02/06 Nominal charge 2,00 EUR HYDRAULIK - HANSA … · Nominal charge 2,00 EUR HYDRAULIK."("; ... laid. In civil engineering, coal mining, quarries and gravel pits, ... like for instance

Destination ZugspitzeWith high pressure in the snow


Page 16

Nom

inal

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HYDRAULIKPRESSE

18

Ausg

abe

01/2

006

04Ships don’t wait up

The Bremen based

Automobile logistics

company E. H. Harms

relies on HANSA-FLEX

products for transports

Unity is strength

HSW / DRESSTA

and Komatsu: Get

things moving

with HANSA-FLEX

hydraulics

Passing the test

Ingersoll-Rand in the

Czech Republic certifi es

HANSA-FLEX ”Power of

Excellence”

10

02/06

HYDRAULIKPRESSE

Editorial 03

HSW / DRESSTA and Komatsu – strength in unity 04

Power Station Calbe – Oil palms and the like 06

Interview with Klaus Behr: „Nothing is impossible“ 08

Ships don’t wait! – Auto logisticans rely on HANSA-FLEX 10

Cooperation takes shape 12

FLEXXPRESS: New Hoses for Flight Simulator 13

HANSA-FLEX Group Ittigen/Switzerland: Breakthrough into new markets 14

HANSA-FLEX branch Paderborn: Centred on axles 15

Destination Zugspitze – With high pressure in the snow 16

Ingersoll-Rand confi rms: „Power of Excellence“ – HANSA-FLEX has what it takes 18

Technical Information: Hydraulic cylinder and seal technology 20

Quiz, Important Dates 22

Information, Entertainment, Outlook 23

CONTENT | IMPRESS

Content

02ISSUE FEBRUARY 2005

12th VOLUME

Editor:

HANSA-FLEX Hydraulik GmbH

Zum Panrepel 44 · 28307 Bremen

Telefon: +49 - 421 - 48 90 70

Fax: +49 - 421 - 4 89 07 48

E-Mail: info@hansa-fl ex.com

www.hansa-fl ex.com

Compilation: Dietbert Keßler, Enrico Kieschnick,

Horst Otto (PAPP advertising agency)

Layout: Nadine Staciwa

Print: Berlin Druck

Photos: S. 16/17: Kässbohrer, Zugspitzbahn AG

Responsible for contents: Wolfgang Rink

Frequency: Bimonthy

An Abo-Service of the is

available at our Website.

HYDRAULIKPRESSE 3ISSUE FEBRUARY 2006

The Managing Directors

Uwe Buschmann Thomas Armerding

Dear Readers,

"Knowledge is power" goes the old German adage. However, what good is all the knowledge if it cannot be

passed on to others. This applies especially to professional knowledge. HANSA-FLEX possesses an enormous

professional knowledge in regard to hydraulic installations and systems. It is our concern to pass this com-

petence and experience of more than 40 years on, thus serving with particular mindfulness and professional

expertise for the operational safety, availability as well as protection of man and environment.

With this initiative we want to strengthen and support you - our customers - with theoretical and practical

know-how that covers all aspects of fl uid technology. Therefore we have expanded the time-honoured serv-

ice for seminaries and schooling programs once more. Experienced trainers are available at all HANSA-FLEX

schooling centres, to pass their knowledge on to you. On page 22 of this issue we introduce you to an extract

from our complete seminary- and schooling program.

The schooling shall pay off for the customer by providing optimal availability at minimal costs through error

prevention. A good example in this regard can be found on pages 20 and 21. There, in the article on cylinder

insert and seal technology, we introduce to you some examples on how to avoid interferences, and thus

unplanned costs.

However, we not only pass on our knowledge of the fl uid technology to our customers. HANSA-FLEX is also a

sought after contact when it comes to adapting the fundamentals for the application of hydraulics in guide-

lines and standards to the current developments of the technical possibilities. Due to its longtime experi-

ence, HANSA-FLEX is a sought after partner of government safety organizations, and actively participates in

their committees. Presently they are occupied with revising the existing regulations. Since the appearance

of the hitherto valid safety regulation issue ZH 1/74, which dates back to 1988, the fl uid technology has

experienced many developments, which now are recorded in the new issue BGR 237. Thus, for instance, the

operating pressures have increased, stricter environmental regulations are in force and the protection of

man and environment is gaining in importance. Furthermore, the liability clauses have become stricter for

the owners due to the current operational safety regulations (BetrsichV) coming into eff ect. We will provide

you with detailed information about all these themes in one of the next issues of the HYDRAULIKPRESSE.

As you can see, we are sticking to it also in 2006. We know our responsibility. HANSA-FLEX will continue

to be intensively engaged in safety and effi ciency in the application of fl uid technology. On behalf of our

customers.

Editorial

FOREWORD

03

HYDRAULIKPRESSEISSUE FEBRUARY 2006

04

HSW / DRESSTA and Komatsu – strength in unityHydraulics on the move

REPORT

They are powerful, robust and yellow - and world-

wide on call wherever ground is moved or pipes are

laid. In civil engineering, coal mining, quarries and

gravel pits, but also in landscaping and pipe con-

struction. In all places where tough and dirty things

are going on, HSW / DRESSTA wheel loaders and

crawler dozers from Poland are well known. They

take on assignments that could not be carried out

without the application of hydraulics. And wherever

hydraulics is confronted with such heavy operational

demands, HANSA-FLEX is close by. All HSW / DRESSTA

wheel loaders and crawler dozers are equipped with

HANSA-FLEX hydraulic connections. This connection

has successfully existed for many years.

The HSW / DRESSTA organization emerged from

cooperation between Huta Stalowa Wola and Ko-

matsu America, which held the majority shares

of 51 percent until the turn of the year.. Now the

Polish government repurchased the 51 percent

of the shares from Komatsu America and contin-

ues the success story. The Polish steel work Huta

Stalowa Wola (HSW), founded in 1937, has been

producing forged parts for leading construction

equipment manufacturers for a long time. Since

several decades they also have been manufactur-

ing heavy construction equipment, which is mar-

keted in the CIS States as well as Eastern Europe,

under their own name. Through the HANSA-FLEX

sales engineer Karl-Heinz Loose, who is in charge of

Eastern Europe, there has been a close contact with

the steel work in Stalowa Wola since more than 25

years.

A name for reliability

Huta Stalowa Wola is located 250 kilometres south-

east of the Polish capital Warsaw, and approximate-

ly 80 kilometres from the Ukrainian border. During

peak times the plant employed 30.000 people,

meanwhile approx. 13.000 staff members work

in the areas of steel production and processing, as

well as in production of construction equipment

and track vehicles.

Following the political and economical changes in

the 20th century at the beginning of the 90's, HSW

was in a position to quickly turn into a modern

operation. Collaboration between the Polish steel

works and the American manufacturer Interna-

tional Harvester Company (IHC) in the production

of construction equipment started already in the

70's. This was replaced at the beginning of the 90's

by a joint venture with the American construction

equipment manufacturer Komatsu America Inter-

national. Heavy construction equipment for civil

engineering is manufactured in a separate division

at HSW since 1990 under the trade name HSW /

DRESSTA / Komatsu and sold on the international

market. A separate division within the company is

responsible for development, design and produc-

tion of the construction equipment.

In addition to the marketing of HSW / DRESSTA

wheel loaders and crawler dozers, the company

is also responsible for the purchase of all com-

ponents, hose lines, fi xtures and pipelines that

cannot be made by HSW itself. At HSW / DRESSTA,

HANSA-FLEX is committed in the areas of initial

equipment as well as spare parts.

Most extreme requirements

throughout the world

HSW / DRESSTA wheel loaders, crawler dozers

and pipelayers of all sizes are produced for civil

engineering, quarries, coal mines, gravel pits and

mines, as well as pipeline construction. The power-

ful construction machines, with up to 520 HP, are

worldwide employed under most extreme require-

ments and at greatly deviating climatic conditions.

By means of versatile auxiliary equipment, the

construction machines of the Polish manufacturer

can be fi tted and converted for each specifi c ap-

plication.

The construction machines are equipped with hy-

draulic systems that far exceed the required stand-

ard and that are exposed to particular stress during

daily operation. Dust, rock slides, fi ne gravel, heat

and frost put much stress on the hose lines under

these extreme operating conditions. Heavy ground


strains the lifting mechanism of the buckets, which

are up to 5 meters wide and hold approx. 5,7 cubic

meter of soil. The exterior hydraulic lines and hose

lines are carefully protected against outside infl u-

ences, like for instance impacts and rock slides. Dur-

ing operation, short load cycles under high pressure

alternate with constant full-load. The hydraulic

system - and this applies also to hydraulic brakes

- is therefore permanently subject to severest con-

ditions. Nevertheless, everything has to function

trouble-free. HSW / DRESSTA wheel loaders and

crawler dozers are designed in such a way that

they are easy to operate and to manoeuvre via hy-

drostatic drive, in spite of all the technical aspects.

Even the largest wheel loaders and crawler doz-

ers are now exclusively equipped with hydrostatic

drive. Modular drive systems make the exchange of

components easier.

Checked and found good

Important components of HSW / DRESSTA construc-

tion machines are produced by HSW with its own

engineering, drive technology and tool making.

Parts procured from suppliers must meet highest

requirements and undergo strictest examinations.

HANSA-FLEX worked hard to gain the approval as

supplier for hose lines in the initial equipment of

all HSW / DRESSTA wheel loaders and crawler doz-

ers by meeting corresponding sampling and qual-

ity requirements. It is of great importance to HSW

/ DRESSTA that all suppliers comply with the very

high standards. In doing so, the Polish company

applies the high standards of the strict American

Komatsu norms, which are considered to be some

of the toughest and consequential test standards

worldwide. All supplied products are checked on

compliance with required quality, which is pre-

cisely documented in the so-called mandatory

specifi cations. It stipulates which hose lines must

be delivered and the corresponding qualities. Only

parts authorized in such a manner are allowed in

production.

HANSA-FLEX is not only listed for the HSW /

DRESSTA construction machines as supplier for

the initial equipment, but also for spare parts. The

HANSA-FLEX team at the Poznań/Poland branch

attends to the Polish construction equipment

manufacturer, together with sales engineer Karl-

Heinz Loose from Bremen. The branch ensures that

daily operation with the customer runs trouble free,

from inquiry, sampling, quote, order acceptance to

production planning and invoicing. HANSA-FLEX

staff member Maciej Szulc is in charge of work or-

ganisation at the Poznań branch, which provides all

HANSA-FLEX products for HSW / DRESSTA. In doing

so, the Polish branch can receive support from the

central warehouse in Bremen, thus guaranteeing

absolute delivery reliability.

REPORT

05

HANSA-FLEX Sp. z o.o.ul. Dàbrowskiego 560 · 60-451 Poznań · PolandPhone: +48- 61 - 6 52 73 37Fax: +48 - 61 - 6 52 73 38E-Mail: poz@hansa-fl ex.com

HYDRAULIKPRESSE6ISSUE FEBRUARY 2006

Currently, energy and safe power supplies are popu-

lar discussion topics. Throughout the world, raw ma-

terial reserves are running short. What type of energy

can still reliably be counted on to provide warmth and

comfort in the future as well? How can regenerative

power sources be utilized, while at the same time

keeping control of the energy costs? Not only consum-

ers are concerned with such questions, but also the

operators of power stations. Fact is that in the future

only effi cient power stations can safely produce en-

ergy in an aff ordable and eco friendly manner. Just

a short while ago the Calbe power station has been

converted into such an effi cient power plant, with the

support of HANSA-FLEX.

The operator of the Calbe power station meets the

future demands made on power supply, and in do-

ing so relies on the application of vegetable oil. At

the beginning of July, the EWR Energiewerke GmbH

& Co. Motorheizkraftwerk Calbe Gmbh, assigned the

HANSA-FLEX Pipe Bending Centre in Schönebeck to

convert the engine fuel supply in the power station

to operate with unprocessed vegetable oil, espe-

cially palm-oil. The coupled production of power

and heat by applying CO2-neutral, unprocessed

vegetable oil is an important contribution to eco

friendly energy production. Vegetable oil takes a

dominant role in the area of fl uid regenerative en-

ergy sources. At the same time, the application of

palm-oil keeps a grip on energy costs.

The power station in Calbe was built in 1995/96

and, in form of a block-type thermal power station

(BHKW), represents state-of-the-art technology in

this fi eld. A BHKW is a smaller, more compact plant

for power and heat generation. Most BHKW plants

are operated with natural gas; others use fuel oil,

bio-diesel, bio-gas or the mentioned vegetable oil.

The BHKW converts the energy from the particular

fuel into power and heat, which are delivered lo-

cally.

The plant in Calbe consists of two twelve-cylinder

diesel-gas motors and a peak load boiler plant. The

motors have an installed electrical total power of 10

MW, at a simultaneously thermal power of 10 MW

high temperature water. The boiler plant consists of

three 9-MW boilers with a maximal temperature of

130°C. Equipped as such, the power station sup-

plies commercial and communal facilities as well as

1.800 residences with reliable, aff ordable and clean

heat by means of a modern, fi ve kilometer long hot

water district heating network. The cogenerated

electric power is supplied to the electro-energy

supplier EON-Avacon.

Cleanly bent and tubed

Jörg Schmechel, the manager of the power sta-

tion, decided in favour of HANSA-FLEX because of

an already long-standing good collaboration with

HANSA-FLEX in supplying hydraulic hose lines and

compensators through sales representative Bernd

Krüger. The Pipe Bending Centre in Schönebeck

had already successfully tubed the fi rst pilot plant

for the operation of the power station motors with

vegetable oil. Of course, the close proximity to the

Pipe Bending Centre also played a role when plac-

ing the order.

The successive order pertained to the installation

of fuel feed cables and encompassed a total of 35

06

REPORT

Power station CalbeOil palms and the like

HANSA-FLEX Hydraulik GmbHTube Bending Center

Grundweg 65 · 39218 SchönebeckPhone: +49 - 39 28 - 42 99 84

Telefax: +49 - 39 28 - 42 99 83E-Mail: bro@hansa-fl ex.com

ISSUE FEBRUARY 2006

REPORT

07

pipes (PR 50x3 and PR 42x2,5) with ball valves,

non-return valves, T-pieces and joints, which lead

from the service tank via the booster system and

fi lter installation to the motors. Here it was of spe-

cial importance to produce neatly bent pipes with

as few as possible weld seams, to avoid contamina-

tions.

HANSA-FLEX sales representative Karsten Watzke,

in charge of the project, made sure that the order

was carried out in a trouble-free manner. For the

HANSA-FLEX service technicians Toni Hellmuth,

Henry Engel and Wilhelm Riel the work in the pow-

er station started fi rst of all with the disassembly of

the original fuel supply. The installation of the new

pipes took place over two levels, with the integra-

tion of a parallel fuel supply of heating oil for start-

up and shutdown of the individual motors.

Large heights and lengths hampered the measur-

ing work and highly complicated the subsequent

assembly of the pipes. All pipes had to be individu-

ally fastened, whereat old fi ttings were used, but

new ones had to be attached as well.

After measuring the pipes to be assembled in the

Calbe power station - two to four pipes at a time

- a detailed bending program was set up at the

HANSA-FLEX Pipe Bending Centre in Schönebeck

under the responsibility of shop manager Andre

Braun, and the pipes were processed accordingly.

Compression rings were mounted to the fi nished

pipes and fl anges welded, respectively. Then the

pipes were assembled on site.

Of course all the data of the bending program and

the specifi cations for each produced pipe line are

stored in Schönebeck, this way HANSA-FLEX can

provide the customer quickly and effi ciently with

spares. This is a benefi t not to be underestimated

when considering the diffi cult measuring of the

pipes on site.

The successful implementation of this power sta-

tion conversion - whose technical design was

carried out by "Neue Maschinenbau Halberstadt

GmbH" - through the HANSA-FLEX Pipe Bending

Centre in Schönebeck has brought forth similar

projects, which are currently in the planning phase

at the hydraulic service provider.

HYDRAULIKPRESSE

Palm-oil

Palm-oil is predominantly a saturated oil of

the oil palm, which is pressed from the pulp.

As raw material, palm-oil is used among other

things for the production of margarine, sweets,

cosmetics, soap and detergents, as well as for

technical lubricants. In addition, palm-oil is also

suitable as source material for the production of

bio-diesel, which is used in block-type thermal

power stations as energy source as well.


INTERVIEW

Interview with Klaus Behr: „Nothing is impossible“

08

Between Brazil, Russia and Oldenburg, Klaus Behr is

dedicated to HANSA-FLEX. In addition to his activities

as team leader for the Oldenburg Group, he is en-

gaged in the international expansion of HANSA-FLEX

into a worldwide positioned system partner, covering

all aspects of fl uid technology.

He started with the company on May 1, 1985 in

the workshop of the Höxter branch, where Klaus

Behr acquired the professional basics from Pe-

ter Weidtkamp senior. He was present in Kassel

when a branch was established there. Later he

went into sales, to enthuse Bavarian customers for

HANSA-FLEX. At the end of 1989, Klaus Behr came

to the Oldenburg branch, a region that is home to

important industrial businesses, civil engineering

companies and - traditionally - agricultural fa-

cilities. Today, he is the team leader of the Olden-

burg Group, to which the branches in Emden and

Wilhlemshaven belong.

Klaus Behr takes on assignments in connection with

directing and developing HANSA-FLEX branches

abroad, which often brings him to Lithuania, Latvia,

Russia and Brazil. HYDRAULIKPRESSE interviewed

Klaus Behr on the theme of customer expectations

and the development of the Group.

HYDRAULIKPRESSE: You are travelling abroad

three months out of the year, how do you manage

to control your group at home?

Klaus Behr: Here I can completely rely on my

team; the team is the hero of our group. The con-

tinuous growth of the Oldenburg Group can mainly

be contributed to the effi ciency of this committed

and qualifi ed team. It is well established and works

together in a confi dent manner. It is important to

me that all staff members act independent and

responsible.

HYDRAULIKPRESSE: How is the HANSA-FLEX

service accepted abroad?

Klaus Behr: In Lithuania, Latvia and Russia, the

economic redirection of the last years has also

opened the way to internationalism for hydraulics.

Meanwhile, aspiring industrial operations, but also

agriculture, heavy industry, as well as steel works

and steel mill operations put their trust in the qual-

ity and competence of the local HANSA-FLEX part-

ners. Thus, we will also develop the capacities for

the repair of hydraulic cylinders, as well as the pro-

duction of purpose-built pipes and fi xtures in these

countries on site. Currently, Brazil has particularly

high requirements in overall hydraulic system solu-

tions.

And something else: Well-known German com-

panies are increasingly selling their machines and

installations in this market. Naturally, they also

would like to have their hydraulic systems abroad

attended to in the reliable HANSA-FLEX quality

as well, to guarantee the high quality standard. A

good example for this is the Hanoverian company

Bucher Schörling, who produces street cleansing

vehicles. Just recently this company has closed

a deal with HANSA-FLEX for the initial equipment

of the special vehicles manufactured in Latvia.

HANSA-FLEX supplies the complete assembly kits

- hose lines, purpose-built pipes and metal hose

lines.

Oldenburg Curitiba – Braz


INTERVIEW

09

HYDRAULIKPRESSE: The Oldenburg Group

distinguishes itself also in the local market as sys-

tem provider.

Klaus Behr: Yes, the market is seeking

HANSA-FLEX as system provider. We continuously

expand our customer base in the areas of initial

equipment. In this process, our HANSA-FLEX ex-

perts - together with the customers' engineers

and technicians - develop perfect solutions. The

customers expect from us sampling, and fi nally

certifi cation and documentation for the series, and

profi t from the latest know-how of our specialists,

who help to avoid mistakes and costs in the early

development phase.

We then supply precisely confi gured components

in the secured HANSA-FLEX quality directly to the

assembly line. Our customers appreciate this com-

petency of the system provider. It has opened doors

for us that have been locked up to now. By the way,

this has the nice side eff ect for us that we receive

subsequent orders in the areas of service and main-

tenance.

HYDRAULIKPRESSE: Do you observe an in-

creased need for industrial assemblies in this re-

gion?

Klaus Behr: This development increases to the

degree that companies reduce the personnel in

their own metalworking shops. Or use this staff for

other assignments. In this region, HANSA-FLEX in-

creasingly takes on such industrial assemblies, with

the support of the Oldenburg branch. Hence, we

not only supply hydraulic components, hose lines

and pipe connections, but also take on disassem-

bly and assembly, control the system and carry out

the start-up. Part of this is the application of the

FLEXXPRESS vehicles, which are equipped - if so

required - to produce hose lines on site during in-

dustrial assemblies.

HYDRAULIKPRESSE: Do you use the X-CODE

in this process?

Klaus Behr: The customers realize the advontages

of X-CODE more and more. But we must specifi cally

discuss this with them and make them familiar with

the advantages of this product. To many customers

the time factor is of great importance when supply-

ing hose line replacements. Alone on the basis of

costs it is decisive for customers to quickly eliminate

unplanned machine downtimes.

With X-CODE they have the assurance to always re-

ceive the identical spare part, which can be installed

without problems. We also specifi cally mention

X-CODE plus and X-CODE OEM to customers that this

applies to and particularly inform OEM's about the

great possibilities they have to profi t from a spare

parts collaboration with HANSA-FLEX for hydraulic

systems. To make a long story short: X-CODE opens

doors for us to new customer.

HYDRAULIKPRESSE: Do these customers ex-

pect not more from HANSA-FLEX than quick supply

of spare parts?

Klaus Behr: Yes, standard alone is no longer

enough, customers take this for granted. Of course,

quick supply of spare parts, integration of all data

and 24-hour delivery service are important. But

over and above this, our customers expect from us

competent solutions and assistance in the develop-

ment of customized solutions: Be it purpose-built

hose lines, fi xtures or pipes with sophisticated

geometries and connection technologies. This is

what the Oldenburg Group is specialized in. To-

gether with the services provided by the special-

ized HANSA-FLEX facilities, like metal and PTFE

hoses, hydraulic cylinders and components, engi-

neering and plant construction, we also can take

on complex assignments in hydraulics. Nothing is

impossible! We continue to demand high customer

satisfaction, in the initial equipment as well as in

the spare parts business. And: The increasing appli-

cation fi elds for hydraulic systems also provide the

opportunity for us to grow as a group. Therefore we

have placed the Oldenburg Group even closer to the

customer by opening a branch in Vechta.

zil Blumenau – Brazil Riga – Latvia Vilnius – Lithunia


10

Germany belongs to the leading locations of auto-

mobile production. German manufacturers ship their

vehicles throughout the world. In addition, every

year thousands of cars are imported from Asia and

America for the German automobile market. With

1.4 million vehicles per year, Bremerhaven is one

of the largest automobile ports worldwide. The BLG

automobile terminal is accessed by approx. 1.500 au-

tomobile transport ships per year. E.H. Harms Auto-

mobile Logistics is in charge for the timely availabil-

ity of the automobiles at the terminal. With a fl eet of

350 automobile transport trucks, the group supplies

7.000 car dealers in Germany. When it comes to the

hydraulic equipment of the trucks, E.H. Harms relies

on HANSA-FLEX.

Automobile transporters or car carriers are special

ships, which are designed for absolute practicality.

The high, rectangular monsters are similar to swim-

ming parking garages, each holding approx. 6.000

cars on up to 13 hydraulically adjustable decks.

From a nautical perspective, the ships are state-of-

the-art. Loading and unloading of such a giant pure

car carrier (PCC) takes place through openings on

the side of the stern via up to 30 to 40 meter long,

electro-hydraulic ramps that can be retracted and

extracted. To make sure that no time is lost, each

ramp can accommodate two cars side by side;

nevertheless, it takes several hours until such an

automobile transport ship is loaded or unloaded.

Car by car is driven on board by the BLG-terminal,

which can accommodate up to 100.000 vehicles.

These cars are then parked on a previously assigned

parking space, so that it can be quickly found at the

corresponding port of destination.

The assigned drivers at the port are transported

with a shuttle bus from the ship back to quay, in

order to bring the next cars on board - under deck

the traffi c is like at the rush hour. Meanwhile the

vehicles are carefully fastened by stevedores with

tension belts, to avoid damage during the long sea

passage.

Important link in the chain

The loading and unloading of an automobile trans-

port ship must be carried out quickly and trouble-

free. Approx. 1.000 cars per shift are handled on the

largest European intercontinental automobile hub.

On schedule, safe and without damages, the hun-

dred thousands of cars reach their buyers. All this is

meticulously planned, and therefore it is of utmost

importance that the vehicles reach the terminals on

time. Because a ship does not wait! The demurrage

in the harbor is extremely tight, so is the time-ta-

ble. If a truck arrives too late, the shipping company

loses the load.

The auto logistician E.H. Harms in Bremen, as part

of the BLG Logistic Group, is an important link in the

logistics chain from automobile manufacturer to

the fi nal customer.

With more than 1.000 staff members and a fl eet of

350 automobile transporters, E.H. Harms handles

for BLG the transport of cars on truck from the car

manufacturer to the loading for overseas, as well as

the delivery of import vehicles from the port to the

destination, the car dealer. Reliability and absolute

adherence to delivery dates means everything in

this type of business, because delays can quickly

damage the image of the manufacturer. If an avail-

able car does not arrive on time at the car dealer,

thus delaying the delivery to the fi nal customer,

the client is made angry, which - in extreme cases

- can even result in an economic damage to the

manufacturer. For this reason the logistician has an

enormously important job. As link in the logistics

chain responsible for the ground transport service,

E.H. Harms is aware of this demand and knowingly

relies on the support of HANSA-FLEX.

Ships don't wait!Auto logisticians rely on HANSA-FLEX

AUTOMOBILE LOGISTICS


11HYDRAULIKPRESSE

Service hub Paderborn

For the supply of available vehicles at E.H. Harms,

the logistics provider Peter-Michael Beling is in

charge. To make sure that everything runs smooth,

he trusts in HANSA-FLEX when it comes to connec-

tion elements for hydraulics. At the Paderborn loca-

tion, the truck fl eet of the automobile logistician is

serviced and maintained for German-wide assign-

ments. Hydraulics plays a decisive role in transport

trucks. Its application enables the driver to carry

out the loading and unloading of the vehicles in a

simple and safe manner. The loading ramps of the

trucks are hydraulically brought into position; the

loading levels are hydraulically lifted and lowered

in a precise manner. It is mandatory that the hy-

draulics functions without any problems under all

conditions, to avoid any unnecessary delays or even

damages to the vehicles.

Problems by the case

Thus, Peter-Michael Beling has recognized the ad-

vantages of X-CODE at an early stage. HANSA-FLEX

Paderborn supplies each hose line replacement

with X-CODE label. This way it is possible to quickly

request the fi tting spare parts. The times are defi -

nitely gone when an E.H. Harms service technician

visited the branch with a large case of disassembled

hose lines that needed replacing, to fi rst measure

them and then have the replacements produced.

Today all it takes is a phone call from Harms to

place an order with X-CODE. The HANSA-FLEX staff

member is able to better schedule the work fl ow

and concentrate on the production of all required

hose lines. Even a specialist needs a certain time

to accomplish this. Then, when the colleague from

Harms drives to our branch, all hose line replace-

ments are ready for delivery. The customer saves

time and money, since the Harms service techni-

cians can pursue their actual job and don't waste

time in picking up the fi nished hose lines. Of course

HANSA-FLEX Paderborn has adapted the inventory

precisely to the requirements of E.H. Harms, to as-

sure immediate availability at any time.

FLEXXPRESS, in case of

emergency

The Harms automobile transporters are on the

road day and night. Throughout Germany cars are

loaded at manufacturers' facilities, and delivered to

the individual car dealers. The same repeats itself at

the automobile loading terminal in Bremerhaven.

In this process the hydraulics is heavily strained

during loading and must function without any

problems. A hydraulic breakdown would not only

result in delays, but could also have eff ects on unin-

volved parties. If an automobile carrier encounters

unexpected hydraulic problems, FLEXXPRESS is at

its side. A FLEXXPRESS service vehicle is close by

throughout Germany and can be quickly requested

in case of an emergency.

AUTOMOBILE LOGISTICS


COOPERATION

After expanding the partnership - entered between

HANSA-FLEX and the ThyssenKrupp Industrieservice

(TKIN) GmbH in 2004 - bit by bit (Hydraulikpresse

reported this in its 02/05 issue), the next step was

made at the end of January 2006. At the Salzgit-

ter location HANSA-FLEX opened a branch, which

is affi liated to the already existing ThyssenKrupp

Industrieservice.

The cooperation focused on the optimal customer

benefi t to be provided by means of maximal avail-

ability of hydraulic equipment and according serv-

ice. This was impressively voiced within the scope

of a mutually organized event that took place at the

local facility.

After the offi cial part of the ceremonial dedica-

tion by representatives of HANSA-FLEX and TKIN,

the attending customers and interested parties

were provided an insight into the production spec-

tra and off ered services of both companies via a

short presentation and numerous showpieces.

For HANSA-FLEX, the main emphasis is placed on

the areas of metal and PTFE hose lines, as well as

FLEXXPRESS. In addition, the possibility was pre-

sented to attend a seminary, which was conducted

by the staff members of the training facility. Topic:

Basic criteria in hydraulic line technology. This form

of activity received much encouragement already

during the organizational phase. In retrospect it

can be said that it was a complete success, which

allows all participants to have an optimistic outlook

into the future.

Photo above:

The managing director of HANSA-FLEX Thomas

Armerding hands over the symbolic key to the

HANSA-FLEX group manager Thomas Hellmann

(branch Salzgitter)

Photo left:

Brisk demand for the training courses in the

HANSA-FLEX training center

Cooperation takes shape


FLEXXPRESS

FLEXXPRESS: New Hoses for Flight Simulator

The client RWL German Flight Academy GmbH has

been attended to by the HANSA-FLEX branch in

Mönchengladbach since several years. The com-

pany has its own schooling and training centre at

the Mönchengladbach Regional Airport, where pilots

as well as pilot instructors for private, business and

commercial airplanes receive training in theory and

practice. A staff of more than 100 members in per-

manent and freelance positions ensures the trouble-

free operation of the instructions.

In October 2005, a fl ight simulator was to be

equipped with new hoses. Following intensive

discussions, an inventory was taken by Steff an Hol-

land, sales representative of HANSA-FLEX, and Mr.

Wagner of RWL.

The heart of the simulator consisted of several

pumps and motors. Here, hose lines in the nomi-

nal width 10 to 60 were represented. The next

step was to get the tape measure and make no

mistakes. About 45 hose lines had to be precisely

measured. After successful measurement, the lines

were produced by Mr. Wartmann at our branch in

Mönchengladbach. For dismounting as well as

mounting of the lines only the FLEXXPRESS special-

ists were considered. Contact with RWL was estab-

lished immediately through Andreas Radig (748).

At this time it became known that the installation

also required fl ood lubrication. No problem for us!

Mr. Apic sent the fi ltering equipment directly to the

installation, where it was quickly connected to the

simulator, and the oil was fi ltered. Since the speci-

fi ed time-frame to complete the entire project was

less than 2 days, the work was carried on until late

in the evening. Thanks to the support of a RWL staff

member, we were supplied with treats from a bak-

ery. A sincere „thank you“ goes out to Walter.

After completion of the work, successful tests were

performed concerning function and tightness.

Thus, the pilots were able to take over the simulator

on time.

HANSA-FLEX gives special thanks for the excellent

cooperation and wishes successful training fl ights

at all times!


Expansion, development of new markets - this was

the objective when Günter Buschmann and Joachim

Armerding, together with Paul Rentsch, founded the

HANSA-FLEX AG in Ittingen/Switzerland in 1993.

Though the expected crowd did not show up on the

opening day in Ittingen, near Bern, it did not take

long until the newly formed team, consisting of Paul

and Heidi Rentsch, as well as Edwin Zürcher, was

able to make a name for itself. Not only the Swiss

National Railway relies on the competence of the 17

HANSA-FLEX staff members in Switzerland, but also

large construction equipment dealers and vehicle

manufacturers. HANSA-FLEX also takes part in the

giant construction site of the St. Gotthard Tunnel or

the western by-pass in Zurich.

The currently most challenging tunnel-project in

Switzerland is called Alp-Transit. The St. Gotthard

Basis Tunnel is part of this project. HANSA-FLEX par-

ticipates through its branch in Lamone (Lugano).

Seven completely equipped HANSA-FLEX work-

shop containers, including inventory, are located

at Swiss construction sites. The two tubes of the

Gotthard Tunnel have a length of 57 kilometres

each. Alongside of this are fi ve construction sites.

In Bodio, two 400 meter long Herrenknecht tunnel

drilling machines (TBM) make their way through

the mountain with a twelve meter shield diameter.

Each of these TBM is accompanied by one container,

in which the mechanics prepare the required hose

lines on site. The HANSA-FLEX branch supplies the

corresponding material.

In addition, HANSA-FLEX Ittingen supports other

companies that participate in this construction

project in hydraulic matters. This requires around-

the-clock readiness and great fl exibility from

the branch. In René Schupp, HANSA-FLEX Zurich

has a staff member that possesses longtime

experience and substantial knowledge in hydraulic

matters. At one time he was responsible for the op-

eration of a TBM himself. As former inventory man-

ager of a large construction company he knows,

like no other, what construction machine operators

need.

Crossing borders

A 24-hour service also requires the support of con-

struction machine manufacturers and dealers by

HANSA-FLEX Ittingen. At times these companies

order complete tubing sets, consisting of ready

prepared hose lines, bent pipes, fi ttings, couplings,

fastening clamps, ball valves, etc. from HANSA-FLEX

for their machines.

On behalf of ThyssenKrupp Industrieservice (Sch-

weiz) AG, HANSA-FLEX Switzerland handled a

challenging project for a pipe plant in eastern

Switzerland shortly before Christmas 2005. During

this project, the Swiss closely collaborated with the

HANSA-FLEX Pipe Bending Centre in Schönebeck. A

complete machine line for strip steel shaping had to

be converted. Several hundred meters of hydraulic

pipes were newly installed and hydraulic units con-

nected to individual machines or existing hydraulic

units. Through the collaboration with the specialists

of the HANSA-FLEX Pipe Bending Centre, the Swiss

colleagues were able to gain a lot of experience, and

the customer was greatly satisfi ed with the profes-

sional job. This has already resulted in subsequent

orders. René Schupp of the HANSA-FLEX AG Zurich

was in charge of the project.

Practically at the same time, large shuttering car-

riages were tubed and the hydraulics started up at

the construction site of the Islisberg tunnel (part

of the western bypass in Zurich). For this project,

more than 5.000 meter hose was prepared and in-

stalled. The delivery included the air ducts for the

pneumatic compactor. In charge of project: Heiko

Schulze of HANSA-FLEX AG Ittigen (near Bern).

Along with the advancement of HANSA-FLEX AG

from hydraulics-line-specialist to overall supplier

for hydraulics, and development of the industrial

assembly group, the Swiss HANSA-FLEX AG is work-

ing on the setup of the service brand FLEXXPRESS.

As is generally known, these are the workshops on

wheels, in which the hoses are ready-prepared and

delivered to the defective hydraulic line, instead of

bringing it to the hose service.

The trend to rent or lease construction machines

is growing in Switzerland as well. This generates a

need for the leasing company to fi nd a partner that

can ready-prepare and replace defective hydraulic

lines at the construction site. Here HANSA-FLEX

with its FLEXXPRESS service is right on time. In

March, the fi rst two service vehicles will be taken

into operation in Zurich. Depending on how well

the Swiss market takes to this service, they will be

introduced accordingly all over Switzerland sooner

or later.

In the future, the presently still blank area of French

Switzerland will also be developed with a branch

and HANSA-FLEX shops.

HANSA-FLEX Group Ittigen/SwitzerlandBreakthrough into new markets

INTERNATIONAL

HANSA-FLEX AGWorblentalstrasse 32 · 3063 Ittigen

Phone: +41 - 31 - 9 17 45 45Fax: + 41 - 31 - 9 17 45 49E-Mail: itt@hansa-fl ex.com


HANSA-FLEX branch in PaderbornCentred on axles

GERMANY

HANSA-FLEX Hydraulik GmbHFrankfurter Weg 48 · 33106 PaderbornPhone: +49 - 52 51 - 75 00 01Fax: +49 - 52 51 - 73 07 10E-Mail: pad@hansa-fl ex.com

Hot coff ee steams in the cups and crisp rolls are on

the table when the staff members of the HANSA-FLEX

branch in Paderborn meet once a month for a joint

breakfast. Branch manager Diethelm Kappe, who is

also the team leader for the operations in Korbach,

Warburg and Blomberg, thinks highly of these meet-

ings. "This is a time of useful conversation, during

which valuable experiences are passed on." It not only

strengthens the team spirit, but also expands the

knowledge of the staff members, "which ultimately

benefi ts the customers".

Since almost 20 years the Paderborn branch with its

fi ve staff members - three in the workshop and two

in the fi eld - as well as an apprentice in warehouse-

logistics, attends to the customers in the region,

which is shaped by its rural character. The regular

customer base of the branch includes agricultural

operations, many contractors who work the ground

or handle the transport of logs from the forest to

the saw mills. Naturally, they rely on quick help

when, for instance, a defect shows up on a loading

crane; loss of working hours can become a costly

matter for them.

Also the construction equipment dealers in the

region trust in the know-how of the branch, when

- for example - ancillary equipment must be con-

nected to the construction machines problem-free.

HANSA-FLEX doesn't merely provide economical

solutions with its reliable couplings, but also has

specifi c suggestions available for special applica-

tions, which exceed the standard of the inventory.

The Paderborn branch receives support from the

specialists of the HANSA-FLEX Group.

Of a completely diff erent nature are the require-

ments of well-known, large-scale businesses in

the region. One of these customers is the sub-

contractor Benteler Automobile, who supplies the

automobile industry with ready-to-assemble axles.

This he does on a just-in-time basis, directly to

the assembly line, which links him to the narrow

time-frame of the manufacturer. HANSA-FLEX

Paderborn is prepared to quickly assist Benteler

Automobile if a problem occurs with hydraulic con-

nection elements. One thing must never happen:

troubles at the fi nal assembly of the automobile

manufacturer.

A trustful collaboration was also developed during

the modifi cation of the Benteler test stands for the

axles. The automobile industry continuously intro-

duces new car models to the market. Thus, Benteler

is forced to often carry out modifi cations on the test

stands. When this happens, HANSA-FLEX Pader-

born supplies the according hose lines, fi ttings and

connection elements for the modifi cations.

Process speed-up - from proto-

type to series production

The initial equipment business that the branch

carries out for Kleine Engineering, who manufac-

tures high-performance sugar beat harvesters and

markets them internationally, has turned out very

well. Recently, when 25 such sugar beet harvesters

of the SF 20 type had to be manufactured at short

notice for export to Russia, the team in Paderborn

made the complete assembly sets of hydraulic hose

lines, connection elements and fi ttings available

for production within shortest time.

The manufacturer of the sugar beet harvesters also

includes HANSA-FLEX in the design and develop-

ment of the prototypes. Together with the design

engineers of Kleine Engineering they work out

solutions to minimize the number of components,

while simultaneously increasing operational safety.

In doing so, the branch speeds-up the design and

development process by quickly providing sample

components. Since HANSA-FLEX stores the design

and development data, the components are later

always available, whereat 90 percent of all the

hose lines supplied by the branch have the X-CODE

label.

This makes HANSA-FLEX Paderborn to one of

the most active branches when applying X-CODE.

"X-CODE thrives on the knowledge of the staff

members, their commitment decides if a customer

understands the benefi ts and can profi t from

them", says Diethelm Kappe. Such experiences are

also exchanged during the joint breakfast.


When "the mountain calls" HANSA-FLEX is on the

spot. The system provider covering the various as-

pects of hydraulics is also active on Germany's utmost

peak, the 2.962 meter high Zugspitze. There, HANS-

FLEX supports the service technicians of the Zugspitz-

bahn AG in hydraulic matters and takes part in pro-

viding tourists, hikers and skiers with the possibility

to experience untroubled and safe hours in this area.

In doing so, the HANSA-FLEX subsidiary HDS Hydrau-

lik GmbH intensively attends to the Kässbohrer snow

cats used on the ski slopes.

This region off ers attractions at any time of the

year. The Zugspitze was fi rst mentioned by name

in 1590. The name supposedly originated in the

many avalanche trails found on the steep slopes of

the northern mountain base, which slowly awak-

ened interest in the 19th century. In August 1820,

Lieutenant Josef Naus was the fi rst person to climb

this peak, according to historical tradition. On some

routes, this tour still presents a challenge to the

alpinists. Today, most visitors reach the top, which

also houses a meteorological station of the Ger-

man Weather Service since 100 years, considerably

easier via mountain railway or cable car.

To the top

Meanwhile with the Zugspitzbahn, operating since

75 years as cogwheel railway, the mountain scenery

reveals itself in less than one hour and is reached

at a speed of up to 70 km/h. The Eibsee-cable car,

which allows a one-of-a-kind view on the Werden-

felser Country and the Eibsee off ers an alternative.

The glacier cable car leads to the Schneeferner gla-

cier, where Germany's highest located church can

be found.

From the observation deck of the Zugspitzplatt an

impressive four country panoramic view can be en-

joyed. Anyone who wishes can also cross the border

from Germany's highest peak into the neighbouring

Austria/Tyrol. Skiers fi nd ideal conditions from No-

vember until March for enjoyable ski-runs, off ering

all levels of diffi culty in a height of 2.000 to 2.720

meters. Five lifts and one cable car are equipped to

transport 11.640 winter athletes per hour.

However, not only tourists reach the top by cog-

wheel railway, but also everything necessary for

the operation of the mountain station and the

preparation of the 21,2 kilometre slopes on Ger-

many's unique glacier ski area. Thus, for instance,

snow cannons and snow cats for the maintenance

of the ski slopes are transported on the mountain

via cogwheel railway. The Zugspitzbahn AG uses a

fl eet of snow cats to distribute, secure and level the

snow masses.

By the way, the powerful Kässbohre slope bullies

are demounted into single assemblies and trans-

ported per cogwheel railway to the top area,

where they are assembled by the manufacturer's

technicians.

Robust duty at frosty

temperatures

These Kässbohrer machines, used on the Zugspitze

for the maintenance of the ski runs and the prepa-

ration of steep slopes, are true powerhouses. The

"Polar" model, for instance, comes with a 430 HP

engine. These machines are extremely fl exible and

equipped to compensate even large downtilts in

order to construct the required tracks also on steep

mountain sections, whereat their hydraulic sys-

tems are subject to extreme exposure. In addition,

frosty coldness has a hampering eff ect, especially

SKI LIFTS



in the start up phase, on the complete technology.

Furthermore, the quickly changing pressure peaks

must be observed when specifying the hydraulic

hose lines. Therefore special HDS spiral hose lines for

highest compression loads are applied in the Käss-

bohrer machines. All spiral hose lines are pressure

tested with 800 bar prior to delivery, and equipped

with fi ttings that are protected against tearing out,

so that they meet all requirements regarding safety

for man and environment and remain mobile also

under the most extreme conditions. HDS spiral hose

lines are optimized against ozone and ultraviolet

infl uences and off er a very high safety and quality

standard. Not without reason is HDS considered the

largest specialist for spiral hose lines in Europe.

Quick partner at the base

Of course cogwheel and glacier railway, as well as

Eibsee cable car cannot do without hydraulics ei-

ther. Thus, for example, the emergency drives are

operated electro-hydraulically or diesel-hydrauli-

cally, respectively. Since eight years the HANSA-

FLEX subsidiary in Garching has been supporting

the service technicians of the Zugspitzbahn AG in

the maintenance of the cogwheel railway, but also

the cable and glacier car in all matters of hydraulic

hose lines, connections and fi ttings. All mountain

railways must be trouble-free and absolutely safe.

Each unplanned standstill of the cogwheel railway,

which can transport a maximum of 720 persons per

hour, aff ects the leave days of the vacationers and

can result in grave consequences.

Hence, the Zugspitzbahn AG operates its own work-

shop at the base station, whose service technicians

carry out all repair and maintenance work, includ-

ing the independent production and assembly of

spare hose lines for the cogwheel railway, as well

as the cable car. In doing so, they are supported

by Hans Stemmer of the HANSA-FLEX subsidiary

in Garching with technical know-how. He sup-

plies the workshop with everything that is needed

in the way of hydraulic spare parts. As partner of

fi rst choice for the Zugspitzbahn AG, HANSA-FLEX

is on site when "the mountain calls", come wind

or weather and in case of emergency also on a 24-

hour basis. This quick availability and the reliable

quality of HANSA-FLEX products have turned the

Zugspitzbahn AG into a satisfi ed customer of long

standing.

SKI LIFTS


Ingersoll-Rand confi rms: „Power of Excellence“HANSA-FLEX has what it takes

The American technology group Ingersoll-Rand

started in 1905 by building drills and compressors.

Meanwhile the company has worldwide operations

with 36.000 staff members and - aside from its core

business - has mad a name for itself in the areas of

cooling technology, construction machinery, as sup-

plier of titanium frames for the automotive industry,

all the way to access control systems and door locks.

In the Czech city of Uničov, Ingersoll-Rand produces

compressors of all sizes for the construction industry.

As system partner covering the various aspects of

hydraulics, HANSA-FLEX seeks to be listed with the

compressor specialists as supplier of purpose-built

fi xtures and purpose-built pipes.

Up to now, HANSA-FLEX supplied the Uničov

plant with hose line replacements. This coopera-

tion has proved itself. Hence, the step to preferred

supplier for serial production is only logical. The

HANSA-FLEX branch in Prague, under the man-

agement of Jaroslav Kratochvil and his colleague

Rudolf Melĉ, aims at this. They are supported by

HANSA-FLEX Bremen through their sales engi-

neer Karl-Heinz Loose, who has been advising the

customer, as well as the complete Ingersoll-Rand

Group for years.

An initial series equipment of hose lines, purpose-

built pipes and sophisticated purpose-built fi xtures,

supplied by HANSA-FLEX on the basis of drawings,

has shown that the interaction between the engi-

neers of HANSA-FLEX and Ingersoll-Rand functions

optimally. For instance when minimizing compo-

nents and decreasing leakage risks.

However, Ingersoll-Rand would not be a global

corporation if it did not apply strict standards. To

be accepted as supplier for series production, HAN-

SA-FLEX was to be put through the paces by the

American manufacturer. This was done in form of

audits on site in Dresden-Weixdorf, the home of the

HANSA-FLEX specialists for the purpose-built pipe

and purpose-built fi xture production, managed by

Wolfgang Liebig.

Prejudices corrected

By delegating Tomaš Přibyl (strategic purchasing),

Daniel Staněk (disponent) and Michal Očenašek

(quality assurance), Ingersoll-Rand sent three

proven experts to Weixdorf for the audit. During

the audit, Jörg Hartmann - responsible for quality

management at HANSA-FLEX - and Wolfgang Lie-

big made sure that the visitors were able to gain

an impressive view of all the departments and that

they were supplied with all the requested informa-

tion.

The auditors were completely thrilled from what

they observed. They thought to visit merely the

small shop of a hose supplier who didn't have

much competence. However, far from it! Imagine

the surprise when they found a company with

state-of-the-art equipment for the manufacturing

of purpose-built pipes and purpose-built fi xtures

with pipe bending centre, which incidentally im-

pressed with its departments of engineering and

hydraulic components, as well as the training fa-

cility. Thus, the Czech inspectors were equally sur-

prised and enthused already before the audit was

started. With this fi rst positive impression in mind

they began their clearly structured check program,

each of them checking in a specifi c and systematic

manner.

QUALITY MANAGEMENT


Down to the last detail

The Ingersoll-Rand inspectors observed the com-

plete production process step by step. This began

with material receiving and ended by no means

with the timely delivery. The inspectors thoroughly

considered all eventualities and also observed the

procedures of claims management. Their check

sheets included detailed questions, for which they

expected concrete answers.

They specifi cally wanted to know how HANSA-

FLEX documents the quality management system,

and how deep-seated it is with the company's

staff members. Under the category "correcting

measures" the methods were checked with which

HANSA-FLEX recognizes and corrects conditions

that are contrary to product quality. Naturally it was

checked if a timely delivery can always be assured

- even the packaging was examined - and if the or-

der requirements within the scope of order verifi ca-

tion are understood in the company, to assess the

abilities for proper manufacturing. Another aspect

was an in-house process, which guarantees that the

drawings and other documents as requested in the

contract, as well as their changes, are incorporated

into the production process.

An inquiry was made into how a drawing was

checked, and if the specifi cations contained therein

and possible changes are properly considered. The

examination in the area of acquisition manage-

ment was to determine how HANSA-FLEX forwards

suitable and meaningful construction drawings to

sub-suppliers. It also was documented to what ex-

tent the receiving department can check the qual-

ity aspects of the material received.

It couldn't be better!

And then the result: Based on the audit carried

out in Weixdorf, the Ingersoll-Rand inspectors

awarded the grade "excellent, passed" in unison!

The question if HANSA-FLEX is in a position to sup-

ply the parts needed by Ingersoll-Rand in Uničov

at required quality and within time, was answered

in the inspection report to the utmost satisfaction

with "yes". It was mentioned therein that the qual-

ity management of HANSA-FLEX “performed very

well", that it is properly established and highly

fl exible.

The international orientation of the hydraulic part-

ner from Bremen was positively emphasized, and

thus the associated proximity to the customers in

Uničov through the HANSA-FLEX branch in Prague.

The inspection process, which started in May 2005,

has now cleared the way: HANSA-FLEX will be listed

as supplier for the series production with the tech-

nology group Ingersoll-Rand.

QUALITY MANAGEMENT


„…and Heinz said that he heard only one strong hiss

during start-up, and then everything was full of oil.

Where can we quickly get a new cylinder now - the

cutter has to be kept running!" Such a scenario is

certainly not common, but it can happen at any time

- the sudden breakdown of a highly utilized hydrau-

lic cylinder. Carsten Kempfert is familiar with such

problems as trainer at HANSA-FLEX, with focus on

cylinder and seal technology.

The hydraulic cylinder is probably the best known

component in fl uid technology, because it is clearly

the link between the hydraulic cycle and the work

machine. Cylinders are practically found wherever

the human work force is supported, or completely

replaced by hydraulics. This can be in conventional

machine building, wind energy technology, avia-

tion and navigation or at the fairground.

Compared to their highly complex areas of applica-

tion and assignment, hydraulic cylinders are kept

very simple, not only in regard to the constructive

principle. The technical-physical aspect is mostly

the same, explains Carsten Kempfert: „During the

work process, a certain pressure p acts upon the

piston area A (F = p x A) via a medium in such a

way that the mechanical force F is reached, from

just a few Newton (N) to far above 250.000 kN, from

very short to meter-long stroke lengths. The driving

movement is mostly straight, though.

Consequently, the occurring hydraulic forces on

machines and installations become clearly visible

to everybody by diff erent work motions." Finally,

the lifting, lowering, shifting and securing of loads

are part of the most distinctive and important ap-

plication areas of hydraulic cylinders.

However, there are not only great forces or strokes

to be noticed, but also other important characteris-

tics of hydraulic cylinders.

• Direct power generation, i.e. without mechanical

interlinks;

• Inlet and outlet speeds can be kept constant over

the complete stroke;

• Possibilities to apply tensile forces and/or pres-

sure forces;

• Force can be applied at each stroke position arbi-

trarily, up to the maximum nominal force;

• High performance at minimal installation space is

possible.

Carsten Kempfert says that the breakdown of a

cylinder, as described at the beginning, can have

various causes. "It can be technically unreasonable

mechanical use, bad design, unfavourable admis-

sion of physical characteristics, and naturally the

interaction of several components mentioned.

In the long run

Daily operation has shown that by regular visual in-

spections such a damage - which is always accom-

panied by immense delay and very high consequen-

tial costs - can be recognized early and eliminated

accordingly. "Most of the machine or installation

breakdowns that are caused by problems show

damage symptoms dating back some time. Though

often it is simply the wear of daily use, which over

a certain period reduces the functionality of the hy-

draulic cylinder", explains the specialist.

Using hydraulic cylinders with large outlet lengths

(comparison stroke > Ø piston) can result in stabil-

ity problems when under load. This diffi culty can

be prevented by according calculations. In doing

so, the collapse load as well as the working load

is calculated by Euler's method (see HANSA-FLEX

training manual, page 74).

The value for the particular free collapse length can

be found in the table "load cases as per Euler"

For standard cylinders, whose operational positions

are seldom known beforehand, this calculation sys-

tem off ers a suffi cient safety factor for practical use

in regard to taking up superimposed bending stress

- … though sometimes it is just too late."

Stay tight

However, by far the greater damage potential is

contributed by the diff erent sealing mechanisms,

i.e. the seals. Although seals make up just a small

part of a cylinder's total cost, the diff erent sealing

systems on a hydraulic cylinder not only determine

its function, but also its safety towards man and

environment. No cylinder is better than its seals,

or so they say. "If particular seals on the piston or

on the rod fail, unreasonably high consequential

costs can occur. In this case the repair costs usually

Hydraulic cylinder and seal technologyWear parts with intelligent force

TECHNICAL INFORMATION

20

Collapse load and working load


exceed the value of the failed seal by a multiple. Or,

for instance, let’s think about the spectacular explo-

sion of the space shuttle Challenger in 1986, which

is still remembered by many of us. This catastrophe

shows the consequences of a sealing system with

a technically poor conception, as well as construc-

tively inadequate installation.

Thus, during construction the utmost care must be

exercised from the beginning when approaching

the prospective technical challenges. The design-

ing, manufacturing as well as operating of diff erent

sealing systems requires knowledge and skills in

many fundamental areas, for instance construction

and production technology, strength of materials

and thermodynamics, and above all things materi-

als sciences.

Increasingly complex

Machines and installations are getting more and

more complex and modern. Consequently, the ap-

plied materials must comply with higher require-

ments. In the case of sealing materials, the classical

application parameters of pressure, temperature,

medium and application speed play the decisive

role, now as before.

"However, for some time now the users demand

additional operational aspects, like longer main-

tenance intervals, increased safety, as well as low

procurement costs.

"Experience", so HANSA-FLEX trainer Carsten

Kempfert, "shows that in daily operation the ma-

terials ultimately accepted as professional solu-

tion are those that are not much more expensive.

When applying allegedly "cheaper" material, the

consequential costs in form of downtime as well as

increased subsequent repair expenses rise unrea-

sonably, when considering the demands placed on

today's machines and installations.

Complexity has not only been added by diff erent

forms of piston linings, rod seals, scrapers, O-rings,

but also by the increasing amount of materials and

material combinations in use. "Where a few years

ago the braided cord was good enough, today we

are facing a multitude of high-tech blends - from

many areas of materials science. Plastics, metals,

but also composite materials must be found that

are designed for the required application.

We are talking about elastomer resin-coated O-

rings, high performance polyurethanes, fl uorsili-

cone-rubbers, in trade language only referred to as

HNBR, FVMQ, FFKM or CSM. This variety naturally

results in a high error ratio. A continuously encoun-

tered classic is the "binding" identifi cation of seals

according to color. "Theoretically, each sealing ma-

terial is available in the requested color. Therefore,

a FKM-O-ring must not necessarily be green, and

NBR is not always black!"

Thus, many factors are important in developing a

functional system and to rationally seal it in the

long run as well. However, breakdowns will contin-

ue to occur, be it due to constructive, purely physi-

cal or application-related reasons. It is important to

be working with a good partner, one who faces the

problems, accepts them and always has a solution

available - we at HANSA-FLEX are aware of our re-

sponsibility!

TECHNICAL INFORMATION

Load cases per Euler

Case 1 Case 2 Case 3 Case 4

one end free, two ends fl exibly one end fl exibly two ends one end fi xed guided guided, the other one fi rmly clamped clamped (basic case) clamped


1 February Grundlagen der Leitungstechnik (LTG01) Bremen

6 to 10 February Grundlagen der Fluidtechnik (FTG02) Weixdorf

20 February Dichtungstechnik (DTG01) Eisenberg

27 February to 3 March Grundlagen der Fluidtechnik (FTG01) Weixdorf

1 to 3 March Grundlagen Metallschläuche (MTG01) Boff zen

6 to 10 March Grundlagen der Fluidtechnik (FTG02) Weixdorf

21 to 24 March Grundlagen der Fluidtechnik (FTG03) Weixdorf

29 to 31 March Grundlagen Metallschläuche (MTG01) Boff zen

3 to 7 April Grundlagen der Fluidtechnik (FTG01) Weixdorf

10 April Dichtungstechnik (DTG01) Eisenberg

24 to 28 April Grundlagen der Fluidtechnik (FTG02) Weixdorf

For further information please contact Mrs. Silvana Wagner (Training center Weixdorf): +49 - 3 51 - 41 39 719.

Please send your replies by e-mail to info@hansa-fl ex.com, or by mail. Please do not forget to include your name and address. Entry deadline is 31th of December 2005. Allowance is made for only one reply per participant. Any recourse to legal action and any liability shall be excluded to the extent permitted by law. The prize may not be paid out in cash.

Answer edition 12/05:

A: 160 bis 180

Quiz

QUIZ | IMPORTANT DATES

How many meters of hose have been

confectioned for the Islisberg tunnel

project in Switzerland?

A: 500 meter

B: 5.000 meter

C: 50.000 meter

Training seminar schedule February – March – April in german only

Training programme 2006 as from now available in every branch

Winner edition 12/05:

Karin Zigun – 21379 Rullstorf

Claus-Dieter Postler – 91052 Erlangen

Manuela Winkler – 31848 Bad Münder-Hasperde

Uwe Klein – 66629 Freisen

Morris Hermann – 22926 Ahrensburg

Peter Töx – 63741 Aschaff enburg

Georg Klaus – 54568 Gerolstein

Michael Pfi ster – 55129 Mainz

Reiner Staske – 61440 Oberursel

Detlef Rapke – 30179 Hannover

Club sponsoring 2006/2007Year by year, the importance of sport sponsoring

by companies becomes increasingly clear. Today,

the realization of sports activities and events has

become more diffi cult than ever without this sup-

port.

Now for the fi fth year, HANSA-FLEX wants to com-

mit itself and equip 30 sports clubs with new tri-

cots at a value of EUR 1.000,- each.

Clubs can apply until May 31, 2006 with an infor-

mal letter, introducing the club and providing con-

tact information.

After the drawing, the selected clubs receive a

confi rmation letter with the contact information

of the supplier where the tricots can be ordered.

Donation receipts from the clubs are not necessary,

since they don't receive any money.

Please send applications to:

HANSA-FLEX Hydraulik GmbH

Marketing Department

Keyword: Club sponsoring 2006/2007

Zum Panrepel 44, 28307 Bremen, Germany

Fax: 04 21/4 89 07 48

e-mail: ma@hansa-fl ex.com

Win three WMF salt/pepper mill sets!

Simply answer our raffl e question, and one of the three WMF salt/pepper

mill sets can be yours.


More interesting topics in our next issue...

Editorial deadline: 1st March 2006

Cartoon

INFORMATION | ENTERTAINMENT | OUTLOOK

Trade fair announcements

Outlook

23

Agricultural implements in the Ukraine: AGRO-SOYUZ, Horsch

Interview with ... Heiko Richter, Group Manager Dresden/Bautzen

Certifi cate HANSA-FLEX attains Q1 approval from the Deutschen Bahn

Metal hoses Report on glassworks Holzminden

HANSA-FLEX branches Shanghai (China) and Celle

Training center Technical information on preventive measures

04/06

Anniversaries 2006February 2006

MAZ/H5 Berlin-Marzahn 10 years

ROS/G5 Rostock 10 years

March 2006

BIE/C2 Bielefeld 25 years

MUE/C1 Münster 25 years

April 2006

BAU/X0 Bautzen 10 years

HWI/G6 Hamburg-Wilhelmsburg 10 years

16 to18 February Technical Fair Timisoara, Romania

21 to 24 February ConMac Ukraine 2006 Kiev, Ukraina

2 to 5 March TIT – Technical International Fair Cluj-Napoca, Romania

2 to 5 March BAUMAG Luzern, Switzerland

22 to 24 March Electra Mining India New Delhi, India

30 March to 2 April Mawev Show Enns/Hafen, Austria

We are aware of our responsibility.

Nothing is impossible with Europe’s leading system partner for fluid technology.

HANSA-FLEX Hydraulik GmbH · Zum Panrepel 44 · D - 28307 Bremen www.hansa-flex.com · E-Mail: [email protected]

It’s not a trick. It’s a system!

Documents

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