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Culture Documents
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CO2 AS A RAW
MATERIAL
RESEARCH FOR
THE ENERGY OF
THE FUTURE
BATTERIES OR
HYDROGEN?
How to store renewably
generated energy
Production,
storage,
distribution:
the new
technologies
we need for
the switch to
renewables
Portal
FOREWORD
1,000
330
gigawatts
by 2030.
FIND OUT WHICH STORAGE DEVICES
THYSSENKRUPP IS DEVELOPING ON PAGE 16
MILLION
metric tons OF
CARBON DIOXIDE
EVERY YEAR.
MORE ON THIS FROM PAGE 14
40%
GERMANY
COULD SAVE
SOME
BY 2030 COMPARED
WITH 1990.
900
GERMANY
ALONE EMITS
SOME
5.6
Dear readers,
03
Preview
PROJECTS
26
26
Joining forces
Experts from several areas of ThyssenKrupp
have come together in the InCar plus project
to develop components for the cars of the future
30
32
34
37
Short cuts
The internet of elevators | New solution for hot
forming | Remote control for shock absorbers
PANORAMA
10
06
04
38
TECHFORUM #02
42
PERSPECTIVES
A female perspective
Nineteen female students have looked into
sustainable shock absorbers as part of the
Femtec initiative
46
48
Short cuts
Working hand in hand with robots | Test rig
for fusion reactor | Temporary storage device
for renewable energies
50
Short cuts
Economical electrolysis technology | Batteries for
BMW i3 | Cooperation with RWTH Aachen University |
Test tower for elevators in Rottweil
08
10
14
16
20
Everyone is a winner
Cross energy management stabilizes power networks
to the benefit of industry and consumers
24
Focus on efficiency
ThyssenKrupp is backing greater energy efficiency.
The Rothe Erde subsidiary shows the way
42
24
ThyssenKrupp techforum 02.2014
short cuts
Economical
PROCESS
Expanded cooperation
with RWTH Aachen University
ThyssenKrupp and RWTH Aachen
University have been working
together intensively for many
years in particular the Steel
Europe business area maintains
close contacts with the renowned
educational establishment. At a
joint R&D Forum in early June the
partners discussed future strategic
cooperation projects: Professors
from RWTH Aachen University
together with representatives from
ThyssenKrupp identified in the
Automotive, Plant Chemical,
Materials, and Industry 4.0
workshops key future topics that are
to be jointly developed further. The
collaboration with RWTH Aachen
University is part of an extensive
program of cooperation between
ThyssenKrupp and leading higher
education institutions across
the globe.
Innovation boosts efficiency: Oxygen depolarized cathodes for the production of chlorine and sodium hydroxide solution.
07
highlight
Airports
Speeding things up
Train stations
Interchanges
8,000
6,000
4,000
Moving
walkway
Cabin system
2,000
Bus
1
Monorail
New
moving
walkway
10
Distance
in km
SPEED CHANGE
Schematic
representation
Dragger
120 cm
100
cm
240 cm
DOUBLY SECURED
Safety chain
SAFETY FIRST
Linear motor
Text: Lena Bulczak
INFOGRAPHIC: Niko Wilkesmann
09
PERSPECTIVES
SMART ENERGY
A
Sustainability
an engine of innovation
Environmentalist meets technology chief:
Professor Hans Joachim Schellnhuber
and Dr. Reinhold Achatz discuss the
21st century economy. They are agreed
that sustainable companies have the better
economic prospects in the long term.
11
PERSPECTIVES
SMART ENERGY
BIGGER
PROFITS
THROUGH
A FORWARDLOOKING,
SUSTAINABLE
FOCUS
WE CAN
GENERATE
MORE
BUSINESS
IF WE HAVE
SUSTAINABLE
OFFERINGS
13
PERSPECTIVES
SMART ENERGY
CO
as a raw
2 material
Methane
+ CO2
H2
The PLANCK
idea: Steel mill
gases contain,
among other
things, carbon
monoxide,
carbon dioxide,
hydrogen,
and nitrogen.
When combined
with additional
hydrogen from
wind power,
they can
produce natural
gas, methanol,
and ammonia.
Turbines
Gas system
Conversion of
electrical energy
into chemical
products
+ N2
Methanol
Ammonia
O2
E-cars
Nitrates
Steel production
consumes large
amounts of
energy but
can also provide
raw materials for
synthesizing base
chemicals.
15
PERSPECTIVEs
SMART ENERGY
T
Wind turbines
are not
governed
by demand.
This is why
we need
new power
storage
devices.
17
PERSPECTIVEs
SMART ENERGY
batteries
We need
Electrolysis cells
at work.
STORAGE DEVICES
NEED TO BE USED FOR
THE FULL RANGE OF
TIME AND VOLUME.
19
perspectives
winner
smart energy
Everyone is a
Precarious balance:
Only if power production
and use are in equilibrium
can our networks remain
stable and industrial and
domestic consumers
receive reliable supplies.
20
Dr. Friedrich
Lser is Head of
ThyssenKrupps
TechCenter
Control
Technology.
PERSPECTIVES
SMART ENERGY
generation
Load must follow
IT
DieIS
Politik
UP TO
POLITICIANS
muss
TObessere
CREATE
Bedingungen
BETTER
CONDITIONS
schaffen
2%
Bilateral agreements with network operators
4%
Participation in the energy balancing market
16%
Used for optimized electricity purchase
47%
Reduction of companys peak load
21%
Examined but not followed up
13%
Other
26%
No experience
23
PERSPECTIVES
SMART ENERGY
In the manufacture of rings and large-diameter bearings,
ThyssenKrupp Rothe Erde is embracing a comprehensive
energy management system under the DIN 50001 standard.
Focus
on efficiency
25
PROJECTS
INCAR PLUS
Joining forces
M
ost drivers would probably be rather
surprised if they were to put one of their
smart aluminum wheel rims on the scales
and then, for comparison, a modern steel
rim. This is because, although aluminum
is a light metal, the wheel made with
high-strength steels weighs less. Nevertheless, the range
of different aluminum designs seems to be simply infinite,
compared with steel wheels. That could change soon,
however, thanks to one of the projects in the InCarplus
research program: Our concept allows for a combination
of attractive styling and minimum weight, says Markus
Zrnack, an expert in lightweight construction at
ThyssenKruppSteelEurope in Dortmund.
Lightweight
construction is not
an end in itself. There are
solutions that make a
greater contribution to
reducing emissions
at lower cost
dr. axel grneklee
27
PROJECTS
100km, Grneklee says. The further development and
increased efficiency of these EPS (electric power steering)
systems was one topic covered by InCarplus. Our new
column EPS power unit is making this technology
available even for mid-range vehicles, Rainer Pudeg of
ThyssenKrupp Presta Steering, head of the chassis and
steering subproject, is delighted to note. The compact
incar plus
29
PROJECTS
Incar plus
T
Innovations
16
60
weight reduction
at component level
19
weight reduction
through efficient design
Bumper system
Electric/hybrid
powertrain
The assembled, modular
rotor of an electric motor
saves up to 16 percent in
weight. The hollow interior
allows for an active internal
cooling system, which
improves efficiency markedly,
especially in conjunction with
high-strength electrical steel.
20
Valve train
weight reduction
through the use of Litecor
Engine hood
Integrated damping
adjustment valve
The pilot-operated pressure relief valve
combines driving comfort and safety with
agility. It switches quickly and offers a high
spread of steam power with high adjustment
dynamics even at the pressure stage.
15
less
weight
31
PROJECTS
inpro
Think
tank
Pooled resources
Spurs plan was to bring all the industrial sectors
involved in car production vehicle manufacturers,
factory equipment providers, suppliers together in
33
PROJECTS
INTERVIEW
leader
We are a world
35
PROJECTS
36
short cuts
INTERVIEW
THE ROAD TO
E-MOBILITY IS NOT
A SPRINT BUT A
LONG-DISTANCE
RACE
matthias wissmann
The internet of
ELEVATORS
New standard in
hot forming
Hot forming is gaining increasing
ground as a cost-efficient lightweight
construction solution in body
manufacture. ThyssenKrupp System
Engineering together with Audi AG and
Ebner Ofenbau has developed a line for
manufacturing hot-formed parts that
is setting new standards. It features
technologies which include tailored
tempering, enabling different strength
levels to be created in a single component.
The line is also prepared for hot trimming
(simultaneous forming and cutting) and
offers fully automated tooling changes,
allowing production to be switched in
extremely short changeover times.
37
panorama
TREND RESEARCH
future
WE ARE DRIVING
FUNDAMENTAL
INNOVATIONS IN
COLLABORATION
WITH PARTNERS
39
panorama
TREND RESEARCH
SANDWICH
MATERIALS
WILL PLAY A
SIGNIFICANT
PART IN THE
FUTURE
OUR
CUSTOMERS
EXPECT
TAILORED
SERVICES AND
SOLUTIONS
41
panorama
PORTRAIT
female
perspective
43
panorama
PORTRAIT
This is a practical challenge we are currently
facing, because our customers are placing ever higher
demands on the sustainability of products, explains
Dr. Andreas Rohde, who supervised the project for
ThyssenKrupp Bilstein. They are focusing chiefly
on environmental performance, compatibility, and of
course the cost-effectiveness of our innovations. It was
therefore increasingly important to take these aspects
into account early on in the development process,
this being the only way to ensure that the subsequent
products are actually sustainable: That means that at
the very start of the process we have to stipulate which
criteria we are considering and plan to implement.
These very criteria were at the heart of the Femtec
project: Sarah Feil and her 18 colleagues were to draw up
a list of requirements for the production of the new shock
absorber. The team was diverse: alongside a few budding
mechanical engineers, students of mathematics,
business studies, and waste management were also
represented. At our kickoff meeting the students still
looked quite puzzled they were simply unsure whether
they were up to it, recalls Rohde. The topic was not only
very abstract but also very extensive. However, following
an initial meeting in March and a few conference calls
I saw that they were equal to the task.
IT WAS
RATHER STRANGE
SUDDENLY TO
FIND YOURSELF
IN A GROUP OF 19
YOUNG WOMEN.
Malena Schulz
Exchange of experience
with other players
He recalls many open debates and the special approach
to a number of tasks adopted by the young women. On
the issue of recyclability, for instance, men might have
researched how to create a recycling-friendly product,
reports Rohde. In contrast, the female students
proposed talking to staff from a recycling firm. I found
this interpersonal aspect and the exchange of experience
with other players interesting.
The project also provided its participants with new
experiences. If you are studying a technical subject,
you are always surrounded by men, says Schulz. The
proportion of women studying mechanical engineering
is about ten percent, for example. With Femtec it was
rather strange suddenly to find yourself in a group of
19 young women.
The result of the Femtec project is a questionnaire
containing 30 points, which is intended to cast light on
the topic of sustainability in the future development of
shock absorbers from various angles and in a structured
manner. The students first subdivided the complex issue
into various categories, such as material, process, and
innovation. Other points concern the life span of a shock
absorber, such as the period of use or end of useful life.
The number of questions per category varies between
two and eight. The respondents can either check preset
answers or provide longer responses in a separate field.
A section of general questions, for example, deals
with whether customers have already asked about
the sustainability of the product, and whether the
relevant data are available at all. Even the respondents
assessment forms part of the list of questions: do you
consider your own product to be sustainable? Some
questions are more general in nature for instance,
the authors want to know whether the readers have
further ideas on the topic of sustainability. They also
touch on whether alternative materials could be used to
reduce noise pollution during the products service life,
45
panorama
Atlanta
RESEARCH TEAMS
App from
of
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it
is
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re
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elevators be redu
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vation Center
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arch
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for all aspects of modern elevator tech
part of the global
make them market-ready. The RIC is
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network of ThyssenKrupp Tech Cen
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fields. This team, established in early
Georgia Institute
in an ideal setting: at the heart of the
of Technology campus in Atlanta.
in the USA
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47
short cuts
Working hand in
hand with
ROBOTS
W
Humans and machines become colleagues.
Seeking contact:
In the future, robots
will assist humans
on production lines.
Proud winners:
The Dortmund
apprentices Tim
Leubecher, Lukas
Latassek, and Kay
Musielak at the
regional contest.
49
COLUMN
portfolio
beauty contest
for heaters
50
First-class
introduction
Value creation
of the future
What profound technological, economic, and social
changes are to be expected
by 2030 and what impact
are they likely to have on the
value chain and jobs in Germany? Experts from the BDI
working group on Innovation
Strategies Geared to Value
Creation have explored such
issues for this study.
DEUTSCHLAND 2030
(GERMANY 2030)
Federation of German
Industries (BDI)
Free of charge at www.bdi.
eu/Publikationen.htm
Diagnosis and
treatment
In this book two of Germanys most well-known
climatologists delve into climate change and its consequences. They start with an
overview of climate history,
explaining what lessons we
can learn from that for our
current situation. Yet they
do not confine themselves
to a mere diagnosis at the
end of the book they put
forward specific proposals
for tackling the problem of
climate change.
DER KLIMAWANDEL
(CLIMATE CHANGE)
Stefan Rahmstorf, Hans
Joachim Schellnhuber
(C.H. Beck) 7.99
IMPRINT
PUBLISHED BY:
ThyssenKrupp AG, Corporate
Function Communications,
ThyssenKrupp Allee 1,
45143 Essen, Germany
RESPONSIBLE EDITOR:
Bernd Overmaat (legally
responsible for content)
contact.techforum@
thyssenkrupp.com
Guide for
companies
The switch to sustainable
energy can succeed only if
we adapt our power consumption in future to the
available supply of renewable
energies. The Handbuch
Lastmanagement (Load Management Handbook) reveals
the potential for intelligent
load management lying dormant in companies and why
this new flexibility will pay
off through revenue from
shiftable loads, for instance.
Practical examples and tips
on the gradual introduction of
load management round off
this dena publication.
HANDBUCH
LASTMANAGEMENT
(LOAD MANAGEMENT
HANDBOOK)
German Energy Agency
(dena) 19.50
PHOTO CREDITS
COPYRIGHT:
ThyssenKrupp AG 2014
Reprints only with the publishers
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Information about ThyssenKrupp
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www.thyssenkrupp.com
A digital version of ThyssenKrupp
techforum can be found at
www.thyssenkrupp.com/techforum
PUBLISHING HOUSE:
Axel Springer SE Corporate Solutions
PROJECT MANAGER: Christopher Brott
EDITOR-IN-CHIEF: Christian Buck
ART DIRECTION: Christian Hruschka
& Stefan Semrau (twotype design)
PICTURE EDITING: Bianca Classen
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ISSN: 1612-2771
Thyssen krupp:
pp. 4-5, 6-7, 15, 18, 24, 26-29,
30-31, 37, 45, 46-47, 48-49.
natalie bothur: pp. 38-41.
Dominik Butzmann/laif: pp. 34-36.
Bianca Classen:
pp. 3, 50. (Illustration)
inpro: pp. 32-33.
irmin eitel: pp. 21, 52.
Getty Images: pp. 1, 2, 16, 20-23,
32-33, 46-47, 48-49, 51.
christoph otto: pp. 5, 42-43.
gtz Schleser: pp. 4-5, 10-13.
Niko Wilkesmann:
pp. 8-9. (Infografic)
51