SCHERDEL enjoys continued growth - Scherdel GmbH

REPORTS ON RESEARCH AND DEVELOPMENT, MANUFACTURING, MATERIAL TECHNOLOGY AND THE PRACTICAL APPLICA-
TIONS OF ENGINEERING SPRINGS AND ON THE SYSTEMS, MACHINERY AND TOOLING DIVISIONS OF THE SCHERDELGROUP
Dear reader,
The SCHERDELGroup is pleased
to announce a healthy level of orders.
Against this background, we
have been able to enhance our capacity
and capability, particularly in
the tool making and fine-blanking
sector, through the takeover of EWS
in Chemnitz. We are also aspiring
towards significant cost leadership in
the mechanical engineering sector
due to leading-edge production technologies.
The identification and realization
of synergies across our internationally
competitive Group is still
geared towards the best interests of
customers. A fact reflected, amongst
other things, in our extensive R&D
and product development services.
This was the only way we were able
to progress from a simple manufacturer
of components to a supplier of
functional modules in specific segments.
Clients rely on us, in particular,
when they require remarkable
solutions for complex components
and challenging problems. Admittedly,
it can become a problem if outstanding
commitment in the development
phase does not result in lucrative
production orders. If this
were the case, it would be very difficult
to sustain our services in the
long-term.
Nevertheless, we look forward to
solving challenging problems and
implementing innovative solutions
together with you and believe that
your business will benefit greatly
from our extensive knowledge and
experience in the field of forming
technology.
SCHERDEL enjoys
continued growth
Takeover ensures increased tool
making capacity
The SCHERDELGroup has had a
new member since the beginning
of 2012. SCHERDEL EWS GmbH is
centrally located in the German industrial
city of Chemnitz close to the A72
autobahn. Fortunately, it was possible
to transfer 30 former employees of the
insolvent company into the Group.
The new SCHERDEL production facility
boasts three production halls covering
roughly 2,800 square metres.
As a service provider, SCHERDEL
EWS GmbH focuses on tool optimization.
Furthermore, the designers, technicians
and tool makers at the company
help to maximize Group synergies.
WEMA Werkzeugbau Marienberg
GmbH & Co. KG is responsible for the
technical management of the new subsidiary
and will benefit greatly from the
array of machinery in Chemnitz; for example,
two erosion and two milling centres.
The prize possession of the new
colleagues is, however, an 8,000 kN
hydraulic tryout press, which offers a
press table and coil system. Besides
being used to test tools measuring up
to 3.70 metres in length, it also allows
the production of components in pilot
and small batches of up to 10,000
pieces. SCHERDEL EWS GmbH is also
the proud owner of a 2-D laser system.
As a result, customers in the tool
making sector can now look forward to
improved services from WEMA
Walter Bach
Werkzeugbau Marienberg GmbH & Co.
Group Managing Director 1
KG. The additional tryout press, for ex-
ample, will help to reduce tool throughput
times considerably and ensure that
tight deadlines can be met with ease.
SCHERDEL Feinschneidtechnik
GmbH is yet another SCHERDEL subsidiary
that will profit from the facilities
of the new Group member: the company
previously known as GL Spezial
Platinen Chemnitz GmbH – a specialist
in the field of fine-blanking technology
whose growth has been cramped by a
lack of space – is located in the immediate
vicinity of SCHERDEL EWS
GmbH.
Aerial view of SCHERDEL EWS GmbH
MECHANICAL ENGINEERING – LOCATIONS – TECHNOLOGY & PRODUCT DEVELOPMENT – NEWS AND INFORMATION EDITION 1/2012 E

MECHANICAL ENGINEERING – LOCATIONS – TECHNOLOGY & PRODUCT DEVELOPMENT – NEWS AND INFORMATION
2
TRADE FAIR NEWS
Contact data
Dipl. Kfm. Gerhard Vollath
International Sales Manager
Tel.: +49 9231 603-408
Email:
gerhard.vollath@scherdel.de
(from left to right)
Ingo Maurach, Chandresh Jajoo,
Gerhard Vollath
The Indian Tiger
powers ahead
SCHERDEL’s successful participation in
AutoExpo in New Delhi
P
articipation in AutoExpo 2012 in
New Delhi marked a major milestone
on the road to SCHERDEL
strengthening its position in the Indian
market. After all, India is seen as a
market with enormous growth potential
by the automotive industry. The
SCHERDELGroup provided impressive
examples of its extensive knowledge
and expertise in the forming technology
division at the trade fair in January. In
the area of powertrains, valve springs,
torsion springs for the variable valve
train and spring elements for piston
rings attracted great interest among visitors
to the automotive show.
SCHERDEL is a global market leader
for these components. The showcased
solutions for the powertrain and the
auxiliary units were also particularly
well received: torsion springs for belt
tensioners, spiral springs for cam adjusters,
spring packs for automatic
transmissions as well as stampings and
shaped components for brake systems.
Presentation of the newly developed
circuitry assembly ring for electric and
hybrid engines was a direct response to
one of the key topics at this yearʼs
show: energy efficiency. This underlined
the high regard in which visionary
drive systems are held at SCHERDEL.
Participation in AutoExpo 2012 in New
Delhi, the largest automotive show in
India, proved to be a great success for
the Group. Most of the leading interna-
tional and national automotive manufacturers
and system suppliers presented
their innovative products and system
solutions across a floor area of roughly
50,000 square metres. It was quite
clear that the German automotive industry
has strengthened its presence in
the Indian market in both an exciting
and dynamic manner and, besides its
leading position in the premium segment,
also has a strong footing in the
compact car market. The increasing
quality demands mean that outstanding
market opportunities are now available
to innovative German suppliers.
India, the worldʼs largest democracy
with a current population of around
1.2 billion, is on course to overtake
China as the most populous nation.
According to recent forecasts, the Indian
subcontinent will achieve an annual
average economic growth rate of 7.5
percent until 2020. The demand for
mobility is also expected to continue to
grow due to the countryʼs demographic
profile with a high proportion of young
people and a rapidly increasing middle
class with more purchasing power. According
to the German Association of
the Automotive Industry (VDA), 2% of
the Indian population already has sufficient
funds to purchase a new car,
which equates to roughly 20 million
potential customers.
In 2011, 2.9 million passenger cars
rolled off Indian production lines, and
this figure is expected to rise to 5.2 million
by 2015. The greater involvement
of German companies resulted in a
new record at AutoExpo 2012 in New
Delhi: a total of 75 German exhibitors
occupied about 10,000 square metres –
one-fifth of the entire floor space.
(vol)

PRODUCTS
Higher quality than demanded
in corrosion test
SCHERDEL hose clamps are impressive as
secure connection elements
I
n the automotive industry, hose
clamps are a small yet essential
component that ensures secure and
lasting hose connections. They are predominantly
used in cooling circuits, for
fuel, charge-air and air-intake systems
or in power steering units. As part of
its proactive strategy, SCHERDEL embarked
on a joint venture with the
world's largest manufacturer of hose
clamps, the Japanese company TOGO
Seisakusyo, eight years ago. This
resulted in the Marienberg-based
TOGO SCHERDEL GmbH (TSG).
The joint venture with its Japanese
partner was also of key strategic importance
to SCHERDEL. After all, the aspiration
to supply all its customers “locally”
is an explicit cornerstone of the corporate
philosophy. After its foundation
in 2004, TOGO SCHERDEL GmbH began
supplying the European locations
of a Japanese car maker. And it did not
take long before German OEMs started
showing an interest in the SCHERDEL
hose clamps.
Strong customer demand ensured that
TSG experienced consistent growth in
sales. The product range also included
hose clamps with a diameter of less
than 14 millimetres, double hose
clamps for extra high pressure as well
as pre-tensioned systems for various
release tools and hose clamp pliers.
The hose clamps are manufactured to
meet either European or Japanese
standards. They can be surface treated
and coated in accordance with the
Delta-Protekt KL 101 or Geomet
method.
TSG always provides an extremely
high quality standard: all finished parts
are subjected to a 100% final inspection.
Furthermore, the company is very
proud of the results of a corrosion test
demanded by customers. On average,
the hose clamps displayed a salt-spray
test resistance of more than 1,000
hours. (dk)
Contact data
Theodor Planner
Tel.: +49 9231 603-341
Fax: +49 9231 603-395
Email:
theodor.planner@scherdel.de
Contact data
TOGO SCHERDEL GmbH
Dörfelstr. 39
09496 Marienberg
Germany
Tel.: +49 3735 710-950
Fax: +49 3735 710-955
Email:
info@togo.scherdel.de
3
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4
SALES
Service centres
Service centre Germany North
Tel.: +49 5308 6949 68
Service centre Germany Rhine-Main
Tel.: +49 6773 91599 14
Service centre Germany South-West
Tel.: +49 7802 93450
Service centre Germany South
Tel.: +49 8142 284404
Service centre China
Tel.: + 86 21 50591 781
Service centre France
Tel.: +33 344 105200
Service centre Great Britain
Tel.: +44 1386 793 443
Service centre Iberia
Tel.: +34 932 804 174
Service centre Italy
Tel.: +41 91 923 34 67
Service centre Poland
Tel.: +48 62 582 1010
Service centre Russia
Tel.: +49 2171 521 38
Service centre Slovakia
Tel.: +421 34 6946 700
Service centre Sweden
Tel.: +46 31 68 0180
Service centre Czech Republic
Tel.: +420 374 702 111
Service centre Turkey
Tel.: +90 224 272 7393
Manufacturing locations and sales
Sales & Marketing headquarters
SCHERDEL GmbH
Marktredwitz, Germany
Tel.: +49 9231 603 400
SCHERDEL Sales Marienberg, Germany
Tel.: +49 3735 710 616
SCHERDEL-MOLTEC Molas Técnicas
S.A., Portugal
Tel.: +351 256 202581
SCHERDEL Sales & Technology,Inc.,
USA
Tel.: +1 231 777 7774 105
SCHERDEL do Brasil Ltda. Brazil
Tel.: +55 15 3235 6730
Service centres ensure su
SCHERDEL provides “local” know-how and advice
E
xcellent customer service is a key
element of SCHERDELʼs corporate
strategy. This includes providing
services where global customers operate
their production facilities. In order to
meet the high demands of local presence,
sales teams are not only active
at the companyʼs headquarters and
SCHERDEL production facilities,
but also in numerous international
service centres. Currently, there are
SCHERDEL service centres in 14 countries
across Europe, Asia and America.
The highly qualified field staff in these
service centres share their wealth of
knowledge and experience with customers
and cooperate with clients to
develop problem solutions. As a result,
they spend most of their time outside
the office “on site”.
A key job of these sales specialists is
to explore and react quickly to future
trends as a basis for further development.
The SSC staff are, therefore, fully
conversant with the language, culture
and mentality of the respective country.
This is essential to ensure optimum or-
Manufacturing location and sales
Service centre
ganization of the supply chain in order
to spot and eliminate supply bottlenecks
in production lines. Further roles
include processing trade enquiries and
providing technical advice and guidance.
In Germany, Europeʼs largest market
which manufactures around six million
cars a year, local support is achieved
through four service centres: SSC Germany
North, SSC Germany Rhine-
Main, SSC Germany South and SSC
Germany South-West. Other western
European countries with a tradition of
car manufacturing include France (approximately
2 million vehicles per year),
Spain (approximately 1.9 million vehicles
per year) and Great Britain (approximately
1.4 million vehicles per
year). Furthermore, the Czech Republic
(approximately 1.1 million vehicles per
year) as well as Poland and Slovakia
(approximately 0.6 million vehicles each
per year) are considered key centres of
car making in Eastern Europe.
SCHERDEL maintains personal contact
with the purchasing and R&D depart-

stainable customer values
for customer product development
ments of the various car manufacturing
plants in all these countries.
These consultancy and technical services
provide customers with special
business benefits; since cooperation
with SCHERDEL experts at a relatively
early stage of development often helps
to shorten development cycles and reduce
costs.
China, Russia and India are the
largest emerging automotive markets.
The service centres are also expected
to quantify the potential for sales and
possibly find suitable options to establish
a SCHERDEL manufacturing location
in the respective region. These are
key prerequisites for the strategic development
of a new sales market.
Generally speaking, all SCHERDEL
customers are provided with sustainable
benefits through the combined
skills and expertise in the service centres,
which is available as free advice
and guidance for product development.
SCHERDEL sees this as an essential
Local presence – SSC staff offer expert development advice
characteristic of successful development
partnerships.
SCHERDEL lives up to its motto
“Global thinking – Local action”. (hs/dk)
Tech Day at AUDI
Thanks to its cutting-edge ideas
in the field of comfort and lightweight
construction, SCHERDEL
recently had the opportunity to
present itself as an innovative development
partner during a Tech
Day at AUDI in Ingolstadt.
SCHERDEL development and
sales experts presented standard
products, prototypes and concept
studies for product innovations at
the development centre in
Gaimersheim.
The high level of participation of
AUDI technicians and developers
as well as renowned engineering
firms that work for AUDI, such as
PSW, Bertrandt and BFFT, led to
an unexpected number of new
project concepts. SCHERDEL
wishes to thank the AUDI employees
and organizers from the
seat development and occupant
sensor systems divisions in
Gaimersheim for a successful
event. The SCHERDELGroup
looks forward to putting its skills
to the test in future AUDI projects.
The editorial team of
SCHERDELnews looks
forward to your contribution.
Please send topic
suggestions, wishes or
feedback to:
scherdelaktuell@scherdel.de
or contact Wolfgang
Schelter on:
+49 9231 603 115
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6
PRODUCTS
Staff profile
Weʼd like to introduce staff members
who will act as your contact
if required.
Jochen Schaede
Sales manager at HAMUEL
Maschinenbau GmbH & Co. KG
Jochen Schaede has been the
sales manager at the SCHERDEL
subsidiary HAMUEL Maschinenbau
GmbH & Co. KG since the
summer of 2011. After leaving
school, he studied mechanical engineering
at RWTH Aachen University.
Jochen subsequently
worked in various medium-sized
companies, specializing in special
machine construction. He initially
operated in the field of development
and application engineering,
focussing on CNC processes, automation
components and integrated
manufacturing cells. At the
beginning of the 1990s, his career
path veered away from technology
and led to him specializing in
the Germany-wide sales of a
Japanese machinery manufacturer.
He successfully developed a
market for an import product in an
environment traditionally dominated
by European competitors. As
an international sales representative
of a German machinery manufacturer,
he gained further sales
and marketing experience.
The new sales manager at
HAMUEL looks forward to the
challenge of implementing trendsetting
technologies in project
sales and to positioning HAMUEL
as a leading medium-sized machine
manufacturer with extensive
in-house production and a highlevel
of flexibility. In order to
achieve these goals, he worked
tirelessly on the HAMUEL stand
at the EMO trade fair in Hanover
in September 2011 and has already
travelled to Japan and India
to discuss projects with international
customers.
Jochen is married with three
grown-up children. His hobbies include
nature and wildlife as well
as art and culture.
High performance is our pr
New HSTM HD series 5-axis CNC machining centr
and improved performance
T
he development of an HSTM HD
series 5-axis CNC machining centre
from HAMUEL Maschinenbau
GmbH & Co. KG – a member of the
SCHERDELGroup – offers an excellent
solution for the machining of relatively
unconventional materials. This applies
in particular to difficult-to-cut materials,
such as titanium and titanium alloys or
Inconel ® . These materials are used, for
example, for the production of gas and
steam turbines or the assembly of jet
engines. Experience has shown that efficiency
can be improved greatly with
high heat and temperature-resistant
materials. However, the machining of
such materials is extremely challenging
and thus an ideal task for the new
HAMUEL HSTM HD machine.
Production requirements
On the one hand, stringent requirements
are placed on the blade geometry
and the blade foot during turbine
production. On the other hand, a series
of solutions is required to reduce the
number of clamping operations when
machining jet engine components. This
means combining process chains in a
machining system which until now have
been dismissed as incompatible technologies.
The latest mechanical concepts and
innovative process technologies are incorporated
in these operating sequences.
A prime example of this is the
exclusive special gas cooling (instead
of a coolant lubricant) which has been
shown to increase service life by up to
approx. 30% or, when working with
other parameters, deliver significant
Integrated process cooling
reductions in the machining cycle times
(in this case without a longer service
life).
When working with vibration-sensitive,
thin-walled work pieces, such as titanium
turbine blades, machine components
with excellent vibration absorption
properties are required. Therefore,
mineral casting machine parts and
body are preferred. Particularly dynamic
and vibration-absorbing hydrostatic
bearing technology is also in great demand,
e.g. for work piece-rotary axes.
Manufacturing turbine blades
The manufacturers of turbine blades
face the following challenges:
In the blade section:
• Freeform high quality surfaces, extremely
complex 3 D profile: the computed
path profile must be created exactly
to achieve the contour required
for the calculated turbine efficiency.
Critical areas are, in particular, the
leading edge and the trailing edge;
extremely high angular acceleration
rates are necessary at these points in
order to work with ideal process conditions.
In the foot section:
• Highest levels of precision for perfect
alignment in the respective installation
position
• Manufacturing tolerances of less than
one hundredth of a millimetre
• Batches usually containing about
400-500 blades
This results in distinctive machine requirements
for the production of turbine
blades. The special work piece-boundary
conditions of blade machining led
to the development of a unique highlydynamic
5-axis machine with up to seven
driven axes. These are divided into:
• Rotary and axial work piece movement
with one-sided work piece
clamping or alternative clamping at
both ends (for longer and thinner
blades and titanium blades)

inciple
e from HAMUEL ensures energy efficiency
• Tool movement on two linear axes as
well as one swivel axis (B axis) with a
high-speed milling spindle
The energy saving potential of CNC
milling has not yet been fully exploited:
this is clearly displayed by the latest
further development of CNC turningmilling
centres from HAMUEL Maschinenbau
GmbH & Co. KG. In addition to
efficient process cooling with carbon
dioxide, HAMUEL also applies integrated
liquid cooling for its HSTM series. A
chiller and two air/water heat exchangers
cool both the machineʼs motors and
the drive modules in the control cabinet
in a single liquid-based refrigeration
cycle. This helps to reduce energy
consumption by 24% compared to the
previous solution.
Just one cooling circuit
An important prerequisite for precision
milling is correct cooling. HAMUEL is
now one of the first companies to utilize
carbon dioxide as a cooling agent for
process cooling, an efficient solution
when machining high-alloyed and heat
resistant steel, titanium or Inconel ® .
This guarantees a significant improvement
in cutting performance, as well as
a reduction in machining cycle times.
HAMUEL therefore offers a healthy
savings potential for the machine operator.
In addition to process cooling, the
Mineral casting rotary axes in action
company also focused on the optimization
of the control cabinet and machine
cooling. Besides sufficient cooling of
the drive modules in the control cabinet,
the motors in the spindles as well
as the rotary axes must be operated at
a defined temperature to stop the
geometry changing during the machining
cycle.
A work piece which clearly demonstrates
the quality of 5-axis machining
is the turbine blade. And it is well documented
that 5-axis machining reduces
the required time by up to 50% compared
to 4-axis machining. Moreover, in
addition to the complex freeform geometry,
this work piece is also produced
from a difficult-to-cut material.
A decisive factor for the performance
of the machining centre is basically the
combination of a compact machine and
perfectly harmonized drive and control
technology. The basis for this is a robust
machine design with a one-piece
machine base – a welded construction
filled with concrete. Clever distribution
of the mass offers outstanding dynamic
rigidity. The alignment of the components
is another key factor which ensures
the horizontally clamped turbine
blades and blisks can be machined
quickly and efficiently. The tilted axes
also contribute positively to this aspect
while guaranteeing optimum chip disposal.
Tech Days at
HAMUEL
HAMUEL in cooperation with
the University of Applied Sciences
Zwickau will host the first
technology days for the 5-axis
machining of difficult-to-cut materials
on 26 and 27 September
2012. Well-known experts from
the fields of industry and research
will present the latest
technologies and developments.
The first day will focus on the 5axis
simultaneous milling of turbine
blades and similar components.
The main topic of the second
day will be the 5-axis machining
of large work pieces with
high contour complexity made of
difficult-to-machine materials. Another
particularly important aspect
of this topic is intelligent machining
concepts which can
achieve significant cost, time and
sustainable quality improvements.
The lecture programme will be
supported by various live presentations,
for example the integrated
measuring of a turbine blade
during titanium machining or ultra
high-speed machining with carbon
dioxide cooling. Moreover,
the latest generation of HAMUEL
portal milling machines will be
demonstrated for the first time.
Anyone interested in participating
in the technology days at
HAMUEL can register at the following
address:
HAMUEL Maschinenbau
GmbH & Co. KG
Industriestr. 6
96484 Meeder b. Coburg
Germany
Tel.: +49 9566 9224-0
Fax: +49 9566 9224-80
Email: info@hamuel.de
Internet: www.hamuel.de
7
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MECHANICAL ENGINEERING – LOCATIONS – TECHNOLOGY & PRODUCT DEVELOPMENT – NEWS AND INFORMATION
8
PRODUCTION
Group synergies
The SCHERDEL subsidiary
AFEMA Automatisierungs- und
Steuerungstechnik GmbH played
a leading role in the realization of
the TLZ robot coating installation.
The company is a recognized
specialist in the fields of special
machine construction and automation.
AFEMA GmbH was
responsible for the planning,
design and construction of the
entire mechanical engineering
systems. Furthermore, it guaranteed
the development and creation
of the general control technology.
Another SCHERDEL subsidiary,
ZARIAN Bewegungssysteme
GmbH, supplied the robot
for the coating installation.
AFEMA Automatisierungs- und
Steuerungstechnik GmbH
Kraußoldstr. 20
95615 Marktredwitz
Germany
Contact:
Dipl. Ing. Hans Messer
Tel.: +49 9231 603-351
Email:
hans.messer@afema.scherdel.de
Internet: www.afema.de
ZARIAN Bewegungssysteme GmbH
Bayreuther Str. 5
95615 Marktredwitz
Germany
Contact:
Dipl. Ing. Thomas Dunkel
Tel.: +49 9231 603-836
Email: thomas.dunkel@zarian.de
Internet: www.zarian.de
Contact data
Oberflächentechnik Sigmund
Scherdel GmbH & Co.
Meusselsdorfer Str. 27
95615 Marktredwitz
Germany
Contact:
Peter Schörner
Tel.: +49 9231 603-375
Email:
peter.schoerner@oftm.de
Internet: www.oftm.de
Development and producti
new coating installation
TLZ robot improves capacity and quality at SCHER
O
berflächentechnik Sigmund
Scherdel GmbH & Co (OFTM) is
a specialist in the field of coating systems
for technical components. The
company – as is common practice in
the SCHERDELGroup – takes an innovative
approach to the application of
technologies and the development of
processes. This formed the basis for
the development of a new coating installation
primarily operated by a robot
– the TLZ robot. The maximum benefit
to customers was uppermost in the
engineersʼ and techniciansʼ minds when
designing and developing the new installation.
The TLZ robot, therefore, not
only ensures increased capacity and
efficiency, but also improves quality.
Furthermore, it enables the automated
coating of parts which were previously
too heavy or too fragile, or which were
considered too complicated due to their
geometry.
The coating process employed by
OFTM leads to a significant improvement
in the service life of technical
components by preventing the formation
of corrosion. Surface coatings also
help to reduce
the frictional resistance
of components,
to prevent
unwanted
noises during
their application
or to provide superior
resistance
to acids and
alkalis. OFTMʼs
extensive knowledge
of coating
techniques and
materials, gained
over many years,
facilitated the inhouse
production
of the new TLZ
robot. This was
complemented
by the expertise
of the engineers
and technicians
at the SCHER-
DEL subsidiaries
AFEMA and
ZARIAN, both
members of the
Groupʼs machines
and

on of a brand
DEL
systems division.
AFEMA GmbH was not only accountable
for the entire mechanical engineering
systems of the installation, but also
guaranteed all the necessary functions
and processes for its programming.
ZARIAN GmbH, a specialist in the field
of automation technology, was responsible
for equipping the installation with
a robot and its flawless performance.
The systematic utilization of synergies
within the SCHERDELGroup resulted in
a coating installation which offers firstclass
performance in the truest sense
of the word. An individual computer
program for coating process optimization
is available for each component.
The sequence control of the TLZ robot
takes various parameters into consideration.
The new installation is naturally
fully enclosed which, on the one hand,
prevents dirt and dust in the air having
a negative impact on the coating
process and, on the other hand, stops
solvents escaping from the system – a
positive contribution to environmental
protection. In terms of energy efficiency,
the closed air circuit in the TLZ robot
is used to the maximum advantage,
i.e. for pre-heating, heating and cooling.
Moreover, a downstream exhaust air
cleaning system helps to keep the environment
clean. However, overall the
most important aspect remains that the
new installation can also coat very
heavy, particularly fragile and highly
complex components. (dk)
Partial view of the exhaust air cleaning system
Delta-Protekt KL 100 / KL 101
Delta-Protekt is an inorganic micro
layer zinc and aluminium
flake coating. During the thermalchemical
conversion process, a
metallically bright silver coating is
provided on the component with
excellent corrosion protection and
a temperature resistance of up to
180°C. The high corrosion resistance
of Delta-Protekt KL 100 is
derived from various protection
mechanisms: cathodic protection
– barrier effect due to zinc and
aluminium flake
– reaction of binder systems with
the base
– consolidation of the Delta-Protekt
KL 100 film under the corrosion
loading.
Protekt KL 101 also offers
greater resistance to white rust.
Delta-Tone 9000
Delta-Tone, the predecessor of
Delta-Protekt KL 100, is basically
an inorganic base coat. The difference
between the two micro
layer coatings is the binder system,
the actual hardness of the
layer and the temperature resistance.
Delta-Seal and Delta-Seal GZ
The Delta-Seal topcoat improves
material properties and is available
in various colours. Delta-
Seal has an insulating effect and
protects against contact corrosion.
It also offers limited resistance
to acids and alkalis. Delta-
Seal is approved for use in the
food industry in the colours black
and silver. The considerable reduction
of frictional resistance is
yet another benefit of the Delta-
Seal-topcoat. The colours black,
black GZ, silver and silver GZ are
applied in the new TLZ robot. In
standard installations, products
can also be coated in light green,
light blue, dark blue, light grey
and yellow.
Delta-Protekt VH 301 with and
without integral lubricant (GZ)
The silicious, water-based topcoat
offers significantly improved
heat setting behaviour especially
for bolts and screws. The thin
layer of Protekt VH enhances
corrosion protection by sealing
pores and the GZ version can
help to ensure that friction coefficients
for screw connections in
the automotive industry fall within
the specified limits.
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10
PRODUCTS
Company anniversary
The SCHERDEL factory in Erlangen
recently celebrated its
75th anniversary. Plant manager
Johann Kerner welcomed the
principal shareholder of the
SCHERDELGroup, Heidelore
Scherdel, as well as the Group
managing director, Walter Bach,
and the shareholder Marcus
Bach to Erlangen on the occasion
of this special anniversary.
Manfred Wegmann, Thilo von
Glass, Josef Söllner and Eberhard
Leidl had also been invited
as representatives of the
SCHERDEL management. The
subsidiary in Erlangen-Bruck was
founded in 1936 by Max and Rudi
Scherdel. Initial products included
valve springs for aircraft
engines. The company later focused
on the production of
springs for mattresses and the
manufacturing of double-body
springs.
Today, the SCHERDEL plant in
Erlangen primarily produces highloaded
tension springs for application
in various industry sectors.
Calculation mask: theoretical prediction
of manual force curve, tension
spring mechanism for opening
car tailgates
Contact data
SCHERDEL INNOTEC
Forschungs- und Entwicklungs-GmbH
Scherdelstr. 2
95615 Marktredwitz
Germany
Contact:
Dipl. Ing. Thomas Heinl
Tel.: +49 9231 603-545
Email:
thomas.heinl@scherdel.de
Tension springs – a notice
Patented material from SCHERDEL used for the co
opening and closing systems
F
uel consumption, environmental
friendliness and safety are key aspects
when buying a car. However, another
very important consideration for
purchasing a new vehicle is the comfort
for both driver and passengers alike.
Therefore, SCHERDEL has, for many
years now, been developing outstanding
solutions for the automotive industry
in cooperation with car makers that pay
great attention to user comfort and convenience.
A prime example is the tension
spring mechanism, which has
been further developed into an assembly
part to facilitate the opening and
closing of car tailgates. Seen from the
viewpoint of OEMs, the SCHERDEL
developments are comfort solutions
which do not add a great deal to the
price of production. SCHERDEL supplies
roughly 6.5 million tension spring
mechanisms for worldwide use each
year.
It is quite easy to explain why
SCHERDEL has gone from being a
leading manufacturer of “simple” tension
springs to a supplier of functional
groups for the opening and closing of
tailgates. On the one hand, it is
SCHERDELʼs extensive knowledge of
materials and production processes
which play a decisive role in product
development using cutting-edge simulation
tools. On the other hand, in addition
to a highly motivated workforce,
SCHERDEL has the technical means to
develop system solutions and to produce
them “from a single source”. And
the exciting and creative synergies
within the Group with its own mechanical
engineering and tool making divisions
and state-of-the-art coating installations
should not be forgotten. Modernday
tailgate opening systems are actually
based on a former trend: the combination
of a bracket hinge and a torsion
spring guarantees the
automatic opening of the
tailgate no matter which
external conditions prevail.
Once application of the
correct material has been
determined, product development
initially involves
calculation of the required
manual force curve together
with the design of the
ideal spring. SCHERDEL
was able to develop a material
which has since been
patented and prevents hydrogen
embrittlement during
the painting process,
thus ensuring the desired service life of
the springs. Further criteria for successful
product development were the FEM
calculations for optimizing the rigidity
and weight of the opening systems and
achievement of the corrosion resistance
desired by the customers.
It is possible to assemble SCHERDEL
tailgate torsion springs before painting.
The joint dimension can be determined
during installation, thus helping to re-
Start model for analysis of the stress curve using
the Finite Element Method (FEM)

able increase in comfort
nstruction of tailgate
View of the assembled tension spring: assembly
before painting
duce costs for the vehicle manufacturer.
Another option is the installation of a
surface-treated torsion spring assembled
by the SCHERDEL assembly technology
division as a complete component
with cushioning foam to minimize
noise and a clip. It can also be installed
after the paint process which also helps
to improve cost efficiency. Besides
SCHERDEL surface finishing and assembly
technology, the in-house tool
making and mechanical engineering capabilities
are much sought after. For ex-
A “ready-to-be-installed” tension spring with integrated assembly aid
ample, special machines were developed
for spring manufacturing which
ensure high pre-tension in the spring
and guarantee the force test result is
100%. All the tools required for spring
manufacturing were produced by
SCHERDEL. The said assembly technology
division is also available for special
bespoke solutions, for example the
integration of gas dampers for cushioning
the limit stop in the boot. Thanks to
the Groupʼs production skills in the field
of tube bending, punching and welding,
a complete gooseneck hinge is available
“Made by SCHERDEL”. The FEM
calculation once again enables the design
of special tube cross-sections, resulting
in a reduction of the component
weight. It should also be mentioned
that, as an alternative to tailgate
springs, SCHERDEL also develops and
manufactures torsion bars, which, likewise,
solve the problem of “comfort” in
a cost-effective manner. (dk)
Röslau plant –
a success story
SCHERDEL Druckfederntechnik
Röslau GmbH & Co. KG – one of
the largest compression spring
production plants in Europe –
recently celebrated its 10th anniversary
at a new location in the
company of the German Federal
Minister of the Interior, Hans-Peter
Friedrich. Under the watchful
eye of plant manager Klaus
Katholing, DFTR, as the company
is known for short, has experienced
unprecedented success
over the past decade. The shop
floor area has gradually increased
from the original 7,500
square metres to the current
12,000 square metres. At the
same time, the number of employees
has risen by over 30%
since the start of production in
2001. Roughly 170 machines are
in operation “24/7” at the
SCHERDEL location in Röslau.
DFTR supplies the majority of
the products – primarily ABS
parts, transmission springs, components
for the engine management
system and springs for
brake systems – to automotive
customers and their main suppliers.
Up to 1,800 different types of
springs are manufactured at the
location in Röslau each year.
Around 350,000 packages of various
shapes and sizes leave the
plant over the course of a year.
DFTR is a key internal supplier of
other plants in the SCHERDEL
Group. For example, Röslau supplies
millions of parts to the
SCHERDEL location in Friedau,
where the DFTR parts are assembled
with other components
to produce a composite part or
even a complete system.
The extremely positive development
has resulted in DFTR becoming
the leading compression
spring plant in the SCHERDEL
Group. This means that technical
developments for new machines,
installations and production
processes are tested in Röslau
with the findings being passed to
other manufacturing locations for
compression springs. Colleagues
from these other locations also
receive professional training and
gain invaluable experience at
DFTR in Röslau.
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12
COMPANY NEWS
The new SCHERDEL
Spring Manual –
now also available
online in an updated
English version
After the successful publication
of the 7th printed edition in 2010,
SCHERDEL now presents the
latest version (7.1) of its online
Spring Manual; available in both
German and English.
Ever since its first publication in
1953, SCHERDEL has been offering
extensive information on
spring types, materials, spring
production and calculation. This
way, SCHERDEL gives even
more readers access to this technical
manual popular with students
and practitioners alike.
In contrast to the printed version,
the online Spring Manual also
contains contact details for all
SCHERDEL locations and their
main fields of activity, as well as
request forms for standard spring
types.
The websites www.federfibel.de
and www.spring-manual.com
offer free access to both language
versions.
The printed version of the
SCHERDEL Spring Manual in
German can be obtained directly
via Buchhandlung Budow at
buchhandlung-budow@
t-online.de and costs EUR 34.90
plus postage and packaging.
New look website
Relaunch of SCHERDEL and Reichenbacher
T
he SCHERDELGroup unveiled a
new website last November. It includes
the latest web technology and
has a modern and fresh look, providing
visitors a vast amount of information on
the SCHERDELGroup. It was particularly
important that the basic values of
the company, e.g., security, responsibility
and innovative strength, are projected
in the online sphere through
strong visual presentation. Despite the
technical and complex nature of
SCHERDELʼs work, the human component
is still dominant on the website,
thus staying true to the SCHERDEL
motto: “People are the focus of the entrepreneurial
thinking and the actions of
the SCHERDELGroup.”
The company has also ensured that
the contents are just as good as the
“packaging”. The goal was to unite the
entire group under one roof in order to
present their collective potential. The
entire SCHERDEL range from metal
working and surface finishing to tool
making and mechanical engineering is
represented in a clear and informative
manner. In “THE GROUP” section,
SCHERDEL locations can be selected
easily according to the country or the
competencies via an interactive map of
the world. It is also possible to take a
look at SCHERDELʼs history with extensive
information dating back to the
companyʼs beginnings. The “Innovation”
menu item provides information on
the Groupʼs extensive development
achievements, e.g. enhancing comfort,
security and energy efficiency. Moreover,
visitors can retrieve the latest
news and information and dates of
worldwide trade shows for all members
of the Group.
The “Career” section has also been
extended and now offers detailed information
on how to join the company and
possible career options as well as current
vacancies at the SCHERDEL
Group. The unveiling of the new look
SCHERDELGroup website was followed
by the launch of the Reichenbacher
Hamuel website. The Reichenbacher
Hamual homepage, whose design
matches SCHERDELʼs, presents
the companyʼs entire product range
and provides examples of standard and
special machine construction. A whole
host of topical and relevant issues are
covered with tips and tricks from industry
or “hot-off-the-press” CNC news.
Detailed information about the company
and its top-quality services, as well
as contact details of the sales and service
staff round off this excellent website.
The optimization of the Reichenbacher
Hamuel website also takes
place in several phases. After implementing
the English pages, informative
video clips will be available
for the respective machine
and industry solutions.
These clips will demonstrate
machine operation
when manufacturing selected
products. (mvw)
www.scherdel.de
www.scherdel.com
www.reichenbacher.com
Responsible in terms of the Press Law: SCHERDEL GmbH, PO Box 440, 95604 Marktredwitz, Germany, Phone: +49 9231603-0, Fax: +49 9231603-462