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2.5 Management report on on the Group Non-financial performance indicators indicators Pages 53-54 53–54 LubriTreat ® LubriTreat will significantly improve the forming behavior of galvanized steels in the future. ® will significantly improve the forming behavior of galvanized steels in the future. Innovations Innovations and new technologies are a key element of the Group’s Strategic Way Forward and therefore also feature strongly in our corporate program ‘impact’; a detailed report on this is provided in the section “Profile and strategy”. We develop new materials, products and processes, identify and explore promising areas of innovation, and improve our technology position. We are also expanding our innovation management systems. Our 3,000 research and development employees demonstrate their strengths in the areas “Material“, “Mechanical” and “Plant”. Their outstanding engineering expertise enables us to develop cost- and resource-efficient solutions in response to global challenges such as rising consumption or sustainable infrastructure. The following examples represent a selection of the wide-ranging innovation activities of our Group companies. Electromobility: StreetScooter development partnership ThyssenKrupp is expanding its capabilities in the area of electromobility. In collaboration with research institutes and industrial partners we are jointly developing body and chassis solutions for the electric vehicles of the future. As part of a consortium of industrial partners and institutes of Aachen University of Technology we are working on the development of a low-cost electric city vehicle called the StreetScooter. ThyssenKrupp has developed and prototyped the floor assembly, which will accommodate the batteries for the electric vehicle. For the crash-relevant parts we use both high-strength lightweight steels and other materials combining high strength and high elongation. In the event of a collision, this allows impact energy to be absorbed effectively. A prototype of the StreetScooter was presented at the 2011 Frankfurt Motor Show. Eco-friendly material for vehicle construction We have developed a new material with a tensile strength of 1,000 megapascals. It is currently our strongest cold-formable steel and is particularly suitable for thin-walled, low-weight parts. Safety-relevant structural parts for automobile bodies can be made up to 20% thinner using this material. This reduces vehicle weight, saves energy and thus lowers CO2 emissions. New coatings for cost-efficient production In collaboration with a lubricant manufacturer, our surface specialists have developed LubriTreat ® , a new coating process that significantly improves the forming behavior of galvanized steels. Moreover, the new coating is free of heavy metals and allows nickel-free, eco-friendly processing. LubriTreat ® reduces friction during the forming process, resulting in lower die wear and reduced scrap rates. Good paint adhesion and optimum finishes are guaranteed. The product has been patented by both companies and is suitable for all hot-dip and electrolytically galvanized steel sheet materials. iwalk – new moving walk sets standards Our newly developed iwalk requires much less space than conventional moving walks. With the same outside dimensions, the passenger area is wider and provides greater space and comfort. The significantly lower pit depth also greatly reduces the amount of civil work required. The iwalk can even be installed on an existing floor without the need for any additional construction measures. Thanks to the new modular design, individual segments can be added or removed as required in the shortest possible time, 94
Management report on the Group 2.5 Management report on the Group Non-financial performance indicators The “cylinder head” project won second prize on the 2011 ThyssenKrupp Innovation Contest. 94 | 95 and it is even possible to move the entire installation to a new location. The iwalk is particularly suitable for metro stations, railway stations, airports and exhibition centers – both as new installations and to upgrade existing systems. In addition the iwalk can be equipped with a new energy saving system which optimizes power consumption depending on passenger numbers without reducing operating speed. The new moving walk was awarded first prize in the 2011 ThyssenKrupp Innovation Contest. Cylinder head cover with integrated camshafts Second prize in this year’s Innovation Contest went to the development team behind a new cylinder head module with integrated camshafts. Our engineers and technicians used the proven Presta joining process for assembled camshafts to produce a complete cylinder head cover with integrated camshafts. This allows us to supply customers with a ready-to-install module rather than just individual camshafts. Modular designs with integrated camshafts were previously unavailable on the market. We have already received the first production order. As well as reducing costs for cylinder head machining, our solution is also easier to install. Integrating the individual, finish-machined camshaft parts in the cylinder head cover makes it possible to dispense with bearing caps. This results in improved hydrodynamics, and antifriction bearings can be integrated simply and without deformation. Bio-based plastics made from succinic acid In order to make sustainable use of resources we need to explore new ways of utilizing renewable raw materials. Since 2006 we have been developing biotechnology processes to produce plastics from renewable raw materials. One focus of the chemical industry has been the use of succinic acid as a raw material for bio-based plastics. In collaboration with a US company we have now developed a production process for this. Following successful trials on a pilot plant in Mexico, the world’s first industrial-scale biotechnology succinic acid plant is now being built in Louisiana/USA. Start-up is scheduled for late 2012. Increasingly efficient gearless conveyor systems With demands on conveyor systems for open pit mines rising all the time, conventional gear units are reaching their limits. Ever greater mining depths and increasing volumes call for longer, steeper and more powerful belt conveyors. For one of our customers we have now developed a gearless drive station for a 6.5 km conveyor system. ThyssenKrupp is the world’s only supplier of conveyors with such high-power direct drives. They offer great dependability, low-cost maintenance and high energy efficiency. In future development projects we will standardize the drive stations, modularize them and further optimize their design. More than €500 million for research and development In 2010/2011 we spent €524 million on product, process and service innovations. Of this, research and development costs of €188 million were expensed immediately, €39 million was amortization of development costs capitalized in previous years, and €297 million was for order-related development costs. Expenditure for research and development was thus 19% higher than a year earlier, with particular increases in order-related development in the areas of “Mechanical” and “Plant”.
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Annual Report 2010/2011 At the cent
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