The attractive design and the 1,100 millimeter wide pallet were the decisive elements for the architect who designed the new high-speed train station in Puerta de Atocha/Spain. Customer interest in this new product is growing, as underlined by the increasing production figures for the iwalk.
Conclusion
The iwalk is a breakthrough technology representing a new milestone in the moving walk industry. Its reduced installation requirements and modular concept offer customers significantly greater flexibility. User safety and convenience are improved by the reduced comb height and the wider pallet, while the new aesthetics fit in with current architectural trends. The reduced carbon footprint is very much in line with ThyssenKrupp Elevators sustainable efficiency program. The iwalk won first prize in the 2011 ThyssenKrupp Innovation Contest.
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Schwelgern coke plant in Duisburg
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Mini-PROven
Reduced emissions from small and medium-size coke ovens thanks to single-chamber pressure control
Dr. rer. NAt. Friedrich HuhN Head of Process Engineering, Coke Plant Technologies Division ThyssenKrupp Uhde GmbH Dortmund Dipl.-ING. FrANk Krebber Senior Process Engineer, Coke Plant Technologies Division ThyssenKrupp Uhde GmbH Dortmund Dr.-ING. JOANNA KhN-GAjdZik Senior Process Engineer, Coke Plant Technologies Division ThyssenKrupp Uhde GmbH Dortmund KerstiN berschr Senior Design Engineer, Coke Plant Technologies Division ThyssenKrupp Uhde GmbH Dortmund
For environment and occupational health reasons it is becoming increasingly important for coke plants to be operated with the lowest possible level of emissions. In the past, changing pressure conditions in each individual oven, with particularly high values at the beginning of the coking period, often resulted in considerable emissions at the oven closures. To prevent this happening on modern large-scale ovens, ThyssenKrupp Uhde developed the PROven (Pressure Regulated Oven), a single-chamber pressure control system which regulates the pressure in the individual coke chambers down to a constantly low level. In the meantime, after many years of successful service, the system has been upgraded in both its design and process engineering. The result is Mini-PROven, which in future can also be retro-fitted to old small and mediumsize coke oven batteries in the interest of better environmental protection.
approx. 18 - 25 h. The coke oven line is comprised of numerous heating chambers, with up to 80 ovens built of refractory bricks joined together to form a so-called battery. Each oven can measure up to 8.5 m high, 20 m long and 0.6 m wide and have a capacity of up to 70 t of coal. The raw gas formed during coking passes through an extraction system (stand pipe, manifold and collecting main), where it is cooled by ammonia water spray and the tarry constituents are condensed out. Then the cooled raw gas is forwarded to the gas treatment plant. Coking is an unpressurized process, which means that the chambers can be sealed at the oven closures, e.g. at the oven doors, by metal-to-metal gaskets. However, given the conditions of coke oven operation (high temperatures, tarry condensates, discontinuous batch mode, equipment age, etc.), it is impossible to fully prevent gas and dust emissions at the oven closures so-called diffuse emissions during the coking process. To ensure the best possible environmental and occupational health protection, ThyssenKrupp Uhde as a technology-oriented plant builder has given increased attention to this subject and driven suitable developments in design and process engineering.
Background
Completely new possibilities have been opened by the emission reduction system PROven (Pressure Regulated Oven), the single-chamber pressure control system de-veloped by ThyssenKrupp Uhde. Unlike conventional coke plant technology, it permits coke oven batteries to be operated with far lower emissions by enabling the pressure in the individual oven chambers to be controlled individually. ThyssenKrupp Uhde secured the development basis at an early stage and turned it into an operational system. Since 2003, when PROven went into industrial use for the first time on the two batteries of the modern largescale coke plant in Schwelgern with 140 ovens / see title picture of this report /, the system has contributed much to improving the environmental footprint of numerous coke plants.
Coking
Coke is an indispensable charge material for producing raw iron in blast furnaces. The coke plant is therefore a typical part of an integrated iron and steel plant. The centerpiece of a coke plant is the coke oven line. Here the charging coal is carbonized in air-tight industrial ovens at temperatures of approx. 1,100 -1,300 C and refined into coke, which can be discharged after a coking period of
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Mini-PROven reduced emissions from small and medium-size coke ovens thanks to single-chamber pressure control
Pressure controller
NH3 -water
Pneumatic cylinder Control valve
Fast flooding pipe Stand pipe Control rod
FixCup Overflow regulation device Sealing plug Gc-main
Fig. 1 / Schematic of single-chamber pressure regulation with Mini-PROven
In the meantime, PROven is being used successfully on more than 2,000 coke ovens with a total coke output of nearly 30 million t/a 12 coke oven batteries in China, 9 coke oven batteries in South Korea, 6 coke oven batteries in Brazil, 1 coke oven battery in the USA, 3 coke oven batteries in Germany as well as 1 coke oven battery in Canada.
by way of the water level in the FixCup using an overflow regulation device. This means: Low pressure at the beginning of coking in order to reduce emissions Gradually rising counter-pressure during the coking period so that in spite of the great variation in gas development during the refinement period the pressure in the coke chamber is always slightly positive and penetration of air into the oven is prevented / Fig. 2 / shows the resulting pressure curve in the area of the stand pipe/collecting main and the impact on the oven door area, which is particularly critical with regard to emissions.
However, the PROven system has been used not only on numerous new plants world-wide. It has also been retrofitted to many older-generation coke plants. And not only in Germany has PROven set the officially recognized environment standard for new plants in the meantime, a chamber pressure control system is prescribed for new coke oven lines in the USA and Canada as well, by order of the EPA (Environmental Protection Agency).
2 Stand pipe Oven door 0 20% 40% 60% Coking time -3 Gas collection main 80% 100%
Pressure [ mbar]
Principle of operation of the PROven system

The main functional elements of the PROven system are shown schematically in / Fig. 1 /. At the center of the system is the FixCup, which acts as a pressure separator between the actual oven chamber and the gas collecting main. A flow resistance for the raw gas formed during coking is built up in the FixCup and can be regulated via the water level. In line with coking progress, the pressure in the oven chamber is individually regulated
Fig. 2 / Pressure control characteristic of the PROven system
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Development of MINI-PROven
The construction of the standard PROven system was developed for the dimensions prevailing in the standpipe/ gas collecting main area of high-capacity coke ovens, i.e. with chamber heights of over 6 m. / Fig. 3 / shows the structural conditions of the PROven equipment by way of example at a large-scale oven battery. The relatively
confined space conditions are already evident on these large ovens with an oven height of 7.6 m. Far less space is available for installation on smaller coke oven batteries with oven heights of 4 - 6 m. The standardized PROven design elements particularly the regulation device are clearly oversized. Consequently it has been impossible up to now to offer PROven
Fig. 3 / Space conditions in the area of the stand pipe/collecting main with standard PROven equipment on a large-scale battery
48 /
as a retrofit. However, they are many such batteries of a mostly older generation to be found on the world market, especially in the CIS countries, Poland, China, Taiwan, India and North America. To be able to explore this market share for reconstruction with the so-called Mini-PROven, the adaptations required for this purpose have been elaborated within the scope of a TK Best Project. The following tasks and objectives posing great challenges in design and process engineering have been solved without having to abandon the proven basic functional and regulating features of the PROven system: General reduction of the dimensions of the design elements Adaptation of adjoining equipment parts and maintenance openings in order to create the greatest possible service access for operating personnel in spite of the confined conditions Complete revision of the important regulation device / Fig. 4 /, which was developed by ThyssenKrupp Uhde, such that a sufficiently large gas passage is possible in spite of the smaller overall size while ruling out tar deposits on the other hand Adaptation of the control characteristic to the reduced raw gas volume by means of corres pondingly re-designed built-in components
Fig. 4 / Overflow regulation device for Mini-PROven
Fig. 5 / Mini-PROven test rig
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Fig. 6 / Mini-PROven retrofit on the old coke oven battery 9 at Essar Algoma/Canada
In the course of development, the function of the redesigned system was tested on a test rig / Fig. 5 /, focusing in particular on The control characteristics with the new overflow regulation valve The wetting characteristics of all the components (the wetting characteristics are important for trouble-free operation) The mechanical adaptation to movements in the system In 2011, the first large-scale implementation of the new Mini-PROven concept was successfully completed in the course of converting the 5 m battery No. 9 of the Essar
Algoma plant in Canada / Fig. 6 /. Here the system resulted in a clear reduction of the diffuse emissions as well.
Conclusion
With the newly developed Mini-PROven system it is now also possible to retrofit older, small and medium-size ovens with a chamber pressure regulation system to reduce emissions while complying with relevant limit values. As a result, the PROven principle can now be used for the complete range of ovens from small to large-scale. This will provide access to further customers and new markets in future.
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Modern gearless drive systems for high-capacity belt conveyors

GNther KerkhOFF BSEE General Manager Electrical ThyssenKrupp Robins Inc. Denver/ USA Dipl.-ING. Peter Sehl General Manager Sales & Service ThyssenKrupp Robins Inc. Denver/ USA VlAdiMir Svirsky MSME Chief Mechanical Engineer ThyssenKrupp Robins Inc. Denver/ USA
Gearless drive system, 2 x 3,800 kW, 63 rpm, 631 kNm
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In many mining areas, ore grades are declining. New mines are being developed in ever more remote areas. Pits are getting deeper and more hard-rock mines are switching to underground operations. This means that more material must be transported over longer distances, which creates new challenges. As mining volumes increase, demands for availability are also rising. As a result, conveying systems need to be equipped with modern drive systems that guarantee a high degree of reliability.
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Partnership with Siemens for large conveying systems

For many years ThyssenKrupp and Siemens have partnered to help build some of the most impressive conveyor systems in the mining industry. One of the greatest success stories is the Los Pelambres downhill conveyor in Chile, installed in 1999, which is the highest tension conveyor belt in the world. It transports copper ore over a distance of 12.7 kilometers from 3,200 meters above sea level down to 1,600 meters and in so doing generates up to 17 MW of electrical energy, which is fed into the grid.
Gearless drive characteristics and advantages

Gearless drives are an attractive alternative for conveyors with higher power requirements. Due to their simple construction, such drives offer very high availability, robustness, reduced operating and maintenance costs, and reduced noise as well as the benefits of a variable-speed drive. With gearless drive systems, a slow-running synchronous motor is directly connected to the shaft of the drive pulley. Because of the slow motor speed, no gear reducer is required. The rotor of the synchronous motor / Fig. 1 / is flanged onto the pulley shaft. Gearless drive technology is nothing new to the mining business. Mining companies have been installing high power gearless drives for mine hoists, excavators, draglines, pumps and mill applications for many years. While the technology is similar, the requirements differ for conveyor applications. Similar to mills, conveyors require a lot of torque during start-up, especially in uphill applications. Gearless drives increase operating efficiency while at the same time providing high reliability and low maintenance requirements. For the previous 20,000 kW example, a gearless drive solution can be accomplished with only 3 or 4 low speed motors and no bearings
Technical limits of conventional drive systems

The gear reducers traditionally used to drive conveyors reach their physical limits in demanding applications, such as steep-angle or highcapacity installations. For example, a modern conveyor system with a total drive power demand of 20,000 kW requires at least eight traditional gear reducer drives, each equipped with 2,500 kW motors. The traditional gear reducer solution has the disadvantage of reduced overall availability associated with the large number of mechanical components (e.g. more than 70 bearings for eight 2,500 kW gearboxes) which results in a lower mean time between failures (MTBF).
Fig. 1 / Gearless drive rotor during shop inspection at Siemens
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Fig. 2 / Reduced footprint of gearless drive system (motor on left is shown in maintenance position with the stator housing moved away)
or couplings. With fewer components, the drive station and electrical building require a smaller footprint / Fig. 2 /. This is especially beneficial for underground applications where the number of expensive excavations for drive stations is minimized. For downhill operation, the drives are able to work in regenerative mode and supply the mine operation with additional electrical energy. Advances in conveyor belt technology are also supporting the capabilities offered by gearless drive systems. Newly developed stronger belts (ST-10000) are now available that can withstand the higher stresses resulting from increased drive power requirements. Mining companies are striving to reduce energy consumption and CO2 emissions and increase system reliability. Gearless drives meet these requirements by significantly reducing the number of mechanical components, such as gears, bearings and couplings, while delivering higher efficiency / Fig. 3 /. The capital expenditure for a gearless drive conveyor is equal to or less than that for conventional geared drives, especially if capital spare parts are a consideration.
Transformer Converter
Transformer C-Converter
Synch. motor
Synch. motor
Coupling
Gear Box
Coupling Brake
Brake
Belt Conveyor
Fig. 3 / Comparison of standard vs. gearless drive solution
Belt Conveyor
Belt Drive Pulley
Belt Drive Pulley
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First reference for gearless drives in German coal mine

In 1985, O&K (now part of ThyssenKrupp) and Siemens installed the first gearless direct-drive belt conveyor with cycloconverter-fed synchronous motors. Engineers at RAG Deutsche Steinkohle were impressed by the converter technology and decided to use it in the underground Prosper-Haniel coal mine in Germany / Fig. 4 /. More than a quarter century later, the belt drives are still in operation to the complete satisfaction of the mine. The conveyor system provides an availability of more than 99%. Managers at RAG indicate that: There have been no significant interruptions or failures attributable to motors and converters. Maintenance costs are significantly lower than for conveyor drives with gearboxes. Estimated electrical energy savings of 10% are achieved annually compared to fixed-speed gear-driven drive arrangements.
New gearless drive system for client in Peru

Continuing their successful teamwork, ThyssenKrupp Robins and Siemens are now delivering an overland conveyor to Xstrata Coppers new Antapaccay mine in Peru with a gearless drive system / Fig. 5 /. The conveyor system will transport ore over a distance of some 6.5 kilometers from the mine to the processing plant on a 1,370 mm wide belt travelling at 6.2 meters/second. When the belt conveyer system is commissioned in 2012, it will be capable of transporting up to 5,260 tons of copper ore per hour. The drive system comprises two low-speed synchronous motors each with a rated power output of 3,800 kW and the associated cycloconverters, motor cooling systems, converter transformers and complete electrical house for the drive station. A closed loop control system improves load sharing between the two motors.
Fig. 4 / Prosper Haniel mine, conveyor drive station with gearless drive system, 2 x 3,100 kW
Modern gearless drive systems for high-capacity belt conveyors / 55
Fig. 5 / Rendering of a drive station for the Xstrata Copper Antapaccay mine in Peru
Summary
Long conveyors with large throughputs and/or high lifts require a significant amount of power. When the demand for power exceeds 3 MW per pulley, gearless drives for the conveyor become the preferred solution. Gearless drive solutions provide many benefits compared to gearreducer drive systems: Higher plant availability by eliminating electrical components, couplings, bearings and gearboxes therefore minimizing the risk of downtime; Up to 4% higher energy efficiency achievable with gearless direct-drive technology; Longer conveyors with fewer drive stations and smaller footprints resulting in less excavation for underground applications; Higher available power at the pulley; Reduced maintenance achieved by reducing the potential for mechanical breakdowns through the use of robust components;
Fewer spare parts resulting in lower inventories and lower investment costs; Reduction in noise levels achieved by eliminating the gear reducers, which are the noisiest component in a traditional drive system. The mining industry, particularly in South America, is looking increasingly at large, high-capacity conveyors as a solution to meet ore and overburden transportation requirements. Gearless drive solutions have the potential to meet these new requirements efficiently and at lower operating costs.
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Two-roller mill for sugarcane milling
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Energy-efficient two-roller mill

YAshwANt SAkhArdANde B.Tech Sr. Vice President, Design & Engineering ThyssenKrupp Industries India Pvt Ltd. Pimpri, Pune/India ArviNd KArMArkAr B.E. (Mech) Head of Research & Development ThyssenKrupp Industries India Pvt Ltd. Pimpri, Pune/India
To meet market demand for energy-efficient equipment, ThyssenKrupp Industries India has developed a highly energy-efficient, trash plate-less two-roller mill to overcome the limitations (frictional losses, complexity and wear) of the conventional three-roller mill. The new mill reflects the pioneering role played by ThyssenKrupp Industries India in the Indian sugar industry. As mills are major power consumers in the sugar industry, there was an urgent need for an energy-efficient alternative. With its large market presence in the sugar industry, ThyssenKrupp Industries India is constantly looking to develop more energy-efficient equipment and processes for all areas of sugar production.
Brief history India is the largest sugar consumer in the world and the second largest producer of sugar. Projected sugarcane production for 2012 is 320 million tons. Postindependence (1950-51) industrial development saw a rise in the number of farmer cooperative sugar factories as a priority sector. Sugar factories began demanding modern equipment and processes to increase crushing capacities and extraction efficiencies and improve sugar quality. ThyssenKrupp Industries India (formerly Buckau Wolf) has played a pioneering role in the Indian sugar industry since 1957. Turnkey project capacities range from 800 to 15,000 tons of cane crushed per day (TCD) including design, manufacturing, installation and commissioning. ThyssenKrupp Industries India has installed more than 132 plants and expansion projects, 543 sugar mills / Fig. 1 / and 4,100 centrifuges in India, Africa, Latin America and the ASEAN region.
Unloader cane Cane chopper knives Cane leveller knives
Fibrizor
Rotary screen
Bagasse to boiler
Feeder table
Feeder table
Magnet
Screened juice to process
2nd mill
3rd mill
Sugar cane unloading
Shredder
Cane Carrier
Cane pre-preparotory devices
Juice extraction mills
Fig. 1 / Schematic view of a sugar mill house
4th mill
Belt conveyor
1st mill
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Fig. 2 / Sugarcane source of energy and sugar
Sugar industrys focus on power exports

Sugarcane is green, carbon neutral, and a source of both food and energy / Fig. 2 / . A power sector reform in the late 1990s enabled sugar factories to export electricity to the grid using bagasse as green fuel. The Kyoto Protocol gave additional impetus to this initiative through carbon credits for green power generation. Today power export is an important revenue stream and more and more sugar plants are being converted to cogeneration plants.
The challenges faced in cane milling

Reduce power consumption: electricity saved is electricity generated Reduce moisture in the bagasse: improved calorific value of fuel in cogeneration plants Reduce initial capital investment: old factories encouraged to expand, better ROI for new plants Increase mill extraction: more sugar produced Reduce maintenance cost: improved plant availability
Limitations of conventional three-roller mills

The basic three-roller mill design / Figs 3 and 4/, developed in the early 1900s incorporated two compressions in the mill with high frictional work between compressions over the trash plate. The frictional work was necessary to loosen the fibers and expose/puncture the juicecontaining cells to make crushing in the second compression more efficient. The speed difference between the rotating top roller and the stationary trash plate combined with heavy hydraulic loading helps achieve this effect / Fig. 5 /. However this also causes high frictional power losses. Additionally the three-roller mill is characterized by the following:
More moving parts, High frictional losses in - the trash plate and - the crown pinions as well as in the square coupling, High juice re-absorption losses over the trash plate; the trash plate obstructs free juice drainage between the feed and discharge rollers and leads to re-absorption, Mill setting and alignment are difficult, All rollers rotate at the same speed, When the top roller floats, the feed and discharge gap-setting ratio does not remain constant, The top roller transmits power and additional hydraulic load to the feed & discharge roller, necessitating bigger shafts and bearings; standardization of roller shafts (feed & discharge same as top) leads to a bigger headstock and a heavier mill, Due to geometrical constraints, roller wear allowance is limited and uneven for the individual rollers; roller wear is maximum for the top roller and minimum for the feed roller.
Concept of the two-roller mill

Today, heavy-duty shredders and fibrizors prepare the sugarcane with up to 90% open cells before it is fed to the mills. As a result, frictional work over the trash plate is no longer necessary, so eliminating the trash plate was an obvious choice for engineers. In conventional mills, the trash plate absorbs almost 25% of the hydraulic load applied to the top roller. Only roughly 75% of the hydraulic load is utilized for juice extraction. Also, approximately 20-25% of the power is lost in dragging the bagasse over the trash plate.
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Fig. 3 / Three-roller mill
Power loss in crown pinions Unbalance force friction loss due to sliding of top roller UFR (Under Feed Roller) Top roller Power loss/ Friction on trash plate
Re-absorption losses
Feed roller
Discharge roller
Fig. 4 / Power losses in a conventional three-roller mill
Power loss due to tail bar & square coupling
100% Top roller
100% Top roller
25% 25% 50% 100% Feed roller Bottom roller Discharge roller
Fig. 5 / Hydraulic load distribution, left: conventional mill, right: two-roller mill
60 /
In the new two-roller mill there is no trash plate, so frictional power losses due to the trash plate are eliminated. 100% of the hydraulic load applied to the top roller is transferred to the bottom roller and utilized for juice extraction / Fig. 5 /. During development, the energy-efficient two-roller mill was compared with the conventional three-roller mill. The basic mill structure has been redesigned in line with the new mill roller configuration. Many standard and proven components/assemblies such as top cap, bearings, Messchaert grooves, lotus holes, and floating top roller are retained in the new design. A speed differential between the top and bottom rollers introduced in the new mill performs the small amount of frictional work still necessary. The new components/systems introduced in the tworoller mill to enhance its energy efficiency are described briefly below.
The re-absorption controlling unit: Reduces sugar loss in the bagasse and lowers bagasse moisture in the final mill, Reduces the recompression effort required in the subsequent mill in the tandem and saves power.
Flexibility to adopt various feeding systems

The two-roller mill can be fed by toothed roller pressure feeders (TRPF), grooved roller pressure feeders (GRPF) or under feed rollers (UFR), depending on the clients requirements / Fig. 7 /.
Implementation of energy-efficient drives

Shaft-mounted planetary drives/hydraulic drives eliminate energy losses in the helical gear box, open gearings and tail-bar couplings / Fig. 8 /. The drive size can be reduced, and the drive-side foundation is no longer necessary. Rope coupling: Eliminate energy losses in tail-bar couplings, Ensure free floating of the top roller, Protect drives by absorbing shocks from the mill roller and Reduce the total installed power requirement of the mill.
Re-absorption controlling unit

As a result of preparation work, the bagasse tends to be spongy and reabsorbs juice if it is allowed to expand freely after compression. The unique re-absorption controlling unit / Fig. 6 / prevents the bagasse from expanding after compression in the mill rollers. This minimizes reabsorption of the extracted juice and conveys the bagasse away from the juice extraction zone. The new design gives maximum attention to ensuring the juice can drain freely.
Fig. 6 / Re-absorption controlling unit
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Donnelley chute GRPF Top roller Lotus* Perforated pressure roller Short space pressure chute - Prevents resorption - Increase bagasse density and capacity of two-roller mill
Mill top roller Lotus* GRPF Bottom roller Lotus* Juice resorption controlling unit
Mill bottom roller deep Messchaert and Lotus*
Juice tray
Donnelley chute
Mill top roller Lotus* Perforated pressure roller
Juice resorption controlling unit
Mill bottom roller deep Messchaert drooves and Lotus holes
* ) Lotus = Pattern of holes in roller for drainage of juice
Juice tray
Fig. 7 / Two-roller mill fed by GRPF/TRPF and single roller
62 /
Product features and advantages of new two-roller mill
Advantages of a two-roller mill tandem

A milling tandem in a sugar plant comprises four to six mills. By installing new two-roller mills we achieve: Higher primary extraction (roughly 2% - 4% more) in the first mill, leading to higher sugar production Reduced bagasse moisture (< 48%) and improved boiler efficiency / Fig. 9 /
Inclined headstock for easy feeding through a Donnelley chute or pressure feeders Individual fine mill setting and speed control on each crushing Roller wear allowance is uniform for both top and bottom rollers due to their equal hydraulic loading and single pressure contact Power saving - drive power up to 60% - 70% lower than on a conventional mill - hydraulic load approx. 70% -75% of that on a conventional mill and transferred directly to the bottom roller investment cost Lower smaller roller shaft and bearings than on a conventional mill of the same size, resulting in a compact, lighter mill - lower drive cost, higher drive efficiency - lower cost of foundations - less time for initial installation Improved drainage and lower re-absorption - re-absorption controlling unit lotus-type top and bottom rollers, deep Messchaert grooves for better drainage Lower maintenance & spare parts cost - fewer varieties of rollers, easy to adjust setting - no trash plate adjustment/replacement - higher roller wear allowance for longer life - fewer moving parts
Project status and market launch

The combination of a floating top roller and a re-absorption controlling unit makes the product unique. Once the conceptual designs were completed, the basic parts such as headstocks, top cap, rollers and bearing housings were closely analyzed, and ThyssenKrupp Industries India is now ready to take a quantum leap. The first order has been received which includes a 50 inch dia. x 100 inch wide two-roller mill with the following specialties: Largest ever mill, even in conventional format GRPF feeding arrangement Final crushing capacity of 12,500 tons per day Performance parameters of final mill: bagasse with 48-49% moisture and 96% sugar juice extraction Given ThyssenKrupp Industries Indias significant market share and its high customer satisfaction rate, the new product is expected to attract numerous conversion and new installation projects once the first mill has been installed and commissioned.
Shaft mounted planetary gear
Rope coupling Foot mounted planetary gear
Shaft mounted hydraulic drive
Fig. 8 / Drive components
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Three-roller mill tandem: Four mills with UFR (Under Feed Roller)
PE (Primary Extraction) 100% 100% 100% 100%
= 70%
RME (Reduced Mill Extraction) = 95%
Bagasse moisture 1st mill Three roller with UFR 2nd mill Three roller with UFR 3rd mill Three roller with UFR 4th mill Three roller with UFR Total power installed
= 50% = 400%
Two-roller mill tandem: Four mills with 1st and 4th mill with GRPF (Grooved Roller Pressure Feeder)
PE (Primary Extraction) 80% 65% 65% 80%
= 75%
RME (Reduced Mill Extraction) = 95.5%
1st mill Two roller with GRPF/TRPF (Toothed Roller Pressure Feeder)
2nd mill Two roller with UFR
3rd mill Two roller with UFR
4th mill Two roller with GRPF
Bagasse moisture Total power installed
= 49% = 290%
Fig. 9 / Mill tandem: installed power comparison and performance comparison
Future challenges of steadily expanding mill capacities

Overhanging weight of shaft-mounted drives or pinion reactions of conventional crown pinions cause extra loads on drive-side bearings. Large diameter rope couplings limit layout flexibility.
The energy-efficient two-roller mill from ThyssenKrupp Industries India presented in this article won ThyssenKrupps special Energy and Environment innovation award in 2011.
Conclusion
Customers will benefit from this innovation on multiple fronts i.e. lower investment cost, lower energy costs, additional power generation thanks to lower bagasse moisture and increased sugar production thanks to better juice extraction. The savings for clients are enormous. Investment costs are 12 to 15% lower and CO2 emissions will be reduced by around 72,000 tons by 2020.
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POLAB Shuttle installation with two mobile robots in Lgerdorf/Germany
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The new generation of laboratory automation

Dipl.-ING. HuGO HASSMANN Senior Manager Development Automation & Electrical Engineering, ThyssenKrupp Polysius AG Neubeckum
POLAB Shuttle
Fast and comprehensive quality analysis in all stages of production is essential in the cement and building materials industry. As well as representative sampling in the various stages of the process, sample preparation and sample analysis are key factors in monitoring the quality of the end product. The increasing use of alternative fuels and raw materials calls for a highly flexible and continuously available laboratory automation system to meet current and future requirements. POLAB Shuttle is a freely configurable laboratory automation system with a common human-machine workspace.
POLAB
The ThyssenKrupp Polysius laboratory automation system POLAB has been an international byword for quality control and process optimization in the cement industry for more than four decades. Innovative automation solutions and intelligent control systems help minimize raw material costs and assure product quality. Fully automatic POLAB samplers are used to take representative samples throughout the process from raw meal production (grinding of limestone, marl, sand, iron ore etc.) to hot meal in the kiln inlet (decarbonated raw meal at a temperature of approx. 900 C) to cement clinker and the finished cement. A sample of approx. 300 grams represents a production quantity of up to 500 tons. These samples are sent in capsules by pneumatic tube to the lab, where they are divided again, prepared, and fed to various analyzers / Fig. 1 /.
Pneumatic tube Plant Laboratory ART APM APM I/O magazine
Sample dispatch station
Sampling point Target specification APM = Automatic Preparation Module ART = Automatic Receiving and Transfer Module XRF = X-Ray Fluorescence XRD = X-Ray Diffraction
POLAB computer
Granulometer Storage Colorimeter XRF XRD
Fig. 1 / POLAB Shuttle laboratory automation system with automatic sampling, pneumatic delivery and process control system
66 /
POLAB Shuttle the new generation of laboratory automation
Fig. 2 / POLAB Shuttle the mobile robot
To guarantee maximum operator protection the robot arm is equipped with a TV-certified power limiting device. This electronic system ensures that the robot arm does not exceed the maximum power allowed for the common human-machine workspace. The individual modules for receiving, preparing, analyzing and storing samples are set up alongside the rails and are served by the mobile robot: POLAB ART (Automatic Receiving and Transfer Module) / Fig. 4 /, a pneumatic tube receiving and metering station for transferring samples into transfer cups for processing POLAB APM (Automatic Preparation Module) / Fig. 5 /, the proven module for sample preparation (optimum grinding of samples and compressing of tablets for X-ray fluorescence analysis and X-ray diffraction analysis) (see ThyssenKrupp techforum 1/2006) Input/output magazine for entering samples manually Storage magazine for collecting average samples Granulometers for measuring grain size distribution Colorimeters for monitoring color consistency X-ray spectrometer (XRF) for X-ray fluorescence analysis (determining the chemical composition of a sample) X-ray diffractometer (XRD) for X-ray diffraction analysis (determining the mineralogy of a sample)
POLAB Shuttle
To gain a larger share of the lab automation market, an innovative laboratory automation system was designed focusing on the following aspects: Collaboration of humans and machines in a common workspace High maximum sample throughput Minimum downtime for maintenance Possibility of full redundancy Extensibility for new components and analyzers Use of proven components
To minimize downtime during maintenance (or avoid it completely in the case of redundant design of the individual components), lab personnel must be able to access the machines while the robot is working. Only a system with a common human-machine workspace could therefore be considered. The POLAB Shuttle is the first system to use a mobile robot / Fig. 2 /, replacing a space-consuming robot with great potential for hazards. The mobile robot consists of a low-powered lightweight robot arm and a transfer robot. A transfer robot is a mobile platform that moves independently on rails to predefined stops. It is fitted with energy storage devices that are charged at the stops. The transfer robot is intrinsically safe and can be operated without additional safety equipment. The rail system is set up using diverters so as to make optimum use of available laboratory space / Fig. 3 /. A lift allows vertical floor changes.
Fig. 3 / POLAB Shuttle configuration options
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Fig. 4 / POLAB ART
Fig. 5 / POLAB APM
68 /
All the modules are designed so that the robot accesses them from the rear. The machines are operated by lab personnel from the front / Fig. 6 /. To carry out maintenance work a machine is logged out at one of the operating stations and the mobile robot then no longer serves that component. In this way, fully automatic operation can continue while individual machines are maintained. With redundant systems, the control system automatically manages the transfer of samples to free machines.
The rail system has two tracks on which two mobile robots transport the samples. The rails are connected using diverters to ensure full redundancy. As the pneumatic tube also has a diverter, samples can be sent to either of the two receiving stations. Further samples can be fed into the system via input/output magazines. It is also possible to place manual samples directly into the analyzers while the robot is in operation.
Conclusion First POLAB Shuttle installation

The cement plant laboratory handles samples from eight sample dispatch stations and a total of eleven sampling points to assure consistent product quality. The extensive use of alternative fuels and raw materials calls for very high availability of the laboratory automation system and high sample throughput rates. For this reason, Holcim (Deutschland) AG opted for a fully redundant POLAB Shuttle laboratory automation system / Figs 7 and 8 /. The laboratory system is designed for a sample throughput of 750 analyses per day and consists of: 2 POLAB ART pneumatic tube receiving stations, 4 POLAB APM preparation modules, 2 X-ray spectrometers, 2 X-ray diffractometers, 3 granulometers, 1 colorimeter, 2 input/output magazines and 2 storage magazines. POLAB Shuttle is a laboratory automation system offering unique flexibility. Sample transfer by means of the mobile robot allows unprecedented freedom of configuration and extensibility. The individual modules, such as receiving station, sample preparation, input/output magazine and analyzers, are interconnected by the rail system on which the robot moves. The innovative safety concept makes the laboratory into a common human-machine workspace. The laboratory is barrier-free and the individual components can be operated either automatically or manually. With the POLAB Shuttle concept, redundant laboratories can be set up to achieve maximum availability and sample throughput rates. Thanks to the success of the first installation a further customer has now placed an order for a POLAB Shuttle system.
Automatic operation
Manual operation
Fig. 6 / Common human-machine workspace
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ca. 15 m
XRD 1
XRF 1
APM 2 APM 1
ART 1
Color Fineness ART 2 XRD 2 XRF 2 ca. 12 m APM 4 APM 3 Fineness Sample divider I/O magazine Storage Fineness I/O magazine Storage APM = Automatic Preparation Module ART = Automatic Receiving and Transfer Module XRF = X-Ray Fluorescence XRD = X-Ray Diffraction
Fig. 7 / Schematic of the fully automatic laboratory at HOLCIM (Deutschland) AG in Lgerdorf/Germany
Fig. 8 / Fully automatic laboratory at HOLCIM (Deutschland) AG in Lgerdorf/Germany
70 /
The status of wind turbines can be monitored online with a Machine Diagnostic Interface.
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MDI Wind Machine Diagnostic Interface

The online condition monitoring system thats not just for wind turbines
Dipl.-ING. ANdreAs Eicke Measurement Technology Supervisor ThyssenKrupp System Engineering GmbH Langenhagen
It is becoming increasingly important to be able to implement condition monitoring to protect highgrade investments such as wind turbines and other major industrial plant and installations. ThyssenKrupp System Engineering has developed a Machine Diagnostic Interface (MDI) for this purpose that is based on proven and reliable standard components in terms of the hardware used. As regards the software, the measuring and automation system used is based on mature technology, was developed in-house and has proved its worth over many years on testing and assembly lines in the automotive and supply industry. The basic concept of the Condition Monitoring System (CMS) and the essential technical elements of the MDI are introduced here. The development was funded by the German Federal Ministry of Economics and Technology (BMWi).
Condition monitoring
Condition monitoring is the term given to the monitoring of the status of a machine through the measurement and analysis of key physical values, such as the vibrations and temperatures of a turbine, in particular with the aim of saving costs by means of condition-led maintenance / Fig. 1 /. This strategy replaces the standard reactive or preventive maintenance measures currently employed. Where reactive maintenance is carried out the damage has already been done and a component needs to be replaced or repaired, while preventive maintenance involves the possibility of unnecessarily replacing components that are still in sound condition. In contrast, condition-led maintenance enables cost savings to be made by utilizing the service life of critical machine elements to the fullest possible extent as well as allowing maintenance measures to be scheduled in good time as they become necessary. Condition monitoring can be carried out either occasionally or continuously. Continuous monitoring systems (i.e. online condition monitoring) constantly measure machine parameters. Long-term trends (e.g. wear) and sudden changes in condition are captured and recorded to ensure an immediate response.
MDI-Wind the online condition monitoring system thats not just for wind turbines
MDI Wind is an online condition monitoring system (CMS) for the continuous monitoring of wind turbines / Fig. 2 / as well as other major industrial plant and machinery. The hardware of the MDI consists of standard industrial components which are housed in an industrial cabinet. The system is suitable for all types of turbines and is designed specific to the turbine concerned (e.g. number of channels, sensors, additional tasks). This is complemented by an MDI Diagnosis service provided in the form of a CMS diagnostic center. It is equipped with PCs and servers to archive the data and allow offline analysis. The MDIs software is based on the proven universal UPS 32 testing and automation system with operating system Microsoft Windows XP or Windows 7.
System functionality
MDI Wind ensures that wind turbines, for example, are continuously monitored online based on a permanently installed diagnostic system. The primary characteristic to be monitored is the structure-borne noise of the power train consisting of main bearing, gear unit and generator as well as key temperature values. The vibration of the nacelle and of the tower, if required is also captured. Other monitoring tasks can also be integrated into the system as options. Relevant operational data for the turbine, e.g. speed, wind speed and output or torque, are also captured. This involves running continuous data acquisition with synchronous measurement of all channels. Data validation is carried out (e.g.
Fig. 1 / A vibration acceleration sensor monitors a high-power gear unit.
72 /
MDI Wind Machine Diagnostic Interface the online condition monitoring system thats not just for wind turbines
Rotor blade
Main bearing Gear unit Generator
Measuring leads
Fig. 2 / Schematic representation of the monitoring of the power train and rotor blades of a wind turbine
to check whether the output was sufficiently stable) as well as a sensor check (e.g. to check whether a cable has parted). The operational condition of the turbine is determined in order to allow classification of the measurement using the output or torque. The evaluation calculates key characteristic values while taking into account the operational condition of the turbine. All the data, including the original values measured (known as raw data), are then initially stored locally. This ensures that no data are lost, e.g. through filtering. Values which exceed the limits are automatically and immediately reported as a warning and if required, as a main alert to the monitoring center and to the operating company by email or SMS, for example. The data is then transmitted to a central database (i.e. to the server at the diagnostic center) for long-term archiving and trend evaluation at the diagnostic center. With respect to the trend evaluation in particular, and in order to be able to compare measurements and/or results better, they are each assigned to a class of service via the operational status. Using the Microsoft Windows operating system, it is very easy for operating companies and the diagnostic center to access the data remotely. Manual analyses and report generation are carried out by experts at the diagnostic center.
equipped with a maintenance-free uninterruptible power supply (i.e. a supercapacitor replaces the battery pack). The system is designed to take modular extensions in terms of the number of measurement channels and functions and provides interfaces to all known sensors and systems. Example of a typical expansion stage of an MDI Wind CMS: 8 analog inputs for vibration sensors (equipped with anti-aliasing filters) Can be extended to 12 or more channels as an option 24 analog inputs for other signals (e.g. speed, wind strength, output) 16 analog inputs for temperature sensors 8 digital inputs (24 V) 8 digital outputs (24 V) Data transfer via internet (by cable or wireless by means of UMTS antenna) A variable number of sensors/channels can be used to capture all signals optimally, depending on the structural design of the turbine to be monitored and the measurement task to be carried out. If these signals are not available at the turbine, the appropriate sensors are installed. Examples of the signals of a wind turbine with gear unit: Vibration signals for the rotor bearing, gear unit, gear bearing, generator bearing and nacelle Speed signals for the rotor and generator Wind speed Output Temperatures: external air, internal nacelle, rotor bearing, generator bearing, gear unit and oil Azimuth control signals and pitch
Hardware features
The hardware of the MDI consists of standard industrial components and is housed in an industrial cabinet with a climate control system adjusted to the ambient conditions. All inputs and connections can be equipped with a lightning protection system as an option. This means that the MDI can also be used in extreme ambient conditions. All components are designed to industrial standards. The hard disk of the MDI is a solid state disk and is therefore not subject to wear. The MDI is also
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Fig. 3 / Order spectrum of a vibration signal presented in logarithmic form marking a number of harmonic components of the meshing (integral multiples of the meshing order)
Fig. 5 / Shaft misalignment at the main bearing of a wind turbine during 16 rotations (average test distance of sensors approx. 4 mm)
Software features
The analytical processes used include those that are fundamentally required, as defined by Germanischer Lloyd, Allianz Zentrum fr Technik and DIN etc. These identify and evaluate the amplitudes of characteristic meshing frequencies and bearing frequencies, e.g. in respect of the vibration signals (Fourier analysis/frequency spectrum). Integral values, such as effective values across certain frequency ranges, are also calculated. To equalize variations in speed, order analysis is applied / Fig. 3 /. To improve the signal-to-noise ratio, a rotational synchronous averaging process is used, if required / Fig. 4 /. The frequencies and orders of the external ring, cage, roller bodies and internal ring are monitored for each bearing. In addition, envelope analysis (frequency and order) and cepstral analysis (a mathematical process for detecting shock impulses) are used to detect periodic shock impulses. Limits are established for warnings and main alerts; these are also calculated automatically using statistical methods. At the
diagnostic center, trend analyses are undertaken offline automatically, and manually if required, for the characteristic values identified. The software also provides the opportunity to carry out manual modifications to test runs online. In other words, making changes even during operations or adding extensions does not require the expense of calling out a service engineer but can be carried out remotely.
Optional extensions and data management

There is flexibility built into the system to permit extensions due to the structure of the hardware and software. Optional extensions for monitoring/evaluation/sensor technology for wind turbines include: Oil quality monitoring Torque measurement Tower vibration monitoring Rotor blade monitoring Rotor shaft misalignment / Fig. 5 /
Low pass
ADC Analogto-DigitalConverter
Digital Resampling
Shaft 1 Rotational Synchronous Averaging
Accelerometer
Shaft 2
Shaft 3 GearBox
Calculate Speed Signal
Speed
Encoder ADC Analogto-DigitalConverter
Low pass
Fig. 4 / Fundamental principle of data acquisition and preprocessing of vibration signals, with digital resampling and rotational synchronous averaging
74 /
MDI 1
e.g . UM TS con nec tion pos sib le
Internet
Communication server
Operational management/ Control room/other PC
SQL server
CMS diagnostic center
Fig. 6 / Example of a single turbine with a connection to the diagnostic center
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All data management models can be realized, from a stand-alone system without server connection, a wind farm with a number of MDIs with server connection, right through to global networking / Fig. 6 /.
Diagnostic center
The MDI is operated by means of a user-friendly menu mode and is protected against unauthorized changes by an access authorization system. When a characteristic value is reported as having exceeded the limit, this is assessed by an expert at the diagnostic center. The event can be investigated in detail via remote access (e.g. Microsoft Windows Remote Desktop connection / Fig. 7 / ) to the MDI at the turbine. Other measurements can also be initiated manually. The characteristic value required is found using the menu, while the location can be identified using a diagram. The software allows user-friendly access to the results stored in the results database. This enables the user to compile an individual list from all the data records and from this to upload individual results or produce statistics, histograms and trends about the results. Histograms are sometimes useful to determine the distribution (and mean value) of a feature when the turbine is at the calibration stage / Fig. 8 / . Automatic calculation and the setting of tolerance limits are also supported. Another important tool for diagnosis is the option of analyzing trends. Impending damage can become evident due to a gradual increase in the respective characteristic value. Furthermore, the trend display allows for a comparison of characteristic values and operating parameters in any combination / Fig. 9 /. When the diagnosis is completed, the expert instructs the wind turbine operating company on the action to be taken. The results and measures are documented in writing.
Fig. 7 / Remote desktop connection to an MDI
Summary
The MDI online condition monitoring system MDI Wind from ThyssenKrupp System Engineering is an outstanding tool for meeting the basic requirements for a CMS. It also provides an exceptional range of benefits that other systems may not be able to offer. It is based on the Microsoft Windows operating system and an industrial PC. The software is fully developed and already proven in the automotive and supply industry. The hardware consists of proven standard components. The system is relatively easy to extend to include additional monitoring tasks. It works reliably and is self-monitoring. In addition, other tests and analyses can be initiated by remote access at all times. ThyssenKrupp System Engineering also acts as an independent systems partner. This means that an effective condition monitoring instrument is now available to operators for the protection of machines and turbines.
Fig. 8 / Histogram of a feature with mean value and tolerance limits
Fig. 9 / The trend display allows two or more signals to be compared.
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Plastic-coated cage
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Development of cages for slewing bearings in wind turbine systems

Dr.-ING. JrG ROllMANN Head of Research and Development Rothe Erde GmbH Lippstadt Dr.-ING. WilFried SpiNtiG Plant Manager Rothe Erde GmbH Lippstadt Dipl.-ING. SteFAN SchNieder Research and Development Rothe Erde GmbH Lippstadt Dipl.-ING. ReiNhArd JrGeNs Production Engineering Rothe Erde GmbH Lippstadt
Slewing bearings are key components in the powertrain of a wind turbine. They are used as blade adjustment bearings and as nacelle bearings. The roller bodies in these bearings are kept separate from each other preferably by steel cages. To preventwear, a plastic coating process for cages was developed at Rothe Erde. Various tests conducted on plasticcoated cages used in heavy-duty blade bearings (dia. 2 m) revealed a considerable increase in wear resistance on these cages compared to uncoated cages. Following the integration of this coating process into the cage production line, the process is one of the standard features of Rothe Erde bearings for wind turbines today, particularly those used in the offshore sector.
Slewing bearings in wind turbines

Slewing bearings are highly versatile machine components which, in a variety of design types, are used in practically all fields of mechanical engineering and materials handling. Characterizing features are that they are delivered ready for installation and are bolted to a companion structure. In terms of design they are generally configured as nonseparable slewing rings, which means that the rotary transmission of axial forces, radial forces and tilting torques is possible by a single bearing. Slewing bearings are key components in the powertrain of a wind turbine for example. They are used as blade adjustment bearings (blade bearings) and as tower house bearings (azimuth bearings). In their function as blade bearings, the slewing bearings take up the wind loads and momentum acting on the blades, and direct them to the rotor. At the same time the freedom of rotation enables the angle of attack of the blades to be adjusted to the given wind velocity and to the operating status (run-down, start-up) of the wind turbine. In their function as nacelle bearings, slewing bearings are used to align the nacelle with the prevailing wind direction. In addition, the growing necessity for lightweight construction is also having an impact on wind turbines, with the result that large diameter bearings are also used to support the main rotor, particularly where gearless wind turbines are concerned.
Slewing bearings Cage External ring Internal ring Fig. 1 / Cross section of a blade bearing Fig. 2 / Components of a blade bearing Seal system
78 /
Bearing structure
Blade adjustment bearings are configured mainly as double-row fourpoint bearings / Figs. 1 and 2 /. This design type has proven to be a rugged and reliable solution for customary wind turbine loads and operating conditions. This design is characterized by an arrangement of two seamless rolled rings which are interconnected by two rows of balls. The term four-point bearing has to do with the fact that the radii of curvature in the cross section of the external ring and the internal ring have four different center points and that, in the unloaded bearing at approx. 45 to the bearing axis, the inter-lying balls therefore have four contact points with the bearing rings Thanks to this geometry the bearings have a high axial load capacity and rigidity. The ball raceways are inductively surface-hardened in order to withstand the surface pressures between the roller body and raceway without suffering any wear. Cages or spacers are used to separate the balls from each other and to prevent friction between them. Other bearing components are greases and gaskets which are specially adapted to the specific operating conditions of blade bearings.
Wear tests
The problem of cage wear was simulated in the Rothe Erde research and development laboratory, in particular on bearings which were bolted to an uneven companion structure. Comparative wear tests were therefore performed on this installation layout so that different cage coating systems could be assessed. As part of a test series, wear tests were carried out on untreated steel cages, manganese-phosphated cages, cages coated with sliding varnish, brass cages, and nitrocarburized and plastic-coated cages. While cage wear was only partly reduced by the use of brass cages, a notable reduction of cage wear was initially achieved by the use of the nitro-carburized cages / Fig. 4 /. One disadvantage of nitro-carburization, however, is the risk of cage distortion through handling, transportation and the relatively high heat treatment temperatures, because any distortion produced after heat treatment cannot be eliminated. Another disadvantage of this coating process is that the necessary coating lines are costintensive and require demanding environmental protection measures. The tests conducted on plastic-coated cages revealed a comparable and sometimes higher level of wear reduction than with the nitrocarburized cages.
The cage
Under certain operating conditions and high cyclic operating loads combined with soft companion structures or large bearing diameters, circumferential forces may arise in the chain of roller bodies and lead to increased friction torque when spacers are used. To prevent this from happening, cages made of steel strip are used in blade bearings to separate the roller bodies / Fig. 3 /. This version has proved itself in practice, but potential local wearing of the cage in sliding contact with the bearing rings is a disadvantage. So far, efforts to eliminate this effect through manganese phosphating and a coating of sliding varnish have met with only limited success. One repercussion in practice has been the discovery of undesirable residues of the cage material in the bearing lubricant.
Plastic-coated cages
Rothe Erde developed a process to provide the steel cages of blade bearings with a plastic coating. The finish-bent and, where applicable, welded steel cages are pretreated to increase adhesive strength. The cages are then heated to coating temperature and dipped briefly into a polyamide bath. The steel cage is left with an approx. 0.4 mm thick coating of high-adhesion polyamide. This coating prevents steel-onsteel sliding contact and therefore permanently reduces wear / Fig. 5 /.
120 100 80 Wear [% ] 60 40 20 0 Steel Brass Steel nitrocarburized Steel PA 12 coated
Fig. 3 /
Roller body cage made of steel
Fig. 4 / Comparison of cage wear with different materials
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Fig. 5 / Cage with polyamide coating
Fig. 6 / Test rig for blade bearings
To develop the process, suitable coating parameters were first established with the help of a laboratory coating system. The samples thus obtained were then used to verify the coatings adhesive strength and its resistance to aging and lubrication. The plastic-coated prototype cages produced by the process proved successful in the previously described wear test. For production coating, a fully automated coating line was developed for slewing bearing cages in a range of diameters from 2 m to 3 m. It was possible to integrate this coating line into the cage production system without having to comply with any environmental regulations. In addition, the plastic coating process enables cage distortions to be corrected by subsequent straightening. It is even possible to coat the strip material first and bend it into round cages later, thus enabling transport costs to be greatly reduced.
Outlook
The plastic-coated cages have proven themselves in diverse systems and test series both at Rothe Erde / Fig. 6 / and at customers. Today, such cages are therefore one of the standard features of Rothe Erde bearings for wind turbines, particularly those used in the offshore sector. Meanwhile, plastic-coated cages are also being used in bearings for other applications such as scanners and antennas. Test are currently underway on further applications and coating materials.
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DampTronic select Sports suspension at the push of a button
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DampTronic select
Dipl.-ING. Ole GtZ Team Leader Simulation & Engineering ThyssenKrupp Bilstein GmbH Ennepetal Dipl.-ING. KlAus SchMidt Head of Development Active Systems ThyssenKrupp Bilstein GmbH Ennepetal
DampTronic select two-stage damping system developed by ThyssenKrupp Bilstein bridges the gap between conventional, passive shock absorbers and complex, infinitely variable electronic damper systems. When configuring his vehicle, the customer no longer needs to decide between normal or sports tuning, but can simply change between two suspension settings by pushbutton. At the heart of the innovation is the highly compact DampTronic select valve with two damping force characteristics which can be tuned largely independently of each other. Low component costs and integration work have reduced the costs of the system so much as to make it attractive even for the compact and small car segment.
Adjustable shock absorber systems

A vehicles handling and comfort depend greatly on the tuning of its shock absorbers. With the conventional shock absorbers customary today, hydraulic valves can be used to define a tight damping force characteristic. However, this goes only some way towards resolving the classic conflict of preference between comfort and agility. Adjustable shock absorber systems which permit the damping characteristics to be adapted to the driving situation or to the drivers wishes are already available as a standard feature in many top-segment cars, and are even available as an optional extra in the compact segment. These systems enable the customer to ride in comfort without dispensing with the safety reserves and the driving enjoyment of a tightly tuned suspension. These complex damping adjustment systems comprise infinitely variable damping valves, diverse sensors for determining the state of movement of the body and wheels and a complex control unit for controlling the shock absorbers on the basis of algorithms. High component costs and a considerable amount of integration work are preventing the further spread of such infinitely variable damping systems. The two-stage DampTronic select developed by ThyssenKrupp Bilstein is positioned between the established infinitely variable damping adjustment systems and the
conventinal shock absorber. A cost-effective valve design, sensorless operation and a mini-malistic control system permit a drastic reduction in system costs / Fig. 1 /. The customer can choose between normal tuning and tight sports tuning by pressing a button on the dashboard. On the one hand he has the sports setting for a notable increase in agility, on the other hand the normal setting for greater comfort on long journeys.
Space requirements
At the beginning of their work on the DampTronic select valve, the development engineers defined not only the requirements to be met by the hydraulic function but also other key parameters such as space requirement, energy consumption, weight and target price. Basically, an adjustable shock absorber can take one of two forms. With integrated valves the adjusting valve is located at the end of the piston rod in the working chamber of the damper. By contrast, the adjusting valve can also be positioned on the outside tube of the damper (adapted valve). Both versions have specific advantages and disadvantages. For the DampTronic select, ThyssenKrupp Bilstein decided in favor of the integrated solution with the valve on the piston rod. In hydraulic terms this is the most favorable solution for use in a monotube shock absorber. For the widely used twin-tube shock absorbers there are dis-
82 /
DampTronic select
advantages in terms of installation length and the characteristic spread of compression stage forces, but these are offset by the advantage of being able to use a far less costly tube assembly (or the unchanged assembly of the conventional production damper). Thanks also to the integrated valve arrangement, the additional weight of a shock absorber with DampTronic select compared with a conventional shock absorber amounts to just around 80 g and is therefore practically negligible when measured against the enhanced functionality. To enable the broadest possible range of application for the DampTronic select, it was necessary to adapt the valve system to the standard shock absorber dimensions. In the compact and small car segment, which is the predestined area of use for the new valve system, the front axles are fitted almost exclusively with McPherson struts with an inside tube diameter of approx. 32-36 mm. The minimum diameter was fixed at 32 mm; use of the valve in 36 mm inside tubes is possible using a housing version with a larger outer diameter. When installed in the McPherson strut, the damper performs wheel steering tasks and is therefore exposed to sometimes considerable lateral forces during deceleration
or cornering. The valve housing and in particular the connection to the piston rod were therefore designed on the basis of finite element calculations and experimental trials so as to safely withstand these loads. On the rear axle the shock absorbers are usually configured as freestanding or sprung shock absorbers in monotube or twin-tube design. With its small diameter of 32 mm the valve can be inserted in both damper versions, usually without having to enlarge the radial space. A major disadvantage of integrated valves is the larger dead length which results from its installation length, i.e. the overall length of the damper is greater than that of a passive damper or an adapted valve with the same stroke range. Given todays extremely confined package requirements, the use of integrated valves may therefore fail due to just a few millimeters of installation length. With the development of DampTronic select valve it was possible to achieve space-saving integration of all the functional elements in a length of 51 mm. Compared with conventional work pistons, the increase in length is an acceptable 20 mm. In / Fig. 2 / a conventional work piston is compared with the DampTronic select valve.
Sport Comfort
Conventional damper
DampTronic select: adjustable in two stages
Continuously adjustable
Additional costs/vehicle (system)
~ 250
~100 0
Fig. 1 / Positioning of the DampTronic select
DampTronic select
/ 83
31 mm
51 mm
Fig. 2 / Length compared with a conventional work piston
Hydraulic functionality characteristic curve configuration

The two-stage valve of the DampTronic select system enables the driver to choose between a sports characteristic and the normal characteristic by pressing a button. Examples of characteristic curves for normal tuning and sports tuning are presented in / Fig. 3 /. Both characteristic curves offer the full tuning potential of conventional dampers, i.e. independent setting of the rebound and compression stage characteristic in various speed ranges. The damping force characteristic curves can thus be ideally adapted to the specific needs of the vehicle or to the tuning philosophy. Compared with conventional dampers, there are no functional restrictions in terms of response, ride comfort or driving dynamics.
than 1 W of power is required per damper when normal tuning is activated. By comparison, continuously variable shock absorbers usually have a power consumption of 5 to 10 W. When the power is switched off, the sports setting is activated automatically and the shock absorber works in purely passive mode, i.e. without any power input.
2,500 2,000 1,500 1,000 F [N] 500 0 -500 -1,000 -1,500 0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0 v [m/s] Sport characteristic Normal characteristic
Energy consumption
Against the background of the current CO2 debate, the energy consumption of every electrical system integrated in the vehicle is highly important. This requirement was taken into account by an electromagnetic drive configuration which was optimized for the given boundary conditions. The solenoid coil is dimensioned so that less
Fig. 3 / Parameters of the DampTronic select: Sport and normal characteristics compared
84 /
DampTronic select
Valve design
The valve design presented in / Fig. 4 / was created with due consideration to the previously mentioned requirements on installation space, characteristic curve configuration, power consumption and of course costs. The DampTronic select valve comprises the passive damping valves for normal and sports tuning as well as a magnetically actuated switching valve. In the upper part of the valve there is a magnetic clamp which when energized pulls up the closing plate positioned below it to open the flow channel through the normal valve. The normal valve is thus switched hydraulically in parallel with the sports valve, resulting in the normal characteristic. When the magnetic clamp is not energized, a return spring presses the closing plate onto the valve seat to interrupt the oil flow. The normal valve is positioned below the closing plate. When the closing plate is open, it is mainly this
valve which creates the normal characteristic. The normal valve is tuned in a similar way to conventional shock absorber valves, i.e. the hydraulic resistances on the rebound and compression sides of the valve are adjusted using suitable pretensioning elements and bypass channels. As this valve stage is mainly used in normal driving, a comprehensive tuning portfolio is available for its setting. The sports valve is located at the lower end of the DampTronic select valve. Its characteristics are set by a spring washer stack which works in both directions to tune the pretensioning of the rebound and compression stages. In parallel with the sports valve there is a bypass valve which allows the start gradient of the sports characteristic to be modified in the compression stage. Overall, the tuning parameters described provide broad scope for adapting the DampTronic select valve to the requirements of a wide range of vehicles.
Magnetic clamp
Closing plate Normal valve supply Normal valve outtake Normal valve intake Sports valve supply Sports valve
Fig. 4 / View of the DampTronic valve
DampTronic select
/ 85
Fig. 5 / ThyssenKrupp Bilstein test vehicle
Test vehicle
To test the potential of DampTronic select and make it tangible for customers, ThyssenKrupp Bilstein equipped a BMW Mini Cooper S as a test vehicle / Fig. 5 /. The vehicle was fitted with DampTronic select shock absorbers on the front and rear axles, a control unit and a selector switch for changing between the chassis settings. During damper tuning, the experts from ThyssenKrupp Bilstein gathered valuable experience with the new valve system. Compared with the production chassis, driving comfort was greatly increased in the normal characteristic setting, without the vehicle losing any of its typical character. When the chassis was changed over to the sports setting, the clearly tighter sports tuning and more direct steering of the vehicle were immediately noticeable.
system, and as much as approx. 50-60% for systems comprised of sensors, control unit and dampers. Thanks to its attractive price, the system is an alternative to the infinitely variable shock absorber system particularly in the compact and small car segment. On the other hand the DampTronic select constitutes a sports chassis which offers considerable added value, as the sports tuning can be switched on and off as required, enabling the vehicle to retain its full suitability for everyday use. Several production orders have since been placed for the DampTronic. One application in the sports car segment is set to go into series production in 2012 already, to be followed shortly afterwards by an application in a compact car.
Conclusion
With its DampTronic select, ThyssenKrupp Bilstein has developed a robust and cost-effective damping adjustment system which allows the driver to select by pushbutton a notably tighter and more agile setting for his vehicles characteristics a sports chassis at the push of a button. The system is consciously positioned between conventional shock absorbers with a fixed characteristic curve and complex, infinitely variable damping adjustment systems. With a switching valve which was developed on a design-to-cost basis and works without sensors or a complex control unit, the system may be limited compared with a fully adjustable system, but it does offer a functionality which the customer experiences as very tangible at a price which is very attractive. The DampTronic select shock absorber offers a potential cost advantage of approx. 40% compared with a continuously variable
ThyssenKrupp AG
P.O. Box
45063 Essen, Germany www.thyssenkrupp.com

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