02/06 nominal charge 2,00 eur hydraulik - hansa … · nominal charge 2,00 eur...
TRANSCRIPT
Destination ZugspitzeWith high pressure in the snow
Destination ZugspitzeWith high pressure in the snow
Page 16
Nom
inal
char
ge 2
,00
EUR
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
HYDRAULIKPRESSE 5ISSUE FEBRUARY 2006
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.
HYDRAULIKPRESSEISSUE FEBRUARY 2006
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
HYDRAULIKPRESSEISSUE FEBRUARY 2006
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
HYDRAULIKPRESSE10ISSUE FEBRUARY 2006
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
HYDRAULIKPRESSE 11ISSUE FEBRUARY 2006
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
HYDRAULIKPRESSE12ISSUE FEBRUARY 2006
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
HYDRAULIKPRESSE 13ISSUE FEBRUARY 2006
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!
HYDRAULIKPRESSE14ISSUE FEBRUARY 2006
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
HYDRAULIKPRESSE 15ISSUE FEBRUARY 2006
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.
HYDRAULIKPRESSE16ISSUE FEBRUARY 2006
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
Destination ZugspitzeWith high pressure in the snow
HYDRAULIKPRESSE 17ISSUE FEBRUARY 2006
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
HYDRAULIKPRESSE18ISSUE FEBRUARY 2006
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
HYDRAULIKPRESSE 19ISSUE FEBRUARY 2006
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
HYDRAULIKPRESSEISSUE FEBRUARY 2006
„…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
HYDRAULIKPRESSE 21ISSUE FEBRUARY 2006
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
HYDRAULIKPRESSE22ISSUE FEBRUARY 2006
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.
HYDRAULIKPRESSEISSUE FEBRUARY 2006
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!