MDA Technologies 4/2015

Motion, Drive and Automation 

INTERNATIONAL 

EDITION 

4 

October 2015 

34 

The 

birth 

of a hybrid giant 

incl. Supplement 

COMPRESSED AIR NEWS 

PTC-Asia: power up in 

06Shanghai 

22 56 

The right accumulation 

chain for your conveying 

system 

Small change, big benefits 

www.mda-technologies.com 

in cooperation with 

Fluidtechnik 

Antriebstechnik

EDITORIAL 

Energy efficiency 

meets Industry 4.0 

Dear Readers, 

Energy saving, waste of energy or energy efficiency – notes, which do not 

only concern the traditional industrial countries today and tomorrow 

anymore, but mostly also the states in which the producing industry just 

strongly develops and in which the demand for energy increases steadily. 

Hence it is a global topic, which we should point the necessary attention to 

everywhere. And it is not sorcery, because the technical developments have 

shown, that engineering in terms of energy efficiency can take a leading 

role – above all the drive and fluid technology. In recent years many 

producing companies have drastically reduced their energy consumption 

by new investments, modernisations or simply by a more prudent use of 

resources by the employees. Today’s machines use significantly less energy 

at a higher productivity at the same time, because energy efficient system 

layout, needs-oriented output or also the recycling of braking energy are no 

foreign words anymore in engineering and drive technology. But how to go 

on? “At present we experience the transfer to a new level of energy efficiency 

in the automation by the horizontal and vertical interconnection”, 

Dr. Steffen Haack, member of the board of Bosch Rexroth AG has summed 

up recently. And exactly this is the key: Because due to Industry 4.0 data 

becoming applicable knowledge and companies can record and steer the 

energy streams via the entire value stream in the future. 

Maybe a super ordinate control system can even independently identify the 

necessary optimisation samples. Also Dr.-Ing. Gunther Reinhart of TU 

Munich aims into the same direction and believes that “energy efficiency is 

an integral part of Industry 4.0.” 

Big players in the drive and fluid technology market are already on the right 

path and small companies develop smart solutions, which support and 

vernier adjust the process. The time is ripe – we just have to use it! 

Dirk Schaar 

– editor-in-chief – 

Simone Robering 

– Hannover Fairs International – 


Editors-in-chief: 

Dirk Schaar, E-Mail: d.schaar@vfmz.de 

Michael Pfister, E-Mail: m.pfister@vfmz.de 

Editorial board: 

Peter Becker, Nicole Steinicke, Sushen Doshi 

Assistant editor: 

Svenja Stenner, E-Mail: s.stenner@vfmz.de 

Design/Layout: 

Conny Grothe, Doris Buchenau, Anette Fröder, 

Melanie Lerch, Sonja Schirmer, Mario Wüst 

E-Paper Designer: 

Katja Rüdell, Mathias Göbel 

Managing editor: 

Dipl.-Ing. (FH) Winfried Bauer 

Publisher: 

Vereinigte Fachverlage GmbH 

Lise-Meitner-Str. 2 

55129 Mainz, Germany 

Managing director: 

Dr. Olaf Theisen 

Publishing director: 

Dr. Michael Werner 

E-Mail: m.werner@vfmz.de 

Advertising sales director: 

Beatrice Thomas-Meyer, 

E-Mail: b.thomas-meyer@vfmz.de 

Advertising sales manager: 

Oliver Jennen, E-Mail: o.jennen@vfmz.de 

Sales representatives 

Austria 

Heinz-Joachim Greiner 

E-Mail: verlagsbuero-greiner@vfmz.de 

Brazil 

Carlos Frederico Graf Schaffgotsch 

E-Mail: datadress@vfmz.de 

China 


France 

Marc Jouanny 

E-Mail: marc-jouanny@wanadoo.fr 

Great Britain 

Rob Brewer 

E-Mail: rob.brewer1@btinternet.com 

India 


Italy, Switzerland 

Hermann Jordi 

E-Mail: info@jordipublipress.de 

Poland 

Dr. Miroslaw Bugajski 

E-Mail: premiummedia.mb@gmail.com 

Sweden, Finland, Norway 

Malte Mezger 

E-Mail: verlagsbuero-mezger@vfmz.de 

USA, Canada 

Aryan Zandieh 

E-Mail: aryan@hfusa.com 

Advertising disposition: 

Annemarie Benthin 

E-Mail: a.benthin@vfmz.de 

In cooperation with: 

Hannover Fairs International GmbH 

Messegelände, 30521 Hannover, Germany 

Additional Partners: 

Fachverband Antriebstechnik im VDMA 

Fachverband Fluidtechnik im VDMA 

Fluid Power Association of India 

Moskauer Deutsche Zeitung 

Internet: 


6 th year (2015) 

MDA Technologies 4/2015 3

TABLE OF CONTENT 

08 Shanghai in focus 

24 

Bearing 

solutions with 

increased efficiency and 

high performance 

28 Powerhouses 

on Tour 

38 A 

A cut above the rest 

40 

valve for every scenario 

60 

ComVac 

ASIA 2015: 

Saving energy, 

maximizing productivity 

COLUMNS 

03 Editorial 

03 Imprint 

18 Worldwide news 

NEWS AND MARKETS 

06 PTC-Asia power up in Shanghai 

08 Shanghai in focus: Interview with James Fu, General 

Manager of Hannover Milano Fairs China 

10 Iran deal, a new chapter for industry 

12 Hannover: the hidden champion 

14 Bolenz & Schäfer opens subsidiary in China 

16 Paving the way for ‘Make In India’ 

DRIVE TECHNOLOGY 

20 Rapird prototyping guided by ‘igus’ linear guides 

22 The right accumulation chain for every conveying system 

24 Bearing solutions with increased efficiency and high 

performance 

27 Product news 

28 Powerhouses on tour 

HYDRAULICS AND PNEUMATICS 

34 The birth of a hybrid giant 

38 A cut above the rest 

40 A valve for every scenario 


44 Variable flow vane pump 

48 Telematic systems enhances safety and 

efficiency of port fleets 

50 Fully automated pipeline inspection 

SUCCESS STORY 

52 A good braking system accelerates growth 

56 Small change, big benefits 

SPECIAL: COMPRESSED AIR NEWS 

60 ComVac Asia 2015: Interview with Wolfgang Pech, 

Senior Vice President Deutsche Messe AG 

62 Industry 4.0: high-tech compressed Air 

for high-tech products 


4 MDA Technologies 4/2015

www.contitech.cn 

INCREASE PRECISION 

DRIVE INNOVATION 

AWAKEN CURIOSITY 

PERFORMANCE NEXT LEVEL 

ContiTech. Engineering Next Level


PTC-Asia power up 

in Shanghai 

Sushen Doshi 

For the last 30 years or so, China has been consistently growing 

at 10 % or more. But this year, China has cut its growth target 

to 7 %, this means it is the ‘slowest’ growth in the last 20 years. 

Even its modest 7 % growth is the envy of most countries. 

Over the last few years, power, transmission and control has 

become an increasingly pivotal factor in the sustainability, 

efficiency, and performance of industrial manufacturing processes. 

The international trade fair, PTC Asia held in Shanghai is the “go to” 

point for the Power and transmission sector in Asia and particularly 

China. For the last 20 years this fair has grown hand in hand along 

with the Chinese economy. Since its foundation in 1991 it has established 

itself as the most important trading platform of the industry 

and for many international companies it is the basis for their entry 

into the Chinese market. 

Shanghai, with its $ 350 billion economy is the most important 

city in China in context of economy. With more than 32 million 

containers every year, it is also the world’s busiest container port. 

The Shanghai & Yangtze River delta has the best industrial clusters 

of automobile, shipbuilding, metallurgy, aerospace & aviation, 

clean energy, die & mould, power generation, IT etc. The economic 

and industrial importance of Shanghai in China cannot be rivaled 

by any other city. Therefore it is an unparalleled location for an 

industrial trade fair. The “PTC-Asia” has been a convenient place for 

the industry leaders to present and demonstrate the latest technologies, 

equipment and the market ready solutions. With more than 

70,000 visitors and 1200+ exhibitors, PTC– Asia has become a must 

attend event in the eastern hemisphere for the manufacturing 

industry. 

The exhibition is divided into the areas of fluid technology, 

mechanical transmission (MTPE), fasteners & springs and bearings. 

Author: Sushen Doshi, Editor, MDA Technologies 

Mechanical transmission, parts and equipment 

The MTPE – Mechanical Transmission, Parts and Equipment is one 

of the most important section of PTC Asia, with more than 550 

exhibitors and 25,000 square meters of exhibition space. The area of 

MTPE is the ideal meeting place and an important platform for 

companies in industries such as gears, chain transmission, belt 

transmission, clutches, brakes, electric power transmission, and 

powder metallurgy. 

In this sector, Germany ranks top with 22 % of the global market 

share, followed by China, 13 % and Japan, 12 %. This sector recorded 

an annual growth of 2 % in 2014, and likewise growth is forecasted 

for the coming few years. 

Increasing Chinese “fluid” power 

In the year 2000, China’s market share in the industry sector ‘Fluid 

power’ was a mere 2 %, in 2014 China was responsible for 29 % of 

the global fluid power sector. Noticing this trend as early as 2001, 

the Fluid power and technology sector was also inculcated to this 

exhibition. It offers and comes up with new technologies and products 

in hydraulics, pneumatics and seals. In case of Hydraulics and 

pneumatics, the forecasted year on year sales growth for China is at 

10 % and 12 % respectively. It is one of the sectors with the greatest 

potential for growth. 

Fasteners, springs and bearings 

In the fields of fasteners, springs and bearings not only the latest 

innovations are shown, but also user-oriented solutions and a variety 

of applications are introduced. The Fastener & Spring Fair which 


is supported by China General Machine Components 

Industry Association, and affiliated by the 

China Fastener Manufacturers Association and 

China Spring Manufacturers Association has grown 

to become a famous industrial show after 6 years of 

quick development. F&S is expected to attract more 

than 100 exhibitors to showcase themselves on 4,000 

square meters of exhibition space. 

Once again, Europe and particularly Germany 

dominates the scene of international exhibitors with 

more than 24 % of international exhibitors being 

from Germany followed by Italy, France and Sweden. 

The 28 % exhibitors from Asia also include the companies 

from Hongkong and Taiwan. But more than 

10 % of the Asian exhibitors are South Korean and 

7 % from Japan. USA dominates the exhibitor participation 

from the Americas. 

Amongst all the visitors at the PTC event in Shanghai, 

more than 40 % of the visitors are the final decision 

makers or joint decision makers. More than 18 % 

visitors are responsible for the purchase and procurement, 

and an equal number of visitors are in 

charge of the sales and distribution. 

The exhibition will be accompanied by numerous 

lectures, seminars and product demonstrations, as 

well as discussions on current issues and therefore 

has established itself as information as well as 

knowledge platform. 

Photographs: Teaser fotolia 

www.ptc-asia.com 

Power Transmission Engineering 

Fluid Power 

VDMA Branch Guide 2015 now available 

Power Transmission Engineering and Fluid Power 

„Motion, Drive &Automation“ 

• Economic/technical situation of German manufacturers 

• List of German suppliers of Power Transmission 

Engineering, Hydraulics and Pneumatics 

• Company portraits 

• VDMA network abroad 

PTC ASIA 27. – 30.10.2015, Shanghai 

pick up your free copy at the VDMA booth in hall E3 

on the German Pavilion or mail to fluid@vdma.org


Shanghai in focus 

Mr. James Fu, General Manager, Hannover Milano Fairs China 

In conversation with Mr. James Fu, General Manager, 

Hannover Milano Fairs China. We talk about the future 

of power, transmission and controls sector in China with 

the international trade show “PTC-Shanghai” in focus 

Last year PTC had more than 1200 exhibitors and 80,000 

visitors what do you think brings the visitors and exhibitors 

big and small to Shanghai and to this event particularly? 

The PTC -Asia owns its unique advantages and success elements to 

welcome global leading companies and visitors every year. With 

over 20 years’ growth, the show has become the largest in Asia and 

the second one in the world. The loyal exhibitors regard this platform 

as their first choice to premiere their innovations and tap the 

new market. This attracts new professionals and visitors to 

experience the trends onsite. What’s more, the PTC -Asia positions 

itself according to the market development to generate a right 

theme for each year. This year we have a theme on “Smart Manufacturing” 

which sharply echoes the strategy of “Made in China 

2025”. It is worth mentioning that the Smart Manufacturing Forum 

2015 will be held during the fair to explore more advanced technologies 

and innovations on the topics of Industry 4.0. 

As organizers, we have a timely insight into the market, interpret 

the industry, make pertinent publicity, provide customized services, 

and convey messages through media to improve the 

influence of the show to the maximum extent. Our Chinese partners’ 

efforts also lend us great support. With all these elements, the 

PTC -Asia can stand out for years. 

What is “Made in China 2025” and how does the Fluid and 

Mechanical transmission industry benefit from this? 

In 2013, Germany put forward the strategy of Industry 4.0. 

And since 2014, the Chinese government has also organized its 

forces to formulate the “Made in China 2025”. For China, this is a 

grand blueprint of rejuvenating the economy through manufacturing 

from the level of national strategy. The so-called Made in 

China 2025 is also a Chinese version of Industry 4.0, which aims 

that, after 10 years of efforts, by 2025, China’s manufacturing 

industry will have a greatly improved overall quality, significantly 

enhanced innovation capability and labor productivity. With 

internationally advanced levels achieved in terms of intelligence, 

service and greenness, China will become one of world’s 

manufacturing powers by that time. 

We hear a lot of talk about how Chinese industry is on its 

way to upgrade, keeping this in mind, how do you see the 

future for the power transmission and control sector? 

The Chinese government now requires the industry upgradation, 

to further adjust and optimize the economy. Against this backdrop, 

the power transmission and control sector will develop into 

a more intelligent and advanced sector. The whole sector will 

improve the core competence in innovation, production of the key 

components, thus realising the transformation of China from 

component manufacturing giant to component manufacturing 

power. In short, it is the change of China from manufacturer of 

quantity to the one of quality. This strategy has a significant 

importance to many sectors including the Fluid and Mechanical 

transmission industry. It will guide the Fluid and Mechanical 

transmission industry in its transformation and upgrading 

towards higher degree of intelligence, network and digitization 

as well as continuous innovations. The basic guideline of 

optimizing the quality and structures will be followed for 

improving the industry’s overall level and quality; and all-new 

talent cultivation approach will be adopted for promoting 

industry management, making contributions to the industry 

and boosting further development. 

Photographs: Fotolia teaser, Hannover Milano Fairs China z 


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Iran deal, a new chapter for industry 

Sushen Doshi 

After almost 15 years of negotiations, 

Iran and the “P5+1” group 

of six major world powers have 

reached a framework agreement 

on Iran’s nuclear program. The 

nuclear deal clears the path for 

the end of sanctions and the 

emergence of a dynamic Iranian 

economy. 

Author: Sushen Doshi, 

editor, MDA Technologies 

Iran is a country of around 80 million 

people, has one of the most diversified 

economies in the Middle East and North 

Africa. Despite sanctions, Iran is one of 

the world’s top 20 economies. In the 

beginning of the 21 st century, Iran’s 

annual growth rates hovered around 5 %, 

sometimes reaching as high as 7 %. The 

2010 round of sanctions though crippled 

the economy, but according to an IMF 

forecast, the return of positive growth in 

Iran is an impressive reversal from the 5 % 

contraction that occurred in 2012. 

While the Iranian economy is still largely 

dependent on oil exports, it has also seen 

significant industrial development. Iran 

invests more in R&D than any other Middle 

Eastern nation and has seen a rapid growth 

in its high-tech sector. In 2009, Iran’s auto 

industry became the 11th largest in the 

world, producing more vehicles than the 

UK or Italy. The country boasts significant 

development in high-tech industries such 

as machinery, automotive, steel, petrochemicals 

and medical technology along 

with a wide range of agricultural products, 

cement and other construction materials. 

But Iran’s industries need to modernize 

their production equipment and technology 

and it needs them Now! 

Impact on Germany 

Iranians prefer doing business with Europeans 

and particularly with the Germans, as 

they have a specially favored status. In part 

that’s because of Germany’s reputation for 

high-quality engineering. Going beyond 

these pragmatic considerations, Iranians 

have also had a long-standing cultural, 

business and personal ties to Germany. 

Historically, German engineers built Iran’s 

railways and bridges back in the 1920s. 

In the past few years the German exports 

to Iran grew by 30 %, as impressive as the 

percent growth may seem the actual volume 

of goods traded sums up to € 3 billion. 

Considering the € 3 trillion German GDP, 

this trade figures with Iran are very low. 

Over the next few years the bilateral trade 

between Germany and Iran could increase 

by as much as a factor of four, depending up 

on further political developments. Even in 

the best case scenario, new deals can’t be 

made operational instantly, because the 

infrastructure for financial transactions 

needs to be rebooted first. That means trade 

volume won’t take off until 2016. Some estimates 

say the bilateral trade between 

Germany and Iran could touch € 6-7 billion 

in 2016. 

But German industrialists haven’t been 

sitting and waiting for the final signing of a 

nuclear deal before reactivating German- 

Iranian business ties. Many mid-sized 

enterprises have been exploring prospective 

opportunities for months anticipating 

that sanctions might be lifted. In the recent 

weeks, flights to Teheran have been full of 

German businessmen. The mood has 

changed considerably during the past year. 

Suppliers of machinery and its components 

for all the industry sectors are keen to do 

business in Iran. There was also a strong 

presence of German firms at the annual 

‘Inotex’ technology trade fair in Tehran in 

June. The biggest German corporations 

have been less visibly active, mainly due to 

the political pressures. But they’re now 

going to position themselves to grab a larger 

share of Iranian markets. 

Photographs: background fotolia z 


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Hannover – the hidden champion 

Airbnb - a hip startup, based in California, with a brand new idea. 

Private hosts offer their accommodations to complete strangers. 

The host earns some extra money, and guests get an affordable place 

to stay – often becoming “a part of the family”. The company was 

created in 2008 and has become well-known worldwide. But do you 

know when people in Hannover came up with such an idea? In 1947, 

nearly seventy years ago, the first industrial fair “Hannover Messe” 

took place. Housing was in short supply among the ruins of post-war 

Germany, so Hannover created a platform for guests from all over the 

world to share private accommodations. Not only was this a brilliant 

and simple idea - it has developed over the years and has been the 

basis of friendly relations between international visitors and their 

local hosts in Hannover. It is one of the reasons why Hannover should 

rank first in Germany in terms of international personal relationships. 

But also typical of Hannover, this has been implemented without 

excessive marketing and PR. The same goes for IT. Do you know 

when the first CeBIT took place? In 1970 – a time when the majority 

of the population did not even know computers existed. Here, again, 

Hanover was a trendsetter. Since then, CeBIT has grown to become a 

global brand in the industry and far beyond. Why? Because facts and 

performance speak for themselves and are still the best form of 

advertising.That is exactly what makes Hannover unstoppable. It 

does not blatantly beat the publicity drum but, rather, stresses the 

facts and figures. This corresponds to the temperament of the people 

who live here. A typical Hannoverian stands out because of his or her 

efficiency and practicality. In Hannover, people would rather be a 

“ hidden champion”. The successful mid-sized companies in Germany 

are an excellent example for 

this; companies that are primarily 

distinguished by the quality of 

their products. These businesses 

do not need to pretend to be larger 

than they really are nor do they 

need advertising referring to old 

traditions, which are now of secondary 

importance. 

Hannover does not boast about 

being a “Gateway to the World”, as 

Peter Eisenschmidt, 

Hannoverimpuls GmbH 

Hamburg has advertised itself 

since the Middle Ages. The city 

does not overemphasize cultural 

events, like Munich with its Oktoberfest, 

like Berlin via its “international” 

attitude towards life or the 

Ruhr area with its industrial competence. 

Hannover has, for 

example, earned the title of a 

“UNESCO City of Music”. The city has the biggest “green lung” in Europe, 

the “Eilenriede”; an urban forest spanning 640 hectares. The 

cost of living is low and medical care is top-notch. 

“Hard facts” - that is what matters. But the city makes an especially 

good impression with regard to its “hard facts”, which are particularly 

important for investors. Hannover is located in the heart of Germany 

and, as a result, it serves as a crossroads for main transport corridors 

between northern and southern Europe or between Paris and 

Moscow. The Deutsche Messe AG is located here - the largest trading 

center in the world. With 463,275 m 2 of hall space it overshadows all 

other trade fairs. The SNIEC in Shanghai has about 200,000 m 2 of 

capacity. Around 100 trade fairs are organised by the operating 

company “ German Messe AG” in Germany and abroad, making it to 

a market leader. 

International companies rely on Hannover 

But let us leave the fairgrounds and focus on Hannover itself. Can 

you name a product from Hannover? No? Have you ever seen a VW 

Bulli? If there were a symbol of the German economic miracle and a 

car that stands for robustness and efficiency, it would be the VW bus. 

And since 1956 it has been produced, of course, in Hannover. Or take 

Continental, a company which not only used to be one of the world’s 

largest tire producers but also a hi-tech supplier for mechanical 

engineering, railway, printing or construction industries, chemicals 

industry as well as the aviation sector. In the spirit of internationalism, 

foreign companies have invested in Hannover and created 

important pillars in the economy. Johnson Controls has established 

its European headquarters in Hannover. The company is considered 

“one of the most admired” and “world’s most innovative companies” 

and it is no coincidence that it opted for Hannover. Further, the 

Hannover Medical School (MHH) serves as just one example of the 

pioneer role Hannover plays in the field of research as well. It is one 

of the leading institutions of its kind worldwide and this position is 

likely to be strengthened in the coming years. 

As a result, Hannover is in many ways an ideal location for innovative 

and pragmatic businesses and investors. In this city, there are a 

multitude of ways to successfully establish a business and network 

in Germany. Here, the economic development agency “Hannoverimpuls” 

is at your service as a reliable partner. We provide pragmatic 

and unbureaucratic assistance, open doors for you, thereby laying 

the foundation for your success in one of the most important 

economies in Europe. 

Photograph: HMTG, Mahramzadeh, Hannoverimpuls GmbH 

www.hannoverimpuls.com

German Pavilion 

Hall E3 

Booth C4-2 

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Bolenz & Schäfer opens 

subsidiary in China 

German manufacturer of hydraulic accumulators, 

Bolenz & Schäfer, extends its global presence. 

By opening a subsidiary in Taicang, the company 

aims at tapping into the growth market of Asia. 

Bolenz & Schäfer (BSD), which is based in Biedenkopf-Eckelshausen, 

Germany, opened a subsidiary in the Chinese city of 

Taicang on 25 March 2015. With around 100 employees, BSD is a 

company of Roth Industries GmbH & Co. KG. Roth Industries comprises 

several firms and more than 1,100 employees around the 

world. 

Frank Fuchs, CEO of BSD, commented: “This marks the beginning 

of a new era in our global activities.” Dr Anne-Kathrin Roth 

from BSD’s parent company is delighted that Roth Industries, 

which operates around the world, now has its first production facility 

in Asia. The two joined staff, customers and representatives 

of the local authorities in opening the new site in Taicang, near 

Shanghai. 

Strategic location 

Taicang is an attractive base for Roth Industries subsidiary Bolenz & 

Schäfer. Home to half a million people, it is just under 50 km northwest 

of the major city of Shanghai. Among other things, it is well 

known for its cleanliness, its attractiveness to industry, its green 

credentials and its popularity with tourists. Situated by the coast, the 

port city enjoys a strategic location and is also easily reached from 

Europe. This is one of the reasons why over 250 foreign firms, including 

many German SMEs, have already set up bases there. 

Strengthening costumer relationships 

Taicang 

The new Chinese subsidiary will supply BSD hydraulic accumulators 

promptly and efficiently to its Asian clientele. With its new 

site, Bolenz & Schäfer hopes to strengthen existing customer relationships 

and better tap into the growth market of Asia. Hartmut 

Kämmer, Head of Sales and Marketing, explained: “In future, our 

own sales team will be able to take on the tasks that until now have 

only been carried out by our distributors. Competitive disadvantages 

arising from long transport times, transport costs, customs 

and time differences will become a thing of the past.” The new site 

is to manufacture bladder accumulators and sell them alongside 


piston and diaphragm accumulators made in Germany. As well as 

850 m² of production space, some 250 m² are also available for use 

as meeting, conference and recreation rooms as well as showrooms. 

Roth Industries also wants to use the company in Taicang as a 

contact point for other business fields within the Group. For 

instance, the business activities for other lines of products can be 

channeled through the office in China and streamlined. 

Experts in hydraulic accumulators 

BSD has manufactured hydraulic accumulators for all manner of 

different applications at its Biedenkopf-Eckelshausen site for over 

60 years. BSD has won customers all around the world with its comprehensive 

range of products. Fuchs explained the company’s global 

focus: “Across the globe, we are seeing a trend towards environmentally 

sustainable processes that preserve resources. Our products 

are supporting this trend, ensuring that many facilities can 

operate safely and save energy – from large plant for heavy industry 

and the energy sector right down to mobile accumulators.” 

This was also confirmed in April 2015 at the Hannover Messe 

trade fair, in which BSD regularly participates as part of the special 

“Drive Technology” exhibition every two years. “Customers are 

coming in from more and more countries. And we’re proud of the 

fact that ours include some well-known manufacturers. Many have 

been relying on our outstanding product quality and our services 

for decades – and we want to expand this position on the global 

market”, emphasized Kämmer. 

Traditional ceremony 

The opening ceremony for BSD Hydraulic Technology Taicang was attended 

by many invited guests, including the city’s mayor, delegates 

from the business development organisation, customers and suppliers 

as well as representatives of other local firms. Dr. Anne-Kathrin 

Roth passed on the congratulations of the owner family. In keeping 

with tradition, a red ribbon was then cut to mark the formal opening. 

Equally traditional was the Chinese fireworks display that proved the 

highlight of the celebrations. 

Photographs: Bolenz & Schäfer GmbH 

www.bolenz-schaefer.com 

The range of products comprises piston accumulators, bladder 

accumulators and diaphragm accumulators 

About 

Company name: Bolenz & Schäfer GmbH 

Headquarters: Biedenkopf, Germany 

Established: 1943 

Employees: 100 

Products: tailored products and systems in the 

field of fluid technology, e.g. accumulators 



Paving the way to ‘Make In 

The manufacturing industry in India is in a process 

of transformation. WIN India 2015 will focus on 

various objectives to support the Indian government’s 

‘Make In India’ vision. 

WIN India 2015, the leading trade fair for the manufacturing 

technologies and intralogistics, will bring together worldclass 

technologies and machinery from India and across the 

globe. Scheduled from 9–11 December 2015, at the Pragati Maidan 

exhibition center in New Delhi, the trade show will bring 

together 4 concurrent shows such as MDA INDIA (Motion Drive 

Automation), Industrial Automation INDIA, Surface Technology 

INDIA and CeMAT INDIA. 

Seminars, workshops and application parks 

WIN India 2015 has partnered with Automation Industry Association 

(AIA), to bring together the Automation Training Zone at WIN 

India 2015. It is a two-day skill development and training program 

designed to boost the Indian government’s “Make in India” and 

“Skill India” initiatives, by educating the end user sectors with latest 

automation technologies. The program addresses the needs of 

equipment makers and automation users in the food and beverage, 

automotive, pharmaceuticals, fast-moving consumer goods, and 



India’ 

consumer durables sectors as well as process industries such as 

chemical, cement, energy, oil & gas and paper & pulp. 

WIN India will also organize seminars and conference under the 

name “WIN Industry Summit” (WIS), with its main theme ‘Integrated 

Industry’. It will focus on all topics related to build and manage 

the factories of the future. 

The show will also host the Automation Application Park (AAP), 

where system integrators will demonstrate live applications, educating 

end users and visitors about the latest automation solutions, 

and CeMAT Application Park, a smart warehouse display that will 

showcase a complete eco system of logistic chain management of 

an end product, right from loading and unloading of a truck, material 

handling in warehouse, sorting of products to automated storage 

system and transportation and shipping services. 

Major potential for the growth of the Indian industry 

“After a successful India Partner Country program at our flagship 

event ‘Hannover Messe 2015’, WIN India 2015 will continue to resonate 

India’s calling to ‘Make In India’. We are very excited about 

this year’s edition of WIN India which will focus on ‘Integrated 

Industry’, a digitally networked industry. WIN India will organize 

seminars and workshops in line with Indian Government’s various 

campaigns – ‘Make In India’, ‘Digital India’ and ‘Skills India’”, 

said Mehul Lanvers-Shah, Managing Director, Hannover Milano 

Fairs India Pvt Ltd. 

Mehul added, “In the pursuit of increasing the manufacturing 

capacity of India, we see a major potential for the growth of the capital 

goods manufacturing industry. With India’s strength of human 

resource, strong base of entrepreneurship, and a robust and growing 

domestic demand, the manufacturing industry in India is about 

to see transformation. WIN India 2015 will provide a platform for 

enterprise and user industry to interact, creating a complete solution 

marketplace.” 

WIN India will showcase around 500 exhibitors with dedicated 

country pavilions from Germany, China and Korea. 

www.win-india.com 


Antriebstechnik 

Worldwide News 

Subsidiary in Eindhoven strengthens 

Faulhaber’s presence in Benelux 

Faulhaber establishes its new distribution company to cater the 

demands of Belgium, Luxembourg and Netherlands. The 

newly-established distribution company is based in Eindhoven, 

Netherlands. Faulhaber was previously represented in these three 

countries by Minimotor Benelux. “We can now look after the 

markets in this region directly from our own company. By doing 

this we become closer to our customers, particularly for the joint 

development of customer-specific products. Furthermore, we are 

strengthening our strategic presence in an important export 

HydraForce moves to new facility in 

HydraForce, an international manufacturer of electrohydraulic 

controls, has moved into a brand new 11,150 sq.meters facility in the 

Advanced Manufacturing Hub in Birmingham. The new facility adds 

7,000 sq.meters of manufacturing capacity. The three-story building 

has production and testing areas on the ground floor, engineering, 

sales offices and training areas on the first and second floors. 

HydraForce is the first tenant of Birmingham’s Advanced Manufacturing 

Hub, one of six economic zones identified by the City Council 

to drive Birmingham’s future growth ambitions. The privately-owned 

company operates a total of five manufacturing facilities, including 

the new facility in Birmingham, its corporate headquarters, innovation 

center, and precision machining center in North America and a 

manifold assembly plant in Asia. The new facility will improve speed 

to market, not just to the UK, but throughout Europe, as more than 

80 % of the products built in Birmingham will be exported. This 

expansion also means an increase in job opportunities. Employment 

at HydraForce in Birmingham is expected to increase from 280 to 500 

people by 2018. 

www.hydraforce.com 

Nanotec increases production 

capacities in China 

market. Not only do the Benelux countries have an excellent 

infrastructure, but they are also an economic cluster of global 

importance with well-constructed cross-border networks.” 

declared Marcus Remmel, Head of Sales and Managing Director 

of Faulhaber, Benelux. Faulhaber specializes in the development, 

production and deployment of high-precision small and 

miniaturized drive systems, servo components and drive 

electronics. Faulhaber also provides customer-specific complete 

solutions for medical technology, automatic placement machines, 

precision optics, telecommunications, aerospace and 

robotics, among other things. 

www.faulhaber.com 

German motor manufacturer Nanotec is 

increasing its production areas in China. In 

early June 2105, Nanotec’s Chinese subsidiary 

moved its production of motor controllers, 

Plug & Drive motors with integrated controller, 

and linear actuators into a new building in 

ChangZhou. In July the stepper and BLDC motor production 

will also be moved into a larger building with a total 

area of 18,000 m 2 on the same site. With the move Nanotec 

expects to increase production capacities by a further 50 % 

in the next two years. Only last year Nanotec opened a 

second development site in Pegnitz, Germany, where the 

focus is primarily on the development of new motor 

controllers and sensors. 

www.nanotec.com 


30 

Maintenance-free bearings 

support one of the world’s longest 

suspension bridges 

I N T E R N AT I O N A L 

E D I T I O N 

6 

September 2013 

Click to read previous issues. 

Inspiration is just one click away. 

News about the following markets: 

18 MDA Technologies 4/2015 

16 geared 

Gravel plant reduces costs 

and maintenance by using 

motors 


18 26 Winter 

Standard components are 

used to drive scraper chain 

conveyors in Norway 

Air Springs: keeping 

things moving at the 2014 

Olympic Games 

in cooperation with Fluidtechnik

Birmingham, England 

Bonfiglioli’s premiers in Shanghai 

Power transmission specialists, Bonfiglioli Group inaugurated its 

new workshop in Qingpu Industrial Park, Shanghai. Established in 

1956, Bonfiglioli Group, today has revenues over € 700 million. 

Bonfiglioli Drives Shanghai (BDS) was established in 2003, as a 

small trading company to cater the Chinese market. With the new 

workshop BDS will consolidate the step to be a manufacturing 

company with full localization strategy. The new production 

Schaeffler Technology Center – Bangkok 

Schaeffler Asia Pacific has added yet another feather to its cap 

with its Bangkok office attaining Schaeffler Technology Center 

(STC) certification. STCs are local centers of technical 

excellence focusing on the region they are located in. The 

Bangkok location joins 26 others spread throughout the globe, 

and demonstrates Schaeffler’s commitment to providing 

customized engineering expertise to customers regardless of 

wherever they may be. The certification is part of the Schaeffler 

Global Technology Network (GTN) where local know ledge 

from within each region is brought together with the knowhow 

and innovative power of Schaeffler experts from all over 

the world. STCs are only given the certification after a 

thorough audit in which the organizations have to demonstrate 

a specific range of high-standard knowledge in twelve 

competencies relating to bearings solutions such as mounting 

services and failure analysis. With Bangkok as STC, the local 

and regional customers now have easier access to Schaeffler’s 

global expertise. This proximity will reduce the lead time for 

delivering solutions from engineers who are familiar with 

local requirements but at the same time, have access to a 

global support system in the shape of the GTN. 

www.schaeffler.com 

SEAL TECHNOLOGY 

PREMIUM QUALITY SINCE 1867 

COG MAKES ITS MARK: 

The world‘s 

largest O-ring warehouse. 

facility of around 30,000 m 2 , with nearly 200 employees, can fully 

support the local demands. The strong after-sales service system 

also could provide the quickest service to the markets, further 

optimizing the supply chain within the group. The local product 

line could produce widely size worm gear, gear-motor, industrial 

heavy duty gearbox, in-line planetary gearbox, slewing gearbox 

and the special gearbox for trans-mixer. These product portfolios 

are able to fully satisfy the Chinese market demands for wind, 

mobile, industrial and marine applications. Through the new 

investment Bonfiglioli group in China can provide local solutions 

with higher cost efficiency product according to the local application 

demands. 

Precision O-rings in 45,000 variants ready fordelivery. 

www.bonfiglioli.com 

PTC ASIA 

SHANGHAI 

27 –30October 2015 

Visit us in: 

hall E6,booth B2-1 

www.COG.de

Rapid prototyping 

guided by “igus” 

linear guides 

Reprap xBot is the printer that 

produces itself. Using the principle 

of “Fused Deposition Modelling” 

(FDM), the xBot from Reprap 

Austria is a 3D printer that can 

produce its own essential parts 

very quickly and precisely. The 

components from igus drive 

modular system make an 

important contribution in order 

for the printer to function. 

T 

he market for 3D printers is rapidly 

growing, and so is the reputation of the 

“Reprap” brand. Especially because, 

“Reprap” is no manufacturer and no company, 

but, as it were, an “open source” 

project freely available on the internet 

which can be used by many. 

English Professor Adrian Bowyer, in 2006 

developed a 3D printer which can produce 

plastic parts that are needed for its own 

construction: the self-replicating printer or 

“replicating rapid prototyper”, in short “RepRap”. 

He published the design data and 

drawings on the internet. His objective was 

to enable as many users as possible to 

About 

Company name: igus GmbH 

Headquarters: Cologne, Germany 

Turnover: € 469 million 

Employees: 2,700 worldwide 

Products: motion plastics, plastic components 

for moving applications: energy chain systems, 

cables, polymer bearings, linear bearings, 

low-cost-automation 

construct the 3D printer and to also 

continue to develop it. This unusual 

approach is successful and attracts wide 

circles. It means that although the RepRap 

uses the same basic structure in different 

countries, their characteristics are quite 

different. 

xBot from Reprap Austria: 

quick and precise 

The second generation xBot (Image 01) 

developed by Benjamin Krux/ Reprap 

Austria is impressive already at first sight by 

the solid aluminium body. However, more 

important are the precision and the operational 

speed, both of which are remarkable, 

as the developer explains: “The xBot prints 

with an accuracy of up to 2/100 mm. But in 

practice, usually a structure made of 

1/10 mm thick layers will suffice. And since 

we have reduced the weight of the moving 

parts to the minimum, the printer achieves 

a very high speed without any vibration.” 

To ensure high speed without any vibration, 

factors such as low dead weight of the 

print head, high quality drive systems and 

the stable, precise guiding of the print head 

and print bed are responsible. The linear 

guides from “igus” are used in the X and Y 

axes with 2 parallel running lead screw 

units from the “igus” drylin range and driven 

by stepper motors, which ensure precise 

positioning of the print bed in the Z axis. 

Drive components from the 

“igus” modular kit 

The trapezoidal threaded nuts made of high 

performance polymer iglidur J, and of the 

type drylin JFRM with a 10 × 2 mm 

trapezoidal lead screw were chosen for this 

operation. Due to its built-in lubricant, they 

provide an excellent gliding properties and 

minimum friction. These properties provide 

a vibration-free, quick travel and precise 

positioning of the print bed. 

Non-driven guides are attached at the 

four corner points of the print bed, drive 

elements from the igus modular system 

are also used here. The vertical guides for 

the travel of heated bed, via drylin R linear 

plain bearings of type RJUM-01, in which 

an enclosed anodised aluminium adapter, 

whose dimensions correspond to the 

standard recirculating ball bearings, is 


MACHINE ELEMENTS 

01 

02 

combined with a liner made of iglidur 

J. With the xBot, Benjamin Krux aims at 

discerning private users as well as schools, 

universities and the industry. “The printer is 

not only fast and accurate, but is also of high 

quality while ensuring durability. It can process 

different materials - from compostable 

“PLA” and the standard material “ABS” up 

to flexible materials such as nylon and 

rubber-like plastics. The construction is 

solid, and all major components are 

produced in Austria or Germany.” 

With Reprap’s identity to offer low cost 3D 

printers, many users can take advantage of 

the generative manufacturing. This is 

another reason for Benjamin Krux to use 

“igus” components and other low-cost 

standard supply components. He got to 

know the company, incidentally, almost on 

site, at the trade fair “Automation” in Linz. 

The headquarters of RepRap Austria is in 

Neuhofen/Krems, just 30 kilometres away. 

“One will use 3D printers 

just like the PC” 

With the design and positioning of the xBot 

as a high quality, durable yet cost- effective 

01 Second generation xBot, developed 

by Benjamin Krux, Reprap Austria 

02 Linear guides from “igus” drylin range, 

ensure precise desired movement and 

positioning (second from top); Top view 

of the linear guides (third from top) 

03 Trapezoidal lead screw from igus 

drylin range, with in-built lubrication 

and excellent gliding properties 

3D printer, Benjamin Krux encounters brisk 

demand. Now he has equipped an “open 

technology laboratory” with eight xBots, 

whose lab was established by several 

schools in Vorchdorf/Austria. He is convinced: 

“In a few years people will use 3D 

printers as they use PCs today.” 

Photographs: Teaser Fotolia, igus GmbH 

www.igus.com 

03 



The right accumulation chain for your 

conveying system 

Throughout all industry sectors, accumulation chains 

are used for conveying, accumulating and separating a 

wide range of different goods. They have proven to be 

exceptionally efficient and durable, and consequently 

cost effective. As a rule, these chains run continually, 

driven by outboard rollers via sprockets. The conveyed 

goods rest on the transport or accumulation rollers, 

which are fitted between the chain links. 

About 

Company name: iwis antriebssysteme GmbH & Co KG 

Headquarters: Munich, Germany 



Products: precision roller and conveyor chains for material 

handling systems, packaging, printing and food industries 

Accumulation chains from Munich- based chain specialist Iwis 

feature special low-friction rollers that ensure an extremely 

efficient operation of the chain and therefore the entire conveying 

system. The low-friction rollers also allow easy positioning of the 

transported material at any point along the transport path and 

eliminate the need to “start-stop” the chain, which could influence 

product orientation and agitate contents. 

For logistics and material handling applications, different 

variants of Iwis accumulation chains are available, including 

versions with 

n Offset accumulation rollers for optimised load distribution 

n Chains with nickel-plated plates and pins for lubricant-free and 

maintenance-free operation 

n Chains with protection for fingers and small parts for increased 

machine and personal safety 

n Side-bow accumulation chains with offset accumulation rollers 

for conveying systems with extremely small bend radii 

Higher efficiency through low-friction rollers 

The idler rollers on both sides of the accumulating chain serve two 

purposes: firstly, they engage with the sprocket teeth to transmit 

power, and secondly, they support the chain in the profile.


01 

02 

01 Side-bow conveyor chains with 

offset accumulating rollers are suitable 

for sideflexing conveyors 

03 

02 Maintenance-free accumulation chain with 

sintered self – lubricating rollers for reduced 

maintenance 

03 b.smart-free conveyor chains are 

suitable for robust applications 

The slightly protruding bushes in the inner link prevent contact 

corrosion between the inner link and outer plate. To ensure that the 

goods being conveyed maintain continual speed, these chains are 

fitted with low-friction sintered metal rollers that provide consistent 

smooth running conditions. These low friction rollers increase 

the chain efficiency by 30 %, thus decreasing motor capacity due to 

lower co-efficients of friction or increasing potential conveyor 

length due to reduced forces. 

Optimised load distribution chains 

The standard accumulation chains have a single wide roller on 

every second pin, this version with offset accumulation rollers has 

offset transport rollers on every pin. As a result, each pin has a 

load-bearing function, so that the load is carried by twice as many 

rollers. This reduces the strain and wear of the chain guide. The offset 

arrangement of the accumulation rollers ensures maximum 

load distribution as well as better support and smoother running of 

the product. It can reduce localised load on chain guides by up to 

50 % so plastic guides can now convey up to twice the normal load. 

Maintenance-free accumulation chains 

A special design with nickel-plated plates and pins and low-friction 

sintered metal rollers are the main features of the maintenance-free 

accumulation chains. These components negate the need for lubrication 

and help to further reduce maintenance costs while exhibiting 

excellent wear resistance under extreme running conditions. 

These chains are widely used in applications where lubrication is 

either not possible or could cause contamination. For example, 

food or medical products, electronics, glass, ceramics and many 

other industries. 

Improved safety 

Prevention is better than the cure! This is aparent for accumulation 

chains with finger and small parts protection feature. They cover the 

space between one transport roller and the next, preventing the 

ingress of small parts that could jam the rollers and/or chain link. In 

addition, the cover prevents deliberate or accidental insertion of 

fingers while the conveyor is operating to increase operator safety. 

Matched to the chain type and required bending radiús, the protectors 

provide 100 % coverage of the space between the transport 

rollers. The plastic clips are permanently fitted to the inner link. 

There is no interference with conveyed goods, workpiece carriers or 

transport rollers. 

Chains for sideflexing conveyor applications 

Side-bow accumulation chains with offset accumulation rollers 

are ideal for sideflexing conveying systems with tight bend radii 

down to 350 mm. The roller arrangement provides multiple 

contact points which reduces pressure on product through the 

bend. This can help to prevent marking or damage and also 

reduces wear on the system. 

Photographs: iwis antriebssysteme GmbH & Co KG 

www.iwis.com 



Bearing solutions with increased 

efficiency and high performance 

Wolfgang Czarnach 

To meet the specific technical and 

economical demands of its 

customers, Schaeffler offers a 

one-stop service for electrical, 

mechanical and hydraulic drive 

technology, from bearing design 

and product development to 

manufacturing and mounting. 

Author: Wolfgang Czarnach 

Vice President, Power Transmission Sector 

Management, Schaeffler Technologies AG & Co. 

KG, Herzogenaurach, Germany 

Schaeffler, using the most up-to-date simulation 

and calculation programs developed 

in-house, such as Bearinx or CABA3D, 

enables its customers to predict the behavior 

of the bearings. This ability to predict 

and analyse the bearing behaviour, right at 

the design stage helps improve the performance 

of the bearing. The reliability gained 

during bearing design reduces the development 

time and thus the development costs. 

Finding solutions using 

calculation and simulation 

“Bearinx”, developed by Schaeffler, can be 

used to model and calculate all types of 

bearings, shaft systems, and even complete 

gearboxes. It maps the complete power flow 

in a gearbox, taking loads and speeds into 

consideration along with many other influencing 

factors. 

To provide the customer with optimum 

support during development various 

versions of Bearinx are avaialble for the customers. 

Long-term development partners 

with a license agreement can use Bearinx- 

VIP. The “Easy versions” are freely available 

online: For example, Schaeffler customers 

can now use the “Easy EMachine” module 

to calculate electric motors and generators 

based on their field loads. 

The simulation program CABA3D, also 

developed by Schaeffler assesses external 

factors like vibrations, shocks or speed 

ramps. This means that the movement 

patterns of the bearing components, the 

forces acting between them and the frictional 

power that is generated can be 

determined. These results allow statements 

to be made regarding, for example, 

minimum load, the risk of smearing and 

cage strength. 



Higher efficiency for 

mobile drives 

Higher efficiency simply means, improving 

the performance levels with increasing 

driving and operating speeds while at the 

same time reducing the fuel consumptions 

and CO 2 

emissions. There must not be any 

negetive effect on the operational safety 

and longevity of the machine. When specifying 

bearing solutions for mobile drives 

high performance density, reduced friction 

and heat, exceptional wear behavior and 

low negative noise levels are the key points. 

Schaeffler provides solutions for applications 

in both mechanical and hydraulic 

transmissions units. 

Optimization of hydraulic units 

With respect to hydraulic units in mobile 

machines, improved efficiency can be 

achieved by reducing the fuel consumption. 

This can be done if the adjustable hydraulic 

units are controlled in an optimum manner 

and are equipped with low-friction, energysaving 

sliding and rolling contacts. 

For good controllability of excavators or 

road construction equipment, a bearing 

support is required, which allows low actuating 

forces and breakaway torques as well 

as high actuator accelerations. The LSGS 

matched bearing/cage system has been developed 

specifically for hydraulic units and 

provides precision, highly dynamic adjustment 

of the volume flow, even under high 

pressures, irrespective of high vibrations. 

In axial piston motors, the tapered roller 

bearing is the central bearing. It must support 

very high radial and axial forces in 

small spaces. The frictional torque of 

conventional tapered roller bearings 

increases sharply, particularly with 

increasing axial loads. The basic dynamic 

load rating of FAG tapered roller bearings 

in X-life quality is up to 20 % higher, the 

nominal operating life up to 70 % longer 

and the frictional torque is up to 50 % less 

than standard products. 

Optimization of mechanical 

transmission units 

In mechanical transmission units, it is important 

not just to focus on increasing the 

efficiency, but also on reducing the overall 

space requirement of the system. This 

requires early collaboration with customers 

in order to assess the whole system. 

For example: Cage bearings are used for 

high speeds and radial accelerations, while 

full complement planetary bearings are 

used for high loads and low speeds. The 

rolling elements run directly in the bore of 

the planet gears, which means the bearings 

only require a small radial design envelope. 

Since these bearings have the largest possible 

number of rolling elements, they have 

extremely high radial load carrying capacity, 

high rigidity and are suitable for compact 

designs. 

Higher efficiency for 

stationary drives: 

Small electric motors are very common in 

all sorts of industries. Significant reductions 

in energy costs can be made with 

FAG Generation C deep groove ball bearings. 

The internal friction in this type of 

bearing is reduced by 35 % compared to 

conventional deep groove ball bearings. As 

Worldwide success 

story in two words: 

Turkish Machinery 

Do you know Turkishmachinery 

sector exports its products to 200 

different countries worldwide? 

Do you know more than 60% 

of the machinery export made 

by Turkey goes to EU andthe US? 

Do you know more than 5.000 

establishments in Turkey 

operate in machinery sector? 

Do you know Turkey is the 

6th largest machinery manufacturer 

of the entire Europe? 

01 

02 FAG cylindrical roller bearing with cage 

02 

Do you know R&D investments of 

Turkish machinery 

sector has doubled in the 

last 10 years? 

Hall 18 -Stand A08 

01 Double row, full complement INA 

cylindrical roller with black-oxide coating 

Stand 2035 

MDA Technologies 4/2015 25 

Turkish-Machinery-Englisch.indd 1 27.08.2015 08:49:05


03 

04 

04 The CABA3D 

simulation software 

allows a precise analysis 

of the dynamic 

processes that take 

place inside a rolling 

bearing 

05 

05 FAG generation 

C deep groove ball 

bearing 

03 The “Bearinx” calculation software is able to assess the behavior 

of bearings under various operating conditions, even in the design 

phase 

a result, the motor uses less energy, rise in 

temperature within the bearing is less and 

the bearing has a longer operating life. For 

example, the bearings in wind turbines 

and large electric motors have to be protected 

against a possible passage of current 

which can occur due to a lack of uniformity 

in the coil and in the geometry of the motor. 

Bearing damage and failure can be prevented 

by using a ceramic coating on the 

outer or inner rings or by using hybrid 

bearings with ceramic rolling elements. 

Magnetic bearing systems 

Magnetic bearing technology is becoming 

more and more important as an alternative 

to conventional bearing supports. Particularly 

in medium and large industrial machinery 

with very high rotational speeds 

and shaft weights of up to several tons. 

Typical application fields include electric 

motors, gas and steam turbines, compressors, 

and chillers. The FAG Active Magnetic 

Bearing system makes a convincing case 

due to its reliability and robustness. The 

optimized system comprises of rolling 

back-up bearings and a proven electronic 

control system with power electronics 

which reduce the outlay, costs and increases 

the performance of the machinery. 

Design expertise for compressors 

and vacuum pumps 

There is also a rising international demand 

for greater energy efficiency in compressors, 

refrigeration and vacuum technology. 

A decisive factor in the energy efficiency of 

turbo and rotary piston compressors is the 

gap dimension between the rotors and the 

housing. Rigidity and tight rotor guidance 

in the bearing support can be effectively 

optimized to achieve optimum compressor 

efficiency using Bearinx parameter studies. 

The influence of inertial forces on the bear- 

About 

Company name: Schaeffler Technologies 

Brands: INA, LuK and FAG 

Headquarters: Herzogenaurach, Germany 

Turnover: € 12,1 billion 

Employees: around 84,000 

Products: Roller bearings and plain bearings, 

linear and direct drive technology 

04 Condition monitoring systems and sensor technology enable the machines 

diagnosing their condition and maintenance requirements in the future. 

ing kinematics must be accurately assessed 

in applications with high rotary speeds such 

as oil-free screw-type compressors or turbo 

chillers. Schaeffler uses its application 

expertise and calculation tools to develop 

robust solutions with low oil volume 

requirements. Calculations of the rotor 

dynamics provided by Bearinx can make a 

further contribution to the development of 

high-speed compressors. 

Sensor technology 

Many anomalies in a manufacturing process 

or products can be detected in the bearings. 

Information on physical variables such as 

temperature, speed, pressure or even paths 

can be captured. 

Schaeffler has developed FAG Smart- 

Check specifically for remote monitoring of 

machines and process parameters: It is a 

compact, modular, online measuring system 

for the early recognition of rolling bearing 

damage, imbalances and alignment errors in 

electric motors, compressors, gearboxes. The 

data are saved and analyzed remotely. The 

machine’s current condition can be 

displayed directly on the device and a control 

function transmitted as required. 

Condition monitoring devices such as 

FAG SmartCheck can also be used to monitor 

the condition of the lubricant in the bearing. 

If FAG SmartCheck sends increasingly 

critical parameters to a control unit, then the 

control unit sends an impulse to a lubricator 

which in turn discharges a relubrication 

dose. The new lubricator FAG Concept2 is 

particularly suitable for electric motors and 

compressors. It has two independently controllable 

outlets and can therefore dispense 

different quantities of lubricant. 

www.schaeffler.com 


Product News 

Miniature spindle for linear positioning tasks 

Spindle drives are the perfect solution for linear positioning systems, lens adjustment, or syringe pumps. The “GP 6 S” micro spindle 

gear from Maxon motor, has a diameter of 6 millimeters and is available in a metal version to provide a spindle drive with optimized 

value. The GP 6 S spindle gear is well suited for compact drives and wide variety of linear drive solutions. The metal version of 

the spindle provides a cost effective alternative to the ceramic version. The maximum feed velocity is 15 mm/s and force of 

10 N. The integrated ball bearings ensure that this drive sustains to higher axial loads as well. The gear easily combines 

with maxon’s DC brushed and brushless motor. 

www.maxonmotor.com 

Incremental rotary 

sensors with high 

versatility and 

programmability 

Posital-Fraba, supplier of 

position and motion sensors 

has introduced its new programmable 

incremental rotary 

encoders. The resolution can be 

set anywhere from 1 to 16,384 

pulses per turn in software. The 

pulse direction and the output 

driver can also be defined 

through software parameters. 

Changes can be made quickly 

using the “Ubifast” programming 

tool. Through its device 

programmability, the distributors, 

or machine builders can 

hold a relatively small stock of 

“standard” models and set them 

up for specific applications on 

an as-needed basis. The unique 

Internet-enabled configuration 

management system for 

programmable encoders 

enables the operator to register 

the changes with “Posital” 

through an automatic email 

interface. Posital will then 

update the configuration of the 

device in a database maintained 

by the company. If a replacement 

part is required, this 

record can be accessed and 

used to manufacture an 

encoder with an identical 

performance profile. It could be 

provided to a distributor who 

could take a mechanically 

compatible device from their 

stock, enter the appropriate 

software parameters and deliver 

the completed unit directly to 

the end user. 

Simply fantastic! 

smartflex ® 

The top model among 

steel bellows couplings 

Visit us: 

PTC ASIA 2015 

Shanghai 

Hall N3/Booth C2-1 

The perfect outfit without any problem areas 

No thermally pre-loaded welded or soldered joints and no mediairresistant 

glued joints, but 

• backlash-free, reliable torque transmission via solid, 

force locking connections 

• maximum misalignment compensation capability by 

means of perfectly formed steel bellows 

smartflex ® 

ordered today – delivered tomorrow 

www.posital.com 

D-87665 Mauerstetten, www.mayr.com 

your reliable partner


Powerhouses on tour 

Technology can be inspired from nature. 

For example, an elephant weighing 4,000 kgs can 

carry not more than 500 kgs. That’s merely a 12.5 % 

of its own body weight. But a tiny ant can lift 

weights many times its own body weight. Not just 

that, it can move quickly with this weight on its 

back and is also able to apply sudden brakes or 

change direction abruptly. Well just like ants, the 

dynamic-lift rope winches are a powerhouse. 

Tours and roadshows demand a maximum flexibility from stage 

technology. For this purpose, AMW have developed compact 

and easily transportable rope winches. “At a weight of under 

100 kilogrammes, they are able to lift double their own weight”, 

explains Uwe Schmidt, Head of Design and Development at the 

AMW Spezialhebezeuge GmbH in Freital near Dresden. “As these 

winches are relatively compact and lightweight, they are particularly 

suitable for mobile use, for example whilst on tours or at roadshows”. 

They can easily be integrated into transportable beam 

constructions, and provide a viable alternative to permanently 

installed constructions where only low ceiling loads are permitted. 

As the rope winches are often used to carry loads over people standing 

below them, or have to transport people, particular safety 

requirements must be fulfilled. 

Being able to carry the weight is one thing, and to provide functional 

and operational safety is another important aspect. Everyone 


must be able to rely 100 % on the safety of stage drives during a 

performance; any failures would have obvious fatal consequences. 

This is where the “Roba-stop-silenzio” stage brakes come into play. 

In the winch drives, these brakes with reliable contactless release 

monitoring by “Mayr power transmission”, take care of the safety 

concerns. 

Safety for people and equipment 

The function of safety brakes is two-fold. First and foremost they 

must be able to save lives in emergencies, secondly they provide 

safety to equipment from any unpermitted operating conditions. 

During power failure or emergency stop, the brakes bring the loads 

to a standstill as quickly as possible and thus reliably avoid injury to 

people or damage to property. This brake system is also equipped 

with two brake circuits, working independently of each other to 

ensure maximum operating safety. The brakes in construction size 

16 have a braking torque of “two times 19 Nm”. Another important 

feature of this system is the inductive proximity sensor for function 

monitoring. This contactless release monitoring system prevents 

unpermitted operating conditions, such as the motor starting up 

against closed brakes. In addition, the contactless system is reliable, 

resistant to magnetic field and it undergoes no “wear and tear”. 

High-performance, all-round talents 

Just like the artists on stage, the dynamic-lift rope winches are also 

multi-talented in event technology due to their flexible rope leadoffs, 

optional carrying and transportation aids and the fact that they 

can be installed in any position. In spite of their lightweight and 

compact construction, they fulfil the strict legal specifications for 

high levels of safety and resistance strengths for lifting devices 



01 The dynamic-lift rope winches, shown here 

for 240 kg lift load 

02 A safety servomotor with the low-noise 

Roba-stop-silenzio brake 

03 The complete drive for high-speed truss winches 

with a planetary gearbox, a safety servomotor, 

a Roba-stop-silenzio brake, an absolute encoder 

and a manually operated emergency drive 

according to BGV-C1. The winches combine maximum mobility 

with high lift loads and speeds. In this way, they can work at speeds 

of up to 1.5 m/s. With reduced loads, they can even reach speeds of 

up to 2.4 m/s. They are available in two construction designs for 

load capacities of up to 125 or 240 kg . A load measurement system 

is integrated into all winches as a standard feature, which measures 

and assesses current data on attached loads in connection with the 

stage control. In addition, overloads and underloads are detected. 

The dynamic stage control, which supplements the winches, 

accords with the requirements laid down for the safety integrity 

level (SIL) 3 according to DIN EN 61508. 

The quietest safety brakes on the market 

01 

02 

Dynamic-lift winches are driven via highly-dynamic synchronous 

servomotors. “These servo drives are our own product. We had to 

develop them ourselves because there was nothing comparable 

available for safety applications on the market. The servo drives 

provide their full torque across the entire speed range and feature 

continuous positive locking to the brake”, says Uwe Schmidt. The 

“Roba-stop-silenzio” safety brakes are located at the end of second 

shaft. They are maintenance-free and are characterised by their 

short construction length. Due to the compact design and the onepiece 

toothed hub, they can be particularly easily installed and 

handled. The working air gap is set in the factory and cannot be 

adjusted by the customer. This excludes malfunctions caused by 

operating and adjustment errors. The plug-and-play solution is in 

keeping with modern trends. They are also equipped with a special 

noise damping system. Switching noises are hardly audible and, in 

new condition, lie below 50 dB. Long-term tests have confirmed 

that the low-noise operation is maintained even after 300,000 

switchings. Even after several million switchings, the switching 

noise levels still lie well below those of other stage brakes. 

In order to meet the consistently increasing demands for higher 

speeds and accelerations, AMW is working on a new development 

in the field of stage winches relying on “Mayr power transmission 

safety brakes. “These new high-speed winches have lifting speeds of 

3-6 m/s”, says Uwe Schmidt, indicating the future-orientated nature 

of the new technology. 

Photographs: AMW 

www.mayr.com 

03 

About 

Company name: Chr. Mayr GmbH + Co. KG 

Headquarters: Mauerstetten, Germany 

Employees: ca. 1 000 worldwide 

Products: Torque limiting clutches, 

safety brakes, shaft couplings 


Product News 

Carbon fibre linear guides by Igus 

When it comes to weight savings, designers rely on carbon fibre 

reinforced plastic (CFRP). To meet this demands, igus has 

developed a drylin W profile. A very lightweight, high stiffness 

and non-magnetic CFRP. For aerospace or medical technology, 

igus offers the lightest linear guide in its magnitude made of 

carbon, for up to 2 000 mm stroke. Here, it is not only the 

support material that is made of CFRP, but the whole rail. The 

entire system is up to 

40 % lighter than 

aluminium and up to 

60 % lighter the than 

steel system. 

Industries where 

high dynamic 

movements plays are 

important, such as 

robotics, are 

increasingly utilising 

CFRP components. 

The high profile geometry of the CFRP rail enables an attachment 

by means of clamping jaws, which makes a complicated 

mechanical reworking superfluous. Moreover, the rail with high 

profile is the basis for a completely metal-free toothed belt axis, 

which is available in lengths up to 1000 mm. Here a deflection 

consisting of a carbon axis, a plastic gear and xiros plastic ball 

bearings from the igus range is used. Thus, it can be used 

without restrictions in X-ray equipment in medical technology. 

The carbon guide, does not require any external lubrication and 

thus is maintenance free. 

Expansion of product 

portfolio at Desch 

The demand for couplings with compact sized and high 

power transmission rate is continuously increasing. With 

requirements for high power density systems are 

increasing the manufacturer are dealing with extremely 

high levels of torque. Consequently, gear couplings are 

becoming more and more significant. They provide 

extremely high torque capacities and can also cope with 

extremely high peak loads. The Desch GC gear coupling 

is a double-cardanic shaft coupling with positive torque 

transmission via the toothing in the mesh. The convex 

toothing of the hub enables compensation of radial, axial 

and angular shaft displacements. The coupling is 

normally installed horizontally. Special customized 

versions, can be installed vertically without any problems. 

The bandwidth of Desch GC gear coupling sizes 

ranges from 50 to 1 000, permitting torque transmissions 

from 1,920 to 8,000,000 Nm, to fit shaft diameters from 20 

to 1 000 mm. Compared to 

other gear couplings, the 

Desch GC’s main distinguishing 

feature is an 

extremely high power 

density combined with 

compact design. 

www.desch.de/en 

www.igus.com 

Measuring technology for industry and machine construction 

Position indicators 

Actuators 

Rotary encoders & Wire-actuated encoders 

Magnetic & Optical measurement 

SIKO, a strong partner for industry and machine construction 

■ Specialising in measuring technology since 1963 

■ Decades of experience in distance, angle & rotary measuring technology 

www.siko-global.com 

■ 

■ 

Individual customisation and developments for our clients 

International sales and support through representatives and subsidiaries

Product News 

Decentralized supply module 

with motion control 

With its new iSA decentralized controller, AMK is 

supplying a system that is fully functional without a 

control cabinet. It places the motion control functiopns 

right where it is needed. With this concept, AMK 

establishes the basis for a machines that are truly fully 

free of control cabinets. The iSA decentralized 

controller has 3-phase power connections and 

provides both a DC bus supply for servo drives and an 

integrated 24V supply and control intelligence 

including motion control. The compact design of the 

iSA is completed by a lean real time Linux operating 

system. The real time capability of the system is 

ensured via EtherCAT. With cross-communication in 

master-slave operation, the controller can also be used 

in combination with other controllers as a gateway fro 

Ethernet/IP and Profibus 

www.amk-group.com 

Ruland disc couplings for highly 

accurate positioning 

Semiconductor and solar equipment such as wafer handlers, 

bonders and screen printers often require rapid movements over 

short increments to precisely position wafers, chips or panels. 

Torsionally stiff Disc couplings from Ruland, operate with 

zero-backlash, and prove to be an excellent choice for these 

precise positioning in highly accurate systems. Their balanced 

design facilitates reduced vibration and allows for higher speed 

capabilities of up to 10,000 rpm. Single disc models are well 

suited for compact installations and double disc models with 

center spacer, increase the misalignment capabilities. Parallel 

misalignment is accommodated by the double disc style or by 

essentially using two single disc couplings in tandem. Ruland 

manufactures disc couplings with or without keyways in inch, 

metric and inch to metric bore combinations 

ranging from 3 mm to 32 mm (1/8" to 1 1/4"). 

All hardware is metric and tests beyond 

industry standards for maximum torque 

capabilities. 

www.ruland.com 

igus ® dry-tech ® ... lubrication-free bearings ... News ´15 ... 

The ideal bearing at your fingertips... 

... that is guaranteed to work. 

Expanded once again - world's largest standard range of lubrication-free bearings 

16 full-range materials, 1,321new items: iglidur ® standard range now with more 

than 3,000 dimensions for most bearing applications. From high-temperature 

to seawater, from food approved to automotive - find, calculate and order the 

ideal bearing immediately. This and other motion plastics ® news items can be 

found at: igus.eu/iglidur-Expert 

igus ® GmbH Spicher Str. 1a D-51147 Cologne Tel. +49-2203-9649-145 info@igus.eu 

plastics for longer life ® 

The terms "igus, dry-tech, iglidur, motion plastics, plastics for longer life" are legally protected trademarks in the Federal Republic of Germany and, where applicable, in some foreign countries. 

Igus-Englisch.indd 1 29.09.2015 14:30:03 


Wittenstein introduces a new high 

performance gearhead series 

The gearhead, fused with a high 

performance motor forms an 

ultra-compact, hollow-shaft 

drive system integrated 

with Industry 4.0 connectivity. 

With efficiency of 

more than 92 %, it sets new 

yardsticks in all technical 

disciplines. Compared to 

the market standard, the 

“Galaxie Drive System” achieves up to 170 % higher 

maximum torque, up to three times better overload 

protection, between three and six times more torsional 

rigidity and up to 70 % larger hollow shaft diameters. 

The multiple gear-teeth engagement, the tooth geometry 

corresponding to a logarithmic spiral, power transmission 

through surface contact and tooth contact surface which is 

6.5 times larger for the same hollow shaft diameter are the 

crucial factors for 170 % improvement in the torque 

conversion and the threefold increase in overload protection. 

The tiny gap between the tooth carrier and the 

internal ring gear, the automatic alignment of the teeth 

leading to an optimal engagement with the internal gear 

teeth – and an optimal transverse load distribution, results 

in torsional backlash of one to two arcminutes – and hence 

up to 580 % more torsional rigidity than the best gearheads 

of comparable design currently available in the market. 

www.wittenstein.de/en-en 

Nabtesco’s new RF-P series gears for 

special and fast applications 

IWIS-Englisch.indd 1 28.09.2015 06:31:42 

Nabtesco’s new cycloidal gears of the RF-P series achieve 

high output speeds of up to 200 rpm and operate with 

extremely high precision. The RF-P series is based on 

Nabtesco RV reduction gears with a two-stage reduction 

principle. It provides excellent gear performance with 

respect to dynamics and smooth operation. The RF-19P 

and RF-32P models can withstand high shock loads up to 

570 and 960 Nm, respectively, which corresponds to three 

times their maximum rated torque. The reduced friction in 

the gear allows not only higher turning speeds with low 

backlash – the low operating temperature also ensures 

extremely low-maintenance and long-lasting gears with a 

high efficiency ratio of up to 80 %. In the zero crossing of 

the hysteresis the maximum opening is two arc minutes. 

During very fast and abrupt movements it also provides 

high repeat and path accuracy. That is especially advantageous 

in fast pick & place 

tasks and also in automated 

transport processes that 

use driverless transport 

systems. For applications 

in the food industry the 

gear heads are available 

already filled with H1 

lubricants. 

www.nabtesco.de/en

ANTRIEBE UND ANTRIEBSELEMENTE 

I HYBRIDANTRIEBE 

The birth of a 

Francois Malard, Hans Wiedemann 

Long-Ma, the dragon-scaled 

winged horse of Chinese 

mythology, had to come to life 

during the official ceremony in 

the Beijing Olympic Stadium in 

October 2014. France and China 

planned to celebrate the 50 th 

anniversary of their diplomatic 

relations. With only 12 months 

lead time Dintec, a well-known 

system integrator for electric 

drives and hybrid applications, 

accepted the challenge to power 

the dragon-horse. 

Authors: Francois Malard, Sales Manager, 

Dintec, Nantes, France 

Hans Wiedemann, Marketing Manager, 

Sensor-Technik Wiedemann, 

Kaufbeuren, Germany 

In October 2013 Compagnie La Machine 

approached their partner Dintec with the 

request to power a giant dragon-horse. It 

should allegorize Long-Ma, a fabled winged 

horse with dragon scales in Chinese mythology. 

Very quickly it became obvious that 

this project would be like no other. 

As Long-Ma should come to life within 12 

months only and then be the main attraction 

at the celebrations for the 50 th anniversary 

of the diplomatic relations between 

China and France, the pressure on Dintec 

was extreme. But being an experienced system 

integrator especially for off-highway 

applications Dintec took on the challenge 

and got the responsibility for the whole 

power system. The passion for mobile 

machines and for the entertainment created 

by the amazing creatures of Compagnie 

La Machine allowed Dintec to master the 

system from power generation, storage and 

distribution to control and sensors. Dintec 

dedicated a multidisciplinary team of 5 engineers 

who started by understanding the 

energy balance of the animal and the constraints 

in terms of operating mode (hybrid, 

fully electric for 45 minutes). After 1,800 

hours of engineering work a complete 

hybrid architecture was defined (Figure 1) 

in detail and the software for the power 

management written and compiled. So only 

7 months after the kick-off a prototype of 

the system could already be seen working in 

Dintec’s workshop. 


DRIVE TECHNOLOGIES 

hybrid giant 

Efficient and silent 

In order to supply the 620 VDC electric net 

Dintec designed a bespoke PowerPack driven 

by a Perkins 6-cylinders Tier 4 Interim 

engine to lower emissions. The diesel engine 

is coupled to the STW powerMELA 140 

kW E-machine. Due to its integrated inverter 

the powerMELA permits four quadrant 

operation and works here as a generator. 

Running at variable speed depending on real-time 

power demand, the combination offers 

best-in-class fuel consumption. Lots of 

efforts have also been made in terms of PowerPack 

enclosure as the giant Long-Ma 

had to remain a silent machine (Figure 2). 

Even when the diesel engine starts advanced 

noise insulation keeps Long-Ma quiet. 

The main electric consumers are two 

STW powerMELA 140kW E-machines 

working as motors. They supply hydraulic 

power for all the movements (head, body, 

legs, eyes…), the hydrostatic transmission 

and the steering system. A brake chopper 

has been implemented on the DC bus to 

avoid over-voltage in case of hard braking. 

The brake chopper is also equipped with an 

electric insulation measurement system 

that permanently controls the electric isolation 

of the DC bus from the machine chassis. 

A shortcut here would be hazardous to 

the operators of Long-Ma. All electric components 

(batteries, motors, generator, 

inverters…) are connected to the DC bus 

through small cabinets integrated into the 

machine. 

The giant also requests a number of additional 

electric networks so Dintec supplied 

appropriate solutions derived from the 

620Vdc bus. Inverters and filters take care of 

the transformation to the AC world with a 

400Vac-50Hz (triphases + neutral) net for 

air compressors and water pumps and a 

230Vac-50Hz net to power small AC motors, 

lights, music systems. A DC/DC converter 

converts the voltage down to 30Vdc to supply 

fans, controllers, and lights. 

A brain with 124 I/Os 

After a deep benchmarking of technologies 

taking the duty cycle of the machine, its 

01 Visual schema 

Long-Ma 



02 Visual PowerPack 

The creature in action 

This video shows the 

dragonhorse „walking“ through 

the city of Nantes, France. 

http://bit.ly/NantesLongMa 

required lifetime and the constraints in 

terms of use and availability into account, 

Dintec selected Sodium Nickel batteries for 

their high power and energy density and 

supplied 5 sets of 23.56 kWh each fitting to 

the 620Vdc net and weighing a total of 

1,000 kg. While each set features its own 

cooling system, the batteries are designed 

to be charged from the grid but can also be 

directly charged from the embedded 

PowerPack when necessary. 

Animating such an animal smoothly and 

realistically means over 50 speed and position 

regulations for the movements of the 

head, the body, the legs and the displacement 

(hydraulic propelling and steering). 

To handle these numerous functions and 

also the communication between the 24 

HMI (display, joysticks, keypads) 

and more than 200 sensors (angles, 

length for cylinder 

heads, pressures, temperatures, 

etc.), Dintec defined 

a complex network 

of 16 embedded controllers 

communicating 

through 17 different 

CAN-buses. 

The STW ESX-3XL was 

selected as the central 

control unit and brain of the 

system. The ESX-3XL can 

handle up to 124 I/Os and offers 

plenty of computing power and memory to 

run the sophisticated application. The steering 

and propelling get managed through 

the off-the-shelf STW ESX-C which is fully 

capable of controlling the rolling chassis. 

Dintec used the ESX-C to implement the 

power management algorithms. These are 

capable of adjusting permanently the power 

generation to the machine requirements 

and make sure all requested movements 

can be operated at the right speed. Two 

ESX-IOX and eleven ESX-IOXp decentral 

I/O control systems for the hydraulic 

movement control of the head, legs, and 

eyes were deployed by Dintec. Also, efficient 

communication between all CAN participants 

was established. At last, a STW 

ESX-C2C with mobile communication 

capabilities was added so that diagnosis, 

software updates and machine follow-up 

was possible remotely using Dintec’s wellproven 

web server. 

Unforgettable moments 

After intensive testing in Nantes, France, 

Long-Ma passed all controls and certifications 

handled by TUV Belgium which is 

specialized in unusual and therefore 

special applications. Long-Ma then left 

Nantes in September 2014 aboard an 

Antonov 124 to land the next day in 

Beijing, China. After being re-assembled 

and after several days of testing and 

Long Ma Jing Shen, 

Original creation of 

François Delaroziere & Cie 

La Machine as part 

of France China 50 and 

supported by 

Institut Français. 

rehearsals for the ceremony, Long-Ma performed 

3 days of intensive shows, leaving 

unforgettable memories to the Chinese 

public. Finally, Long-Ma returned back to 

Nantes in June 2015 for a couple of presentations 

and performances. After those 

Long-Ma is due to be permanently located 

in China as part of a larger project. 

Both companies, Dintec as the system integrator 

and STW as the provider of the control 

system, the power generation and motors 

were proud to work on a project of this 

scale. This pride reached its peak when 

after 12 months the engineered system gave 

life to the animal which took part in the big 

show for the celebrations of the 50 th anniversary 

of China’s and France’s diplomatic 

relations. This project could be realized 

on time only due to the 

long term relationship between 

Dintec and STW. 

Only this way the requirements 

of the machine 

manufacturer could be 

met as all technical 

challenges could be 

solved by seamless 

communication. 

Dintec’s deep know-how 

in electrification and electrohydraulic 

systems combined 

with the quality of the STW 

components once again achieved customer 

satisfaction. 

www.sensor-technik.com 

www.dintec.eu 

Company name: Dintec 

Headquarters: Nantes, France 

Turnover: € 5 m 


Employees: 35 

Products: Engineering services, PowerPacks, 

electric drives, electrohydraulic systems 

About 

Company name: Sensor-Technik Wiedemann GmbH 

Headquarters: Kaufbeuren, Germany 

Turnover: € 56 m 


Employees: ca. 450 

Products: Hybrid technology, teleservice, 

measurement and controller technology 

THIS ARTICLE IS A CONTRIBUTION BY 

About 


ased on modular design. 

Zero leakage. 

Directional seated 

valve BVE 

■ 3 sizes 

■ p max 

500 bar 

■ Q max 

300 lpm 

Uniquely combined. 

Proportional directional 

spool valve PSM 

Flexible. 

Proportional directional 

spool valve PSL 

■ 4 sizes 

■ P max 

400 bar 

■ Q max 

350 lpm 

It‘s always the right hydraulic control matching your application! 

HAWE Hydraulik’s directional valves are designed and manufactured with modularity in mind. 

With minimal installation, our vast product range couples space-saving directional valve 

banks to proportional controlled functions or zero leakage technology. There are literally 

billions of combination options to choose from, for you this means one thing: we always have 

the right solution! That’s: 

Smart. Efficient. Technology. 

Made by HAWE Hydraulik. 

www.hawe.com | info@hawe.de


A cut above the rest 

The perfect cutting ring tube fitting 

is reliable when it comes to leaks 

and processes and offers maximum 

load and pressure resistance, while 

preventing system-immanent 

assembly errors. Voss Fluid has now 

brought out a solution that 

combines all these advantages in a 

single cutting ring system, enabling 

even inexperienced fitters to 

achieve precision work. 

Cutting ring systems guarantee safety. 

They ensure leak-free tube connections 

in hydraulic systems. Well at least in theory. 

In actual fact, a process-reliable fitting 

almost always depended on the fitter’s experience 

and concentration. To overcome 

these less than adequate circumstances, 

Voss Fluid has developed an assembly-reliable 

system: the Voss Ring M with VossRing 

pre-assembly stud. The patented solution 

for connecting steel and stainless steel 

tubes is easy to handle and enables even 

inexperienced or fast-turnover personnel to 

achieve 100 % precise pre- and final assembly. 

The ring of rings 

The basis of the intelligent solution is the Voss 

Ring M. The optimized twin-cutting technology 

ensures a perfect indentation and firm fit 

at the tube, even for thin-walled tubes. The 

stable cutting ring cross-section along with 

other geometric details guarantee the highest 

pressure resistance and dynamic load bea- 

ring capacity. That means the ring can withstand 

pressures of up to 800 bar at a fourfold 

safety factor without any problem. FEM-optimized 

rounding of the cutting ring reduces 

the risk of damage to the stud and effectively 

prevents the tubes from rotating during assembly. 

Process-reliable pre-assembly 

Yet completion of the Voss Ring M did not 

mark the end of the project. “What use is the 

best ring”, states Gerd Berghaus, Product 

Developer at Voss Fluid, “if the error sources 

during assembly can be as diverse as the 

people installing it?” To eliminate this safety 

gap with an effective design, the company 

has developed a highly reliable assembly 

tool: the VossRing pre-assembly stud. The 

solution prevents assembly errors by signaling 

the exact end point of the pre-assembly 

to the fitter via an unmistakable increase in 

force. Once the assembly is completed, the 

stud comes into contact with a definite 


01 Leak-free and process-reliable cutting ring system: Voss Ring M 

with VossRing pre-assembly stud 

02 The new cutting ring system allows even inexperienced fitters 

to perform precision work 

locating surface at the end point of the ring. 

This means the assembly process is finished 

at the optimum point – an excessive assembly 

is effectively prevented. Besides the 

highest level of safety, the new stud also 

makes the fitter’s work easier: The sophisticated 

geometry of the tool in the tube limit 

stop range reduces the final assembly route 

from 90 ° to 30 °, thereby decreasing the 

work to be performed by the fitter by around 

half. This advantage is especially apparent 

under difficult installation conditions. 

Precision and corrosion protection 

The VossRing pre-assembly stud consists of 

high-performance steel, which does not wear 

like conventional standard tools, in addition 

its tool service life is 20 times longer. These 

properties make wear inspections totally 

superfluous: Although normal pre-assembly 

studs have to be inspected regularly for proper 

functioning owing to flaring of the cone 

contour, this negative property is absent from 

the Voss tool. Upon reaching the application 

limit, the stud breaks – thereby effectively 

preventing assembly errors due to tool wear. 

The 100 % effective design of the new cutting 

ring system regarding safety, load bearing 

capacity and durability can also be seen in 

the unique surface quality of the cutting 

ring. “The zinc and nickel based coating 

Voss coat-BLACK combats even aggressive 

media and therefore guarantees the high 

corrosion resistance expected by the customer”, 

explains Berghaus. As a result, this 

surface not only attains corrosion resistance 

class K5 according to VDMA standard sheet 

24576, but also exceeds the required resistance 

values against white and red rust both 

under laboratory conditions as well as in 

more demanding practical tests. 

Reliable and user-friendly 

The cutting ring system ensures leak-free 

and process-reliable tube connection with 

maximum pressure resistance and load 

bearing capacity. Assembly errors are reliably 

prevented by the patented limit stop 

concept. The shorter final assembly route 

reduces the required force and makes the 

fitter’s work easier – even in constricted 

installation spaces. That makes the system 

highly reliable and user-friendly. 

Photographs: Voss Fluid GmbH 

www.voss-fluid.net 

Company name: Voss Fluid GmbH 

Headquarters: Wipperfürth, Germany 

Turnover: € 111 m (2014) 


Employees: 400 

Products: Tube couplings, valves, flanges, … 

About 


A valve for 

every scenario 

Ulrike Ballnath, Tobias Kohler, 

Korbinian Mayer 

Control functions in mobile work machines have 

to meet varying requirements, but one that 

is common to all is the need, in most cases, 

for several hydraulic consumers to be operated 

simultaneously. Hawe Hydraulik offers valves 

for almost every scenario. 

Authors: Ulrike Ballnath, Press Officer 

Tobias Kohler, Key Market Manager 

Korbinian Mayer, Key Market Manager 

All Three: Hawe Hydraulik SE, Munich 

Whether they’re used in cranes, lifting 

platforms, agricultural and forestry 

machinery, or mining machines – the ideal 

solution is to use proportional directional 

spool valves with a load sensing system, because 

these adapt the pressure and volume 

flow to the momentary requirements of one 

or more consumers. The machine operator 

can precisely adjust the direction of motion 

and the speed of the hydraulic consumers, 

with infinitely variable control. 

The load sensing system was first used 

back in the late 1970s in the proportional directional 

spool valves produced by Munichbased 

Hawe Hydraulik SE. Over the past decades, 

it has been continuously developed 

so that today it is possible to construct a 

custom hydraulic control unit with one valve 

type in several sizes. It is common practice 

to also equip the valve with a flow controller 

–so it becomes possible to perform several 

functions not only in parallel but also 

independent of the load. 

For low volume flows 

The hydraulic positioning and actuator 

functions that are essential in agricultural 

machines and municipal vehicles usually 

only require low rates of flow. What counts 

is the precision with which the functions are 

implemented. Flow rates of less than 40 l/ 

min are usually adequate, and Hawe Hydraulik 

has now developed the proportional 

directional spool valve type EDL for precisely 

this purpose. 

The valve is controlled directly and actuated 

electrically. The flow rates for individual 

consumers can be controlled proportionally 

and limited if necessary: for example, 

for functions in combine harvesters, forage 

harvesters and root crop harvesters and/or 

street- and drain-cleaning vehicles. A maximum 

of 50 l/min per consumer is possible. 

Spool pistons in seven graduated sizes offer 

optimal resolution and allow the speed of 

hydraulic motors in particular to be cont- 


MEASUREMENT AND CONTROL 

POS-123-U 

rolled with great precision. Flow rate can be 

reduced to as low as 3 l/min. 

Designed for system pressures of up to 

320 bar, the type EDL has a higher compressive 

strength than comparable products 

on the market. The flow resistance is 

50 % lower than normal, so that the valve 

improves the energy efficiency of the hydraulic 

system. 

For high speeds 

If pressures over 320 bar are required for additional 

consumers, the EDL valve can be 

combined with the proportional directional 

spool valves type PSL. These are used when 

flow rates up to 400 l/min are required. They 

are of valve bank design and manifold 

mounting design and are appropriate for 

connection to fixed-displacement and variable-displacement 

pumps. Each valve segment 

is load-compensated, and segments 

of different sizes can be combined. 

This type of valve can be used, for example, 

to speed up loader or forwarder cranes in 

forestry work. Special spool pistons allow 

precise and jerk-free acceleration and braking 

of the loading crane. The Hawe hydrau- 

01 A valve bank consisting of 

proportional directional spool valves and 

directional seated valves for all types 

of functions in a loader wagon 

For every function there 

is a matching valve, 

all valves can be combined 

with one another 

lics specialists collaborate closely with their 

customers to determine what counter-pressure 

is needed. The valves are equipped 

with a spool piston that is matched to the 

cylinder conditions of the application and 

contains a precisely defined fine-control 

range that makes it as easy and straightforward 

as possible for the driver to move tree 

trunks. The product construction kit contains 

numerous spool variants that manage 

different pressure conditions. 

For improved energy balance 

Spool pistons with a regenerative function 

for lowering the articulated arm and extending 

the telescopic system on forestry vehicles 

also help improve the vehicle’s energy 

balance. The oil from the piston rod side 

is also used for this purpose: Instead of circulating 

it back into the tank, it is fed directly 

to the piston side. The pump only needs 

to deliver an amount equivalent to the volume 

of the piston rod. 

The regenerative spool-valve piston reduces 

the volume flow requirement of the hydraulic 

consumers. As a result, the hydraulic 

system is not only energy-efficient, it is also 

better protected against an insufficient supply 

of oil. This makes proportional directional 

spool valves with regenerative spool pistons 

especially desirable for hydraulic systems 

with small pumps and large numbers 

of parallel functions. 

Many different functions can be implemented 

in mobile machines with modular 

systems like those manufactured by Hawe 

Hydraulik. An agricultural loader wagon, 

for example, has drive functions that are 

digital positioning control 

modern and inexpensive 

design 

with analogue signal interface 

suitable for all proportional valves 

with OBE 

best positioning due to optimized 

and practical control functions 

Start-Up-Assistant 

expandable with power output 

stage or SSI-interface 

Elektronik GmbH 

Gewerbering 31 

D-41372 Niederkrüchten 

Telephone: +49 (0)2163 577355-0 

Telefax: +49 (0)2163 577355-11 

E-Mail: info@w-e-st.de 

Internet: www.w-e-st.de 

For 16 years your partner 

for dynamic drive solutions


02 Proportionaldirectional 

spool 

valve including control 

electronics and CAN 

bus interface 

03 Proportional 

directional spool valve 

with explosion-proved 

magnet, on a valve 

designed for flow rates 

up to 1,000 l/min 

controlled proportionally as well as actuator 

functions that essentially have to stay in 

one position. The loading flap, for instance, 

is moved into position by an actuating 

cylinder and remains in that position. 

Directional seated valves are perfect for this 

actuator function. They are simply flangemounted 

on the proportional directional 

spool-valve bank, with no need for separate 

inflow and outflow pipes. 

For demanding applications 

Proportional directional spool valves are 

available with integrated control electronics 

for machine manufacturers that rely on digital 

data transmission: Data is transmitted 

via a CAN bus interface. The response times 

of this valve variant from Hawe Hydraulik 

are up to twice as fast as those of conventional 

proportional valves. This allows highly 

dynamic controlling of work functions: for 

example, in the steering systems of heavy 

freight vehicles, mobile cranes and agricultural 

vehicles. In excavators, the bucket can 

About 

Company name: Hawe Hydraulik SE 

Headquarters: Munich, Germany 


Employees: about 2100 

Products: technologically advanced, high-quality 

hydraulic components and systems 

be controlled in such a way that the hydraulic 

cylinder pulsates backwards and 

forwards, and better penetration results are 

obtained in impact mode. Incidentally – 

with ECE E1 certification, the valves comply 

with the approval requirement for components 

in motorized vehicles. 

The CAN bus interface facilitates the control 

of complex systems with distributed 

valve controllers, sensors and actuators. 

Diagnostic options display faults and signal 

the position of the spool-valve piston. High 

repeat accuracy makes steering heavy load 

transporters and similar vehicles very precise, 

which makes it easier for the driver to 

control the vehicle. 

Unlike standard commercial daisy-chain 

versions, Hawe Hydraulik has integrated 

the cabling in these valves. This means that 

less mounting space is needed and the 

equipment can be securely installed in the 

vehicle. The valve bank is delivered with the 

customer’s parameters already preset, so 

the valve control is ready for connection by 

the customer. The plug-and-play feature 

has proven its value, especially in the production 

of large vehicle series. Flow rates of 

up to 150 l/min are now managed by a new 

third size for functions in municipal vehicles, 

mobile cranes, heavy freight vehicles, 

lifting platforms and other machines. 

For explosive environments 

To meet the special requirements of explosive 

environments, Hawe Hydraulik equips 

proportional directional spool valves with 

explosion-proved twin magnets. In addition 

to the approvals issued in accordance with 

the ATEX directives and the international 

IECEx system, these valves are also certified 

to American Standard NEC 500, Class I, 

Division 1. This allows manufacturers of 

machinery and systems to use valves with 

these magnets in explosive gas or dust 

atmospheres anywhere in the world – for 

example, in oil and natural gas drilling rigs, 

drilling equipment, tankers or tanker 

wagons and in the oil refining industry. 

Intrinsically safe, fire damp-protected magnets 

are certified for use in the mining 

industry in accordance with international 

regulations such as ATEX, IECEx, ANZEx, 

MSHA, MA and TR. 

Hawe Hydraulik always devises the optimal 

solution in close collaboration with the 

manufacturers of mobile work machines. 

The size and design of the proportional directional 

spool valves are chosen to correspond 

to the functions needed. By working 

with the system as a whole, the valve bank 

can be upgraded with a customized pump, 

programmable logic valve control and 

amplifier card to create an energy-efficient 

hydraulic control. 

www.Hawe.com 



Product News 

Hydraulic drive Hydre-Mac reduces 

wear of the components 

Eaton has developed a directly powered radial piston motor with high 

torque and low RPM in cam design for applications with variable speed. The 

hydraulic unit Hydre-Mac is suitable for closed circulation applications in 

offshore technology, in shipbuilding, in metal extraction, paper and pulp 

industry or in the shredder systems. It builds on a MacTaggart Scott heavy 

duty motor. Two input and output connections reduce the pressure 

reduction at high output. The overall lower heat generation and 

symmetric design with 18 pistons/roller units avoid a lateral 

stress of the piston. The repairable wear surfaces of the 

motor such as shaft seals, wear ring, piston seals and 

bearing pads can be replaced on site by a Eaton sales 

partner. The drive is available in versions with a displacement 

volumes of 20 160 cm 3 /U and 25 320 cm 3 /U. 

www.eaton.com/hydraulics 

New endless rotating tool 

with optimised design 

HKS has introduced the new generation Rotobox RB 200 in the market. The 

endless rotating tool enables in expanding the action radius of each auxiliary 

product to 360 °. Thus work can be completed faster, precisely and more 

efficiently. The RB 200 is a new entry in the desired weights of the construction 

machinery technology – the bagger class 14 to 20 tonnes. Keeping the 

weight and size of the Rotobox to a minimum and to design these such that 

the can be used in spite of the requested bagger class and keeping the oil 

supply to common 160 l/min was a great challenge for the designers. The 

auxiliary device is now lower and has an optimised design, which helped us 

in reducing the overall height and to keep the weight at 173 kg. The tool is 

available with a standard oil flow and a torque of 4,700 NM at 175 bar 

operating pressure. 

www.hks-partner.com 

Assortment boxes for any workflow 

For example new construction, repair of existing machines or repair works 

need appropriate tools on site. This is also applicable for mechanical 

connection elements. Therefore mbo Oßwald offers assortment boxes for 

small requirements, filled with different dimensions of individual components. 

The containers are available in twelve 

different filling variants: Fork heads according to 

DIN 71752 / ISO 8140, folding spring bolts and 

bolts for fork heads, splint bolts DIN 1434, 

washers DIN 125-A and splints DIN 94-St, bolts 

with grooves, angle joints DIN 71802, SL- and 

KL-fuses, locking washers DIN 6799, spring 

washers. A custom filling, which is based on the 

requirements of specific workflows, is possible. 

www.mbo-osswald.com 


New option: 

variable flow 

vane pump 

Dr.-Ing. Gerd Scheffel, Dr.-Ing. Roland Bublitz 

The variable-speed hydraulic pump, with 

its potential for energy savings, power density 

and temporary noise reduction, is currently 

the dominant pressure supply system in 

the media. Variable flow vane pump provide 

even more advantages. 

Promotions for the variable-speed pump 

like to suggest that standalone individual 

drives are the future for hydraulics. Electrohydraulic 

actuators have their uses, of 

course, but it is important to remember that 

electric motors, and their converters, are 

what make electromechanical drives so 

costly. Each drive needs a fixed motor, 

which makes the drive large and expensive. 

If this principle is applied to hydraulics, it 

restricts the choice of appropriate pumps to 

those variants that are suitable for fourquadrant 

operation. This limits options and 

increases costs as well. 

The multiple use of the electric motor in 

the central supply, together with the large 

range of suitable two-quadrant pumps 

(pumps in which the P- and T-attachments 

on the pump remain in place unchanged, 

regardless of the direction of flow; that is, 

the high pressure is always on P, and T is 

always connected to the tank), provide good 

economic arguments in favor of hydraulics 

as opposed to electromechanical systems. 

Because the central supply is connected to 

the drive with pipes and hoses – this is why 

hydraulic drives are often so compact – the 

power can be fed around any corner. 

01 Options for varying flow rate 

Authors: Dr.-Ing. Gerd Scheffel, Industrial 

Applicatons Engineerng Manager, Hydraulics 

Group Europe in Kaarst 

Dr.-Ing. Roland Bublitzist, Industrial Applications 

Engineering Manager, Hydraulic Controls 

Division Europe in Kaarst 

When marrying hydraulic pumps with 

electric motors, one has to take into 

account the behavior of each system, as 

determined by its construction type, with 

respect to its hydraulic, electrical and 

mechanical characteristics. 

A variable hydraulic flow can be created 

with an adjustable-flow pump, a fixeddisplacement 

pump on a variable-speed 

electric motor, or a combination of both: a 

variable-flow pump on a variable-speed 

electric motor (Figure 1). 

Studies so far suggest that the last of these 

is the most energy-efficient combination, 

but also the most expensive. With smaller 

flow rates in particular, this expense cannot 

be justified, and it is preferable to adopt 

more economical solutions involving fixeddisplacement 

pumps. The long-established 

option of a variable-flow pump on a constant-speed 

asynchronous motor is almost 

unanimously considered to be the benchmark 

solution. 

Characteristics of 

electric machines 

Among electric motors, the asynchronous 

motor was essentially designed to permit an 

automatic start without electronics on a 

three-phase supply. As a result of the 

motor’s construction, it couples relatively 

loosely with the rotating field (slow speedchange), 

and rotates at a speed determined 

by the number of poles in the stator and the 

mains frequency; e.g., at 3,000 rpm with a 

50 Hz 2-pole supply, at 1,500 rpm with a 

4-pole supply, and at 1,000 rpm with a 

6-pole supply. If a frequency converter is 

installed, the rotation speed of the asynchronous 

motor can be adjusted from zero 

to almost double the rated speed attainable 

on the grid without a converter. Above the 

rated speed, however, in the so-called fieldweakening 

range, motor torque decreases 

quadratic with the rotation speed. Whether 

the lower rotation speed can be used depends 

on the type of engine cooling. In selfcooled 

engines, cooling capacity decreases 

with rotation speed (the fan turns at the 

speed of the motor). To achieve a very low 

rotation speed over a longer period of time, 

therefore, external cooling (a self-propelled 

fan) is necessary. For cost reasons, asynchronous 

motors generally come without 

sensors; that is, they operate without speed 

feedback. If the motor is to be operated at 

rotation speeds under 50 rpm, however, the 

use of speed feedback is recommended. 

There are also asynchronous motors that are 

designed differently from IEC or “standard” 

motors in order to achieve better dynamics 

with a smaller rotor diameter (the “main 

spindle drive” design). These motors have a 

rectangular flange and are longer at the 

same power rating. Many of these motors 

are fitted with encoder feedback, and are 

therefore also known as asynchronous servo 

motors. 

The synchronous motor cannot run by 

itself on a three-phase supply, and needs a 

frequency converter to do so. The rotor is 

fitted with permanent magnets, and is therefore 

coupled very firmly with the rotating 

field of the stator. The speed range is often 

greater than with standard asynchronous 

motors, and the dynamics are considerably 

better. Because no induction is needed in 

the rotor, power dissipation is lower, thus 

reducing heating of the motor. 

Electric motors can achieve considerably 

higher rotation speeds than most hydraulic 

pumps. When choosing a motor, therefore, 

it is important to consider the usability of 

the rotation speed. The rotation speed of 

hydraulic pumps is restricted by noise 



characteristics, centrifugal forces and suction 

capacity. These restrictions are particularly 

clear with electric drives on a 60 Hz 

grid and with diesel drives. Small pumps 

reach their limits at around 3,000 rpm, and 

large pumps at around 2,000 rpm, if they 

are self-primed. 

Pumps with adjustable 

rotation speed 

An adjustable pump can vary the flow rate 

very quickly; e.g., by adjusting the pivoting 

angle at a fixed rotation speed. With a fixeddisplacement 

pump on a variable-speed 

electric motor, the rotation speed of the 

electric motor unit as a whole must be 

adjusted with a hydraulic pump coupled 

with the motor. The torque, which will 

change very quickly as a result of this 

adjustment, must be transmitted through 

all hydraulic components of the pump that 

lie in the power flux (Figure 2). 

Pumps with an adjustable rotation speed 

must satisfy requirements and operating 

conditions that do not arise under operating 

conditions with a fixed drive speed. An 

axial piston pump of the swashplate type is 

ill-equipped for a rapid change in speed: 

the torque is transferred in the motor via 

the oscillating pistons through short contact 

lines to the piston barrel. This restricts 

the rotation adjustment speed, and hence 

the dynamics. Thus, the high dynamics of a 

synchronous motor cannot be used, 

because the mechanical components of the 

hydraulic pump cannot transfer them. For 

this reason, pivot-adjustable piston pumps, 

both with fixed and with variable rotation, 

mostly run on a cheaper asynchronous 

motor, and the dynamics are created by 

adjusting the pump. 

The alternative to the swashplate piston 

motor is the fixed-displacement bent-axis 

piston motor. The shaft torque in some 

designs is transferred to the piston barrel 

through mechanical coupling; e.g., through 

two gears in mesh. The pistons move without 

being subject to shear forces, and this 

design is therefore very suitable for rapid 

speed change. This machine shows particular 

mechanical robustness when the motor 

is in operation, as it operates with rotation 

speeds of up to 14,000 rpm. 

The internal gear pump, which currently 

dominates the field in variable-speed 

pumps, has two interlocking gears in mesh. 

This is useful for transferring a rapid speed 

change, such as the kind that occurs in pressure 

control, between the rotating/moving 

parts in a mechanically sound way. 

Just like the internal gear pump, the external 

gear pump is very well-suited to rapid 

speed changes on a synchronous motor. 

Because of its larger pressurized surfaces, 

however, it is less favorable in the resulting 

bearing forces it creates, which reduce the 

maximum pressure and create a higher 

level of friction, particularly at low rotation 

speeds. There are numerous pumps on the 

market that have helical gears for noiserelated 

reasons. 

Advantages of vane pumps 

Another pump that is very suitable for internally 

transferring the varying levels of 

torque is the vane pump. In this pump, 

large-surface vanes occupy slots in the 

rotor. The torque is transferred not through 

linear contact, but through full-area contact 

of the vane with the rotor, which makes this 

design particularly robust. The hydraulically 

balanced vanes, which are pressed onto the 

external curved path by centrifugal force, 

are also spring-loaded, which ensures contact 

with the external curved path even at 

lowest rotation speeds. Two opposing 

pump chambers balance the hydraulic load 

02 Combinations of electric motors and hydraulic pumps 

fully, so bearings are not needed to carry 

the load, but only to guide the shaft. As a 

result, the pump rotor can also be operated 

directly from the extended shaft end of an 

electric motor. This means that the shaft 

bearing, the bell housing and the coupling 

are not required, which results in a firmer 

coupling of the pump with the electric motor. 

This not only shortens the overall length 

of the unit as a whole, but also reduces its 

inertia and prevents torsional vibrations as 

a result of the elasticity of the coupling, 

which permits a high level of dynamics. The 

vane pump is suitable for various fluids, as 

it has no roller- or ball-bearings in the liquid. 

Because of the bearing-free installation 

of the pump cartridge, in cases of repair it 

can easily be replaced with a built-in pump 

by loosening the four screws on the cover 

(Figure 3). 

The use of variable-speed pumps enables 

control of flow rate and pressure directly 

through the pump rotation speed. Pressure 

control, in particular, imposes different 

requirements on the pumps. Thus, depending 

on the application, it may be necessary 



03 Integrated vane pump on a synchronous motor 

to set the working pressure between low 

and no initial flow volume for a period of 

time. In this state, the pumps heat up 

because of internal leakage. The smaller the 

internal leakage of the pump, the longer the 

dwell time of the pump before a critical 

temperature is reached in the pump. Once 

this temperature is reached, the lubrication 

properties of the hydraulic medium are no 

longer sufficient to separate the moving 

parts of the pump, and this results in a 

mechanical failure. The two most important 

requirements for variable-speed pumps are 

the ability to transfer high torques, and low 

internal leakage. 

Internal leakage includes not just leakage 

in the displacement space, but also all other 

oil flows inside the pump, because such 

flows also cause losses and, in the case of 

pressure control, heating of the pump. 

Adjustable swashplate piston pumps 

must feed the hydrostatic bearings of the 

piston shoe and supply the control unit for 

adjusting the swashplate with pilot oil. 

These additional oil flows lead to a reduction 

in the efficiency of the machine, which 

operates with such low losses in the 

displacement space. 

04 Overall efficiency of the T7B vane pump and internal gear pump of 32 ccm and 50 ccm 



The fixed-displacement bent-axis machine 

has the advantage over the swashplate machine, 

in variable-speed operation, that 

the pistons are supported on the bearing 

by spherical balls. This reduces the supply 

to the hydrostatic bearings, and because it 

operates constantly, it has no control unit 

that needs to be supplied. This machine has 

very high efficiency. On the other hand, its 

construction costs are high. 

Internal leakage mainly depends on the 

length and height of the sealing gaps of the 

displacement spaces. In this sense, piston 

machines have a clear advantage, because a 

round piston in a round hole can be manufactured 

with very narrow tolerances. Pistons 

with a larger diameter and a longer piston 

stroke create larger displacement volumes. 

There is a proportional relation between leakage 

and displacement. 

Toothed flanks or vanes vary in their 

suitability for sealing the cross-sectional 

displacement space, and the side flanks of 

the gears or vane rotors are also difficult to 

seal without creating large frictional forces. 

There is more leakage at these points than 

with piston machines. Gear pumps, both 

with external and internal gear teeth, are 

manufactured with different gear sizes, and 

the displacement volumes within a construction 

size are defined by different gear 

widths. There is a proportional relation 

between leakage and displacement. In pressure-compensated 

designs for internal gear 

pumps, the sealing gap at the tooth tip reduces 

as pressure increases. This increases 

volumetric efficiency, but also increases 

mechanical losses. 

Vane pumps are manufactured with different 

rotor diameters, and within a construction 

size the displacement volumes are 

defined by the profile of the stroke ring. In 

this construction type, the lengths of 

sealing gaps remain almost constant. Internal 

leakage only varies slightly as a result of 

the differences in vane stroke size. Thus, 

the pump with the largest displacement 

volumes, which has the largest vane stroke, 

has almost the same internal leakage as the 

pump with the smallest. There is a proportional 

relation between leakage and displacement 

volumes across the range, but 

this declines within a given construction 

size, thus increasing the efficiency. The 

most effective combinations are almost as 

good as the most effective internal gear 

pumps (Figure 4). 

The lengths of sealing gaps are roughly 

the same in internal gear and vane pumps, 

and thus both types of pumps exhibit very 

similar leakage rates up to medium pressures. 

In terms of energy efficiency of the 

system, efficiency is crucial at high rotation 

speeds and pressures, because this is where 

the most energy is used. At small rotation 

speeds, efficiency is important for the pump 

itself, because in pressure-holding operation 

the pump is barely able to dissipate heat. 

In the absence of flow, only internal leaking 

is pumped. The T7E15 pump is of the same 

construction size as the T7E10, but has the 

largest vane stroke and hence is better in 

terms of efficiency. At identical displacement 

volumes, the pump has to turn faster 

the greater the leakage is. Internal gear and 

vane pumps are equivalent; at higher pressures, 

the vane pump has to turn somewhat 

faster (Figure 5). 

Because this heat cannot be dissipated 

without a drain port (which is normally dispreferred 

with fixed-displacement pumps 

in order to simplify installation), the maximum 

pressure-holding time up to the heating 

limit is a function of leakage. A higher 

level of leakage means a shorter pressureholding 

time in the absence of flow. However, 

a higher level of leakage also entails a 

higher rotation speed and thus a lower pressure 

pulsation. If the pressure-holding time 

that can be achieved is not sufficient for the 

application, a small amount of flow to eliminate 

the dissipation loss of the pump will 

extend this time considerably. For the most 

part, leakage will provide sufficient flow for 

the connected device to achieve sufficiently 

long pressure-holding times for the application 

(Figure 6). 

Compact und robust 

The trend towards variable flow rates is forcing 

manufacturers of fixed-displacement 

pumps to adapt their products for variablespeed 

operation. In the future, a wider range 

of designs is to be expected on the market. A 

variable-flow vane pump is already available 

as an additional option alongside more established 

products. This pump is quieter than a 

piston machine and has a considerably simpler 

design. The vane pump is comparable in 

terms of hydraulic efficiency and noise characteristics, 

and, at medium pressure at no 

flow condition, it has almost the same pressure-holding 

times as an internal gear pump. 

With respect to the pressure-holding times of 

fixed-displacement pumps in general, it 

should be noted that, in practice, the need 

for pilot oil and the leakages of the components 

of the total hydraulic system, impose 

no restrictions. The vane pump is the only 

pump that can run on the extended shaft 

of the electric motor, which makes this 

integrated solution uniquely compact and 

robust. 

Photographs: Parker Hannifin 

05 Comparison of rotation speeds in 

pressure-holding operation depending 

on volume of efficiency of a vane pump 

and an internal gear pump of 31.8 ccm 

06 Pressure-holding time (T ≤ 90 °C, HLP32) 

of a vane pump of 50 ccm depending 

on volume of efficiency 

Bibliography: [1] H. Murrenhoff, Grundlagen 

der Fluidtechnik, Band 1: Hydraulik, 

6. Auflage, 2011 

[2] R. Bublitz, K. Roosen, Energetic optimization 

of variable speed pump systems, 9. Internationales 

Fluidtechnisches Kolloquium, Aachen, 2014 

[3] T. Neubert, J. Wolff, S. Helduser, H. Spath, 

Untersuchung elektrischer Antriebssysteme am 

Beispiel von Hydraulikpumpen; 

Antriebstechnik 43 Nr. 1, 2004 

[4] I. Rühlicke, Elektrohydraulische Antriebssysteme 

mit drehzahlveränderbarer Pumpe, Dissertation, 

Technische Universität Dresden, 1997 

www.parker.com 

About 

Company name: Parker Hannifin GmbH & Co. KG 

Headquarters: Cleveland, OH, USA 

Turnover: $ 13 bn 



Products: pumps, fittings, adapters, valves, 

flanges, sensor control 



Telematics system 

enhances safety and 

efficiency of port fleets 

In recent years, port logistics have shown a steady market 

growth. But growth brings challenges. To live up 

to these challenges, Continental Commercial Specialty 

Tires developed the ContiFlexBox. 

Ports are the chokepoints of world trade and international logistic 

chains. Limited space often restrains additional growth 

potential. Constantly increasing cargo volumes have to be handled 

in tighter and tighter schedules. Big operational challenges for port 

operators. 

Mimizing tire failures 

Port fleets are a decisive factor for the smooth operation of harbors. 

And reliable tires are essential for their safety and operating 

stability. Especially tire failures frequently cause problems in the 

logistics chain. A tire puncture on an oversized heavy-duty vehicle 

such as a rubber tire gantry crane or a reach stacker can lead to 

severe accidents involving injuries and human fatalities and it can 

cause tremendous difficulties in the logistics chain. Even a simple 

tire related downtime of a vehicle can cost a lot of money and 

coordination efforts. 

To reduce tire failures and downtimes, Continental Commercial 

Specialty Tires (CST) developed a new telematic system: the ContiFlexBox. 

It complements the successful ContiPressureCheck tire 

pressure monitoring system, by collecting and deploying tire- and 

vehicle-referenced data, and forwarding it on to a central server. This 

new addition expands Continentals comprehensive product portfolio 

to include a telematics solution for the efficient management of 

vehicle fleets. The ContiFlexBox will be suitable for use in vehicles 

operating in a huge range of different industrial sectors. In particular 

port operations, where fast loading times and short downtimes 

times are vital, the new telematics system provides many advantages 

including minimizing costly tire and vehicle damage. The combined 

system, comprising of the ContiFlexBox and ContiPressure- 

Check, will be available from 2016. 

“Telematics rank among the growth drivers in port logistics. 

Efficient analysis and utilization of data enable fleet managers to 

optimize their processes and reduce their operating costs”, explains 

Julian Alexander, Business Line Manager Material Handling at Continental 

CST. “With our new combined package, the ContiFlexBox 

and ContiPressureCheck, we will offer ourcustomers a tailored 

system that synergizes the measurement of tire data with telematic 

capabilities to optimum effect, and ideally supplements our unique 

port tire portfolio.” 

Intelligently combined 

The ContiFlexBox is mounted in the driver’s cab of a vehicle, and 

powered via the engine’s ignition. The ContiPressureCheck tire 

pressure monitoring system provides automatic collection of data 

on tire pressure and temperature using sensors placed inside the 

tire. A GPS signal in the ContiFlexBox will enable additional 


01 The system allows collecting, making available and forwarding 

tire- and vehicle-referenced data for efficient fleet management 

02 Growth sector port logistics: In recent years, port logistics have 

shown a growth of 7 % per year, the global port business is expected 

to double its capacity until 2024 

vehicle-referenced data to be measured, like deployment duration 

and current location. Via WLAN or GSM, all information can be 

transmitted to a central server for analysis and editing. Fleet managers 

can then use the vehicle data collected to increase the efficiency 

of their fleet management operations. Data stored in the system is 

protected with individual access rights. 

Optimizing maintenance 

With the new telematics solution, fleet managers, drivers and the 

maintenance team are kept continuously informed of relevant tireand 

vehicle-referenced data. Provisions will also be made for forwarding 

the data to mobile terminals like tablets or mobile phones. 

This will allow drivers, technicians and fleet managers to be alerted 

by SMS or email when the air pressure has to be corrected. 

This reduces downtime since the risk of tire damage is minimized, 

and the workload involved in regular, time-intensive maintenance 

is lessened. As a result fleet operators are able to increase 

the efficiency of their fleets and significantly downsize their operating 

costs. At the same time, the environmental impact is reduced, 

thanks to lower CO 2 

emissions and a lengthier useful lifetime of the 

tires. Another advantage of the telematics system is the simple installation 

procedure, which will be handled by a team of experienced 

technicians, ensuring fast deployment and minimized downtime in 

daily operations. The tire pressure monitoring system is, moreover, 

compatible with tubeless tires from all manufacturers’ brands, and 

for vehicles of every size, rendering it exceptionally versatile – the 

latter also applies for the ContiFlexBox. 

Photographs: CST, 02 fotolia 

www.continental-specialty-tires.com 

About 

Company name: Continental AG 

Division: Commercial Specialty Tires 

Headquarters: Hanover, Germany 

Turnover: € 3,7 bn (whole company) 

Employees: 175 000 (whole company) 

Products: telematics, tires, braking systems, drive and running gear systems 



SCHLUSSLICHT I SERIE 


Fully automated 

pipeline inspection 

Equipped with a scanControllaser 

scanner from Micro-Epsilon, 

a special vehicle inspects the inside 

of a pipeline for deformations and 

cracks. This mobile device is used 

in harsh environmental conditions 

and high ambient temperatures, 

e.g. in the middle of the desert 

and is ideally suited to automatic 

inspection and recording of 

measured data. 

To meet safety regulations, the inspection 

of the internal parts of pipelines is mandatory, 

as any deformations can lead to 

cracks, which could result in complete pipe 

failure or, in the worst case, to personal injury. 

The critical factor is the weld seam. 

Dekradeveloped a fully automatic vehicle 

that solves this task by using a combination 

of visual inspection and geometrical measurements 

performed by a scanControllaser 

scanner from Micro-Epsilon. 

To make the vehicle suitable for different 

types of pipeline in all regions of the world, 

it is protected against sand, dust and ambient 

temperatures up to 100 °C. In combination 

with the fifth wheel on the top of the vehicle 

pressed against the top of the pipeline, 

the ROV can travel up a high gradient of 

around +/- 45 °. All data can be output for 

further use or, if desired, trigger an alarm as 

soon as an anomaly is found in the geometry 

(roundness, defects, welds, etc.). 

Photographs: Micro-Epsilon, teaser fotolia 

www.micro-epsilon.com 

About 

Company name: Micro-Epsilon GmbH & Co. KG 

Headquarters: Ortenburg, Germany 

Turnover: € 110 Mio. (2014) 

Employees: more than 600 worldwide 

Products: high-precision displacement sensors, 

temperature sensors as well as measuring 

instruments and systems 


Product News 

Keyboard module K2000 and displays 

form the modules for control units 

The keyboard module K2000 from Graf-Syteco can be 

combined with the displays of the automation specialists 

to customised control units. They are available with five, 

four or three keys of size 15 mm × 15 mm. The keys are 

illuminated individually and independent of each other. 

As an option individual keys can also be replaced with 

digital potentiometers. Even larger keyboards can be 

assembled in a flexible way by combining multiple 

modules. Along with the control units - for example from 

D-series – the keyboard modules constitute a system 

module, which can be used to implement customerspecific 

control solutions without requiring in-house 

electronics development. They fulfil all the relevant 

tests standards with reference to EMC, vibration and 

shock. Thus they are suitable for mobile machines, for 

example for construction and agricultural machinery 

and municipal vehicles. 

Solutions and Services for your Company’s Success 

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Business Development 

Marketing & Sales consultancy and services 

Financing 

Industry networks 

For further information please contact 

www.hannoverimpuls.de/international 

WIRTSCHAFTSFÖRDERUNG 

hannoverimpuls 

www.graf-systeco.de/home-2 

BlueSeal reduces friction and 

saves space and weight 

Valve Solenoids for 

Hydraulic Application 

Hannoverimpuls.indd 1 13.03.2015 08:18:34 

Freudenberg’s BlueSeal design is based on developing the 

PTFE Simmerring into the friction-optimized POP Simmerring. 

By fine-tuning the material and the seal’s geometry, the 

frictional losses of the POP-Simmerring reached the low 

level of an Energy Saving Seal (ESS). The development of the 

BlueSeal is opening up enormous potential in optimizing 

the drivetrain and thus reducing 

energy consumption and 

emissions. With weight 

savings of 40 %, a 50 % 

reduction in installation 

space axially; and a 30 % 

decline in frictional losses, 

seals are becoming more robust 

and creating options for powertrain downsizing. What is 

fundamentally new is, the static seal toward the housing is 

made of PTFE instead of elastomer. The seal design thus 

employs just two materials: PTFE and metal. Unlike all the 

conventional concepts, the BlueSeal dispenses the axial 

rubber lining and attaches the PTFE sleeve externally on the 

air side of the metal ring stiffener. This saves space and 

simplifies the design of the seal. The seal lip, based on the 

POP principle, also guarantees minimal friction and thus 

reduced shaft wear. 

www.fst.com 

• Electrical connection in 

different variants 

• Proportional Solenoids with 

and without stroke transducer 

• Applications inindustrial and 

mobile hydraulics 

• Fastening with central thread or flange 

• High protection class 

More Information: 

Catalogue Hydraulics 

D-87700Memmingen●Tel.:+4983311040●Mail:info@Magnet-Schultz.com 

MDA Technologies 4/2015 51 

Magnet-Schutz-Englisch.indd 1 12.08.2015 07:58:24

A good braking 

system accelerates growth 

Thomas Wienkotte 

The wind energy sector spends a great deal of money and resources to spin 

faster, longer, and generate more energy. An often under-appreciated part 

of the wind turbine system is the brakes. They perform an important job 

in keeping the turbine’s operation in control and as efficient as possible. 

For example, brakes hold the blade pitch steady and keep the nacelle pointed 

in the right direction.Brakes also steady the turbine in a violent storm 

mitigating the risk of damage while protecting the operator’s investment.

SUCCESS STORY 


SUCCESS STORY 

01 The high-performance KTR-“Stop” 

brake systems were developed particularly 

for harsh environmental conditions 

01 

02 The “KTR Competence Center for 

Brake Systems” is located in Schloß 

Holte-Stukenbrock in East Westphalia 

03 The intelligent brake regulation 

enables controlled and coordinated 

braking operations that can be accurately 

adjusted to the requested parameters 

04 The new EMB-“Stop” brake systems 

are a flexible and clean solution for 

an extremely long service life with low 

operating costs and maximum safety 

of the system 

03 04 

For more than a decade, the wind mills all over the globe have 

been relying on KTR’s “Stop” brake systems for high performance 

braking and locking. From its experience in the wind industry, KTR 

has gained competence and expert understanding of the braking 

applications that it effectively transfers into other core markets. No 

matter whether it’s marine or mining technology, on-shore or offshore 

applications, or crane manufacturing. 

Every braking situation is different and brake systems must be 

matched and adjusted to the individual conditions of each application. 

These systems should be designed in a way that allows maximum 

adaptability to varying applications and flexibility across a 

wide range of performance demands. KTR, the Rheine based expert 

in “braking” realizes this fact . 

KTR brakes, used in Sierra Leone, Africa 

Sierra Leone is rich in mineral resources, like chromium, diamonds, 

gold and platinum and Iron ore. In particular, the major iron ore 

deposit of Africa – is located in Sierra Leone with an estimated total 

volume of up to 12.8 billion tons. The Tonkolili district, in the heart 

of the Sierra Leone, is the central extraction area in the country and 

the mineral resources located here could make West Africa a critical 

supplier of raw material for the worldwide steel production. The 

brake systems provided by KTR currently contribute to the mining 

of this mineral resource. 

Strong drive – smooth brakes 

The conveyor system in the ore mining of Tonkolili consists of an 

overland conveyor system, 2.6 km in length that is operated by 

four high-performance drives. The belt transports around 3,500 

tons of ore - containing tailings, each hour - a load that needs to be 

moved powerfully but also controlled and braked in a reliable and 

responsible fashion. Each conveyor belt operates with 12 KTR- 

“Stop”-disk brakes (Figure 1) with a clamping force of 150 kN 

each (total clamping force 1,800 kN). However, this power needs 

to be appropriately applied otherwise the belts could be overloaded, 

leading to damages with high financial impacts. Accordingly, 

KTR-“Stop” brake systems transmit power, sensitively via an 

electronic control system “IntelliRamp” (Figure 3). This system 

constantly compares the nominal and the actual values of the 

system: if the belt speed is below the nominal value, the brake 

force is reduced; if it exceeds the nominal value, the brake force is 

increased. 

Typically 3 braking scenarios are available: 

n Typical frequency converter braking: monitored by the “Intelli- 

Ramp” control system, the belt gradually and safely comes to a 

halt within 20 seconds. 

n If the frequency converter is overloaded or fails due to a potential 

power outage, the emergency stop function makes the system 

come to a stop within 10 seconds. 


02 

About 

Company name: KTR Kupplungstechnik GmbH 

Headquarters: Rheine, Germany 


Employees: more than 900 worldwide 

Products: mechanical couplings, brakes systems, 

hydraulic componets, cooling systems 

Competence Center for brakes 

All activities of the KTR Group relating to brakes, brake systems and components 

are concentrated at KTR Brake Systems GmbH (formerly EMB Brake Systems AG). 

The “KTR Competence Center for Brake Systems” is located in the East Westphalia 

Schloß Holte-Stukenbrock (Figure 2). In addition to the development and 

construction of the brake components, extensive function tests of the KTR-“Stop” 

and EMB-“Stop” lines take place here, for example: in a special low temperature 

climate chamber enabling tests with temperatures of up to -40 ° C. 

n In outright emergencies there is an immediate and unregulated 

emergency stop. 

Ultimately, the combination use of KTR-“Stop” and “IntelliRamp” 

works like an intelligent ABS car brake system – just larger, stronger 

and more flexible. A good braking system is not only about 

controlling large forces, but also about its ability to encounter 

adverse environmental conditions. The Brakes have to be tough 

just like the conditions in Sierra Leone. With intense heat, wind, 

sand, dust and more than 4,000 litres of rain per year scratch the 

surfaces and crawl in to every pore. Therefore, all vital components 

of the KTR-“Stop” brakes are completely encapsulated and 

thus they are optimally equipped for use under tough environmental 

conditions. In order to withstand these challenges, the 

engineers at KTR have optimized the material composition of the 

brake, improved the corrosion protection and extended the brake 

selection process. 

Continuous development 

The design and development team at KTR’s Rheine facility recently 

undertook the task to re-design various ranges of KTR”s brake systems, 

starting with hydraulic brakes. This dedicated effort has 

yielded decisive improvements in performance on many levels. 

For example, the installation space of the KTR-“Stop” line has 

been optimized, now enabling a higher force with lower weight 

– from 1 to 1,400 kN, in either an active or spring-actuated design. 

The compact dimensions have extended the application range 

while reducing the transport, storage and assembly costs at the 

same time. 

Electromechanics + hydraulics 

Taking over the East Westphalian EM Brake Systems AG (EMB), 

KTR has extended its portfolio of high-performance brake components 

with the addition of electromechanical brake systems. The 

brake systems of the EMB-“Stop” (Figure 4) series are suitable for 

systems conceptualized without hydraulics. The maintenance work 

usually required for hydraulic units is not necessary here as the 

clamping force of up to 400 kN is electromechanically generated. 

The special feature of these brakes is the setup of the braking force: 

it can be softly applied by the touch of a button, continuously 

increasing until achieving the maximum braking performance. 

Photographs: KTR Kupplungstechnik GmbH 

www.ktr.com 

Author: Thomas Wienkotte, Sales Manager - Brakes Industry, 

KTR Kupplungstechnik GmbH, Rheine, Germany 


Small change, 

big benefits 

Christopher Monka 

Germany, the export based economic 

powerhouse of Europe currently 

produces about 43 million tons 

of crude steel annually. 

This corresponds to approximately 

25 % of the total EU output of 

approximately 174 million tons and 

barely 5 % of the output by China, 

which totals 810 million tons. 

T 

o successfully compete on the world market, along with the 

development and production of high quality specialty steels, 

in-factory optimizations that result in a sustainable increase in productivity 

in the manufacturing process are now required more than 

ever. This “in-factory optimization” does not always have to be the 

large individual projects. The multitude of small improvements in 

everyday operating procedure that often appear to be insignificant 

offers enormous savings potential in this area. 

Example one: A leading steel producer from the western Ruhr 

district was able to reduce its operating costs for the steel transport 

vessel by several tens of thousands of euros in the last five years. The 

steel removal trolley is a rail-bound vehicle that transports a pan 

beneath the converter that is filled there with molten crude steel. 

After that, this vehicle transports the pan with the crude steel to the 

SMP (secondary metallurgical plant). There, the steel is poured 

using a crane, e.g. into the vacuum system. The SMP is the device in 

which the steel receives its quality features through various 

processes (such as degasification, purity optimization, deoxidation, 

etc.) before it comes to the continuous casting plant, where it is cast 

into a solid condition, the slab. 

The vehicle (Figure1) has a specific weight of 340 tons. A filled 

pan weighs around 385 tons. The total weight of around 725 tons 

is driven by 8 slip ring motors having an individual capacity of 

30 kW each. 

Author: Christopher Monka, Area Sales Manager, 

R+W Antriebselemente GmbH, 

Klingenberg,Germany 

n Each of these motors is connected via a simple bolt coupling to a 

spur gear. After a reduction of i=36.8, the spur gear generates a 

nominal torque of around 14.85 kNm on its driven shaft. 

n The driven shaft is connected again via a bolt coupling to a 

mounted shaft at the end of which a pinion is located. 

n This pinion in turn engages in the outer ring gear of the gear set 

that moves the vehicle over the tracks. 

With 24/7 use in which the pan is filled up to 30 times per day, the 

primary importance of this device for the overall process quickly 

becomes clear. 

When the gears fail 

In the past, cracked gears repeatedly resulted in the failure of the 

vessel. This resulted in the vehicle having to be pulled out of the 

continuous production process, at considerable expense. This 

became extremely difficult if the pan was also being filled with the 

crude steel heated to over 1 000 °C. Moreover, there was great 

expense in releasing the latter from the pan after it hardened. This 

resulted in enormous costs, consisting of the procurement of a new 

gear and the associated replacement as well as the repair of the steel 

pan. Not to mention the costs of the general drop in production. 

Why the gears fail 

There were various reasons for the gear failures, but they were 

always of identical origin: stress too high due to excessive torque. 

These resulted first of all from blockages on the rail path. Negligently 

operated third party vehicles, incorrectly deposited material or 

paths that are just heavily soiled are not uncommon in the giant, 

dimly lit halls despite maximum safety precautions. Another cause 


SUCCESS STORY 

is the slag and dirt on the gear teeth. Figure 2 shows a gear after a 

service time of approximately 6 months. Here, it quickly becomes 

clear that discharging slag gets deposited on the drive components. 

Eventually, the slag coating is then so solid that the force acting on 

the gears is simply too great. 

How to Increase process safety ? 

At this point, the coupling specialist, R+W Antriebselemente based 

in Klingenberg, was able to help. The most obvious approach to a 

solution was the integration of an overload or safety coupling. The 

purpose of this coupling was to mechanically cut out torque that is 

present in the drive train at a defined value in a mechanically 

controlled manner. However, the great challenges in this were: 

n The extremely restricted installation space relative to the power 

density of the coupling 

n The extreme environmental conditions 

n The cut-off torque, which can be defined only with difficulty 

n Easy operation or fast restoration in the event of damage 

For the extremely restricted installation space, R+W therefore 

developed a special variant of the “TorqSet ST4” Heavy Duty Safety 

Coupling (Figure 3). This replaces the bolt coupling located 

between gear and drive pinion shaft. The ST4 has not only the function 

of overload protection, but also takes on the function of an 

02 

01 

01 The Steel removal trolley, is rail bound and weighs 340 tons 

02 A gear after a service time of approximately 6 months 

03 For extremely restricted installation space, a special variant 

of the “Torqset” ST4 Heavy Duty Safety Coupling was developed 

03 


SUCCESS STORY 

Company name: R+W Antriebselemente GmbH 

Headquarters: Klingenberg, Germany 

Employees: approx. 200 

Products: precision couplings, industrial 

couplings, line shafts, safety couplings 

04 The couplings of ST-series with feather key connection, conical clamp connection, 

elastic coupling and flexible tooth coupling (from top left to bottom right) 

offset-compensating shaft-to-shaft connection. Nevertheless, R+W 

decided to use a low-backlash tooth coupling instead of an elastic 

bolt coupling. This had the advantage of being able to transmit 

higher torques with a reduced size. In this way, open installation 

space was gained for the operating area of the safety coupling. Due 

to the low rotational speed of not even 20 rpm, it was possible to 

eliminate an elastic damping element. 

However, there was yet a further challenge: At which level of 

torque is the coupling to cut out? A machine that has been in use 

this long, on which already generations have provided proof of their 

technical capabilities in day-to-day operation simply does not have 

the required documentation to permit exact calculations. Based on 

rough calculations and empirical values, a value of 42 000 Nm was 

settled upon. Then, as soon as such a torque was present in the 

drive unit, the coupling disconnected the flow of driving force within 

the span of a few milliseconds. Indeed, already at the initial startup 

with a filled pan, the coupling released to the surprise of everyone 

involved. The reason: The startup torque under full load was 

evidently substantially greater than everyone assumed. The simple 

and advantageous handling of the ST series revealed itself here. 

With a face wrench and a few moves of the hand, it was possible to 

adjust the pre-set disengagement torque. With steps in the 1 kNm 

range, it was ultimately possible to precisely approach the required 

target mark. Today, the coupling is set to a disengagement torque of 

57 000 Nm and switches only in the event of genuine crash. Once 

this happens, an employee corrects the fault in the travel path or 

manually clears the gear of its coating of slag. Then, he just has to 

re-engage the coupling and already production can resume. 

Here, an additional advantage of the ST model series from the 

R+W house becomes clear. No special tools at all are required for 

the restoration of operation. Unlike as it was with the shearing pin 

couplings that were standard in the past, no special replacement 

parts have to be additionally stockpiled. The coupling operates 

according to the backlash-free ball-detent principle, which has 

proven itself over the years. The two halves of the ST coupling are 

connected to each other in a positive-lock arrangement by a defined 

number of switching elements. In the interior of each switching 

element, a ball is axially pre-tensioned via disk spring assembly. 

One half of the ball shows from the element and sits on the second 

coupling half in a form-fitting detent. The torque is backlash-free 

and reliably transmitted via this force/form fitting. As soon as the 

tangential force generated by the applied torque and acting on the 

balls is great enough that the spring assemblies can no longer pretension 

the balls, the ball slips completely back into the interior of 

the switching element within the span of milliseconds. The ball is 

guided inside the switching element by a bolt that is correspondingly 

moved axially during the switching operation. To place the coupling 

back in operation, the two coupling halves just need to be turned 

into the correct position, and with the force of a soft-faced mallet on 

the bolt of each element, the ball is then pressed back into its detent 

recess in order to restore the flow of force. However, R+W had a few 

more advantageous features for the customer in the described 

scenario for the steel trolley. For easier turning of the coupling 

halves after a switching operation, the customer can also insert a 

lever into radially placed holes that are provided for this purpose. In 

addition, a re-engagement groove was placed on the hub of the 

coupling half with the switching elements. This is because, due to 

the scarce installation space because of the shortened hub on the 

safety coupling side, re-engagement using the soft-faced mallet is 

not possible. However, with the aid of the groove, the customer can 

insert a mounting iron there and push back the ball using the lever 

force created with it. 

According to the testimony of the employees in the steel mill, the 

coupling has already reliably switched multiple times. Since then, 

there have not been any failures as described at the outset. Accordingly, 

the coupling has already paid for itself several times over. 

Photographs: R+W Antriebselemente 

www.rw-couplings.com 



Compressed Air and Vacuum Technology


COMVAC ASIA 

ComVac ASIA 2015: 

Saving energy, 

maximizing 

productivity 

Wolfgang Pech, Senior Vice President, 

Deutsche Messe AG 

China is on the way to becoming a high-tech nation. As its 

manufacturing base continues to grow, so too does its need 

to outfit factories and plants with modern equipment. 

ComVac ASIA, a leading platform for the compressed air and 

vacuum technology sector, runs October 27–30, 2015, in 

Shanghai. Wolfgang Pech, senior vice president at Deutsche 

Messe AG, told us what visitors can expect. 

In 2013 you established ComVac ASIA as 

a stand-alone fair running parallel to PTC 

ASIA. What has changed since then? 

Strong market growth in China led us to 

launch ComVac ASIA as a dedicated platform 

for the compressed air and vacuum 

technology sector. This enables us to more 

effectively promote the event, especially 

when it comes to targeting specific visitor 

groups. ComVac ASIA is located between 

PTC ASIA’s new smart manufacturing hall 

and CeMAT ASIA, which is Asia’s leading 

intralogistics trade fair, so there is a good 

tie-in regarding energy efficiency. Since 

2013 we have seen display area at ComVac 

ASIA grow roughly 45 percent. So far 149 

companies have signed up to exhibit in 

2015, including Bauer Compressors, 

Fusheng, Ingersoll Rand, Klüber Lubrication, 

Kobelco, and Mann + Hummel. 

Why should international companies 

participate in ComVac ASIA? 

After years of growth based on selling large 

quantities at low prices, China is now shifting 

to competing based on quality, which 

means Chinese manufactures have to upgrade 

their plants and equipment. Since 

compressed air and vacuum technology 

are used in practically all production and 

processing facilities, we can expect big 

demand in China for these products and 

services. Furthermore, customers are more 

and more looking for turnkey solutions 

that include maintenance and financing 

options, so ComVac ASIA is the perfect 

platform for international providers to 

present the breadth of their product and 

service offerings. 

What can visitors expect at ComVac ASIA? 

Visitors will find a full range of products 

and services for saving energy in their 

plants – everything from generation, treatment 

and distribution of compressed and 

vacuum air to its use in machines and 

systems to contracting and service agreements. 

As I previously indicated, many 

customers want turnkey solutions, so 

ComVac ASIA is a great place for visitors to 

compare the product and service portfolios 

of many different companies and then 

negotiate the deal that best serves their 

specific needs. 

What are currently the main topics of 

the Chinese industry? 

I think innovation, quality and modernization, 

because these three topics form the 

foundation of the Chinese government’s 

“Made in China 2025” initiative. China is 

no longer the world’s go-to workbench: 

its manufacturers are under tremendous 

pressure from other low-cost producers in 

Asia and world leaders such as Germany 

and the U.S. Add to this increasing labor 

costs and a growing Chinese middle class 

that demands better products and service 

and it is clear that Chinese companies 

have to completely overhaul their production 

and logistic systems, otherwise they 

will not be able to compete in the global 

marketplace. 

Which role does the compressed air 

sector play in “Industrie 4.0”? 

Compressed air is important to Industrie 

4.0 because it delivers significant energy 

savings. This goes hand-in-hand with the 

Industrie 4.0 goal of maximizing overall 

efficiency and productivity. Plus, Industrie 

4.0 tools such as automation technology, 

IT and Big Data now enable companies to 

seamlessly integrate compressed-air systems 

into complex industrial infrastructures. 

And compressed-air systems themselves 

are becoming more intelligent so 

that they can communicate with other 

systems within the factory. 

www.comvac-asia.com 


INAUGURAL 

ComVac North America at IMTS 

Trade Fair For Compressed Air and Vacuum Technology 

Your Gateway to the Thriving 

U.S. Manufacturing Sector 

September 12 - 17, 2016 | McCormick Place | Chicago, IL 

comvacna.com

01 

Authors: Dipl.-Ing. (FH) Erwin Ruppelt, 

Head Project Engineer, 

Dipl.-Betriebswirtin Daniela Koehler, 

Press Officer, both of Kaeser 

Kompressoren SE, Coburg, Germany

COMVAC ASIA 


Industry 4.0: High-tech compressed 

air for high-tech products 

Erwin Ruppelt, Daniela Koehler 

Scholz, a high-tech company in the plastics industry, 

is currently revolutionising its compressed air supply 

to ensure continued company success into the 

future – and is enjoying significantly reduced energy 

costs as a result. 

02 

Horst Scholz GmbH & Co. KG, based in Kronach, Upper Franconia, 

is a manufacturer of precision plastic parts. These include 

products used in medical technology and precision engineering 

parts, destined primarily for the automotive industry, medical technology 

industry and lifestyle products. The medical sector in particular 

insists on stringent requirements to ensure high product 

quality – and it’s no different when it comes to the quality standards 

for the compressed air the company relies on for control and 

process air. 

03 

Rooftop container station 

When it came to the recent modernisation of the existing compressed 

air station, the company’s management decided to opt for a 

compressed air contracting arrangement to ensure that the compressed 

air supply will always meet the latest technical standards 

and be capable of taking advantage of the benefits that Industry 4.0 

has to offer – and not least due to the frequent fluctuations in 

demand in the automotive supplier industry. In this contracting 

model, the compressed air station itself remains the property of the 

air system provider whilst the customer simply uses the compressed 

air as needed, just like power from an electrical socket, paying only 

for the volume of compressed air actually used – and always at the 

same fixed rate. From an accounting perspective, this effectively 

turns fixed costs into variable costs. Other than the fact that the customer 

doesn’t actually own the station, they enjoy all the advantages 

of a highly advanced compressed air supply system. 

Customers who choose contracting models only have to provide 

a suitable room or area on their production premises. Since space 

was at a premium at Scholz, an especially compact and convenient 

04 

01 Inside the station highly advanced technology, such as the 

Sigma Air Manager 2, ensures dependable compressed air availability 

and maximum efficiency to deliver impressive energy cost savings 

02 The compact compressed air station at Scholz is housed in a 

container located on the roof of the company building to save space 

03 Karl-Herbert Ebert, Technical Director, is very happy 

with the first-rate compressed air supply 

04 Scholz HTIK manufactures plastic precision parts, including 

micro-components and products used in medical technology 



COMVAC ASIA 

solution was required: the new station was installed in a container, 

on the roof of the company building. This required precision work 

down to the exact millimetre during installation, yet once installed, 

the system could begin its work immediately. 

Detailed analysis results in a tailored solution 

Following a detailed compressed air audit to identify the company’s 

exact compressed air needs, Scholz’s compressed air station was 

designed to incorporate the very latest technology, including all of 

the features that today’s advanced stations should offer. Of course, 

first and foremost, this includes outstanding reliability, quality and 

Demand-oriented 

Collection and analysis of performance data makes it possible to 

revolutionise system servicing and maintenance: compliance with 

fixed intervals is no longer necessary, as service is performed only 

as required. When service is needed, the master controller simply 

sends notification accordingly and the material-flow infrastructure 

is managed in parallel through the manufacturer’s worldwide data 

centre. In practice, this means that orders of materials can be automatically 

forwarded to the distribution centre, which then coordinates 

delivery of materials with the manufacturer’s production or 

subcontractors. This both ensures a ready supply of materials and 

The new concept has delivered the promised significant 

energy cost savings 

efficiency, as well as impressive energy savings. In addition, ease of 

maintenance together with networking and integrated control features 

consistent with the Industry 4.0 environment also play a key 

role, not least in laying the foundation for predictive maintenance. 

A safety concept was also devised. 

The data gathered during compressed air system analysis were 

input into the controller of the new system, in this case a Sigma Air 

Manager (SAM 2), and provided the foundation for highly efficient 

operation of the entire station. Since the compressors and compressed 

air treatment components are equipped with integrated 

industrial PC technology, they are able to forward their data to the 

master controller. As a result, the master controller can monitor all 

components, as well as the environmental and production conditions, 

and is also able to precisely adapt compressed air production 

to match the company’s actual compressed air requirement. Furthermore, 

amongst many other key benefits, the SAM 2 optimises 

pressure values, automatically adjusts compressor system air delivery 

to accommodate fluctuating air demand and optimises system 

efficiency through constant analysis of the relationship between 

control losses, switching losses and pressure flexibility. 

This advanced controller also enables the compressed air station 

to benefit from future services, such as predictive maintenance and 

allows remote diagnostics capability. If requested by the customer, 

this option means that performance data are constantly sent to a 

data centre operated by the compressed air system provider for 

monitoring. The master controller independently analyses the situation 

at all times and if appropriate, sends a message to the service 

team, directly to the local installation technician or the central data 

centre. The air system provider’s central data centre then acts as the 

dispatching point for all further activities – worldwide. 

Fast and secure with Sima Network 

To ensure rapid, secure transmission of data both internally 

and externally, the compressed air station at Scholz is 

additionally equipped with Sigma Network. This powerful 

and secure closed network is Ethernet-based and guarantees 

optimal monitoring and efficient control of the compressed 

air station as well as maximum data security. 

keeps costs to a minimum, since unnecessary production is avoided; 

the materials can be delivered directly to the customer. 

All of these innovative measures help to enhance operational reliability 

and efficiency, and, at the same time, reduce both energy 

and total lifecycle costs. The master controller is already designed to 

accommodate potential future growth of the compressed air station. 

A straightforward software update is all that’s required for expansion, 

with no need for additional investment in new hardware. 

Heat recovery reduces energy costs 

Karl-Herbert Ebert, Head of Technology and Development at 

Scholz, is more than happy with the compressed air solution: “The 

entire compressed air supply ran smoothly right from the outset,” 

he says. “The container was delivered and once connected, we had 

our air supply”. In this case, the predictive maintenance capability is 

only indirectly beneficial to Ebert personally, since the company is 

not responsible for any aspect of servicing under this contracting 

plan. Yet he says with satisfaction, “The service is excellent. The 

technicians came overnight to perform the required maintenance 

and really didn’t notice a thing.” 

He is especially pleased that the new concept has also delivered 

the promised significant energy cost savings. The new compressed 

air station provided Scholz with the opportunity to take advantage 

of the benefits of heat recovery for the first time. Scholz now uses 

the recyclable heat from the compressors that occurs as a result of 

the compressed air production process to heat the company’s facilities; 

a measure that has already resulted in a reduction of some 

50 percent in oil consumption in the first year alone. 

The ability to perform energy management in compliance with 

ISO 50001 is yet another major advantage for Ebert. Overall, he’s 

extremely satisfied. “We now have a convenient compressed air 

supply solution that offers a wide range of benefits. Not only can we 

now directly offset the compressed air costs, we no longer have to 

perform service work ourselves and have an excellent overview of 

our air consumption.” 

www.kaeser.com 


Product News 

Screw compressors with asymmetric 

profile for intense industrial use 

The Renner RS Range is 

shown amongst other Renner 

compressors at the ComVac 

Asia. Nowadays, for the 

relevant output range, 

oil-injected screw compressors 

represent the most 

modern and cost-effective 

method of generating 

compressed air. This type 

of compression highlights 

Renner’s advanced knowhow. 

With a range of 

performance from 3.0 to 355 kW, the compressors reach a 

final pressure of up to 15 bars. Renner screw compressors 

with their asymmetric profile are designed for intense 

industrial use. When developing a product, Renner places 

great importance to cost-effectiveness, long service life 

as well as low maintenance at low cost. 

Advantages RS-serie are: 2-year fully functional guarantee. 

Encapsulated air end: Compact design eliminates 

unwanted pipe work and potential oil leaks, as well as the 

need for pressure test certificates. Spin on & off separators 

save time and reduce maintenance costs. Easily removable 

doors: Very good access to individual components 

and ease of maintenance result in low costs for the user. 

Standard components: High quality German made parts 

and use of standard mineral oils ensure long life and low 

running costs. 

www.renner-kompressoren.com 

Precise flow measurement 

for compressed air and gases 

Due to its robust design, the aluminum die cast housing, the 

robust sensor tip made from stainless steel 1,4571, the new flow 

sensors VA 550/570 are suitable for demanding industrial 

applications. An ATEX version is available for applications in 

explosive areas. For flow measurement e.g. of natural gas there 

is a version with a DVWG admission. 

VA 550/ 570 has an integrated Modbus output as a standard 

with which all parameters like Nm³/h, Nm³, Nm/s, Nl/min, 

Nl/s, kg/h, 

kg/min, ft/min, °C etc. can be transferred. All parameters can 

be adjusted directly at the instrument (via display) or via the 

PI 500 hand-held measuring instrument resp. the Service 

Software. Of course there are also 2 x 4...20 mA analogue 

outputs available for flow and temperature and a galvanically 

isolated pulse output for the total consumption. A remote 

diagnosis can be carried out via Modbus and all relevant 

parameters can be checked and changed if 

necessary. So it is possible to change e. g. 

the gas type, the inner diameter, the scaling 

and so on or the zero point resp. the leak 

flow volume suppression in case of 

changed process conditions. 

The application range is wide: Compressed 

air measurement and distribution, leakage 

measurement of compressed air and gases, 

flow measurement of gases, flow measurement 

in vacuum systems, flow measurement 

of explosive gases with ATEX 

approval, flow measurement of corrosive, 

acid gases, measurement of oxygen and 

natural gas at gas burners and flow 

measurement of gas mixtures. The sensors 

can also be used in the outdoor area. 

www.cs-instruments.com 

FAD Measurement of Compressors 

Measuring the FAD (Free Air Delivery) of a compressor can be challenging. Standard methods 

used by the compressor manufacturers in their factories are not convenient or practical in the 

field. However, with a proper flow meter and some mathematics this task is manageable. 

CS-iTEC’s pitot tube flow meter S 430 is designed for this purpose of the discharge flow measurements 

at compressors to evaluate the FAD and monitor performance. The installation is through 

a 1/2” ball valve and can be done even under operation. Through an optional color display, 

the discharge flow and the FAD can be displayed and various settings are available. It comes 

with 4-20 mA, pulse and Modbus interface. In combination with a S 331 data logger, several 

flow sensors can be connected to one display. By adding a power meter to measure the 

compressor power, a complete performance solution is in place. 

www.cs-itec.com 


Product News 

Gas compressors for 

extreme pressure up to 17 bar 

As OEM supplier, Rotorcomp Verdichter GmbH, a subsidiary 

of Bauer Comp Holding, supplies oil-injected air ends 

and compact modules to the manufacturers of gas compressor 

for more than 10 years now. Rotorcomp delivers gas 

compressors as air ends of the series EVO Gas with drive 

power of 2.2 to 670 kW, whereby the air ends are made of 

casing and integrated rotor pair and compact module of the 

series EVO-NK Gas with drive power of 2.2 to 90 kW, whereby 

the module consists of an air end with integrated rotor pair 

and oil container supplemented with flanged multi-functional 

block, fine separation, thermostat and minimum 

pressure control valve for 

controlling oil circulation. 

We have not only 

updated the rotor 

profiles in both the EVO 

series, but we have also 

reworked the casing and 

in particular oil circulation 

and suction range 

were optimised. We were 

able to increase the 

specific performance due to these measures and thus 

increased energy efficiency significantly. Therefore, the new 

system is far more economical now and offers even better 

conveyor performance with same energy consumption. Both 

series are available with integrated drives for sizes up to 18.5 

kW. The compact module is also available in Atex design. 

In particular, new modular design of the compact module 

helps in its use as pressure compressor, because oil 

container volumes as well as multi-block with fine separation 

and pressure control valve are available in different 

sizes for each type and thus extend the application range 

significantly with reference to conveyor quantity and 

working pressure. In addition, a rated working pressure of 

up to 16 bar and a complete feed into PN16 gas pipes are 

possible according to the test conducted by Rotorcomp. 

Individual compressor blocks are designed for an operating 

pressure of up to 17 bar. 

Rotorcomp provides easy-to-use, computer-assisted design 

and calculation program so that its customers can select 

optimal gas compressors. 

www.rotorcomp.com 

New air cleaner for 4 m 3 /min 

Mann+Hummel presents the new Entaron HD air cleaner for 

nominal flow rates up to 4 m 3 /min. The air cleaner convinces 

offering many advantages in its performance class. It was developed 

for mobile compressors and gensets. 

The Entradon HD 4 series extends the existing range of 

Mann+Hummel air cleaners for nominal flow rates up to 4 m 3 /min. 

The Entaron HD is available as a two-stage or optionally as a single 

stage version. Its design offers customers many advantages with a 

long service life, high separation efficiency and excellent flexibility 

when adapting to limited installation space. Thanks to its new 

design customised versions are possible without changing the tool 

and are therefore available faster than with conventional air 

cleaner designs. In addition, its size is approximately a third 

smaller with the same filtration performance than the comparable 

Europiclon 200 within the Mann+Hummel product range. This 

makes life easier for application engineers looking for high 

performance air cleaners suitable for limited installation space. 

Furthermore, the Entaron HD can also be delivered with a metric 

or inch version of the clean air port and a 90 ° elbow with optional 

outlet for an mass airflow sensor. The position of the service switch 

connection on the air cleaner is designed to fully exploit the 

installation space. The brackets integrated on the housing offer two 

mounting positions either as 

standard with through-holes, 

or optionally with threaded 

inserts. This means the air 

cleaner is easy and quick to fit. 

The Entaron HD 4 is also 

maintenance friendly and can 

be serviced without the need 

for tools. 

www.mann-hummel.com 

Imprint 

Compressed Air News is published in cooperation with ComVac, 

the leading trade fair for compressed air and vacuum technology. 

Vereinigte Fachverlage GmbH, Lise-Meitner-Straße 2, 

D-55129 Mainz / P.O.Box 100465, 55135 Mainz, 

phone: 0049/6131/992-0, fax: 0049/6131/992-100 

Managing Director: Dr. Olaf Theisen 

Publishing Director: Dr. Michael Werner, Tel: 0049/6131/992-401 

Editorial: Dipl.-Geogr. Martina Laun, Phone: 0049/6131/992-233 

(Responsible according to the press law) 

Design: Cornelia Grothe 


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THE WORLD OF ENGINEERING 

www.engineering-news.net

MDA Technologies 4/2015

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