achievements and potentials in lightweight … · in lightweight and non-automotive applications ....
TRANSCRIPT
Dr. Martin Habert
CAPITAL MARKET DAY, OCTOBER 6TH, 2015
ACHIEVEMENTS AND POTENTIALS IN LIGHTWEIGHT AND NON-AUTOMOTIVE APPLICATIONS
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ACHIEVEMENTS AND POTENTIALS IN LIGHTWEIGHT AND NON-AUTOMOTIVE APPLICATIONS
SMI MAI 2015 – ZUR VERTRAULICHEN VERWENDUNG UND PERSÖNLICHEN INFORMATION DER MITARBEITER 2
• Division Hydraulic
• Non-automotive applications
• Lightweight automotive solutions
SCHULER GROUP STRUCTURE
SMI MAI 2015 – ZUR VERTRAULICHEN VERWENDUNG UND PERSÖNLICHEN INFORMATION DER MITARBEITER 3
6 DIVISIONS WITH GLOBAL RESPONSIBILITIES
SYSTEMS AUTOMATION SERVICE
AUTOMOTIVE INDUSTRY HYDRAULIC
Facts and figures
HYDRAULIC DIVISION
12.10.2015 SCHULER CORPORATE PRESENTATION 4
Technological and global market leader in hydraulic presses and forming systems
History: Schuler, Müller-Weingarten, Hydrap Products: Hydraulic presses and complete systems for cold
or hot metal forming, forging and composites production Applications:
Automotive (ca. 55 %), Railway (ca. 25 %), Aerospace, Heat Exchangers, General industry
Key Technologies: Hot Stamping Railway wheels Hydroforming Titanium Forming Fineblanking
1by 30.09.2013
Hydraulic division 2015 Sales ca. 150 Mio. €
Order Entry ca. 160 Mio. €
Order Backlog ca. 170 Mio. €
Employees 165
Markets
Europe ca. 30% Asia ca. 30%
Americas ca. 30% Russia ca. 10%
TRADITIONAL APPLICATIONS
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HYDRAULIC PRESS LINE @ JAGUAR, 2001
WHAT REALLY COUNTS
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HYDRAULIC PRESS LINE @ TODAY
Hydraulic presses: ….very high press forces ….at any position ….as long as necessary
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NON-AUTOMOTIVE APPLICATIONS
GROWTH MARKET RAILWAY
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80
100
120
140
160
2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023
Freight rail Passenger rail Urban rail
Source: SCI Verkehr 2014, „Rail Transport Markets – Global Market Trends 2014-2023
Worldwide rail transport performance 2013-2023 [Index 100=2013]
100 = 10,711 billion tkm 100 = 3,536 billion pkm 100 = 448 billion pkm
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NON-AUTOMOTIVE APPLICATIONS
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SYSTEMS FOR RAILS SYSTEMS FOR AXLES SYSTEMS FOR WHEELS
RAILWAY
Upsetting Preforming Dishing Rolling
SYSTEMS FOR WHEELS FORMING SEQUENCE
SYSTEMS FOR WHEELS CLOSING THE GAP – NEW SCHULER WHEEL ROLLING MACHINE
Customer Shandong Heli / China • MH 10000 and 2x MH 5000 • Wheel Rolling Machine MHRV 180/80 • Tools • Automation and Line Control
2012
SYSTEMS FOR WHEELS COMPLETE FORGING LINE
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2007 2009 2011 2013 2015 20xx
NEW PRODUCTS CREATE NEW BUSINESS
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Order Intake Mio. € 1 I € 9.200.000.-
CUSTOMER CAF, SPAIN 2007
Hydraulic forging presses MH 10000 & MH 5000
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2 I € 3.200.000.-
CUSTOMER MWL, BRAZIL 2009
• Hydraulic forging press MH 3000
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3 I € 32.600.000.-
CUSTOMER SHANDONG HELI , CHINA 2011 Hydraulic forging presses
MH 10000 & 2 x MH 5000 Wheel roller MHRV 180/80 Dies & automation & auxiliary equipment
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4 I € 92.000.000.-
CUSTOMER KARDEMIR , TURKEY 2013 Sawing lines for billets Furnaces (Andritz Metals) Hydraulic forging presses MH 10000 & MH 5000 Wheel roller MHRV 180/80 Dies Machining equipment (FFG) Automation, line control, auxiliary equipment
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5 I € 52.500.000.-
NEW ORDER 2015 SCHULER & ANDRITZ METALS Hydraulic presses Wheel roller Dies, autom., aux. equipm
Schuler: € 36.500.000-
Rotary furnace and heat treatment (Andritz Metals) Andritz: € 16.000.000.-
SCHULER AEROSPACE TITANIUM AND SPECIAL METALS HOT FORMING
HOT DEEP DRAWING
12.10.2015 15 SCHULER IN-HOUSE SHOW "AEROSPACE" JULY 1-2 2015
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LIGHTWEIGHT AUTOMOTIVE SOLUTIONS
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20
40
60
80
100
120
140
160
180
200
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2000 2005 2010 2015 2020 2025
AUTOMOTIVE LIGHTWEIGHT DESIGN MOTIVATION
17 Source: ICCT 2014, Historical fleet CO2 emissions performance and current or proposed light commercial vehicle/light truck standard:s
LIGHT-DUTY VEHICLE STANDARDS ON CO2 EMISSIONS
Grams CO2 per km, normalized to NEDC
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Liters per 100 km (gasoline equivalent)
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8
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2
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Historical performance Enacted targets Proposed targets or targets under study
US 2025:
China 2020:
KSA 2020:
Canada 2025:
India 2021:
Japan 2020:
S. Korea 2020:
Mexico 2016:
EU 2021:
Brazil 2017:
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117
142
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113
122
97
145
95
138
AUTOMOTIVE LIGHT WEIGHT DESIGN MOTIVATION
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INFLUENCE OF THE WEIGHT TO FUEL CONSUMPTION AND PERFORMANCE
Rolling resistance
Acceleration resistance
Gradient resistance:
R
G
A
AUTOMOTIVE LIGHT WEIGHT DESIGN - MOTIVATION
12.10.2015 19 Source: Volkswagen
NETWEIGHT OF THE GOLF (1974-2013)
600
800
1000
1200
1400
1600
1 2 3 4 5 6 7
Netweight in kgDepending on model type and configuration
AUTOMOTIVE LIGHT WEIGHT DESIGN
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The multi-material body in white combines different components of light weight metals:
High-strenght steels
Cold and hotformed steels
Aluminium
Magnesium
Carbon fiber reinforces plastics
Less use of soft deep drawing steels
Material mix increases the complexity in the joining technology
CLEVER LIGHT WEIGHT DESIGN
THE DESIGN CONCEPT OF THE HYBRID CONSTRUCTION:
The right material – (depending on the function) at the right place – in the smallest amount possible!
AUTOMOTIVE LIGHT WEIGHT DESIGN
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SCHULER FORMING TECHNOLOGY FOR LIGHT WEIGHT MATERIALS
PRESSHARDENING HYDROFORMING COMPOSITES
Hardening
HIGH-STRENGTH STEELS FOR AUTOMOTIVE
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Steel qualities
HARDENING PROCESS IMPROVES TENSILE STRENGHT
Elon
gatio
n
Tensile strenght
PRESS HARDENING
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WHAT HAPPENS WITH THE MATERIAL? USIBOR, 1500 MPA, ELONGATION<10%, STRUCTURAL PARTS
Blanks are heated to 950 °C in a furnace. The heating time of 5 minutes is important to
achieve the proper material structure (austenite)
The heated blank has to be fed into the press as fast as possible to avoid cooling of the material by air.
The press has to close fast, form the part and keep it closed for several seconds.
During this time the cooling circuits in the upper and lower dies are cooling the part down to approximately 200 °C.
Forming and cooling down
Heating
Parts or Blanks
Martensite
Perlite
Austenite
Competence center press hardening
14/05/2014 FORD VISIT
PRESS HARDENING TURN-KEY SOLUTIONS FROM SCHULER
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Schuler Hot Forming - dies, prototypes & process - hydraulic presses & entire process - automation for press hardening line - Line control & integration of furnace
CURRENT SITUATION AND FUTURE NEEDS
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SIGNIFICANT INVESTMENTS FOR NEW LINES
Trend upwards
Number of hot forming parts per vehicle will increase from an average of 10 today to more than 30 in 2018
OEM experts say that by 2018 up to 600 Mio parts/year are needed
End of 2014: ca. 240 lines in operation
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50
100
150
200
250
300
350
1984 1988 1992 1996 2000 2004 2008 2012 2016
Today approx. 250 Mill.
Million parts/Year
3 Mill. 8 Mill.
Forecast 2018: 500 - 600 Mill
Hot Stamping Part Production
1/3 OF INSTALLED BASE BY SCHULER
25-30 NEW LINES PER YEAR
FOR THE NEXT 5-6 YEARS
NEW PRODUCT: HIGHEST PRODUCTIVITY AND ENERGY EFFICIENCY
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Production time = 20 shifts/ week x 8h / shift x 50 weeks/ year = 8000 h/year
Conventional others
PCH flex with EHF 1-4
Stroke Rate
OEE
Strokes / year
Energy per 1 Mio. Stroke
3.6 SPM
60 %
1,000,000
1,500 MWh Press only!
5.2 SPM
70 %
1,750,000
900 MWh Press only!
Demonstration & Training Technology development Prototype production Back-up line for customers
Servo TechCenter
SCHULER TECHCENTER 2015
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Göppingen, D I MSD 250
Erfurt, D I TST 1.600, TSD 1.100
Tianjin, China I TST 1.600
Automation TechCenter
Gemmingen, D I Crossbar Roboter 4.0
Canton, Mi USA I Crossbar Roboter 4.0
Hessdorf, D I Intratrans
Scope of Services
Hot Stamping TechCenter
Göppingen, D I PCH-Linie
Hydroforming TechCenter
Canton, Mi USA I Hydroforming-Presse
LOCATIONS
• Processing from the coil
• 3 cutting heads
• Flexible stacking
• Continous feeding
• Cleaning (class A)
• No tools
LASER BLANKING LINE SCHULER AUTOMATION
SOUTRAC WELDING LINE FOR HOT STAMPED DOOR RINGS
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ANDRITZ SOUTEC
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THANK YOU!