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Issue November 2017

Flexibly exploiting opportunities

Precision, innovation and flexibility are the key elements of our strategy for success. And we have once again set new standards in all these areas: R+W has produced what is probably the world's largest coupling, and our know-how is helping to drastically reduce CO2 emissions from commercial vehicles.

With a new building we have once again expanded our production capacity for precision parts and our mechanical engineering experts have developed a specialized system for testing cooling and heating components in the field of E-mobility.

As a Group with international operations, we are broadly diversified. The ups and downs of individual submarkets present us with challenges that we can use as opportunities for growth. Our employees and our manufacturing facilities are designed for maximum flexibility.

We are firmly convinced that we are well positioned for the future. The economy has just begun to pick up speed again. This will give us additional momentum in developing new markets and innovative technologies.

Enjoy reading our latest news!

Dipl. Ing. Rüdiger Faustmann (CEO) and Dr. Christian Potthoff-Sewing (President/CFO)

A Giant for the Guinness Book

Safety is a major priority at R+W – for this coupling this is particularly true: The colossus has an outside diameter of 4,000 mm and an inside diameter of 700 mm. 470 mm long, the torque limiter weighs a massive 21,500 kg.

The safety coupling of the type STF 20,000 will in future protect two six-megawatt motors of a wind turbine test facility. It operates in the rotational speed range from 0 to 20 rpm and with its manual engagement it is designed for a torque of 15,000 to 20,000 kNm.

This summer, the giant clutch developed by R+W was assembled in Klingenberg and delivered with a special vehicle. A film documents the spectacular event. The entry on Guinness World Records as the "world's biggest mechanical torque limiter" is currently being reviewed.

R+W has developed a giant coupling with a diameter of 4,000 mm, which in the future will protect two six-megawatt motors of a wind turbine test facility from overloading.

High-pressure components for a new natural and biogas injection system

Now the time has come to speed up with alternative fuels: As of spring 2018, a European OEM will be offering two new heavy-duty trucks running on liquid natural gas or biogas. This enables CO2 emissions to be reduced by 20 to 100 percent compared with diesel – without sacrificing performance.

The new LNG drive is based on proven diesel technology: When the engine is running, the liquefied gas in the tank is heated and converted to compressed gas. During injection, a small amount of diesel or HVO (hydrogenated vegetable oils) is added to ignite the gas.

The technology is based on the Westport™ High Pressure Direct Injection engine technology (“Westport™ HPDI 2.0”) and was developed by Westport Fuel Systems. Under high pressure, injectors spray approx. 5 percent diesel or HVO and 95 percent compressed gas into the combustion chambers of the engine.

"As a development partner of Westport Fuel Systems, we supply high-pressure tubes for gas and diesel in various dimensions," explains Christian Rabe, the responsible project manager at Poppe + Potthoff. Especially the gas lines (OD: 9 mm, ID 6 mm) have to meet the highest demands regarding tightness and pressure resistance (<600bar).

During intensive screw and vibration tests at the customer's site, the lines convinced with their optimal performance and safety. The cooperation with Westport Fuel Systems has been so successful throughout the entire project, with numerous challenges and international coordination, that the two partners are already working together on further projects in this field.

Liquefied natural gas and biogas (LNG) could well become an alternative fuel for commercial vehicles in the medium term. The advantage of gas engines is that they combust the fuel cleaner and therefore require less exhaust gas aftertreatment. Gas engines produce significantly reduced greenhouse gases, which is of major importance for climate protection.

With its new Euro 6 engine, an inline six-cylinder common-rail engine with a cylinder capacity of 13 liters, the OEM revs up trucks with a permissible total weight of up to 64 tons. Versions with 420 hp and up to 2,100 Nm torque or 460 hp and 2,300 Nm will be available.

The fuel consumption of the new engine is on a par with comparable diesel engines and 15-20 percent lower than that of conventional gas engines. Depending on the size of the LNG tank, the new trucks have a range of up to 1000 km with one filling.

Driving with liquefied gas (LNG) can reduce CO2 emissions by 20 to 100 percent. The Westport™ HPDI 2.0 injectors and high-pressure lines required for this are based on proven diesel injection technology.
Source: Westport Fuel Systems

New production hall inaugurated

On July 11th, the inauguration of a new production hall in Kunovice was celebrated by the directors together with numerous employees and guests. Since 1999, P+P has been manufacturing precision components in complex geometries in the Czech Republic. The site with currently 140 employees was expanded by 4000 sqm to 8000 sqm.

Alongside the production area, a new warehouse for metallurgical material was built with a roofed delivery area for the trucks. In addition, new social facilities have been created for employees: dining, relaxation and changing rooms. All the company's premises are fully air-conditioned.

Construction and furnishing work lasted from January to December 2016. After four months of probationary operation, regular production began in early summer 2017. Poppe + Potthoff invested about 125 million Czech crowns in the new energy-efficient building.

In addition, new machines and technical equipment worth 250 million Czech crowns were purchased, including a three-chamber vacuum furnace - the only one of its kind in the Czech Republic. This allows complex workpieces to be heat treated with minimal deforming.

Poppe + Potthoff s. r. o. offers a wide variety of manufacturing technologies. The materials processed are steel, steel alloys and stainless steel as well as aluminum, copper and alloys such as bronze and brass. Highly flexible machinery enables a wide range of processing operations.

In large, medium and small series, fine mechanical precision components are manufactured here, especially for automotive applications. Hydraulic systems, performance-enhancing drives, comfort and safety systems for vehicles such as ABS, TCS and ESP are typical areas of application.

Poppe + Potthoff s. r. o. in Kunovice, Czech Republic, manufactures a large range of precision components with 140 employees on an area of now 8000 sqm.
The compact functions test bench from PPM measures the consumption and performance data of heating and cooling units under changing temperature conditions so that their efficiency can be optimized.

PPM puts heating and cooling units for E-Mobility to the test

Heating and cooling costs a lot of range on the way to electromobility, because the required electricity must be tapped from the battery capacity. A new functions test bench from Poppe + Potthoff Maschinenbau (PPM) tests climate-control units under realistic conditions and provides developers with data at an early stage to sustainably optimize the energy efficiency of their products.

Following the identification of weak points on the material side in the pressure cycling test bench, the functional test bench focuses on power consumption and heating or cooling performance at varying temperatures. To simulate operation with an on-board or traction battery, the unit is supplied with low (0 to 20VDC / 5A) or high voltage (0 to 600VDC / 150A).

In long-term tests (usually 20 days), the temperature (-35 to +100 degrees Celsius) and the volume flow rate (3 to 30 l/min) of the test medium (water-glycol mixture or pure glycol) vary according to the programmed test cycles. Optionally, the test can also be carried out in a climatic chamber at -40 to +140 degrees Celsius to simulate changing ambient temperatures.

Sensors measure the temperature of the test medium at the inlet and outlet of the test object as well as the ambient temperature. The flow rate, pressure and pressure drop as well as current and power in the high and low voltage range are also documented. Based on realistic tests, the thermal and electrical performance of the heating/cooling unit can be precisely determined and optimized.