fluid - fischer-group.com€¦ · Hans-Peter Fischer Managing Director of the fischer group. 4 5...
Transcript of fluid - fischer-group.com€¦ · Hans-Peter Fischer Managing Director of the fischer group. 4 5...
fluidInternational news & information of the fischer group
Technology for people and the environment.A new addition to the group: fischer eco solutions
Technology for people and the environment.A new addition to the group: fischer eco solutions
1 | 2011
fischer Hydroforming:Rotary swaging as a new forming technology in Chemnitz
fischer eco solutions:On a great journey with Aida
fischer Edelstahlrohre:Many new sizes, tailored to customer requirements
2 3fluid 1 | 2011 // fluid 1 | 2011 //
Publisher: fischer group, Gewerbegebiet 7, 77855 Achern, Germany
Editor: Peter Hils (responsible)
Contributors to this issue: Hans Fischer, Hans-Peter Fischer, Roland Fischer, Christian Behrle, Brigitte Antal, Dr. Stefan Geißler, Erich Kotzenmacher, Thomas Prell, Hans Wolfgang Szymanek, Jens Helmbrecht
Contact: Phone: +49 7841 6803-0, E-mail: [email protected]
Design: Frank & Konsorten Werbeagentur, Lahr, Germany
Print: Straub Druck+Medien, Schramberg, Germany
Photo credits: fischer group, Aida Cruises, Udo Loster, Jörg Wilhelm
Editorial
Greeting
fischer China
Quality management certified
News
Effective October 2010, fischer Tubetech (Taicang) Co. Ltd. in Taicang ,
China, is now also certified according to DIN ISO EN 9001:2008.
With this step, the young Chinese fischer branch office becomes part of
the internationally uniform quality standards within the fischer group.
You will read a detailed report on that topic in the next fluid. ‹‹
fischer eco solutions
TÜV approval for flue gas desulfurization
fischer group has had the quality of its weld seams tested and
confirmed by TÜV. Now laser-welded fischer tubes made of particularly
high-quality materials such as NiCr23Mo16Al (2.4605) can also be used
in sensitive areas such as flue gas desulfurization for example. ‹‹
Title themefischer eco solutions: Technology for people and the environment . . . . . 4Trigeneration: On a great journey with Aida . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Companyfischer eco solutions at IFAT ENTSORGA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6fischer Hydroforming & fischer Maschinentechnik:
Internal group teamwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Team Talkfischer South Africa: Computer training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8fischer South Africa: Action Cricket Team . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8fischer South Africa: Soccer team on the path to success . . . . . . . . . . . . . . . 9fischer Canada: Longtime employees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8fischer Canada: Thomas Prell turns 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9fischer Germany: Congratulations on qualifications . . . . . . . . . . . . . . . . . . 16
Tech TalkMechanical rotary swaging at fischer Hydroforming . . . . . . . . . . . . . . . . . . 10Automated press cuts for special section tubes . . . . . . . . . . . . . . . . . . . . . . . . 14
CustomersMEIKO: Revolutionary rinsing technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15REMUS-SEBRING: Great sound from fischer tubes . . . . . . . . . . . . . . . . . . . 15
fischer AquaDesalt
Minister visits trade fair stand Saudi Water & Power Forum 2010
Last year, fischer AquaDesalt again participated in the lar-
gest conference and trade fair for energy and water which
was held in Jeddah, Saudi Arabia. The company presented its
seawater desalination competence from 2 – 6 October. In additi-
on to many other interested parties, the Saudi minister for water
and electricity, Abdullah Al-Hussayen, also visited the fischer
trade fair stand and was impressed by the company‘s innovative
technology. ‹‹
With an ear to the market
Under a new flagDear Customers,
Dear Employees,
We have been the specialists for welded stainless
steel tubes for decades. We made our name with
the production and processing of such tubes. With
the continuous expansion of available tube sizes,
new materials and processing methods, we have
gradually developed our expertise in our core
segment. So we are especially happy to see that a
new project has achieved a surprising amount of
success in a very short time period: the formati-
on of fischer AquaDesalt. With the establishment
of this company, we entered a new direction in
2009 – with a subsidiary that specifically took up
the issue of seawater desalination on an applied
basis. The creation of this company has set in mo-
tion dynamics which led to significant demand
in adjacent application areas. Therefore the focus
was no longer just on seawater desalination but
also refrigeration equipment and evaporators.
Or, to put it more generally, methods in which
highly corrosion-resistant heat exchangers play
a key role. In this context, fischer group was able
to combine its processing competence with this
newly gained process competence for the first
time. This created entirely new perspectives in
a promising market segment. To reflect the new
direction of the company, we quickly decided on a
new name: fischer AquaDesalt became fischer eco
solutions. The name is encompassing enough to
combine a number of different applications under
one roof. In addition, it also signals the direction
of the company: fischer eco solutions develops
and promotes highly-efficient methods of thermal
energy conversion that offer not only economic
but also considerable ecological benefits.
Personally, I am very happy and proud of what
the committed employees and partners of the for-
mer fischer AquaDesalt and current fischer eco
solutions have already achieved in such a short
time period. A big thank you to all who played
a part in this development. To a successful and
energy-efficient future.
Sincerely yours,
Hans Fischer
Founder and Chairman of the fischer group
High-profile visitor: the Saline Water Conversation Corporation (SWCC) from Saudi Arabia at the fischer trade fair stand.
Dear Customers,
Dear Employees,
In addition to product and process competence,
outstanding customer orientation has also long
been an important success criteria for fischer
group. This competence was again proven last
year, as we have taken a market-oriented ap-
proach and expanded our product range for the
production and processing of welded stainless
steel tubes according to in-house market studies.
With respect to the products, we have ex-
panded the fischer Edelstahlrohre delivery
program in key segments. These include
larger tube diameters, small thick-walled
tubes and laser-welded thin-walled tubes
with small diameters.
In the case of processes, fischer group has in-
troduced rotary swaging as the forming tech-
nology at fischer Hydroforming Chemnitz.
The order situation and customer reactions have
already provided positive confirmation of the
decision to invest in new areas. We are pleased
to be able to engage in continuous further
developments together with our customers –
towards ever new possibilities for fluid shapes
from welded tubes.
Sincerely,
Hans-Peter Fischer
Managing Director of the fischer group
4 5
Technology for people and the environmentfischer eco solutions follows fischer AquaDesaltOne and a half years ago, fischer group
established fischer AquaDesalt – the first
group company specializing in one indus-
try. But sometimes success has a way of
overtaking your plans. The developments
and contacts of this special company
were so successful, that they soon led to
a demand for new application areas. To
address this demand, the business area
of the new company has been expanded:
refrigeration machines and heat distil-
lation have now been added to seawater
desalination. To reflect this natural de-
velopment, management has decided to
transfer fischer AquaDesalt GmbH into
fischer eco solutions GmbH.
Continuity in all business areasThe new company therefore becomes the legal
successor to the previous company and will
continue all of the business operations of its
predecessor. The sole purpose of the transfer
process was to lend adequate expression to the
new alignment and expansion of this business
segment. “With the new company fischer eco
solutions we are setting a clear signal of where
the journey is headed”, says the former and now
also new Managing Director Christian Behrle.
For the first time in fischer group‘s history, the
group company has developed a special compe-
tence in plant construction in a very short time.
“Until now, we always supplied our customers
with high-quality products and components
and thus displayed our excellent production
competence. With fischer eco solutions, we are
also providing proof of our solution competence
for complex and highly innovative thermody-
namic processes”, says Hans Fischer, founder
of the fischer group, about the new quality.
The product spectrum of fischer eco solu-
tions also includes highly corrosion-resistant
heat exchangers. They represent an important
component of different applications, such as
seawater desalination, refrigeration and heat-
ing systems, equipment for the beverage and
process industry, power plants and more.
Added to these are special solutions such as
the modular multi-effect distillation systems
(MED), absorption refrigeration units (ARU)
and systems with combined processes – the
so-called “trigeneration” – for combined heat,
Products and solutions by fischer eco solutions
power and refrigeration facilities. This process
involves the production of mechanical energy
from a heat source, e.g. for electricity genera-
tion, cold water and drinking water. ‹‹
On a great journey with AidaTrigeneration for more energy efficiency On the new AIDA 6
cruise ship, fischer
eco solutions is
showing how ef-
ficient energy uti-
lization can work
in practice. This
is where trigen-
eration is being
tested in a pilot
facility. The cool-
ing water of the
diesel engines is used to generate elec-
tricity, cooled water and drinking water
on board of the cruise ship. The facility
can achieve a cooling capacity of up to
1300 kW and produces up to 150 m³ fresh
water every day. The project was imple-
mented in close cooperation with INVEN
Absorptions GmbH and the shipbuilders
of the Meyer Werft
i n P a p e n b u r g
(Germany) .
By using a MED
facility for desali-
nat ion purposes
and an absorption
cooling facility for
cooling purposes,
instead of reverse
osmosis and me-
chanical compressor cooling , it is possible
to achieve a noticeable increase in the pro-
duction of valuable electrical energy on the
ship. ‹‹
AIDA cruise ship: More on-board energy efficiency in the future – thanks to fischer eco solutions.
4 5
Energy conversion comparison
Conventional: Trigeneration:
Diesel /Gas
Electricity
Heat
Losses
Freshwater
Cooling
Diesel /Gas
Electricity
Heat
Losses
Freshwater
Cooling
The heat added to the cooling water of the diesel engines is used to desalinate seawater and produce refrigerated air for air-conditioning purposes.
This principle can also be used in the port. The desalination (MED) and refrigeration machines
(ARU) consume much less electricity as compared to reverse osmosis systems and refrigeration compressors.
The systems consist of compact and removable modular components.
Maintenance requirements are very minimal The operating temperature of the MED system is
max. 44° C. Both systems are based on the same design
principle: namely modular components. Optimized heat recovery ensures that waste heat is
better utilized. Attractive ROI (Return on Investment)
Advantages at a glance
fluid 1 | 2011 // fluid 1 | 2011 //
fischer AquaDesalt becomes fischer eco solutions.
Consistently modular: the MED seawater desalination system for Aida.
Title theme
A U-flow heat exchanger up close.
Compact and efficient: heat exchanger modules by fischer eco solutions.
6 7fluid 1 | 2011 // fluid 1 | 2011 // 7
News
fischer Edelstahlrohre
Larger diameters:168.3 – 203.2 mmCustomer satisfaction plays a key role at
fischer group. After the company‘s own mar-
ket studies showed an increased demand for
larger pipe diameters, activities in the large
tube segment increased accordingly. Invest-
ments in existing tube profiling systems mean
that longitudinal seam welded stainless steel
tubes can now be produced up to a diameter
of 203.20 mm (8 inches) since the second half
of 2010. The first completed orders for this size
segment have shown that this was the right in-
vestment to make, and that the expanded range
is accepted by customers. ‹‹
News
fischer group know-how for the production
of longitudinal seam and welded stainless
steel tubes has been transferred to the small
tube segment, resulting in the development
of an entirely new market segment focus-
ing on small thick-walled tubes with diam-
eters ranging from 6.00 to 12.00 mm. While
Achern mainly produces tubes for the automo-
bile industry with diameter tolerances of D4
pursuant to DIN EN ISO 1127 (+/- 0.5 % min.
0.10 mm), fischer Edelstahlrohre Austria in
Griffen now rounds off the product portfolio
in the small pipe segment with its WIG welded
and inline bright annealed stainless steel tubes
all the way to high-precision tubes (HP tubes)
with displayable diameter tolerances beyond
existing standards at +/- 0.05 mm.
Of course fischer is also active in the small
EGR round tube segment, with one produc-
tion line dedicated to producing small lon-
gitudinal welded stainless steel tubes with
diameters ranging from 5 – 10 mm and a
wall thickness of 0.10 – 0.50 mm.
To achieve maximum efficiency, fischer
relies on the proven welding method for the
production of thin-walled stainless steel tubes.
It is particularly in the EGR segment that
welding can exhibit its strengths due to its
continuous and constant process. ‹‹
Existing tube profiling systems for this seg-
ment reached their capacity limits a mere 18
months after the completion of this portfolio
extension at the Achern site. Another reason
to continue to invest in this area. One example
is the state-of-the-art profiling system for
small thick-walled stainless steel tubes (6 x 1.0,
8 x 1.0/1.5, 10 x 1.5/2.0, 12 x 2.0) which has been
in operation since November 2010. The system
produces both fixed and production lengths (in
technical coordination with our customers). It
can also produce stainless steel tubes wound on
coiling stands. This program is mainly directed
at customers wishing to reduce transport, ware-
housing and production costs by minimizing
cut-offs. ‹‹
fischer Edelstahlrohre
Small thick-walled round tubes: 6 x 1.0, 8 x 1.0/1.5, 10 x 1.5/2.0, 12 x 2.0 mm
fischer Edelstahlrohre
Small thin-walled round tubes: welded!
6fluid 1 | 2011 //
IFAT ENTSORGA 2010 in Munich
Core competence: Heat exchanger modulesfischer eco solutions impresses with innovative thermo-dynamic applications
Company
The environmental technology industry
met at its new major global trade fair IFAT
ENTSORGA between September 13 – 17,
2010 in Munich. And in the middle of it all:
fischer eco solutions. The new fischer heat
exchanger modules were the centerpiece of
the trade fair stand. They play a key role in
a variety of different applications: in ther-
mal seawater desalination, refrigeration
machines and heat pumps, and as an inno-
vative heat exchanger concept for creameries
and breweries. “IFAT ENTSORGA is the ideal
platform for our new technologies”, says a
happy Christian Behrle, Managing Director
of fischer eco solutions. “We have made a lot
of interesting contacts and have shown that
fischer eco solutions will consistently pursue
the path started by fischer AquaDesalt.” ‹‹
8 9
Long-time Managing Director of fischer
Canada – Thomas Prell – celebrated his
50th birthday last year. Of course this was a
reason for celebration, which took place on
Friday, 13 August.
The evening event, which included many
fischer Canada
Happy 50th Managing Director Thomas Prell celebrated his birthday
9
Team Talk Team Talk
Thomas Prell with daughters Sabrina, Kristina and Sarah
8
fischer South Africa
Silver at first tryNewly formed Action Cricket Team reaches finale
Great interest in computer training
fischer South Africa has been imple-
menting a program for improving
the computer skills of its employ-
ees for almost a year. The initiative
is evidence of fischer group‘s com-
mitment to opening up professional
development opportunities for its
employees – and not just in South
Africa.
The voluntary and free com-
puter courses are managed by Cedric
Kotzenmacher , who has a Bachelor
degree in information technology from
Bond University in Australia. The
courses are held every Saturday, in
two-hour blocks. Each course takes four
weeks and ends with a written exam.
To date, two course cycles consist-
ing of a basic and advanced course
have been completed. Course topics
range from basic PC knowledge and
Office applications to using the Inter-
net. More than 35 percent of employees
have attended the courses – and an
increasing number of employees have
expressed their interest. ‹‹
fischer South Africa
From the World Cup to the Industrial League The fischer soccer team on the path to success
When the 2010 FIFA World Cup was held in
South Africa, employees of fischer South
Africa decided to host their own “fischer
World Cup”. The teams that were formed
represented the various football soccer
nations. fischer’s “Germany Team” was the
overall winner.
The “German” team consisted of young
players who were very quick on the ball. They
were as creative as the stars of the real German
national team, such as Müller, Podolski and
Klose. The “fischer South Africa World Cup”
was greeted with enthusiasm by all employees,
and was very well attended.
Following the success of this idea, col-
leagues formed a fischer group South Africa
team, which includes all of the good players of
the “fischer World Cup”. Fired up by the World
Cup spirit, the fischer selection played its first
official game against a customer team on
14 August. The fischer team won 6:2.
Now fischer South Africa is in the process
of registering the team for the “Industrial
League”. With the great support offered by
management, the players are confident that
they will reach the top of the league standings.
Finally, these activities also aim to create an
inspiring and healthier work environment for
all fischer employees. At the same time, rela-
tionships with current and future customers
and suppliers are also strengthened, according
to Henry Free, the “fischer South Africa Soccer
Manager”. ‹‹
“Gemuetlichkeit” at the Concordia Club
In attendance (from left to right, front): Stanislaw Wawrzaszek, Birgit Prell, Jan Twardus, Al Loft, Jaroslaw Michalak, Kim Lizun, (back row) Thomas Prell, Kris Bulawa, Jerzy Walczyk, Uta Prell and Nelson Gow.
guests, friends and family, took place at the local
Concordia Club, a traditional club for German
immigrants in Ontario. They were also joined
by several international Managing Directors of
the fischer group as well as group founder Hans
Fischer and his son Hans-Peter.
We would like to take this opportunity to
send congratulatory greetings to Thomas Prell
in Canada. ‹‹
On 11 July 2010, fischer Canada hosted an
anniversary event for all employees who
have been with the company for
more than 20 years. At this event,
the company also said good-bye
to Nelson Gow, who retired.
On this occasion, fischer Canada
Managing Director Thomas Prell
personally thanked all employees who have
stayed loyal to the company during the
good and not so good times.
The celebrations took place at the
Charcoal Steakhouse. The “good old
times” were remembered with many an-
ecdotes and stories, which also made for an
entertaining and successful evening. ‹‹
fluid 1 | 2011 // fluid 1 | 2011 //
“Team building” and the promotion of good
relationships among employees forms an
integral part of a good work environment.
This is why fischer South Africa recently
formed an Action Cricket Team.
Action Cricket is the faster indoor version of
conventional cricket. The new team has already
played its first season in a local league with five
other teams. It got off to a slow start with two
consecutive losses. But thanks to its excellent
team spirit, the fischer South Africa team was
able to turn things around and made it all the
way to the finals.
While the new team was not yet able to win
“Gold”, it proudly returned with a silver medal
– proving that teamwork and persistence do
indeed pay off. And the fischer team is com-
mitted to consistently improving its game. But
just the fact that the team made it all the way to
the finals after only one season and without any
previous competitive experience is an achieve-
ment to be proud of. ‹‹
fischer Canada
A part of the team for more than 20 yearsAnniversary celebrations for long-standing employees
10 11fluid 1 | 2011 // fluid 1 | 2011 //
Rotary swaged series components: Gearbox locking sleeve I (1 – 3), gearbox locking sleeve II (4 – 6), exhaust manifold six-cylinder (7 – 8), exhaust inlet tube (9 – 10)
fischer Hydroforming
Mechanical rotary swaging Now under the fischer group umbrella
fischer Hydroforming Chemnitz has added
rotary swaging to its processing activities.
Rotary swaging refers to a chipless form-
ing method. It reduces the cross section
of rods, tubes and wires. It involves two to
four, and in exceptional cases eight, tool
segments which perform radial upward
and downward movements at the same
time, in very quick succession. A part of the
tool is reformed at every downward move-
ment of the toolset. Rotary swaging is an
incremental forming method, as the tool
gradually achieves its desired shape. fisch-
er Hydroforming Chemnitz has been suc-
cessfully using this processing method as
the pre-forming stage for the Hydroform-
ing process for almost a year. Previously,
these processing steps were performed
outside of the plant. The project was imple-
mented with hmp Maschinenfabrik GmbH
(Heinrich Müller Maschinenfabrik in
Pforzheim), which had already been sup-
plying services in the past. The companies
concluded a cooperation agreement to en-
sure that the corresponding know-how for
the tools and process could be integrated
into the fischer group.
At this time, approximately 600,000 com-
ponents are formed on the system every year
Tech Talk Tech Talk
10 11
for a total of four series products, in three-
shift operations. Rotary swaging is used as a
pre-stage to Hydroforming so that the Hydro-
forming process can be started with the largest
possible starting cross section. This reduces
the number of required Hydroforming steps.
A locally occurring restriction, which is due
to the component design, is already included
before, using the process of rotary swaging.
Depending on the task at hand, the pro-
cess can also be supplemented by a pin that is
placed inside. This allows for internal geom-
etries to be mapped to the precise tolerance
level, and also enables internal contours.
New rotary swaged components
fischer Hydroforming views rotary swaging
as the ideal method to achieve an economical
pre-stage to the Hydroforming process, which
can be supplied at both the Chemnitz as well as
Menden sites.
In addition to serving as a Hydroforming pre-
stage, however, the method also has the potential
of producing specific finished components – and
thus continue to expand the fischer group port-
folio. To this end, the group is developing the
required know-how through external training,
joint feasibility studies with cooperation partner
hmp and other internal training courses.
Typical applications outside of the pre-stage for
the Hydroforming process include:
Hollow steering columns
Hollow axle drive shafts
Eyeglass temple pieces
Tube fittings
“We are pleased to have added rotary swag-
ing as another reforming method to our own
processes. Another piece of the puzzle in the
increasing customer orientation of the entire
fischer group”, says Hans-Peter Fischer, Man-
aging Director of fischer group, who is very
satisfied with the new machine-based swaging
method. ‹‹The principle behind rotary swaging The illustration shows the main process principle. The tool that is placed on the inside is machined using rotating segments, which perform axial strokes for the reforming process, which reduce the circumference of the corresponding piece of the tube. This process results in a radial and axial material flow in the entire cross section of the component.
Rotary swaging in detailThe axial preparation to the desired final diameter is carried out by wedges, which are moved in accordance with the process stage. They allow for a high degree of forming. For one, a cross section of the machine has been illustrated in the figure to the left; the red elements drive the tool segments to the inside in a circular manner. The right figure shows how a continuously progressive diminution can be achieved for the component cross section with the use of wedges.
A summary of the advantages of rotary swaging:
Production that achieves close to final contours, installation-ready precision:
The tolerances that must be adhered to are so close that subsequent machining (involving cutting) is not usually necessary. This saves on material grades and shortens the process chain. The result – lower unit costs.
High form representation potential, weight optimization: Rotary swaging allows for the implementation of a very
diverse form spectrum both outside and inside of the tool. Average weight savings for rotary swaged components range between 30 and 50% as compared to conventional production.
Good component quality: Rotary swaging allows for an uninterrupted fiber flow in
the tool. The cold working of the tool that occurs due to the reforming process can be utilized for component stability. The surface quality achieved by rotary swaging is at the level of ground surfaces.
High degree of formation, processing of brittle materials: Rotary swaging can achieve high degrees of formation with-
out heat treatments. The method is suitable for the forming of brittle material grades. This is due to the favorable stress state during the forming process and the homogeneous forming process.
High degree of flexibility: Rotary swaging equipment can be converted very quickly.
The replacement of tools and adjustments for a new part usually only takes a few minutes.
Short cycle times, high availability: Due to the horizontal configuration and relatively low space
requirements, rotary swaging machines are combined into effective transfer systems which are used to produce larges series in several shifts. A robust and maintenance-friendly design warrants a high level of availability.
1 4 72 5 83 6 9 10
12 13fluid 1 | 2011 // fluid 1 | 2011 //
process technology into a new component
of the customer. The task now was to imple-
ment the process optimization and new series
component at the same time. At this point,
fischer Maschinentechnik was included in
the project as a tool supplier and special ma-
chinery builder. Led by the Achern site, the
following individuals became active in the
project: Viktor Kimmig with responsibil-
ity for the development of the series tool,
Roland Moser for the construction of the se-
ries tool, and Dirk Müller for the linking of a
supplementary compression unit to the rotary
swaging system. The compression unit was
integrated into the process chain to achieve
an ideal transition between the swaging area
and the unformed tube. To this end, prototyp-
ing experience – with Markus Niebecker (fH,
Menden) responsible for design – was also in-
cluded in the considerations. The project has
now been successfully implemented, and the
new components, which feature an improved
switch function, have been approved by the
customer. ‹‹
mization project, under the leadership of Theo
Ostermann (fH, Menden) and Peter Juraschek.
In the new process, the starting material is
also designed as a double part, but is formed
in the middle using plunge rotary swaging.
This allows for a better stamping of switch
geometries through the subsequent feeding of
material grades using the ends of the compo-
nents during the Hydroforming process. In ad-
dition, the stamping of final switch geometry
has been integrated into the Hydroforming
process, doing away with the repeated addi-
tion to another stamping machine.
New process chain in prototyping
Initially, the new process chain was investi-
gated in a prototyping tool and successfully
mapped. In addition, this process was also
supported through a forming simulation, as
implemented by Thorsten Junge (fH, Men-
den). At the same time, Andreas Gräve (fH,
Menden) was also able to integrate the same
1312
Company Company
Almost three years ago, the former hde So-
lutions GmbH, with sites in Menden and
Chemnitz, was added to fischer group as
fischer Hydroforning GmbH (fH). It was also
the start date for the cooperation between
fischer Maschinentechnik (fMT) and the
new group member. fischer Maschinentech-
nik became an important supplier for the
tool manufacture segment and special solu-
tions in machine and equipment engineer-
ing. Hence fischer Hydroforming became an
important customer of fischer Maschinen-
technik. In this context, the two Managing
Directors, Roland Fischer (fMT) und Stefan
Geißler (fH), can look back not just on the
sales figures that have been achieved, but
also on the technical developments that have
created enormous benefits for the two com-
panies – and of course also the customers of
fischer group.
On the one hand, fischer Maschinentech-
nik experience was used to further develop
issues related to the automation and linking
of machines, which was not a strong focus of
the former hde Solutions. For the coming year,
additional investments for the automation of
Hydroforming systems and bending machines
are already being planned in addition to already
implemented projects. On the other hand, fMt
benefitted from the long-standing know-how
and extensive series experience of the new
Menden and Chemnitz colleagues in the area of
Hydroforming. The synergy of this knowledge
together with already existing knowledge re-
lated to fischer group‘s own Hydroforming proj-
ects made it possible to combine the advantages
and good ideas into optimized design concepts,
which contain different tool configurations
depending on the series application.
Another step towards ideal teamwork consist-
ed of the introduction of the Pro/Engineer devel-
opment platform, which is already used by fischer
group, at fischer Hydroforming. It makes it pos-
sible to work together on different projects without
problems and version difficulties. Design data is
administered and backed up in a central database.
fischer Hydroforming & fischer Maschinentechnik
Working together for our customersInternal group teamwork
From practice: Process optimization of locking sleeve production
One example of good cooperation: Process
optimization for locking sleeve production in
Chemnitz. Peter Jurascheck from the Chem-
nitz site is the project manager responsible for
implementing this process optimization.
In the original process, the starting mate-
rial (as a double component) was reduced at
both ends using rotary swaging (see also the
article on this technology on pages 10 / 11 of
this fluid edition). This process is following by
Hydroforming. This Hydroforming step mere-
ly preforms the switch geometry. The next
process step involves the separation of the
component. At the end, the final switch geom-
etry for the two resulting individual parts is
generated as part of a final stamping process.
The problem with this sequence of processes
is the repeated addition of components to dif-
ferent processing units, frequently resulting in
inaccuracies associated with the exact forma-
tion of the functional geometry – with the cor-
responding reject volumes. A new production
concept was developed as part of a joint opti-
Simulation results for the new locking sleeve process
Wall thicknesses Forming limit curve and stress distribution in the component
Feasibility analysis
FEM simulation
Hydroforming component development / design
Process development
Tool construction
Prototype / Pre-series production
Series production
ZSB / Assembly production
Tool design
The development process at fischer Hydroforming
Step by step to a new component.
Designed at fischer Maschinentechnik: Series tools (left) and compression unit for the new process.
14 15fluid 1 | 2011 // 1514
Customers
The system combines these work steps for the fuel rails:
Separation of the tubes to the required
length.
Trimming for clean cut edges.
Weld seam positioning using a camera.
Calibrating the ends for true-to-size
connections.
Leakage test: The entire component is
tested for leakages.
Eight punching stations: This is where
tube parts are exactly positioned and
punched as required. Standard punching
forms are round or oval, but other
forms and special forms can also be
implemented.
Testing of punching results: A sensor
checks the final product.
Automated rejection of parts that do not
correspond with specifications.
Final visual inspection: Following a
final visual inspection, components are
degreased and packaged according to
customer specifications.
Additional quality assurance measures by
testing random samples on the 3D measure-
ment device are carried out by trained ma-
chinery personnel at regular intervals.
“In a way, the punched precision com-
ponents could be viewed as pieces of art”,
according to Peter Hils, manager at fischer
Rohrtechnik. “At the same time, with the ex-
tended workbench of our partner companies,
we can offer our customers even more.” fisch-
er specialists are also looking at correspond-
ing components related to sanitary, heating,
air-conditioning and solar technology. ‹‹
fischer Rohrtechnik
Automated press cuts for special section tubesFor fuel rails and other precision components
Another example of fischer Rohrtechnik’s
processing competence is the company’s
tube processing system, which impresses
with its eight punching stations. This is
where openings are punched into tubes at
very high precision levels; at this time, the
tubes are further processed into vehicle fuel
rails. “This process hinges on very clean and
error-free work. Chips or cuttings in the tubes
can lead to engine damages in the finished
vehicle. For this reason we are subject to very
high requirements, which we are able to meet
fully”, says Frank Schneider, production man-
ager, who is very proud of the machine – and
the qualified and diligent employees who op-
erate the precision device.
There are eight fully automated work steps
and the visual final inspection. It starts with
a round tube (currently at 18 x 1 mm) or a
16 x 13 mm square tube. The tubes may fea-
ture an edge length or diameter of up to ap-
prox. 50 mm. Up to now, they were smaller
however. The length of the part can be up to
approx. 500 mm.
Tech Talkfischer Germany
Revolutionary rinsing technology MEIKO guarantees cleanliness with fischer tubes
MEIKO, the Offenburg dishwasher special-
ist, has garnered a lot of market attention
with a new machine – and
fischer stainless steel tubes
and components are also
playing a part. The new
dishwasher series „M-iQ“
contains different models of
rising pipes and connecting
pieces as well as stainless
steel tubes from fischer.
30 % savings in operating
costs, no need for direct ex-
haust air connections, flexibili-
ty due to a modular design – all of these are inno-
vations that do not compromise quality. Experts
agree: Anyone looking for a modern dishwasher
will eventually be looking at a MEIKO M-iQ.
With its revolutionary filter technology, innova-
tive ventilation technology and state-of-the-art
operating and control concept with Bluetooth or
GSM/GPRS interfaces, the M-iQ is the new stan-
dard for all professional rinsing applications in
the food service and large kitchen segment.
Based on this innovation, MEIKO
has once more defended its position
in the market. The company slogan
“Meiko – The clean solution” not only
refers to “clean” as a characteristic but
also a value. This includes fresh ideas,
orderly structures, hygienic results,
ecological and economical technology,
perfect quality, sustainability and fair
treatment of customers.
fischer group is proud to be assist-
ing MEIKO with this unique innovation by
supplying sophisticated components. ‹‹
fischer Germany
Great sound from fischer tubes Sport mufflers by REMUS-SEBRING
“Sound Design is one of our most impor-
tant product features”, knows Ing. Otto
Kresch from REMUS-SEBRING. The group
produces high-quality sport mufflers and
exhaust equipment for the world market –
and fischer group supplies the appropriate
stainless steel tubes for this purpose.
REMUS Innovation Forschungs- und
Abgasanlagen Produktionsgesellschaft m.b.H.
was founded in September 1990. In only five
years, it made a name for itself among manu-
facturers of sport mufflers. Another milestone
occurred in 1997 with the purchase of SE-
BRING and the construction of the SEBRING
Technology Center in Voitsberg, which opened
in June 1998. The new research and develop-
ment center opened in the summer of 2002.
In 2006, the company expanded its production
space by 5,000 square meters and established
a modern logistics centre. Today, the REMUS-
SEBRING group has a production area of over
33,000 square meters.
State-of-the-art processing and process
technologies guarantee products with the
highest dimensional and fitting accuracy. Raw
material is cut mainly with laser cutting tech-
nology and sometimes in automated mechani-
cal sawmills. The bending processes for the
stainless steel tubes are only performed with
computer-controlled and hydraulically oper-
ated tube bending machines. Thin sheet weld-
ing processes, consisting of both manual and
robot welding processes, form an essential part
of the production of high-quality exhaust sys-
tems. Muffler units are produced in a partially
automated muffler production line.
The centerpiece of the REMUS-SEBRING
Technology Center is the acoustics measure-
ment room, where the sound that is typical
for the brand is created and optimized. This is
where measurements of vehicle and idle noise,
sound quality and sound intensity for locating
sound sources are conducted in compliance
with the strictest confidentiality requirements.
Everything so that car enthusiasts are able
to identify their car by its individual sound. ‹‹
fluid 1 | 2011 //
fluid 2 / 2010:
Fiery moments with Blomus stainless steel garden torches
Your opinion is rewarded!
A big thank you to all who have
sent us their opinions. The lucky
winners below can now keep the
flame using their new Blomus stain-
less steel “ORCHOS ” garden torch:
Stefan Heinrich, Herrmann Haas,
Klaus Wessel, Michael Elabor,
Dr.-Ing. Franz Rückert
Congratulations!
Team Talk
O u t s t a n d i n g
quality can only
be achieved with
qualified person-
nel. This is why
fischer group has
always emphasized
its commitment to
apprenticeships
and professional
development. We would like to provide com-
mitted people with development and creative
opportunities. Of course, this also benefits
every one’s work, as a company culture can only
be built with loyal and motivated employees – a
company culture that makes it possible to work
together even during difficult times.
At the Achern headquarters site, seven em-
ployees successfully completed their appren-
ticeships and six the professional development
programs (6) this year. Today, all of them hold
full-time positions at the Achern-based fischer
companies.
The spectrum
of work completed
is as diverse as the
work areas of the
group companies.
For example, Mario
Rummel and Bernd
Waltersbacher –
former laborers
– took the opportu-
nity to complete successfully conversion train-
ing for industrial mechanics while on reduced
work hours. Another special feature of this
year: Isabell Schmälzle was the first employee
to complete the material inspection appren-
ticeship, who now works in the quality assur-
ance department of fischer Edelstahlrohre.
Of course, congratulations are also due to
those employees who have not been specifically
mentioned in this context. Hence we would like
to say it once more: Congratulations to all
2010 graduates. ‹‹
2010 graduates at a glance
Apprentices:
fischer Maschinentechnik
Stefan Fuchs, Industrial Sales Representative
Mario Rummel, Industrial Mechanic
Daniel Schmidt, Industrial Mechanic
Bernd Waltersbacher, Industrial Mechanic
fischer Edelstahlrohre
Pascal Huber, Industrial Mechanic,
Specialization: Production Technology
Isabell Schmälzle, Material Inspector
Andreas Pillin, Bachelor
(Applied Informatics)
fischer Rohrtechnik
Corina Hund, Industrial Sales Representative
with additional qualifications
Professional development:
fischer Edelstahlrohre
Christian Zink, SPS expert
Daniel Wonsik, Foreman (Metal)
Ralf Panther, Master Electrician
fischer Rohrtechnik
Klaus Riehle, Technical Business Graduate
Konrad Fallert, Technical Business Graduate
Thomas Jörger, Technical Business Graduate
fischer Germany
Congratulations on qualificationsSeven apprenticeships and six professional development diplomas in 2010
Ms. Isabell Schmälzle, the first quality inspector trained by fischer, at work.
We mean it: Tell us what you think, so we can ensure that fluid
remains an interesting magazine.
To express our thanks, we will be drawing for 10 x 8 GB sticks
in a trendy stainless steel design from all responses. Now you
can carry your most important information with you at all times.
All e-mails to [email protected] with the subject line
“fluid” will be entered into the draw for the memory sticks.
Thank you very much for your opinion and good luck in the draw!
Carry your important information with you Win one of ten 8 GB USB sticks!