Engineering

Management report on the Group
2.5 Management report on the Group Non-financial performance indicators
The “cylinder head” project won
second prize on the 2011 ThyssenKrupp
Innovation Contest.
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and it is even possible to move the entire installation to a new location. The iwalk is particularly suitable for
metro stations, railway stations, airports and exhibition centers – both as new installations and to upgrade
existing systems. In addition the iwalk can be equipped with a new energy saving system which optimizes
power consumption depending on passenger numbers without reducing operating speed. The new moving
walk was awarded first prize in the 2011 ThyssenKrupp Innovation Contest.
Cylinder head cover with integrated camshafts
Second prize in this year’s Innovation Contest went to the development team behind a new cylinder head
module with integrated camshafts. Our engineers and technicians used the proven Presta joining process for
assembled camshafts to produce a complete cylinder head cover with integrated camshafts. This allows us
to supply customers with a ready-to-install module rather than just individual camshafts. Modular designs
with integrated camshafts were previously unavailable on the market. We have already received the first
production order. As well as reducing costs for cylinder head machining, our solution is also easier to install.
Integrating the individual, finish-machined camshaft parts in the cylinder head cover makes it possible to
dispense with bearing caps. This results in improved hydrodynamics, and antifriction bearings can be
integrated simply and without deformation.
Bio-based plastics made from succinic acid
In order to make sustainable use of resources we need to explore new ways of utilizing renewable raw
materials. Since 2006 we have been developing biotechnology processes to produce plastics from
renewable raw materials. One focus of the chemical industry has been the use of succinic acid as a raw
material for bio-based plastics. In collaboration with a US company we have now developed a production
process for this. Following successful trials on a pilot plant in Mexico, the world’s first industrial-scale
biotechnology succinic acid plant is now being built in Louisiana/USA. Start-up is scheduled for late 2012.
Increasingly efficient gearless conveyor systems
With demands on conveyor systems for open pit mines rising all the time, conventional gear units are
reaching their limits. Ever greater mining depths and increasing volumes call for longer, steeper and more
powerful belt conveyors. For one of our customers we have now developed a gearless drive station for a
6.5 km conveyor system. ThyssenKrupp is the world’s only supplier of conveyors with such high-power
direct drives. They offer great dependability, low-cost maintenance and high energy efficiency. In future
development projects we will standardize the drive stations, modularize them and further optimize their
design.
More than €500 million for research and development
In 2010/2011 we spent €524 million on product, process and service innovations. Of this, research and
development costs of €188 million were expensed immediately, €39 million was amortization of
development costs capitalized in previous years, and €297 million was for order-related development costs.
Expenditure for research and development was thus 19% higher than a year earlier, with particular increases
in order-related development in the areas of “Mechanical” and “Plant”.