THE MOOD IS UPBEAT AND NO END IN SIGHT - Rheinmetall Automotive
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www.kspg.com The magazine of the KSPG Group ISSUE 01/2015 SLOWING DOWN ON TWO WHEELS Manfred Mäules’s heart belongs to an old Harley SPORT IS THE DRIVING FORCE Sponsoring and health management at KSPG // THE MOOD IS PBEAT AND NO U END IN SIGHT China’s booming market A Rheinmetall Company
EDITORIAL/CONTENTS // CONTENTS PASSIONATE WILD WORLD OF ENGINES NEWS FROM KSPG DEVELOPERS 4 8 Day by day our developers are busy working Inspiration in steel By gondola over the The latest news from the company on products that reduce emissions and con- Nervión—the Vizcaya Bridge in Bilbao sumption, prolong engine life and help shed vehicle weight. This passion for details, precision FOCUS and perfection is an essential aspect of our success story that stretches back over a century. Yet we don’t want to simply rest on our laurels. 10 Autonomous driving, alternative propulsion systems, networking, downsizing: terms that THE MOOD IS UPBEAT AND 26 20 years ago seemed rather utopian, has now become reality. KSPG is already represented in a multitude of vehicles with alternative types NO END IN SIGHT 34 4 of propulsion. These components are also China’s booming market A test drive with Olaf Hedden Head of relevant for the Chinese market. In China, too, KSPG’s Mechatronics division which has the world’s steepest growth rates, efficient and eco-friendly solutions are much in demand. In discussing China, the main topic 37 of this issue, we are taking a look at these. It pays to hit the books A voyage of Heartbeat is presenting to you people from discovery in the Far East various parts of KSPG such as basketball “giant” Marvin Kruchen and Pierburg CEO “test driver” Olaf Hedden. And you will learn more about our TECHNOLOGY PEOPLE GOOD TO KNOW social and local community commitments in the article about our sponsoring activities. 16 22 38 Enjoy your read! New generation of plain bearing Milliseconds for cleaner air In China, A megacity with a traditional soul partners: metal and polymer Marriage PhD student Yintong Liu is researching Shanghai—from tiny fishing village to of convenience into more efficient and cleaner engines teeming metropolis Peter Hartung 18 26 Senior Vice President Inside StreetScooter KSPG technology Slowing down on two wheels Manfred Corporate Communications helps deliver letters and parcels Mäules’s heart belongs to an old Harley with the battery-powered StreetScooter // IMPRINT 30 Published by: KSPG AG—A Rheinmetall Company HIGHLIGHTS From dribbling to controlling Karl-Schmidt-Strasse, D-74172 Neckarsulm, www.kspg.com Responsible: Peter Hartung, Folke Heyer Marvin Kruchen talks about discipline Edited by: Folke Heyer, Marco Kittel, Markus Koch, Philipp Mattheis, Bernhard Schenk, Stefan Schlott, 20 and team spirit 10 Ulrike Volkmann, Stefanie Wesslein Innovations by Kolbenschmidt and 32 34 Implementation: RTS Rieger Team Werbeagentur GmbH, Pierburg Publik. Agentur für Kommunikation GmbH Picture Credits: KSPG, Getty Images, Shutterstock, Sport is the driving force Sponsoring StreetScooter GmbH/Deutsche Post DHL, Team AutoArenA Motorsport, Dwight Cendrowski, Memo Filiz, and health management at KSPG Kay Herschelmann, Karl-Heinz Leitz, Hartmut Oehmen, Giovanni Perna, Michael Rennertz, Jan Siefke, Private 2 HEARTBEAT 3
WILD WORLD OF ENGINES // INSPIRATION IN STEEL By gondola over the Nervión—the Vizcaya Bridge in Bilbao Because of its spectacular esthetics and trend- setting technology, UNESCO added it to the World Cultural Heritage list on July 13, 2006. 4 HEARTBEAT 5
Steel frame structure modeled on the Eiffel Tower in Paris. The architect Palacio was a student of renowned Gustave Eiffel. You never know where you’re going The task facing architect Alberto de towers supporting the two ends of a 160 m fully integrated in the city’s transport system Palacio y Elissague was anything but simple. long girder truss. Suspended from it on steel and saves travelers a 20 km detour on the to find drives next. In this case, a It was his job to join the Bilbao communities ropes is a gondola that crosses the river freeway. The gondola carrying up to six cars of Portugalete and Getxo separated by the without disrupting passing ships. This stroke and 200 foot passengers runs at 8 minute remarkable twelve motors can be found Nervión River that meanders from the interior of genius served as a model worldwide and intervals, with a trip costing 35 cents. The of the country into the Bay of Biscay. While stimulated a boom in Spanish technology gondola was originally driven by a steam in a UNESCO World Cultural Heritage serving as an important traffic link in the abroad. The Bizkaiko Zubia, as it is known engine, but today the required power comes city, the bridge was not to disrupt shipping. in Basque, has been the inspiration for 20 from twelve electric motors. A few years back, monument—making it one you can not Long approach ramps that would scar the such bridges in Africa, America and Europe. the bridge operator introduced a new attrac- townscape were also out of the question. tion when the panorama footbridge via the only admire, but also ride on. To the But the Basque architect solved the problem Beautiful and functional girder truss was opened by former King Juan with bravura. As a student of the famous The Vizcaya Bridge was justifiably included Carlos and his wife Sophia in 1999. Those joy of locals and tourists, the Vizcaya Gustave Eiffel, he was fully conversant with in the UNESCO World Cultural Heritage list with a head for heights take an elevator up the construction of steel frames. Palacio’s in 2006 and is Bilbao’s pride and joy. It is the tower to the walkway across the steel Bridge in Bilbao is still going strong masterpiece, the world’s first transporter important for Bilbao’s population not only as girder truss. Ideal for enjoying the sunset over bridge, was officially opened in 1893. On the a cultural monument, but also as a means the city and its port or for looking down at 122 years after its construction. shores of the Nervión stand 45 m tall steel of transport. The bridge, even today, is still passing ships from a breath-taking height. The gondola and the steel rope system make it possible to carry a weight of up to 22 t across the river. UNESCO WORLD CULTURAL HERITAGE 6 HEARTBEAT
NEWS FROM KSPG PERSONNEL PRODUCTION UP AND RUNNING AT THE NEW PIERBURG PLANT 16,500 KS Gleitlager sqm KS GLEITLAGER GMBH KSSP UNDER NEW MANAGEMENT IN CHINA BUILDS NEW factory in Supa PLANT IN INDIA Over 100 languages, 23 of them official The plain bearings unit, KS Gleitlager, is setting up a new modern plant this year Since March 1, Ralf Buschbeck has been General Manager at Kolbenschmidt in Supa, India, some 75 km to the east of Shanghai Piston (KSSP) in Shanghai, Pune, population of around 3 million, in the China. He succeeds Wen Jiang who Production at the new Pierburg plant in Neuss has started up successfully federal state of Maharashtra. The foundation is taking on new responsibilities for the 1.252 and meanwhile almost all of the employees from the previous Neuss and stone was laid on January 28 and before the future organization of the China orga- Nettetal plants have migrated here. The move will have been completed end of the year it is planned to complete nization of the KSPG Group. Previously, mid-2015. After a construction period of only 1 year and starting from the billion construction of the 16,500 m² factory. Em- Buschbeck had been in charge of Prod- spring of 2014, the production machinery from Neuss and Nettetal was people in India ployees and equipment from the previous uct and Technology Development of the shipped step by step to the new Lower Rhine plant to be reinstalled. Con- plant in Ahmednagar, located not far away, Pistons division with R&D locations in currently, the ultramodern high-bay warehouse was commissioned. Next will then move into the new premises. This Japan, China, Germany, USA, and Brazil. on the movers’ list was the finish-machining shop. Right from the planning ultramodern production facility will allow KSSP is a 50/50 joint venture between phase of the construction project Pierburg had set its sights on certifica- KS Gleitlager to re-emphasize its presence KS Kolbenschmidt GmbH and HUAYU Au- tion to DGNB Silver (German Sustainable Building Council). This latter sets on the important growth market of India. tomotive Systems Co., Ltd. The company stringent criteria when awarding its certificates and Lower Rhine is very was established in 1997. Annual ship- likely the first production plant with a foundry to have received certification. ments this year will be around 27 million piston modules. REWARDS FOR QUALITY EXCELLENCE MORE SPACE AT NEUENSTADT BY PIERBURG DIETER SCHADENBERGER Pierburg, the KSPG Group’s Mechatronics suppliers. Pierburg’s pump plant in Hartha, Motorservice’s Neuenstadt location is busy building: the present offices division, is doubly happy to have received Saxony, likewise has reason to be proud of MOVES TO SHANGHAI are being topped up to add space for 30 new jobs. The Logistics depart- two customer awards. The Czech plant, having pocketed the coveted Ford Q1 Award. ment is also being remodeled: a new automated small-parts warehouse Pierburg, s.r.o., was recently presented the Presented annually since 1981, this is Ford’s is designed to shorten the order-picking times, allow more efficient space General Motors Supplier Quality Excellence highest recognition and appreciation of utilization and generally leaner logistics processes. Work on the office Award for exceptional product and delivery supplier quality. Pierburg Hartha thus joins building started in March, completion is scheduled for October. The con- quality of its solenoid valves, exhaust-gas the US plant in Fountain Inn/South Carolina, struction of the new warehouse will begin in September and the building flaps, and secondary-air pumps. This was the Mexican piston and pump plant in Cel- will be up and running as from January 2016. the third time that the Supplier Quality aya and KSPG in India among those having KSPG AND HASCO: Excellence Award has gone to outstanding earned this prestigious distinction. JOINT VENTURE NOW LEGALLY CONSUMMATED Since March 1, Dieter Schadenberger has stepped into the position of Director Following the signing of the agreement between KSPG Finance and Controlling (CFO) at Kolben- and HUAYU Automotive Systems Co., Ltd. (HASCO), a schmidt Shanghai Piston (KSSP). Previ- member of China’s SAIC Group, the o.k. to the venture ously he had been CFO at the Castings has now been given by the relevant cartel authorities division and on the Management Board and hence the transaction was legally consummated. of KS HUAYU AluTech GmbH, a Joint Each party has a 50-percent stake in the new company Venture between KSPG AG und HUAYU whose name is KS HUAYU AluTech GmbH and in Automotive Systems Co., Ltd. (HASCO) Werkzeugbau Walldürn GmbH, which belongs to it, which is majority owned by the Chinese as well as in the 50-percent stake in the joint venture SAIC Group. Since 2005, Schadenberger KS ATAG TRIMET Guss GmbH. has served in various positions at the KSPG Group. 8 HEARTBEAT 9
FOCUS The Chinese automobile market has kept the industry on the edge of its seat for several years // THE MOOD now. Dynamism and double-digit growth are its twin hallmarks. For KSPG, too, investing in China has long since paid off. Last year alone, sales jumped by 30 percent, well above the industry average. IS UPBEAT When it comes to the Chinese auto mar- ket, journalists, commentators and analysts understandably turn to superlatives. They call it the engine of growth for the entire Volkswagen Automotive Company Ltd. (SVW) paved the way for motorizing Chinese society. Until then, the bicycle ruled the road in China. Then came a period when AND NO END industry, the world’s most important car car buyers in China had a choice between a market—and a profit-spinner for the German VW Santana and a VW Santana. automotive sector. And the numbers cer- tainly support these statements. “Auto IN RAPID SUCCESSION, motive sales in China went into high gear: 2013 over 16 million new cars were sold in AUTOMAKERS AND the People’s Republic—weaker economic PARTS SUPPLIERS growth notwithstanding, car sales in China IN SIGHT rose by a brisk 23 percent, making it the HAVE BEEN REPORTING world’s largest single market in terms of RECORD FIGURES volume”, writes the German Association of the Automotive Industry (VDA) in its latest The pioneering success of SVW did not go “Markt international” analysis. Based on unnoticed. Before long, flights between preliminary figures, sales in 2014 are sup- Chinese cities and western centers of the posed to have reached 18.4 million units, auto industry were booked solid. One after while the forecast for this year points to a another, original equipment makers and further increase approaching 20 million. their suppliers announced new joint ven- In order to comprehend the dynamic expan- tures, plant openings—and record-breaking China’s booming market sion of the automotive industry in China, figures. By the turn of the century, the former it’s important to look at recent history. It bastion of the bicycle had wholeheartedly was only 31 years ago in 1984 that China embraced the automobile, its roads suddenly began to open up and reform its economy. crowded, hectic and loud. Frenetic honking, The founding of the joint venture Shanghai- lane changing without signaling, passing 10 HEARTBEAT 11
KSPG IN CHINA PRODUCTION: Pistons, exhaust gas recycling valves, throttle valves, coolant and oil pumps, cylinder heads TOTAL SALES*: for cars**, aluminum structural parts and engine blocks €680 MILLION ** largest producer in China * joint ventures at 100% NUMBER OF LOCATIONS: 9 (joint ventures and wholly owned subsidiaries) RATE OF GROWTH, PRESENT IN THE MARKET YEAR ON YEAR: +30% SINCE THE ’80s wherever there’s room, and countless pe- of rapidly multiplying mega traffic jams and In addition, with incomes on the rise and car destrians in the middle of the road are now a road system that’s often groaning under density still lower, new automobile sales are par for the course in China—all of which can the strain. At the very least, this is certainly being driven by increased demand in C hina’s be quite a shock for western visitors. The at true of the metropolises in the country’s cities of the third and fourth rank. Many times anarchic free-for-all on the highways of northeast. In the meantime, the regional observers compare modern China to West the People’s Republic is a result of China’s authorities there are attempting to get a grip Germany in the ’50s and ’60s: a self-con- car ownership boom, which is unparalleled on the situation by introducing limits on new sciously hard-working, dynamic, ambitious, anywhere and shows no sign of slowing. car registrations, etc. China’s automotive in- highly motivated nation with rising aspira- company took the daring step of cooperating owned subsidiary of Shanghai Automo- bsolescent technologies with low value o Indeed, in 2015 the desire to own a car is as dustry is currently experiencing a shift in its tions. In post-war Germany, too, consumers with a Chinese partner, Shanghai Piston tive Industry Corporation (SAIC), to set up added, including simple die cast compo- strong as ever in China—this despite reports center of gravity toward the south and west. were initially happy with vehicles like the Factory. At the start of 1989, a complete the joint venture Kolbenschmidt Pierburg nents and intake manifolds, focusing instead Messerschmitt Kabinenroller, the Opel piston manufacturing facility was shipped Shanghai Nonferrous Components (KPSNC). on future-oriented products such as pres- Laubfrosch or the Goggomobil, which at least to China, where it was installed in a newly KPSNC develops, produces and markets sure-cast aluminum engine blocks, alumi- provided them with individual mobility. built plant in Shanghai. Pierburg too secured suction modules, cylinder heads, steering num wheel rims, structural and chassis parts a foothold in China by moving an entire components as well as complete oil and along with other advanced components. KSPG HAS BEEN factory there: when European emission water pumps. This period also witnessed KSPG’s endow- regulations put an end to the carburetor era ment of a professorial chair for automotive ACTIVE IN CHINA in Germany, it found a new lease on life in Sales double in the space of a few years technology at Tongji University in Shanghai, SINCE THE ’80s China. The People’s Republic entered into In this phase of the Group’s entry into China, whose current incumbent is the long serving an agreement with state-owned automaker which lasted until the start of 2005, the main vice dean of the Institute for Mechanical As car ownership gradually became some- First Automobile Works (FAW) for the sale of challenge was to get production up and Engineering, Prof. Dr. Liguang Li (see short thing to take for granted, expectations rose large-scale series production equipment for running and to create structures. Moreover, interview). Establishing two wholly owned with regard to dependability, performance 2E carburetors, which were supplied to FAW the first employees had to be initiated into subsidiaries in China was another aspect of and comfort. In the phase that followed, in Changchun at the end of 1992. Five years KSPG’s culture of quality. The reward for the second of phase of KSPG’s entry into the the focus shifted to safety as well as fuel later, things really took off. Partnering with these efforts: in 2005 the two new joint ven- Chinese market. MS Motor Service Shang- efficiency and lower emissions, though Deutsche Entwicklungsgesellschaft (DEG, tures generated sales of € 80 million. Eager hai Trading Co. Ltd., the first wholly owned consumers also expected to see simultane- the German Development and Investment to build on this, between 2005 and 2009 subsidiary of KSPG AG in China, was founded ous improvements in other areas. Against Corporation) and the previous licensee, KSPG continued to invest in further growth. in 2008, emerging from the Representative this backdrop, it is easy to understand how Shanghai Piston Works (SPW), in July 1997 At the same time, it became necessary to Office established in 2007 in the free trade KSPG – with its comprehensive array of Kolbenschmidt became the first major piston automate parts of the production process in zone in northeast Shanghai. The following lightweight parts and emission reduction producer to be present in China in a joint order to boost output. The creation of new year saw the creation of Pierburg China Ltd. solutions – has been so successful in China. venture. In 2001 Pierburg followed suit and production capacities went hand in hand in Kunshan. A further glance at the num- As early as the second half of the ’80s, joined forces with Shanghai Automobile with changes in the product range. The joint bers reveals just how quickly investments management of the then-Kolbenschmidt Nonferrous Casting Plant (SANCP), a wholly venture partners jettisoned obsolete and in China can pay off. By 2009, sales had The secret of KSPG’s success in the Middle Kingdom: our people. 12 HEARTBEAT 13
Increasingly significant: Components for reducing emissions are becoming more and more important in the Chinese market. Inquired! and other market factors are the large // Is the implementation of connected financial incentives from both central and cars or autonomous driving systems also local government. Nonetheless, invest- being discussed in your country? ments are tied to heavy financial risks as This is a hot topic in China and lots of batteries and related areas are attracting research institutes, universities and large sums of money, especially since OEM’s Research & Development Centers the Internet companies are planning and are involved in this topic and research actually investing in this area. Because programs. Some of the research over the reached €160 million, double the figure for dedicated to manufacturing and marketing of the challenges posed by the driving next 5 to 10 years is focusing on various 2005. Events continue to proceed apace. pumps. In order to create customer-specific distances and the high costs involved it product dimensions and levels. However, After 2009, the Group pursued a policy of applications on location, this joint venture is is hard to forecast the BEV market over these are subjects of very high safety consolidating what it had already achieved, also equipped with a test bed and prototype the next five years. Financial support from concern and at present there are no cor- widening its lead, diversifying its product center for developing new applications. government will stop in 2020 and so the responding laws, either in China or else- range and building new plants—all aimed at next five years will be critical in showing where in the world. So, before discussing further strengthening its powerful position KSPG LEADS THE WAY whether BEVs can survive without govern- any relevant legislation it is hard to say in the market. As part of this strategy, at the ment aid. when and how this technology will be end of 2012 the Group opened KSPG House IN CHINA IN LIGHT- applied. If and when it is, it will certainly in Shanghai, which serves as the head office WEIGHT ENGINEERING // What about fuel-cell cars compared lead to another revolution in automobile for its wholly owned Chinese subsidiaries and Prof. Ph.D. Liguang Li to BEVs in China? driving mode. as an initial point of contact for all customers In November 2013 a new large pistons factory used for casting and processing aluminum Executive Vice Dean, College of Mechanical At present there is no sign of FCVs Engineering, Tongji University in China. In 2013 a new production facility went into operation at Shanghai. And in engine blocks and cylinder heads, which entering the market before 2020. FCVs was built for Pierburg China Ltd., which March 2014 the Group’s longstanding already takes place at its sister plant across face many more challenges even though produces pneumatic pumps, electric throttle cooperation with SAIC subsidiary HASCO the street, or at facilities in Waigang, Toyota has launched such vehicles valves and magnetic valves. A few months expanded to include another new produc- Kunshan and Yantai. This plant marks the // What are China’s major emission- onto the market. There is a shortage of later, another plant followed—a joint venture tion facility. The new plant won’t just be launch of a new product segment in the reduction challenges? hydrogen supply and other infrastructure increasingly important field of lightweight For passenger cars, to comply with Euro 6 facilities and so these cars will not be automotive engineering. In the future, alumi- or newer regulations by 2018 or later. The among the market players before about num structural components will be cast and biggest challenge, however, is to arrive at 2025. Later by 2030 or 2050, they may processed here for the Chinese automobile a fuel consumption goal of 5 L/100 km by become reality depending on CO2 limits industry. “This makes us one of the first 2020. Regarding commercial vehicles, a and adequate supplies of low-price H2. companies in China to offer our customers severe challenge will be to meet Euro 5 or additional weight-saving potential in auto- newer emission control limits. mobile design thanks to this forward-looking approach, which in turn helps to protect // What is the present market situation the environment”, declared Horst Binnig, for hybrid propulsion systems in passen- Chairman of the Executive Board of KSPG ger cars in China? at the opening ceremony, underscoring the Because of consumption reduction pres- importance of the new facility. sure future production will increasingly feature hybrid propulsion—from mild Cooperation benefits Europe, too hybrid with start/stop to plug-in systems. Incidentally, early commitment and a HEV will become more popular over the sound working relationship with Chinese next decade. partners have benefitted KSPG outside of China as well. At the Group’s headquarters // Do you see a relevant market for in Neckarsulm, Germany, a joint venture battery electric vehicles (BEVs) in China company was founded in summer 2014 with within the next five years? its longstanding partner HASCO. The mutual It is very hard to predict the market for goal of the two partners, each of which has BEVs in China in the next five years. In an equal stake in the new company, is to 2014, there were about 37,500 p assenger promote the current positive trend in cast and bus BEVs produced plus other By Stefan Schlott lightweight automotive components on an low-speed micro passenger BEVs with enduring global basis. Global in this context lead-acid batteries, giving a total of doesn’t just mean China and Germany, but some 183,000 in the Shandong province. all relevant triad markets. Driving distances are still an issue there 14 HEARTBEAT 15
TECHNOLOGY //NEW GENERATION OF PLAIN BEARING PARTNERS: METAL Friction reduction across the entire engine speed range AND POLYMER Among the prime objectives in the devel- opment of KS R55Q was to reduce crank- shaft-related friction and wear. Especially low engine speeds and low-viscosity oils lead to critical mixed-friction conditions while new operating strategies for cutting back fuel consumption considerably in- Marriage of convenience crease the number of start/stop cycles com- pared with conventional modes. Counteract- ing these are the wear-abating fillers of the polymer layer combined with the high wear resilience of the bearing metal. The special Until now bi-material bearing metals were largely left feature of the new generation of bearings is, however, that this friction-reducing to themselves but on the new plain bearing generation effect is not limited to lower engine speeds. “We are especially proud that despite the KS R55Q, metal and polymer act as the perfect couple. polymer layer we have been able to retain the hydrodynamically advantageous grooved With the new technology from Kolbenschmidt engines run texture of the spindled contact surface,” A closer look reveals a high-tech product. emphasizes Jens Reepmeyer, project engi- more efficiently and CO2 emissions are reduced. It may not be easy to see, but plain bearings are the product of a massive R&D effort and neer who has introduced the new coating technology at Kolbenschmidt. “Even at low state-of-the-art manufacturing techniques. engine speeds we can now ensure minimum hydrodynamic losses.” Lowering average CO2 emissions in metal and hence the counterpart to the 20 percent added resilience their car fleets to 95 g/km by 2020 is a shaft,” explains Dr. Klaus Pucher, head of “The bearing metal we use is our own propri- THE CONTACT SUR- prime objective of European automakers. R&D at KS Gleitlager GmbH. Steel back in g etary silicon-enriched aluminum alloy that FACE HAS BEEN IN To achieve this, they are moving in various is both highly resilient and extremely wear directions with regard to engine technolo- AISnSi be resistant,” says Pucher. Sprayed onto this SERIES PRODUCTION gy: from downsizing and the use of lower ADAPTABILITY, aring met al is a layer of polymer made up of a tempera- SINCE MID-2014 AND and lower viscosity oils and employing WEAR RESISTANCE AND, Polymer contact ture- and fluid-resistant polyamide resin MARKET RESPONSE new running strategies such as start/stop surface comprising a generous proportion of fillers and cruising, right through to fully hybrid AT THE SAME TIME, for reducing friction and wear. To this end, HAS BEEN GOOD power trains. The crankshaft main bearings THE ABILITY TO AB- Kolbenschmidt applies a special coating and the connecting rod bearings play an process whose precision largely determines Because of its high resilience, wear resis- important role in this context. Thanks to SORB PUNISHMENT— optimum bearing functions within the en- tance and ruggedness it is now being tried the KS R55Q, its new generation of plain THESE ARE THREE gine. “The outcome of this marriage of metal out on light- to medium-duty commercial bearings, Kolbenschmidt is helping OEMs and polymer: 20 percent greater resilience vehicle engines. Pucher identifies vast move closer to achieving the new CO2 limits. VERY CONTRASTING over conventional bi-material bearings. A big potential for polymer layers on engine plain “Until now aluminum alloys have mainly REQUIREMENTS step in the right direction since the added bearings. “Our aim is to develop further been used on bi-material bearings as the resilience helps our customers both in their products on the basis of the technology first bearing or contact metal. Since the steel Kolbenschmidt’s answer is to give KS R55Q systematic downsizing efforts and in dimen- used on the KS R55Q to allow customers backing simply serves as the seat within the an extra polymer contact surface so that the Current plant capacity sioning for optimum friction effect both the to maximize engine efficiency and perfor- housing, it is left to the aluminum alloy to bearing metal and the polymer layer can take main and connecting rod bearings,” says the mance, ideally merging the two on future do all the work, acting as the anti-friction over complementary functions. per year: Head of R&D. engine generations!” 16 HEARTBEAT 6 million units 17
TECHNOLOGY ment services provider, FEV GmbH, is (as yet) powered by a 2-cylinder gasoline engine in V design which is installed as a pre-assem- bled module. This makes it relatively easy to be integrated via just a few interfaces into StreetScooter Work and other vehicles of this type. The extender also permits installation of a smaller, less costly lithium-ion battery. Battery powered with extended range. The universally installable unit reduces battery costs and size while adapting readily DEVELOPMENT WORK to any operating mode. GOES ON: THE RANGE EXTENDER WILL SOON Easy on nature and easy to operate: letters and parcels If the term “scooter” conjures up the delivery. Deutsche Post DHL had commis- BE RUNNING ON // INSIDE delivered by electric vehicle and bicycle. funfair you’re not far off. Amusement park sioned the Aachen-based engineers to BIOGAS METHANE rides normally use electric autos and the develop a compact battery electric vehicle StreetScooter fleet is battery powered when for delivering letters and parcels. Job de- As part of a combined Green Rex project, working as a mail and package carrier. The scription: on duty up to 300 days a year, up KSPG and FEV have joined up with the inventor is StreetScooter GmbH, a spin-off to 200 stop/re-start cycles a day, enough research institute Fraunhofer ICT to develop STREETSCOOTER from a project at RWTH Aachen university loading space, robust, and safe. Meanwhile a natural-gas powered range extender that headed by Prof. Dr.-.Ing. Achim Kampker. over 50 StreetScooter Work units are on de- made its debut at the commercial vehicle Since mid-2010, the ingenious innovators livery duty throughout Germany. At the start fair IAA Hannover in 2014. A power unit that have been re-inventing urban mobility and of 2015, the Aachen-based company was uses biogas methane instead of normal come up with a unique vehicular concept: taken over by Deutsche Post DHL.During the fuel, is likely (when) to undergo testing in reasonably priced electric vehicles engi- design phase, not just environmental crite- StreetScooter Work—one more step toward a neered around an eco-friendly propulsion ria were taken into account, but economic lightweight commercial vehicle run on purely system. factors as well. This led the designers to regenerative resources. KSPG technology helps deliver letters and parcels opt for a modular lightweight construction ELECTRIC, ENTER to serve as the basis for the functional Efficient heating and cooling with the battery-powered StreetScooter PRISING, EFFICIENT: architecture, from which individually de- signed model variations could be derived in Likewise engineered as a compact plug-and- play system is the heater/cooler module STREETSCOOTER an easy, cost-efficient manner. The flexible being tested by KSPG and a number of design also allows damaged parts to be customers. The innovation here is that Among the vehicles being used by Germany’s parcel service Deutsche Post WORK IS THE COMPACT inexpensively replaced, while minimizing existing equipment such as the propulsion SOLUTION FOR service and maintenance costs. unit and generator acts as heat sources. In DHL on urban services in the city of Bonn is a transporter from Aachener HAULAGE DISTANCES summer, the module has a cooling effect Greater range thanks to KSPG and serves as a comfortable air conditioner. StreetScooter GmbH which has engineered its own version of electric- OF UP TO 80 KM There was still the mileage challenge and Its high energy efficiency spares the battery in order to further prolong the distances trav- and helps StreetScooter Work carry its letters propulsion vehicle. Combined with range extender unit and thermo module The transporter version of the StreetScooter elled between recharging, a range extender and parcels to their destinations, quietly fleet is named Work and that’s just what it will in future be installed. The extender, a humming to itself. The extended range is from KSPG the scooter’s range before recharging will become even greater. does: act as a tool for “last mile” doorstep joint effort between KSPG and the develop- now 80 km. 18 HEARTBEAT 19
HIGHLIGHTS USA: COMPACT EGR VALVE FOR GASOLINE ENGINES 75 MILLION EGR VALVES TO GO INTO SERIES PRODUCTION FROM THE BASQUE COUNTRY Pierburg, international leader in the market in the ongoing reduction of engine compart- The end of 2014 saw the 75 millionth exhaust- and this is made possible with the specially for diesel engine EGR systems, has devel- ment space on present engine series. The gas recirculating valve (EGR) exiting the developed low-pressure EGR valves. Pierburg oped a compact EGR valve which can also compact EGR valve is operated by a geared assembly line at Pierburg S.A. in Abadiano, has a varied product lineup to achieve further be used on gasoline engines. Starting from DC motor and has a contactless Hall sensor Spain. Fueling the success of this emis- emission and consumption reduction on 2016 it will be built at Pierburg’s South for detecting valve position. Depending on sion-abating component have been the present and future I.C. engines. Pierburg’s Carolina facility for delivery to a notable US customer wishes, it may feature electro- worldwide ever stricter emission stan- newest model is an especially compact, OEM. Ever since the early ’80s, exhaust-gas magnetic protection and integrated water dards. As from Euro 4, cooled recirculating low-weight product and since 2013 has been recirculation valves have been employed cooling. It is available in standalone, plug-in exhaust gases have become increasingly used on series-production models of a major chiefly for emission control on diesel en- as well as fully integrated cooler module necessary and for this purpose Pierburg German OEM. gines. Given their incremental fuel-savings versions. The newly developed module will has come up with complete EGR modules potential they are now also increasingly enable Pierburg to further expand its posi- combining outstanding and lasting cooling being adopted on and adapted to gasoline tion on the North American market. performance with compact dimensions. engines. With its relatively compact foot- With the advent of Euro 6 an even higher print, the newly developed valve plays a role rate of exhaust-gas recirculation is required LARGE ORDER FOR TANDEM PUMPS KSPG has been awarded by a notable US auto- maker a series contract worth triple-digit million dollars for a combined oil and vacuum (tandem) pump. The pump is due to go into series produc- Size comparison of old and tion at the start of 2015 at Pierburg’s Mexican new generation valves plant at Celaya. This innovative product allows fuel savings and reduced CO2 emissions. Both the oil and vacuum pump as well as the related drive components are engineered for especially COPPER FOR quiet operation. Another advantage of this de- sign is the compact footprint which more readily DRINKING WATER allows installation where space is tight. The SYSTEMS vacuum pump permits parallel activation of two circuits with differing levels of pressure. A sole- Under the banner “Your Strong Supplier for noid valve specifically developed by Pierburg for Drinking Water Systems” KS Gleitlager GmbH Front: hydraulic applications is used for controlling exhibited mid-March at ISH, the world’s new 5th generation the oil pump and allows it to operate according leading trade fair for the Bathroom Experience, compact valve to two performance curves. Building, Energy, Air-conditioning Technolo- gy, and Renewable Energies, proven copper alloys as well as leadfree options for drinking ANOTHER CAUSE FOR CELEBRATION: water systems. Included was the leadfree 25 MILLION DIVERT-AIR VALVES alloy Ecocast which the manufacturer has Back: been the first in Europe to industrialize with 4th generation valve One more record at the start of 2015, this time a record number of the continuous casting p rocess. The alloy has divert-air valves, altogether 25 million, so far shipped out to customers. been marketed since 2013 under license from Back in 2004 Pierburg was the first in the world to commence series Wieland-Werke AG and is included on the production of a wholly new electric divert-air valve. On turbocharged official recommendation list for drinking water engines this device is indispensable in preventing unnecessary turbo systems of Germany’s Environmental Agency. charger braking when the throttle suddenly closes and hence reducing On its Frankfurt fair stand the company also “turbo lag.” Divert-air valves are a standard product used by almost displayed round and hollow bars and rods, all the notable OEMs. Because of the downsizing trend, which has been hexagonal and octagonal sections plus special going on for years now, there is a rising demand for valves coupled with shapes all continuously cast. Shown alongside the need to repeatedly adapt to more and more sophisticated challenges. these were finished customer products. With its just developed fifth generation Pierburg is fit for the future. 20 HEARTBEAT 21
PEOPLE // MILLISECONDS FOR CLEANER AIR In China, Ph.D. candidate Yintong Liu is investigating ways In China’s megacities, traffic is in creasing exponentially and air pollution of making engines cleaner and more efficient is one of the biggest problems. This makes the need for efficient, low-emission engines especially urgent. Yintong Liu’s life currently takes place behind armored glass. Not far from Shanghai and its multi-million population, for Liu everything revolves around his engine test bench and the goal of perfecting the gasoline engine. I’VE BEEN WORK- At renowned Tongji University he is important, more and more companies are ING IN RESEARCH carrying out experiments on a futuristic setting up their own R&D centers in China. experimental engine fitted out with a host of In fact, it is in R&D the Liu sees his personal FOR THE PAST colored measuring wires and cables. On the future. “For seven years now I have been surface of the cylinder head cover are the looking into this subject,” he says. “This is SEVEN YEARS words “Pierburg UniValve” and “Tongji-Uni- what I would like to go on doing.” versität.” Together with Pierburg of Neuss, Germany, Liu has developed an engine with The KSPG workforce: more than 4,000 strong a mechanical, fully variable valve train, which China is booming. For 20 years now the is dotted with dozens of sensors and fitted economy of this vast nation has been with the very latest instrumentation, now expanding at a rate of almost ten percent being meticulously fine-tuned and measured annually. This growth has allowed millions for performance here in China. Separated by of Chinese to enjoy a life of new prosperi- the protective screen and within reaching ty. More and more foreign companies are distance of the engine, Liu is seated at his investing in this market—especially carmak- computer and noting the latest measure- ers, closely followed by their component ments. Carefully he modifies certain of the suppliers. In 1997, KSPG opened its first valve train parameters and observes how plant in China, followed by many others, output, torque, consumption and emissions mostly around Shanghai, one of the nation’s move up and down. Analyzing and refining biggest business centers. KSPG has a this innovative valve train is the subject mat- workforce of over 4,000 in China. Sales in ter of the 28-year-old’s doctoral dissertation. 2014 exceeded €650 million. Yet not all aspects of development in the country are Car ownership in China is still surging keeping pace with this rapid growth. Many The relatively new Jiading campus of Tongji companies complain about a lack of trained University is a good one-hour drive by car from and skilled employees. Resourceful firms the 23 million-strong metropolis of Shanghai. are therefore training their own people. In The route stretches along a brand new high- fact, there are already promising signs that way. The cars are almost all new: BMWs, VWs, Chinese apprentices are being trained in Chinese-German College for Postgraduate and Audis. With its burgeoning middle class, accordance with Germany’s Dual System, Studies, a cooperative venture between the this vast nation has become one of the most while professorships jointly sponsored by German Academic Exchange Service and important buyers of German cars. In 2014, German companies and Chinese universi- Tongji University. The long-serving executive more than 20 million light vehicles were sold ties are also being established. Since 2007, vice dean of the Tongji College of Mechanical With its striking architecture, the Jiading Campus of in China, and each year it will be even more. KSPG has been funding one such project, Engineering, Prof. Ph.D. Liguang Li, holds the Tongji University is Yintong Liu’s academic home. Because this market is becoming increasingly which is organized under the aegis of the Chair of Automotive Engine Technology. 22 HEARTBEAT 23
swimming pool is just being built. But Liu was German cuisine that he enjoyed most. very tight in China. Being able to care for has little time for sports at present, as he is “I love sausages in curry sauce,” he says. one’s parents is something that many young too busy with the project. “Normally I play And yet there can hardly be a cuisine more Chinese value highly. With annual growth basketball and table tennis but right now different from the German than that of his in China still running at 7 percent, Liu will the dissertation enjoys priority.” Part of home region. The province of Sichuan, certainly be needed in an economy where his work is done in an open-plan office in where Liu is from, is noted and notorious for skilled employees are in short supply. SOMETIMES I SPEND the neighboring building. This is where the its hot and spicy dishes. But that’s not all. More efficient and cleaner measurements are analyzed and summa- engines are urgently need in China, too. TEN OR MORE HOURS rized in writing. Liu hopes to have completed Family is still very important. On this late wintry afternoon, through the the measurements in two months from now. Back in China, he spends his precious time murky air the reddish sun is setting. Shang- IN THE LAB Then comes the written work. “If all goes off with his girlfriend, who lives in Pudong, hai, too, suffers from severe air pollution smoothly, I’ll have finished the project by a newly developed district of Shanghai, at and more efficient engines are an important the summer of this year,” he says. the other end of the city. To see her he has to way to combat this. drive for at least ninety minutes. Just like Liu, A love of the famous German “currywurst” she comes from Chongqing and works in the For seven years now Liu has lived and auto industry. Liu’s parents still live there. engaged in research here. He spent the first He visits them twice a year. The boom that three years of his studies in Mechanical began in China’s big east coast cities some Engineering on another campus in the city 20 years ago is gradually spilling over into center, before moving on to the Anting cam- the interior of the country. With a popula- pus close to the Volkswagen plant for his tion of 30 million, Chongqing—depending master’s degree. For two years now he has on what you include—ranks as the world’s been working on his Ph.D. The cooperation most populous city, and is already experi- IN THE LONG RUN, agreement existing between the university encing the boom. More and more foreign and KSPG allowed him to spend a 12-month companies are moving into the mega- I’D LIKE TO LIVE AUTOMOBILE MARKET research stay in Germany in 2013, where he metropolis and the surrounding province of IN CHINA (2014) lived with a German family in Neuss near Sichuan. This is fine with Liu. “In the long AND WORK CLOSE Düsseldorf. During the day he worked at the term, I would like to live and work close to local KSPG plant. Besides the work itself, it my parents,” he says. Family ties are still TO MY FAMILY Since 2012 biggest car market in the world 6.9% LCV production growth rate 2014-2017 The longstanding focus of Liu’s research is an engine with a mechanically fully variable valve drive. Over and over again, he makes minute changes 18.4 to the parameters, conscientiously documenting the effects. million new cars sold (largest automobile market worldwide) It was the latter who proposed Liu for the restart the engine, modify the parameters project. “Of course, I’m very proud of this,” by a fraction of a second, and note down he says in English. Liu introduces himself the results. “There are times when I spend 9% as Leon since, lkie many young Chinese, ten or more hours here,” says Liu. “The only he has given himself an English first name. interruptions are for lunch and dinner.” His day starts at 8 o’clock in the morning in growth his single room. As a postgraduate he no LIFE REVOLVES AROUND longer sleeps in a multi-bed room as do the other students. He makes his way to the THE CAMPUS FOR SOME Beijing 5 canteen, a large hall loud with the rattling 15,000 STUDENTS of hundreds of spoons and plates. By nine (= Euro 5) at the latest, he’s at work in the lab. “Right The campus of Tongji University is a town Emission standard now we’re measuring for seven to ten hours in itself. Some 15,000 scholars from all Starting in 2016: Beijing 6 daily,” he says. There are another five stu- over China live and study here. The campus dents in his team, one of whom is also doing has its own supermarkets, restaurants, Source: IHS postgraduate studies. Again and again they sports grounds, and dormitories. An indoor 24 HEARTBEAT 25
PEOPLE // SLOWING DOWN ON TWO WHEELS Manfred Mäules’s heart belongs to an old Harley How much passion can someone muster for an old motorcycle? In search of an answer, Heartbeat learned a lot about style, craftsmanship and the art of never finishing. This man doesn’t conform to the wall hangs a doctoral certificate from the A stable full of chrome horses standard biker cliché. The Chief Operating Academy of M aintenance. “A little joke from At the MeMoTech company, we are greeted Officer of KS HUAYU AluTech GmbH wears my colleagues”, he grins. He appreciates a by workshop manager Alexander Ronto. a conservative suit and a clean white shirt. relaxed work atmosphere—and his old “Alex”, confides Manfred Mäule, is someone Chatting over a cup of coffee with him, Harley, too, a 1972 Shovelhead Hydraglide. he knows he can trust, and a welcome spar- we can already tell that this senior execu- We naturally want to have a look, and make ring partner when it comes to technical and tive is a pleasant person. Colleagues and our way to nearby Flehn, where the machine aesthetic questions. It quickly becomes clear staff pass by for a quick word: “My door is was due to have new brakes installed. that he shares Mäule’s passion for beautiful always open”, says Manfred Mäule. On the motorcycles—only with him it became his 26 HEARTBEAT 27
IT’S ABOUT DOING IT YOURSELF, GETTING YOUR HANDS DIRTY HEAVY UP FRONT, NARROW IN THE BACK The incomparable silhouette of a 1972 motorcycle vocation. We’re surrounded by a plethora of dures. When it comes to improving the bike’s also from actual encounters with men and vintage bikes—countless Harleys, but also performance, though, engineering trumps motorcycles. His thing? “Heavy up front, exotics like the MV Agusta from the ’80s or nostalgia: instead of an oily wet clutch for his narrow in the back.” Anybody who’s seen an antique Triumph from the ’20s. Having Shovelhead, he developed a more effective his special interpretation of a Hydraglide will so many models means the staff needs dry clutch, including the pinion. After all, this know exactly what he means: the massive tremendous know-how—which is exactly is what he’s trained to do. headlight—known as the “ox head” by afi- why Manfred Mäule turns to them for help with his Shovelhead. KOLBENSCHMIDT Tightening bolts instead of shooting • HARLEY-DAVIDSON SUPPLIER FOR OVER 30 YEARS the breeze • SUPPLIED SOME TEN MILLION PISTONS And he knows a lot himself—he’s not one of desires. For example, the two exhaust pipes The ideal counterbalance maybe that’s the whole point. You have to those ostentatious bikers who spend tens • A 90% SUPPLIER SHARE AT HARLEY that run parallel from the header to the back What’s so fascinating about tightening keep coming up with no ideas and approach- of thousands on a glitzy machine and would unfortunately won’t be allowed to stay that screws on old Harleys? “It’s the ideal es, always striving for the optimum solution. rather show off than tighten a screw: “The Beauty is in the eye of the beholder ciandos—and the powerful fork with the first way. “In the USA it’s okay, but in Germany counterbalance for what I do all day at With the Shovelhead, that’s no problem: the last thing I wanted was a high-priced cus- Apart from engineering, aesthetics kept hydraulic shock absorbers give the Harley it’s too loud for the TÜV inspectors”, notes Kolbenschmidt”, declares Mäule. “At work brakes may soon be repaired, but the iconic tom-built bike where everything was new and coming up in our conversations. “There are its distinctive front-heavy look. Naturally Mäule, his pained expression revealing the it’s mostly numbers—here I can get my hands mount is still missing a seat. “We still need to different. I wanted to keep as much of the so many different Harley models and types enough, the back of the bike looks very dif- disapproval of a true motorcycle aesthete. dirty and literally get to grips with a prob- talk about that”, adds Alexander Ronto, with original Shovelhead motor as possible and and different ways of modifying them”, says ferent—in fact it seems almost effeminately It’s easy to see how the neutered version lem.” On the job, everything revolves around a mischievous wink. Fortunately, Manfred restore the rest as accurately as possible”, Mäule. “Over the years, everyone develops delicate, while the rear tire is barely wider with “bags”—as the experts dub the exhaust efficiency; here he enjoys the luxury of Mäule must be thinking. In two weeks he’s he explains. As a matter of fact he does a lot his own preferences”, he adds. Inspira- than the front one. “And the opposite exists, muffler terminals—just don’t pack the same having tons of time. “To be honest, restoring off to Daytona Beach on vacation. Waiting for of the work himself, machining the smaller tion comes from every direction—pictures too”, he tells us: “But I don’t like it.” Yet aesthetic punch as the original design. a machine like this is a process that never him there won’t just be thousands of Harleys, parts and even carrying out difficult proce- in magazines and books, of course, but sometimes the powers that be constrain our really ends”, he confesses with a sly grin. But but plenty of inspiration to boot. 28 HEARTBEAT 29
PEOPLE Along with a basketball career and grad school, Marvin Kruchen wants to make his mark at Pierburg, too. // FROM DRIBBLING TO CONTROLLING // Basketball, grad school, your job— Marvin Kruchen talks about discipline and team spirit that sounds like a pretty busy schedule. Do you ever have time to relax? It’s all a question of time management. In the What influence can sport have on life at work? Heartbeat met meantime I only train three times a week, a lot less than before. The 1st Regional League is the fourth- highest league, meaning you with the Pierburg employee and graduate student, can just barely combine it with a day job. I use my free time to study, because work who plays basketball in Germany’s 1st Regional Division. and basketball games mean that I can’t always attend lectures. It works pretty well. // Team spirit—is being a team player The fact that most people look up to important in other areas, too? At work, him clearly has something to do with his for instance? height: Marvin Kruchen is 2.10 meters tall – Since I haven’t been at this all that long, that’s almost 6 foot 9 inches. But in an I really appreciate it when my colleagues interview with Heartbeat, it was his friendly, // Apart from basketball, what are your quickly. Things can get stressful at work, too. give me a hand. The team spirit that you open manner that impressed the most. greatest talents? But it’s like comparing apples and oranges develop playing basketball can definitely That’s a tough one. I guess my main talent— and grapefruits. help at work. You become better at em // Mr Kruchen, you work at Pierburg. What if that’s what you can call it—is being pathizing with others and getting along with do you there? an open-minded, communicative person. // When you’re always being called a “giant” different kinds of people. I work part-time in Sales Controlling on a That’s a big advantage at work, at school or a “colossus”, does that lead to greater 30 hour a week basis. Our team produces and in sport. pressure to perform in other areas? Do you monthly reports for the company’s sales THE 1ST REGIONAL have that feeling that more is expected of people. Right now we’re preparing the bu- LEAGUE CAN JUST // What are you most passionate about you than from others? siness plan for the next few years. Basically right now? No, I don’t think so. I don’t really put myself we collect data and process it in a way that BARELY BE COMBINED I’ve always been fascinated by the auto- under pressure, expect when it comes to our colleagues can use it. This is the kind of WITH A DAY JOB mobile industry, especially the big German basketball. And we’re not under nearly as work you do at a desk, of course, interrupted makers. Not that I make enough yet to drive much pressure to perform as professional by the occasional meeting. // Somebody who plays so well and is so a big German car! soccer players, for example, including from eager to get ahead must be ambitious. the press. I take off my hat to Germany’s First // And you’re studying at the same time? Does this same ambition affect they way // Do you approach a basketball game, a test Division players. That’s right. I’m doing my Master’s in you study and work? or a project at work with the same attitude, Business Administration at the University of A little bit, I guess, though I’m not sure if the same methods and the same tactics? Cologne, where I’m now in my third semes- it doesn’t just have something to do with It’s not really the same. A test is always going ter. Once I’ve completed by degree, I plan to my personality. Many of my fellow students to make you nervous. Basketball’s different. work for Pierburg full time. have had semesters when they’ve hardly Despite a thousand spectators, there’s a lifted a finger. That’s not the case with me. certain routine involved that takes over pretty 30 HEARTBEAT 31
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