ELECTROMOBILITY COMES FROM BELOW - ICONS IN BLACK - Rheinmetall Automotive
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The magazine of Rheinmetall Automotive ISSUE 02/2017
ICONS IN BLACK
Retro look with state-of-the-art technology
STARTING EARLY PAYS OFF
Trainees become design engineers of electric vehicles
// ELECTROMOBILITY
COMES FROM BELOW
Drive system and energy storage for electric vehicles
in development
EDITORIAL/CONTENTS
DIVERSITY ON THE RISE
Electrification of the drivetrain is going into high gear.
10E-MOBILITY
COMES FROM
Wherever you look, whether in China, the USA, or in the
streets of Europe, this trend is plain to see and gathering
BELOW
pace. For Rheinmetall Automotive, this is a highly significant
development: In the future-oriented e-mobility segment,
we’ve already booked orders worth over 500 million EUR. And
now, just in time for IAA 2017, we’re expanding our product
range with a new electric motor and an advanced battery
pack. But innovative new developments and improvements in
our legacy product lines are becoming increasingly relevant,
too, particularly in light of heightened requirements for
greater fuel efficiency and lower emissions. At IAA 2017 in
Frankfurt, we’ll be showcasing these as well. This varied issue
of Heartbeat focuses on the diverse range of contemporary
drive technologies as well as the innovative manufacturing
techniques, such as friction welding of steel pistons – but it
also highlights the growing diversity of our company. Offering
an overview, the first Rheinmetall CSR report revealed that
we have a great deal to offer besides products and technol-
ogies. Protecting the environment, personnel development,
and social and community commitment have long formed an
integral part of our corporate ethos. You’ll find a number of
concrete examples of this in the second section of this mag-
azine. Equally up to date is Heartbeat’s new interactive web
magazine format, which is going online in a Chinese language
version, too. Between issues, we’ll also be informing you THE WILD WORLD HIGHLIGHTS
about all the latest news at Rheinmetall Automotive. Whether
OF ENGINES
you’re reading this in the print version or browsing through it
online (www.heart-online.de/en), we wish you an enjoyable
8
and informative experience! 4 Latest from IAA and Personnel
News
Focused on action
Hunting for perfect pictures with
four cameras
4
Peter Hartung FOCUS
Head of Corporate Communications
Rheinmetall Automotive AG 10
E-mobility comes from below
Developing drive system and
// IMPRINT
energy storage for e-vehicles
Published by: Rheinmetall Automotive AG, Karl-Schmidt-Strasse 2–8,
74172 Neckarsulm, Germany, www.rheinmetall-automotive.com
Responsible: Peter Hartung, Folke Heyer
Edited by: Folke Heyer, Annemarie Köhler, Jacquelyn Marsiglio,
Ursula Pohen, Manuela Schall, Bernhard Schenk
// OUR TITLE PAGE
Implementation: Publik. Agentur für Kommunikation GmbH
Picture credits: Fotolia/karepa; Thomas Frank; Freepik; Getty Images/ The new electric motor and the
Michael H, stockstudiox; Ralf Grothe; iStockphoto: corfoto, Pawel Gaul, underfloor battery of Rheinmetall
jacus, RiverNorthPhotography, smontgom65, Sussenn, Terriana, TommL; Automotive are currently being
Thomas Klink; Jakub Pojmicz; Rheinmetall Automotive AG; Gary Paul Lewis/ integrated into a testbed vehicle
Shutterstock.com based on a Fiat 500.
2 HEARTBEAT 02|2017
// CONTENTS
20
PEOPLE
34
A step ahead in every respect
Fifty years ago, NSU launched the Ro 80
36
Joining forces to build a new home
US employees support social housing
project
38
Test drive with Horst Binnig
CEO of Rheinmetall Automotive
41
The hunt for energy savings
Trainees with an eye for the environment
TECHNOLOGY PEOPLE
16 26 ON SITE
E-mobility by law Taking responsibility for the future
The global automobile industry is
looking to China
Report on Corporate Social
Responsibility published
42
The cradle of the American car
18 30 Auburn Hills plant near Detroit
Starting early pays off
Welding in forging quality
Trainees learn to construct e-vehicles
Modern spin welding cell in Neckarsulm
20
Icons in black
Retro look with state-of-the-art
technology
You can find additional
information about these
articles by going to
RHEINMETALL GROUP www.heartbeat-online.de/en
24
Blue-light driving
Rescue units practice extreme
situations
3
THE WILD WORLD OF ENGINES 4 HEARTBEAT 02|2017
// FOCUSED
ON ACTION
Hunting for perfect pictures with four cameras
Monte Carlo, Mexico, Wales, Finland, Germany, Portugal, Sardinia …
– there is hardly any spectacular WRC (World Rally Championship)
rally or race event that Jakub Pojmicz has not already chronicled as a
photographer. He even covered the 100th Hill Climb at Pikes Peak.
5
The 39-year-old Motor at the international sporting service employee from Kraków, events. “This accreditation as Poland became a rally pho- an official photographer is im- tographer because he had portant because that gets you always been fascinated by into the raceway areas that are action photography at races. off-limits to the normal hobby Of course, it is not easy for an snapshooter, which in turn is amateur to establish himself important for obtaining the re- among the many profession- ally good photo angles,” says als along the racetrack. In a Pojmicz. Moreover, this even certain sense, the publication allows him into the paddock, of a few spectacular photos which affords him a totally in trade magazines was his different insight into how the entry ticket for accreditation rally transpires. 6 HEARTBEAT 02|2017
He has attended 35 rallies in this way and I might have to quickly jump to the side and
shows no signs of slowing down, even though get to safety,” admits Pojmicz. In the mean-
a rally photographer’s day starts very early time, however, he knows the critical spots
and ends late most of the time. Early in the along the racetracks and photographs from
morning, he must scout for access routes to protected positions or uses a tripod and
the critical photo outposts and coordinate remote camera trigger wherever possible.
the general logistics of the day. Evenings are
filled with processing the garnered shots That he still manages to bring home captivat-
and sending them to the home agency as ing racing photos every time is underscored
quickly as possible. Not much time remains not only by having a photo published in the
for sleep. Furthermore, a rally photographer official Mini Auto Calendar but also by his
not only needs to remain permanently “ready many Facebook page visitors (Kuba Pojmicz
to shoot” but must also keep himself wide photo), who have already awarded his images
awake at all times: “I always stand when I’m several thousand “likes”.
taking photos, because I never know when
Above right: If you’re
allergic to dust, rallies
are not for you.
Below right: A 67 Ford
Falcon approaches
the checkered flag at
legendary Pikes Peak
Hill Climb in Colorado.
Below: Jakub Pojmicz
with his tools.
At rallies, it’s not just
the cars that produce
an adrenaline kick:
take Rally Sardegna
2015, for example.
All pictures © Jakub Pojmicz.
Who says cars For more of his photos, please go to
can’t fly? www.heartbeat-online.de/en/wild-world
7
HIGHLIGHTS
VAPOR PUMP
RINSES WITH-
OUT VACUUM
// TAKING ACCOUNT
OF CHANGE
Today it’s not just vehicle
exhaust emissions that
“ChangeDriven” at IAA 2017 are subject to stricter
controls, but fuel fumes,
too. A granular activated
carbon container is used
IAA Cars takes place in Frankfurt, September 14–24, 2017. for catching these fumes,
which has to be regularly
Rheinmetall Automotive will be displaying its products in a rinsed. Pierburg has now
two-story stand with over 500 square meters of floor space developed a compact pump
for this purpose. It rinses
(Hall 8/F26). Adopting the motto “ChangeDriven”, the out the carbon container
company is taking full account of the increasing electrification without the vacuum in the
suction pipe that used to
of the drivetrain. Kolbenschmidt and Pierburg will be be necessary. The first of
its kind, this electric pump
showcasing their latest innovations, including the electric goes into production in
vapor pump that sucks up fuel vapors – a world first. series in 2018.
80 %
INNOVATIVE PLAIN BEARINGS FOR THE INTERIOR
Because electric driving is so quiet, A new Permaglide material,
any noise becomes that much more KS P150 expands the operating
noticeable. This has led to new limits of the company’s tried-and-
requirements for moving parts in tested KS P141. In combination with
the vehicle interior and plain bear- these smooth-running materials,
LE SS WEAR
ing-mounted guides. KS Gleitlager the extremely robust KS P209 is
A N D TEAR
has responded by developing a new particularly well suited to car seat
line of plain bearing materials. applications.
8 HEARTBEAT 02|2017
PEOPLE
HEDDEN SUCCEEDS
DR. MERTEN
1.7 % LE SS CO 2
Specially designed for gasoline-powered engines, the Liteks-4
lightweight piston concept is ready to go into series produc-
tion. It is already being offered for high-performance applica- On July 31, 2017, after 17 successful years with
tions in connection with ring carriers and cooling ducts. Mea- the high-tech Rheinmetall Group, Dr. Peter
Merten (63, left) retired after stepping down
surements on the test stand and in a vehicle simulator resulted from his post as Chief Financial Officer of Rhein-
in a CO2 reduction of around 1.7 percent in the NEDC. Over a metall Automotive AG. The Supervisory Board of
100 million Liteks pistons have been installed since 2006. Rheinmetall Automotive AG has appointed Olaf
Hedden (53) to the Executive Board of Rhein-
metall Automotive AG as his successor, effective
August 1, 2017. Facilitating a smooth transition,
Dr. Merten will continue to serve the company in
an advisory capacity.
ACTUATOR ASSURES OPTIMUM Merten was appointed to the post of CFO on the
Executive Board in 2002. During his success-
BOOST PRESSURE CONTROL ful tenure, the company achieved sustained
profitability and emerged as a global auto parts
maker, with units in North and South America,
At IAA, Pierburg is presenting a con- – is so well cooled that it can take a Europe, and Asia, a trend which he fostered and
cept for a wastegate actuator which heavier load, enabling a lower gear guided. Horst Binnig, Chairman of the Executive
(among other things) improves the ratio between the motor and actuator Board, thanked Merten for outstanding services
boost charge control. Because it is sit- shaft and a higher dynamic response. to the company: “During his time at Rheinmetall
uated on the hot turbine, the actuator Furthermore, it is also possible to seal Automotive, company sales more than doubled.
directly propels the wastegate valve. the shaft against the aluminum hous- What’s more, CAGR during this period reached
Thermal decoupling from the housing ing to protect it from gushing water a double-digit 12 percent. This tremendous
in combination with the refrigerant without risking heat damage. achievement, accompanied in recent years by
cooling prevents overheating. This steadily high ROCE figures, was due in very
means that the 12 V DC motor used large measure to Dr. Peter Merten’s unstinting
here – an EC motor is another option efforts.”
Another seasoned industry expert, Olaf Hedden
has been with the Rheinmetall Group for many
years. He joined Rheinmetall AG in 1988, mov-
ing to Pierburg GmbH in 2002 as commercial
managing director. In 2010 he was appointed
chief executive officer of the auto parts supplier
Läpple, returning to Rheinmetall Automotive
in 2014, where, as chairman of the boards of
management of Pierburg GmbH and Pierburg
Pump Technology GmbH, he headed Mechatron-
ics, the company’s largest division, with annual
More information about sales of 1.5 billion EUR.
Pierburg actuators can be
found at www.rheinmetall-
automotive.com/en/products/
actuators
9
FOCUS
// ELECTRO-
MOBILITY
COMES FROM
BELOW
Drive system and energy storage for electric vehicles in development
10 HEARTBEAT 02|201711
With its wide range of products, Rheinmetall Automotive is
ready to accommodate the increasing electrification of power
transmission. The company is busy developing a new kind of
modular battery pack as well as a 90 kW electric powertrain.
Both systems are currently being integrated into a testbed
based on a subcompact vehicle. Heartbeat spoke about this
project with Rheinmetall Automotive CTO Heinrich Dismon.
The journey along this path began a long time and series production of electric drives,” says Heinrich
ago, for electric motors are certainly nothing new for Dismon, the company’s Chief Technical Officer, “allow
the design engineers of Rheinmetall Automotive. In us to converge toward the development goal here rela-
the case of ancillary units, the OEM supplier has had tively quickly.” However, he adds that they fell back on
an established development competence for electric additional support from development service providers
powertrains for decades. For example, the company in the initial phase. Dismon’s goal is a completely elec-
conceived the first fully electric coolant pump for the tric traction drive that, in addition to the electric motor,
main cooling system via its subsidiary Pierburg as early also has the control and power electronics as well as a
as 2004 and successfully introduced it onto the market step-down gear made by Rheinmetall Automotive and
in the six-cylinder engines of BMW. designed according to the application.
Orders for electric motor casings
Since its market launch in 1995, the electrically com-
mutated water recirculation pump, likewise developed
by Pierburg and produced at the Hartha plant site in
Saxony has meanwhile already exceeded an output of
50 million units and is utilized worldwide by leading PRODUCTION OF
manufacturers and suppliers in automotive engi- BATTERY-POWERED VEHICLES
neering and beyond. In addition orders come from Forecast of IHS Automotive for worldwide production
international OEMs for electric motor and aluminum of battery-powered vehicles in million units
battery casings soon to go into series production at
Rheinmetall Automotive. The product range of the 2025
company in electromobility is supplemented through 4 3.84
electric oil and vacuum pumps, electric coolant valves
and actuating elements, a heat pump and special light
aluminum constructional components. 3
Complete traction drive as the goal
Now, with its new electric drive and parallelly de- 2 2017
veloped battery pack, the international automotive
supplier is starting a new chapter in its development 0.77
history. For its newly conceived products in electromo- 1
bility, Rheinmetall Automotive decided not to focus on
energy storage and electric drive (with its peripheral
equipment) solely due to market-related reasons. 0
“Our basic competences in the development chain 2010 2017 2025
12 HEARTBEAT 02|2017Inquired!
their car three times per week
and even then merely for short
trips most of the time.
Moreover, due to the technical
Compact class targeted parameters, e-mobility will bring
The newly introduced electric powertrain with 90 kW us into a situation in which
power, however, aims not at the absolute upper levels we must compensate for our
of performance à la Tesla but rather is located in the previous “carefree attitude”
upper segment of compact electric engines. In its cur- through a more well-planned
rent design, it aims at smaller vehicle classes, whereby way of acting. In the future, we
the scalability of the system also enables utilization will certainly have to give more
in larger vehicles. The reason for this was the insight thought to which distance we
that “electromobility will develop from the bottom Heinrich Dismon can master in which timeframes
up,” says Dismon. He estimates that the future will Chief Technical Officer and calculate accordingly.
Rheinmetall Automotive AG
bring various forms of drive systems ranging from the
central drive unit to drives close to the wheels. At the In the medium term, I believe
same time, electric vehicles for, say, urban zones will // Will electrical mobility alter electromobility will happen
be more likely to come in smaller power performance our driving habits? within a range of up to 400
ranges of 30 to 50 kW. We currently have the situation km radius. That’s absolutely
that vehicles are offering ever adequate for the predominant
more comfort, but also bearing share of our normal driving
ONE ALSO NEEDS TO CONSIDER more weight. In e-mobility we destinations.
will increasingly see vehicles
SMALL VEHICLES BEYOND that are decidedly conceived In 2030, we won’t yet be ready
THE PASSENGER CAR for electric driving. Inevitably, to fully replace the combustion
they will have to be smaller and engine with new technologies.
lighter and have less power. I even believe we won’t be able
New players on the market to completely replace it.
Furthermore, new manufacturers (OEMs), for whom In this respect, e-mobility will
a proprietary development of an electric drive is not influence us. But there are also
necessarily a priority, will be active in this area in the people today who only drive
future. In addition there will be new market segments,
such as multipurpose applications extending beyond
pedelecs. The drive that will therefore be proprietarily
manufactured by Rheinmetall Automotive in the future
is tunable and scalable for the intended use in terms
of performance and torque. The engine technology
is also basically insertable into a mild hybrid and
applicable there for functions such as electric parking,
autonomous driving into the garage, or for shifting the
operation range of the combustion engine to save fuel.
Underfloor batteries preferred tion space requirements, enables a very flexible and
In the layout design of the developed battery pack, broad application basis in electrified vehicle concepts.
Rheinmetall Automotive assumed that a significant
portion of future electric vehicles and even hybrids An important question at the outset was whether one
will possess underfloor batteries. They do not sig- should commit to using a certain cell type. Howev-
nificantly limit the load volume of the vehicle and, in er, the company pursues an open strategy here that
addition, also offer advantages regarding both weight enables integration of various different battery cell
distribution and possible incorporation into the vehicle types and can therefore be interesting for many OEMs.
structure. Dismon: “Today almost all vehicles on the Dismon: “We don’t want to get into cell technology, but
market are derivatives of existing concepts on the rather to configure a system for our customers with the
basis of combustion engine drives. In the future, that cells of their choice.”
will no longer be seen.”
High energy density
The battery pack features a very high energy density in Due to their high specific energy density and good
proportion to its weight and, due to its small installa- thermal conditionability, Rheinmetall Automotive
13utilizes pouch cells for the rechargeable batteries of its
testbed. Beyond this, however, concepts with cylindri-
cal or prismatic cells also exist, enabling one to cater
135
to customer-specific requirements. KM/H
is the top speed attained by
Temperature control also in the battery pack the Rheinmetall Automotive
To ensure that the battery packs can also withstand testbed vehicle, which is
high power drains and prove suitable for heat-intensive based on a Fiat 500 with an
rapid charging, they were outfitted with a coolant-per- electric motor.
fused floor cooling, which drew from the manufactur-
ing expertise of the supplier in aluminum die casting.
An electric coolant pump conducts the coolant into
a heat exchanger. In connection with the similarly
developed heat pump, recuperation can occur or the COMPACT
energy can be used for heating or cooling the interior. DESIGN
Moreover, at low temperatures it is also possible to
The space-saving design of the
regulate the temperature in order to avoid damage to
drive used here is intended for
the battery.
smaller vehicles.
WE DON’T WANT TO GET
INTO CELL TECHNOLOGY
Underfloor battery pack with special protection
The skeletal structure of the battery casings developed
by Rheinmetall Automotive for these applications
consists of aluminum, which is additionally protected
from damage through a superimposed fiber compos-
ite structure. The corresponding fiber is supplied by SCALEABLE
a Rheinmetall affiliate that specializes in protective
applications. SYSTEM
In terms of output and torque,
Testbed with systems approach the drive is scalable. This
The battery pack of Rheinmetall Automotive’s Fiat means that it can also be used
500-based testbed (see cover image) is equipped with for powering larger vehicles.
a nominal storage capacity of 29 kWh. In connection
with the new electric drive, the vehicle achieves a top
speed of 135 km/h and a range of up to 275 kilome-
ters. These parameters are accomplished without
limiting the usable space for the trunk or passenger
compartment known from the series production
vehicle. Rheinmetall Automotive sees this configura-
tion oriented toward future electric vehicle concepts
as an example for a possible series concept, whereby
of course other constellations can also be realized in
accordance with customer wishes. POUCH CELLS
Pouch cells are built into the
testbed vehicle’s batteries;
but it is also possible to
integrate other cell types.
14 HEARTBEAT 02|2017AT A GL ANCE
A multitude of innovative features characterize
the electric motor and underfloor battery.
Rheinmetall Automotive is currently integrating both
new systems into a testbed vehicle. 90KW
output produced by the
Rheinmetall Automotive
motor.
275
KM
is the operating range of the
QUICK CHARGING testbed vehicle equipped
Thanks to the coolant- with the battery pack.
circulating floor cooling system,
the battery pack is suitable for
heat-intensive quick charging.
29 COMPOSITE FIBER
STRUCTURE
KWH
is the nominal storage capacity
MODULAR A composite fiber structure encloses
the battery case, providing it with
of the battery pack built into the DESIGN added protection from damage.
testbed vehicle. The modular design enables
a high degree of flexibility
with regard to application.
15TECHNOLOGY
// E-MOBILITY
BY LAW
The global automotive industry is looking to China
China is emerging as the world’s leading market for electrically powered
vehicles. Eager to help e-mobility make the ultimate breakthrough, the
government in Beijing has adopted a policy of ambitious legal quotas,
massive subsidies, and systematic expansion of infrastructure.
Measured in absolute numbers, China e-vehicles and 98,000 plug-in hybrids were action in the country’s urban centers: many
is already the world’s most important sold last year in China, including 336,000 of China’s megacities suffer from severe
market for new energy vehicles, or NEVs. passenger cars and 171,000 commercial air pollution; switching to e-buses is an
The government in Beijing defines these as vehicles. By way of comparison, during the efficient means of improving air quality.
electrically powered cars, plug-in hybrids, same period in Germany, a mere 11,400
and fuel-cell vehicles, although the latter pure electric vehicles were sold, plus Incentives and infrastructure
still play no role. 13,744 plug-in hybrids. When it comes to passenger cars, the
government is also taking the lead. For one
NEVs in the fast lane Of those 171,000 commercial vehicles, thing, the purchase of e-cars and plug-in
In 2016, some 417,000 electric cars were 115,000 are electrically powered buses – hybrids is being promoted financially in a
produced in China. With annual production an excellent example of China’s top-down multitude of different ways; for another,
of around 200,000 e-vehicles, Germany “e-volution”: more and more public trans- vehicles with alternative drive technologies
comes in second place, followed by the port companies are converting their fleets in metropolitan areas receive coveted reg-
USA with 148,000. When it comes to new to nonpolluting vehicles. In doing so, they istration much more quickly than conven-
registrations, however, China’s lead is even are toeing the party line. The government in tional vehicles. Last but not least, China is
more impressive: no less than 409,000 pure Beijing has recognized the need for urgent swiftly expanding its network of charging
16 HEARTBEAT 02|2017poles. In the future, all new buildings will cles. The production licenses are valid only
be required to have charging stations for for NEVs and are awarded in an accelerated
electric vehicles. Ten percent of existing process. In May 2017, for example, a license
parking places are being retrofitted with of this type was awarded for a joint venture
charging units. By 2020, no fewer than 4.8 between Volkswagen and Anhui Jianghuai
AMOUNT OF NEW
million charging stations are to be installed Automobile Company.
in the People’s Republic of China.
ENERGY VEHICLES FOR
NEW CARS IN CHINA Rheinmetall Automotive is upbeat
(OBJECTIVE OF THE CENTRAL
In the future, the share of e-cars will con- “The Chinese government’s extensive pack-
GOVERNMENT)
tinue to increase significantly. The central age of measures in conjunction with new
government has set ambitious targets: in forms of supply will continue to spur the
the year 2020, two million NEVs are to be market for electric vehicles on, solidifying
built in China, and by 2025, somewhere China’s pioneering role as the world’s most
between 15 and 20 percent of all new 2025 important automobile market,” declares
vehicles sold in the country are supposed
to be e-vehicles or plug-in hybrids. By 2030,
15–20% Horst Binnig, Rheinmetall Automotive’s
chief executive. In the meantime, the
the share should rise to forty or even fifty 2030 Neckarsulm, Germany-based Group sees
percent. There is no room for doubt that
Beijing is serious about this plan. The first
40–50% itself as well equipped to deal with the
altered underlying conditions. The company
big step – at least as things stand at the has been present in China for over twenty
moment – is due to take place very soon: in years. In the meantime, its 5,000 employ-
June 2017, the central government passed ees generate annual sales of just under
a law stipulating that, starting next year, 1 billion EUR. Rheinmetall Automotive’s
PRODUCTION OF
carmakers will have to make sure that eight presence in China now runs to ten com-
percent of all vehicles sold are either purely E-CARS IN 2016 panies: three fifty-fifty joint ventures, two
electric or plug-in hybrids. This rule applies majority joint ventures, and one minority
to all carmakers with a production volume joint venture for piston rings.
CHINA
of over 50,000 units per year. Despite
political resistance from Germany, Beijing is
409,000 Rheinmetall Automotive’s array of products
sticking to its guns. extends from electrified components for
hybrid drives (e.g. controllable ancillary
These government measures are also shap- GERMANY generators and pumps) to lightweight
ing the structure of the industry. Following 200,000 designs and products for pure e-mobility.
a decision by the Central Committee in Oc- These include battery mounts for electric
tober 2016, new vehicle manufacturers will vehicles and special casings for complete
receive a permit without difficulty only if USA electric motors, which in the future Rhein-
they are capable of producing electric vehi- 148,000 metall Automotive plans to manufacture on
location for the Chinese market. Moreover,
both the company’s Range Extender REx
and new heating and cooling module offer
numerous potential uses in electric vehicles
Chinese police departments also (see Focus story page 10 onwards ).
increasingly opt for electric vehicles.
For more information about
Rheinmetall Automotive in China visit
cn.rheinmetall-automotive.com
17TECHNOLOGY
// WELDING IN
FORGING QUALITY
Modern spin welding cell in Neckarsulm
The Kolbenschmidt factory site Neckarsulm is the main
plant for steel pistons within the Group. In its state-of-
the-art premachining line for steel pistons, Rheinmetall
Automotive exploits an innovative technology: spin welding.
The premachining line consolidates
all of the working steps downstream from
forging under one roof. This has not only
increased the in-house production depth
in the Neckarsulm plant but has also
cemented its status as a worldwide leading
production facility for steel pistons. One
particular highlight of the line is its spin
welding cell.
Frictional heat instead of electric arcs
Now to explain how the process works
or, more precisely, the flywheel friction
welding variant used here: firstly, the top
and bottom sections of the steel piston are
machined. The bottom section is tightly
mounted in a tailstock; the upper section is
held from the chuck of a spindle possess-
ing a flywheel. The flywheel is accelerated
until it reaches a predetermined rotational
speed. The power is then switched off and
both parts are pressed together through a
hydraulic cylinder exerting up to 100 metric
tons of pressure. The resulting friction de-
celerates the flywheel and simultaneously
The heat caused by converts the kinetic energy into frictional
friction makes metal heat, which is sufficient to melt both the
so soft that the
work-pieces fuse to
adjacent surfaces of the two parts. In this
each other. state, the two component parts can be
bonded. Besides the automotive industry,
18 HEARTBEAT 02|201780–200
MILLIMETERS
IS THE DIAMETER
RANGE OF THE
PROCESSED STEEL
PISTONS
60
SECONDS
REQUIRED FOR A
WELDING PROCESS
270,000
COMMERCIAL VEHICLE
STEEL PISTONS C AN
BE PRODUCED AN-
NUALLY ON THE NEW
PRODUCTION LINE IN
Processes in the welding NECKARSULM
cell are extensively
automated.
the flywheel friction welding process also process, thermal stress on the material is
for example finds application in aerospace minimal, which bears out in the outstand-
technology. ing quality of the resulting bond. Schaller
can also list further advantages: “The base
Flexible cells material isn’t melted, so that prevents any
The facility in Neckarsulm is now exclusive- danger of pore formation, solidification
ly used for manufacturing steel pistons, defects (like gas porosities) or slag inclu-
having also been especially designed for sions. Even liquations – meaning undesired
this purpose. The friction welding cell is separations – can’t occur. The quality is on
flexible in terms of the size and design the same level as forging.”
of pistons it can accommodate: welding
is possible for pistons with diameters No emissions
ranging from 80 to 200 mm. Currently Employees also appreciate flywheel friction
manufactured steel pistons are composed welding when they are working near the
of the heat-treatable steel 42CrMo4 or the largely automated welding cell: the process
micro-alloyed steel 38MnVS6. However, normally requires neither additional weld-
one can also use alternative steel material ing material or gas nor emits harmful radi-
grades, such as Inconel steel. ation, splatters, or fumes. “No suction is
necessary because workers face absolutely
The procedure offers many advantages over zero danger from hazardous substances,”
Christian Schaller with friction-welded conventional welding with regard to both explains Schaller. “Friction welding does
steel piston components. production flow and quality. For example, without electric arcs or laser beams, which
welding times are exceedingly short. “In thereby eliminates any risk from optical
the new friction welding cell, a commercial radiation. This not only makes it easier to
vehicle piston can be welded every 60 view the process but also removes any pos-
seconds,” explains Project Leader Christian sible qualms or uneasiness about getting
Schaller. Furthermore, because the material hands-on.”
is only heated and not melted during the
19TECHNOLOGY
// ICONS IN
BLACK
Retro look with state-of-the-art technology
Back in black: The majority of the
next generation of London taxis
will also be painted in black.
20 HEARTBEAT 02|2017Just like Tower Bridge, Big Ben, or the red double-
decker buses, they are the emblem of the British
capital: the characteristic black cabs. Locals
and tourists use this means of transportation
300,000 times per day to reach their destination
through the maze of streets in the vibrant city. The
manufacturer is LEVC – a company that produces
only taxis, and soon a model with electric drive.
Around 20,000 of the rolling classic Despite the retro look, the London Electric
cabs are currently driving through the Vehicle Company (LEVC), that operated as
London streets. Not only the current mod- the London Taxi Company until July 2017,
el, the TX4, but also many older versions builds modern technology. It’s no surprise
– an indication of the robust design that – after all, the latest generation of black
characterizes the London taxis. With their cabs was a new product in 2007, and is
striking radiator grille, round headlamps, undergoing constant development.
and tapering snout the black cabs give
the impression they are behind the times. Nimbler than a Polo
The strength of the concept lies in the
details. From the very beginning the
TURNING CIRCLE ONLY vehicle was designed as a taxi, which has
AROUND EIGHT METERS – manifested itself in many unique design
features. One example would be the small
LESS THAN THE CURRENT turning circle: the black cab needs only
POLO about eight meters to turn on the road;
which is two meters less than the current
VW Polo.
This can clearly be seen in the heredity
of their famous predecessor – we are High comfort
speaking about the Austin FX4 which was There is room for five people in the
constructed with the nearly the same look separated passenger compartment as
from 1958 to 1997. But this itself is one of standard. Where the front passenger seat
the reasons why the traditionally-minded would be – of course on the left in the
English still love their taxis so much today. United Kingdom – there is no seat. Passen-
21Whether in narrow
alleys or in front of
luxury hotels – the
new electric black
cabs look good
everywhere.
ger baggage is stowed here. The cab is ex-
emplary when it comes to comfort for the
elderly and disabled: a seat can be folded
out towards the sidewalk when the door is
open, and a wheelchair ramp is standard
equipment. But LEVC has not only thought
about the passengers, but also about
the driver. The taxi has a special safety
feature: the rear doors cannot be opened
when the driver keeps the brake pedal
pressed down. So passengers cannot
disappear before they have paid.
HOW DO I GET THE GREEN BADGE?
Not everyone in London can Mental and physical health: The FROM 2018, TAXIS WITH
get one of the sought-after taxi applicant may not suffer from, for
licenses, called the Green Badge. example, heart conditions, mental DIESEL ENGINES WILL NO
Applicant requirements are among disorders or nervous disorders.
the strictest in the world.
LONGER BE LICENSED
“The Knowledge”: the biggest
Minimum age: An applicant must hurdle is to pass this test. The
be at least 21 years old, although applicant must prove knowledge Zero-emission future
there is no maximum age. of 320 routes in a six-mile radius For all of its tradition, LEVC knows the im-
around Charing Cross. These portance of keeping up with the times. The
Character: Each applicant must include around 25,000 streets and next taxi generation, the TX5, will there-
declare any previous convictions. 20,000 landmarks. Most drivers fore be electrically powered. On the one
Suitability as a taxi driver may be need a preparation time of between hand, LEVC is following the general trend
ruled out for serious offences. A two and five years before they can towards sustainability. Additionally, there
person who withholds information pass this test. is also a very special reason for this in
is barred from the application
London itself: since 2008, nearly the entire
procedure.
city area has been a low emission zone in
which very strict conditions for operation
22 HEARTBEAT 02|2017The hard tests for the
new model were held
in the widest range of
climatic conditions.
of motor vehicles apply today. In 2020, the grounds, please see the next issue of
inner city area, which extends from Victo- Heartbeat.
ria Station in the west up to Tower Bridge
in the east, will also be designated as an First pure electric car plant in Europe
ultra low emission zone with even greater The electric car comes from a brand-new
demands on emissions. This will have mas- factory in Ansty near Coventry that opened
sive effects on the taxi industry as early as in March 2017. The plant is not only the
next year: from January 1, 2018 taxis with first new car factory in the United Kingdom
diesel engines will no longer be licensed. from some ten years, it is also the first in
The vehicles must be able to drive for up Europe that builds only electric vehicles.
to 48 kilometers with zero emissions. They The LEVC parent company, the Chinese
may discharge a maximum of 50 grams Geely Group, has invested over 300 million
CO2 per kilometer. pounds here in the Midlands. The plant ca-
pacity lies at over 20,000 vehicles per year
Revolution under the hood and over 1,000 new jobs were created. The THE LONDON ELECTRIC
The TX5 fulfils exactly these requirements. TX5 market launch is planned for late 2017
VEHICLE COMPANY
The electric motor made by the LEVC sister in the United Kingdom, and 2018 for the
company Volvo is derived from the T8 Twin rest of the world. But whilst new ground In 1899, LEVC was originally
Engine that is currently in service in the has been broken with the inner workings, founded as London Taxi Company
Volvo XC90. Exact performance details the optical changes are moderate. A black Ltd. From the very beginning its
have not yet been announced, but they cab will remain a black cab, even in the operations covered solely the
are good enough to accelerate the TX5 to future! development and production of
130 kph. The lithium-ion battery enables taxis. The company has been a
pure electric driving for over 160 kilome- wholly owned subsidiary of the
ters. When the battery reaches its limits a Chinese Zhejiang Geely Holding
since 2013. The manufacturer is
three-cylinder range extender takes over.
on the road to success, as is illus-
The range extends to over 640 kilometers trated by the new plant in Ansty.
with the Volvo 91 hp gasoline engine. Since July 2017, the company has
Rheinmetall Automotive supplies several been operating as the London
components for these vehicles. To learn Further information at w
ww.theelectrictaxi.co.uk Electric Vehicle Company – a clear
more about details and technical back- and www.tiny.cc/taxis-minicabs statement on electric mobility.
23RHEINMETALL GROUP
// BLUE-LIGHT
DRIVING
Rescue units practice extreme situations
As realistic as
possible: Software
engineer Peter
Hürzeler experiences
emergency driving
in a simulator from
Rheinmetall Swiss
SIMTEC.
24 HEARTBEAT 02|2017The rhythmically flashing blue lights reflect
on the walls of the buildings in the deepening
twilight. Meanwhile, rain droplets beat
down upon the ambulance windshield in since early this year. Among other product lines, his
company specializes in this type of training simulators
loud exploding spheres, accompanied only within the Rheinmetall Technology Group.
by the penetrating blare of the siren. At the forefront of technology
In the meantime, the special blue light driving simula-
tors account for about 20 percent of its annual sales
revenue. Walther knows that maintaining as much
realism as possible is crucial for the success of the
exercise: “The realism depicted in the simulators never
ceases to delight our customers.” By contrast with
The dispatcher reconfirms the emergency location competing systems, his almost 180,000-EUR-machines
over the radio. Through the vibrations in his seat and feature ultrahigh 4K resolution monitors. In a certain
steering wheel, the driver senses the cobblestone pave- sense, they function as the windshields of the emergen-
ment beneath his racing ambulance. He instinctively cy vehicle – and can even fog up when desired to make
moves in parallel with the rolling motion of his vehicle the exercise more challenging. Furthermore, the entire
as he speeds across downtown Zurich to the reported driver’s cab rests on servomotors that are maneuver-
scene of the accident. He glances in the rearview mirror able in six directions. Jolts and vibrations are directly
to see whether he can switch back into his lane after relayed to the driver via the seat. The simulators are
just passing a motor scooter. He has just spotted the equipped with very complex software jointly developed
“School Crossing” sign in the corner of his eye when with the parent company in Bremen that – whether it be
a child suddenly jumps out from behind a parked car in a police car, ambulance, or fire truck – simulates vir-
onto the rain-slicked street. tually any conceivable crisis situation, thereby enabling
it to be drilled and practiced.
Deer on the right
IT’S NOT ONLY IN SWITZER- It doesn’t matter what the road condition, weather,
crisis scene or dangerous situation might be. From the
LAND THAT PRACTICING aforementioned urban street scenario to an unexpected
EMERGENCY AMBULANCE deer crossing on an icy country road to a multi-vehicle
pursuit of a lunatic driver on the highway, almost every
DRIVING PROCEDURES IS possible contingency can be trained and prepared for.
Other realistic situations increasingly encountered
GENERALLY PROHIBITED. include a missing emergency lane or a traffic partic-
ipant overwhelmed by the flashing blue lights of an
Johann Walther, Managing Director of approaching vehicle.
Rheinmetall Swiss SIMTEC AG
Eye tracker sees everything
Test persons in the driver’s seat are thoroughly pushed
A situation absolutely no one wants to encounter – the to their limits. For example, even when using blue
kind that tests the nerves of even the most highly expe- lights and the siren while in hot pursuit of a potential
rienced ambulance drivers. A situation everyone is hap- criminal, police must constantly weigh the appropriate-
py to have faced as an exercise in a simulator without ness of their actions and decide accordingly. No wonder
anyone actually getting hurt. “Since Switzerland isn’t sweat appears on the foreheads of practicing drivers
the only country where running rescue training mis- as a modern, completely helmetless and goggleless
sions with blue lights and sirens is generally forbidden, eye-tracking system registers the fixed points in the
police, ambulance, and fire rescue units have no other rearview mirror or direction of travel and relays them to
option than to practice their crisis skills in a simulator,” the monitor of the exercise instructor. After all, practice
explains Johann Walther, who has been CEO of Rhein- makes perfect – especially when driving under blue-
metall Swiss SIMTEC AG based in Thun, Switzerland light conditions.
25PEOPLE
// TAKING RESPON-
SIBILITY FOR THE
FUTURE
Corporate Social Responsibility report published
We live in an age of far-reaching changes and worldwide challenges. The rise
in geopolitical and economic insecurities, demographic imbalances, altered
societal values, resource scarcity, climate change and new mobility concepts
and production precepts like Industry 4.0 are only a few of the underlying
trends. Public interest in sustainability and environmental and ecological
protection is increasing. At the same time, companies are also increasingly
called upon to contribute toward sustainable societal development.
26 HEARTBEAT 02|2017their activities upon society. This includes
economic, ecological, and social aspects.
In concrete terms, for example, it involves
fair business practices, an employee-orient-
ed personnel policy, frugal use of natural
resources, protection of our climate, ecol-
ogy, and environment, sincere social and
societal dedication in our local areas, and
assumption of responsibility, especially in
the supply chain.
// Was that uncharted territory for the
company?
Ursula Pohen: No, sustainability is nothing
new and no “buzzword” within the Rhein-
metall Group. Rather, it has already been
an established component of the company
culture for many years. The Management
Board is committed to holistic, transparent
management oriented toward long-term
business success which, in addition to eco-
logical factors, also integrates social and
Corporate Governance factors into business
operations. At the same time, assuming
The companies within the Rheinmetall responsibility has always been a matter of
Group are doing a great deal for the envi- course.
ronment and society in numerous ways and
the first report on Corporate Social Respon- // The first sustainability report has now
sibility (CSR) was also recently published. been published. What was the deciding
Why this area is so highly important within factor for this?
the Group is explained in the following Ursula Pohen: Rheinmetall has already
interview with Ursula Pohen, responsi- been reporting about CSR on its web-
ble for CSR both at Group level and the site and in the annual report since 2011.
corporate Defence Division, and Annemarie However, the requirements for content
Köhler, responsible for CSR at Rheinmetall and structure placed on reporting about
Automotive. sustainability topics have significantly in-
creased in the past several years. This trend
// First, a basic question: how do you de- has been strengthened not only through
fine Corporate Social Responsibility? national initiatives, international standards,
Ursula Pohen: Corporate Social Responsi- and CSR indices but also through legisla-
bility, CSR, encompasses the responsibility tion. Starting in the 2017 fiscal year, the
of companies for the repercussions of CSR Guideline Implementation Act will ob-
CORPORATE RESPONSIBILITY
CORPORATE CORPORATE
CORPORATE GOVERNANCE
SOCIAL RESPONSIBILITY CITIZENSHIP
ECONOMIC ECOLOGICAL SOCIAL
RESPONSIBILITY RESPONSIBILITY RESPONSIBILITY
27ligate certain large capital market-oriented we are naturally in the public eye. But
companies, as well as large credit institu- customers and business partners also need
tions and insurance companies in Germany, detailed information from us regarding
to report about essential nonfinancial organization, structures, and procedures in
matters. As a minimum, the reporting here the area of CSR. Above all, comprehensively
280,000 * encompasses details about environmental, evaluating the supply chain in terms of sus-
employee, and social concerns, observance tainability is becoming increasingly import-
LITERS OF FUEL
OIL SAVED of human rights, and combating corruption ant. We need to ensure that environmental
AT UNTERLÜSS and bribery. and social standards are maintained along
the entire value chain. For example, the
Annemarie Köhler: Our stakeholders, guiding principles of the industry standards
which include shareholders, customers, AIAG and the European Automotive Working
employees, applicants, investors, suppli- Group on Supply Chain Sustainability are
ers, analysts, creditors, media, the local very important for Rheinmetall Automotive
communities at our sites, and of course the within this context. All prominent manufac-
50,000 general public, expect transparent, infor-
mative, and understandable information
turers are working to fulfill these standards
and pass them along the supply chain.
KWH SAVED about how our corporate Group handles its
BY LED LIGHTING societal responsibility. What we do, how we Ursula Pohen: One should also add that in-
AT TRITTAU
do it, and why. With the CSR report, which vestors are increasingly taking environmen-
is oriented based on the internationally tal, sustainability, and human rights factors
leading Version 4.0 standard of the Global into consideration in their decision-making
Reporting Initiative, we present many processes. In this respect, rating agencies
examples of responsible conduct in a broad also evaluate Rheinmetall regarding Com-
survey across the entire Group. pliance, Corporate Governance, HR, and en-
vironmental aspects. With the data material
// Leaving legislation aside for the mo- prepared in a structured way for the CSR
300,000 ment, were there additional reasons for
publication?
report, we can now answer enquiries more
completely and thoroughly. We have here
KWH SAVED Annemarie Köhler: As a company listed in the chance to score better in the ratings. In
AT BREMEN
the German MDax stock exchange index, addition, this allows us to further develop
* All numbers refer to the
2016 fiscal year.
Rheinmetall Automotive
backs Formula Student,
helping to pave the way
to sustainable mobility.
28 HEARTBEAT 02|2017SUSTAINABILITY REPORT
2017
The Sustainability Report documents
Rheinmetall Group’s commitment
to economic, ecological, and social
responsibility.
Ursula Pohen, CSR Officer, Annemarie Köhler, CSR
Rheinmetall Group and Officer, Rheinmetall
Rheinmetall Defence. Automotive. CO R P O R AT E R E S P O N S I B I L I TY R E P O RT 2 01 7
our CSR activities in an even more targeted system. Prudent handling of materials,
manner, to start Group-wide campaigns energy, water, and waste – as well as the
regarding individual topic clusters, and plan avoidance of hazardous consequences to
our goals more easily. the environment in business and produc-
tion processes – are among the central
// Which subjects do you believe come bases for the business operations of the
as a surprise to the readers of the CSR companies. This not only preserves the
report? environment but at the same time can also
Ursula Pohen: Many ecological and societal reduce costs. Moreover, 40 companies and
aspects of our sustainability activities plant sites are currently certified pursuant
are little known to the public or are not to ISO 14001, according to ISO 50001, as The complete Sustainability Report
necessarily associated with us. In addition well as eight according to OHSAS 18001 – is available to download:
www.rheinmetall.com/en/rheinmetall_ag/
to our involvement in ecological and animal with more to follow. corporate_social_responsibility/csr_report
protection on plant premises in Germany,
Switzerland, and South Africa, these in- // In your view, which sustainability activi-
clude for example the creation of 100 train- ties are important for the employees of the
ee and apprenticeship positions to support Rheinmetall Group?
integration of foreign refugees in Germany. Annemarie Köhler: I think that the diverse
And they also include entire urban district advanced training programs, numerous
building developments in Düsseldorf and offers regarding work-life balance, and
Hamburg. frequent events within the framework of
health management are very well received
// How is sustainability anchored in the by our colleagues. In addition, the dedica- 5,000
company organization? tion of the Rheinmetall Group is positively M 3 WATER
Annemarie Köhler: First of all, sustain- evaluated in the areas of science, educa- SAVED AT
NECKARSULM
ability falls directly within the responsibil- tion, athletics, and regional aid projects.
ity of the CEO of Rheinmetall AG. Due to
advancing developments in this sector, we
restructured this area in 2014. The Corpo-
rate Responsibility Panel, which represents
executives from all Divisions as well as the
Management Holding, promotes the ex-
pansion of sustainable activities. The topic
areas comprise Corporate Governance,
Corporate Citizenship, and Corporate Social
Responsibility with a focus on economic, 8,700
ecological, and social responsibility. TREES DONATED BY
KS KOLBENSCHMIDT
// Does that also apply in Production? WITH PARTNERS AT
NOVA ODESSA,
Annemarie Köhler: Absolutely. We define BRAZIL
conservative use of natural resources as
an integral component of the management
29PEOPLE
// STARTING EARLY
PAYS OFF
Trainees become design engineers of electric vehicles
Starting calls for
full concentration.
So don’t get dis-
tracted, even when
SWR television is
present.
30 HEARTBEAT 02|2017Neckarsulm’s training officer
Nobert Roth gave the starting
signal for “The Race“.
Racing fever has hit Rheinmetall Automotive.
The staff parking lot at the Neckarsulm plant
has been transformed into a mini autodrome
overnight. Pup tents and a workshop truck line
the track. Alongside are the pit box positions
of five small but quick-to-accelerate electric Clear rules
vehicles, to which the various young design The young design engineers were able to
let their creativity run free in the project,
engineers are busily putting their finishing but had to observe precise guidelines
regarding necessary safety requirements.
touches in preparation for the race. At the same time, the shape of the vehicle
bodywork and the applied material could
be freely chosen. However, the vehicle
A start and finish line with a velocity dimensions were subject to a size lim-
indicator complete the image of a drag itation. Guidelines also governed the
relay demanding to be mastered. 280 train- chassis frame: in addition to a floorboard
ees of the automotive supplier encircle the and pneumatic tires of variable size,
course, roaring cheers for their individual front-wheel steering had to be installed.
teams at the drop of the starter’s flag. The mandatory braking system was also
supposed to withstand repeated brake
Everything began a good half a year ago applications.
when the company announced the race
competition to its trainees, thereby also As in real racing sport, drivers of course
bringing the subject of new drive technol- had to wear helmets. Moreover, the vehi-
ogies into focus for its young employees. cles were only allowed to drive at a maxi-
With a budget of 2,500 EUR each, their mum of 25 km/h, which was controlled by
task was to develop and build a fully func- a speedometer panel. High standards were
tional race car with an alternative drive in also set for the energy storage system,
only a few months. At the German national which had to be designed to last for the
trainee day, now hosted for the fifth time, entire race because switching batteries
they were then supposed to test their was not allowed.
mettle in a drag race. This challenge drew
plenty of takers: in total, five teams from High demands
Berlin, Neckarsulm, Neuss, Papenburg, and “We’re of course aware of the challenges in
St. Leon-Rot entered the race. the planning,” says Werner Böckle, Senior
31The winning team:
Pierburg from Neuss.
Vice President of Human Resources at challenge. “Our advantage also lay in
Rheinmetall Automotive, “but this is how constructing the auto in a way that allowed
our trainees learn to take responsibility the driver to get in and out quickly,” Simon
for handling the project in a team and Rambow summarized. The mechatronics
completing it on time – in addition to the engineer in his second year of apprentice-
purely technical contest involving electric ship was responsible for the drive devel-
vehicles.” opment for the Niederrhein team. Further-
more, intensive preparatory training also
The self-built electric vehicles presented proved to be an advantage and saved the
subsequently came about through metic- winning team precious seconds.
ulous preparation, though things did not
always run smoothly. As Robert Hüsken,
student apprentice responsible for the NOT ONLY THE PER-
chassis frame on the Niederrhein team,
summed it up: “You only realize all the FORMANCE OF THE
things that can go wrong and learn how to CONSTRUCTION WAS
collaborate with people effectively and well
during the actual work.” The project was CREATIVE, BUT ALSO
thus a meaningful experience for him. THE PRESENTATION
In the end, everyone came out as winners
In the final race, the five teams needed However, winning the drag race was not
to complete a short 100-meter-long track. the sole factor in determining the over-
The vehicle was turned around at the all result. Teams were also evaluated on
end points and then it was time to switch the presentation of the project, technical
Also this young colleague drivers. That allowed each team member implementation, and design quality of
from Papenburg jumped to drive along the raceway themselves the vehicle, as well as general teamwork
straight into action.
and navigate the team vehicle under race and internal organization. The teams also
conditions. At the end of the time trial, demonstrated a high degree of creativity
the trainees and student-apprentices in their presentations. Introductions of
from Pierburg in Neuss came out on top, participants and vehicles were peppered
whereby however everyone unanimously with special effects and video messag-
agreed that every team profited from the es, while the poetry slam composed by
32 HEARTBEAT 02|2017You can also read
