Simrit insight magazine 01 12

insight.

No. 1 / 2012

Custom-Made SUrFACES Treating Elastomers using Nanotechnology

Applications 360째 rotation

Applications Virtually maintenance-free

Applications Close cooperation

Products Air and oil tight

www.simrit.co.uk/customermagazine

Editorial

José Caro, President Simrit Global

At the beginning of this year I assumed new duties and am now responsible for Simrit’s international business.

I am pleased to be devoting myself to this area because I know I can continue to count on its smoothly functioning team and efficient organization. This change in management will not mean a change in direction.

We will continue to apply our strategy of precisely matching our business activities to customer needs, market segments and regions—to combining global orientation with local presence. The new issue of Simrit Insight, in which we report on Simrit projects in Brazil (page 14) and China (page 16), shows this strategy in action.

The work we have been doing for the U.S. company Eaton Hydraulics is an example of our strong customer orientation. A test stand that we designed and built for the company allows it to test all of the various seals that it uses (page 10).

Another one of our strategic principles is to keep setting the bar higher and higher. One goal is to continually expand our range of customer services and to keep making the processes that we perform for our customers more and more efficient and transparent. This is illustrated by our newly developed packaging program, which guarantees that our products are protected better than ever before and that we can track the movement of every single component that we produce. The new program also uses just the right packaging units to meet the needs of users (page 4).

At the same time, we continue to focus more than ever on what we do best—on our competence in materials technology, for example. This issue describes RFN®, an innovative surface treatment technology developed

by Simrit that improves the performance of sealing components (pages 5–7). Another Simrit strength is our know-how in specific industries, such as aerospace. You can see for yourself at the Farnborough International Airshow on July 9–15, 2012. As in the past, we will be exhibiting at the Airshow.

I hope you enjoy reading this issue of Simrit Insight as much as I have. And I look forward to working with you closely and exchanging more good ideas with you in the future.

Yours

José Caro President Simrit Global

Trade shows & events Date

Name

Place

Hall / Stand

July 9-15, 2012

Farnborough Airshow

Farnborough – UK

4 / D 10

September 18-22, 2012

Husum Wind

Husum – GERMANY

3 / E12

Oct.29 - Nov.1, 2012

PTC Asia

Shanghai – CHINA

Stand A1

Date

Topic

Language

Place

July 17, 2012

Sealing Technology – Basic seminar

English

Weinheim – GER

August 28, 2012

Mobile Hydraulics – Professional seminar

English

Schwalmstadt – GER

August 29, 2012

Hydraulic Accumulators – Professional seminar

English

Remagen – GER

Seminars

Visit www.simrit.co.uk for additional dates.

Imprint Simrit® insight is the magazine for Simrit customers. Publisher: Freudenberg Sealing Technologies GmbH & Co KG, ­69465 Weinheim E-mail: insight@simrit.de Project management: Waldemar Stein E-mail: waldemar.stein@simrit.de Cooperation: Clarissa Fitzgerald, Dominik Müller, Dr. Thomas Schnetz, Achim Löll, Robert Podgorschek, Chuck White, Hans Kettl, André Borghi, Bruna Misquita Alves, Christine Wunderlich, René Dauphin, Bianca Wolf Internet: www.simrit.com Editorial & design: Frank Trurnit & Partner Verlag GmbH. Reproduction only with permission of the publisher. Pictures: Simrit, Freudenberg Sealing Technologies, Freudenberg Forschungsdienste, Honeywell (7), HGO InfraSea Solutions (8/9), Eaton Hydraulics (10/11), KUKA (12/13), TGM Brasil (14/15), Sany Heavy Machine Co. (16/17)

02 Simrit insight 01|2012

News | Contents

IN THE FAST LANE AT THE BORDER Germany’s main customs office in Karlsruhe has granted the status of “Authorized Economic Operator” (AEO) to Freudenberg Sealing Technologies GmbH & Co. KG, holder of the Simrit trademark. The company received the most comprehensive version of the certificate, the AEO F (customs streamlining/security), which is valid throughout the entire European Union. Freudenberg Sealing Technologies is now listed in the European Commission’s registry of AEO-certified companies. The status of “Authorized Economic Operator” is a key element of the EU’s international trade security concept. Authorized Economic Operators are deemed to be particularly reliable and trustworthy and therefore get preferential treatment in clearing cus­ toms. The certificate shows that Simrit has implemented a secure export supply chain extending from the manufacturer to the final con­sumer. This is important from the standpoint of customs law.

For customers it is an important indicator of the company’s ability to manage the supply chain and risk efficiently.

IKU INNOVATION PRIZE

Content News

04

New packaging program

Cover Story

05|07

Long live small differences

Applications

08|09

Full sail

Applications 10|11 Real-life tests

Applications

12|13

360° rotation Innovation Prize for Climate and Environment awarded: Norbert Röttgen, (former) German Minister for the Environment, Nature Conservation and Nuclear Safety, Claus Möhlenkamp, Speaker of the Management Board of Freudenberg Sealing Technologies and Dr. Markus Kerber, CEO/Director General Federation of German Industries (BDI) (from left to right)

The German Innovation Prize for the Climate and Environment (IKU 2011) was awarded to a patented narrow-strip laser cutting and welding technology (SUL) by a jury chaired by Prof. Klaus Töpfer.

The prize was awarded jointly by the German Ministry for the Environment and the Federation of German Industries. At the award ceremony Claus Möhlenkamp, Speaker of the Management Board of Freudenberg Sealing Technologies, noted, “This award honors our continual striving for improvements and innovations in products as well as our efforts to use lean, resource-conserving production processes.” In the narrow-strip laser cutting and welding system the metal rings used in rotary shaft seals are no longer punched from the strip steel roll stock but rather are laser-cut. The same laser then welds the blanks directly into rings. As a result, nearly 100% material utilization is possible. The fact that less stock and waste needs to be transported also reduces CO2 emissions. The metal rings are of exception high quality and precision. The novel manufacturing process completely eliminates the need for drawing fluids.

Applications 14|15 Virtually maintenance-free

Applications

16|17

Close cooperation

Products

18

Air and oil tight

Simrit insight 01|2012 03

News

NEW PACKAGING PROGRAM Even better product protection, trademark visibility all the way to the final consumer and trackability right down to the individual part level are some of the highlights of a new Simrit packaging concept. Two packaging types will be used in the future: large packaging systems focusing on the needs of industry and small packaging systems mainly focusing on the needs of Simrit distributors. In the course of the changeover, new article numbers will be assigned for about 4500 articles. These new article numbers will be correlated with the given packaging unit being used.

Since the change amounts to a major packaging and logistics project, it will be done in phases. The project will begin with single-part rotationally symmetric seals in the Simmering and Fluid Power (mobile hydraulics) product groups that are supplied from warehouse stock. The implementation date for the changeover of the first project phase, consisting of about 1000 ar­ ticles, is scheduled for June 1, 2012.

From this date on, these articles will be supplied exclusively in the new packaging units. With small quantities the packaging units are defined according

to outside diameters. Up to an outside diameter of ≤ 130 mm, five products will be packaged per small carton.

Beginning with an outside diameter of > 130 mm, a single product will be contained in the packaging unit.

Order quantities that deviate from the quantity resulting from the new packaging unit will be rounded up. See www.simrit.de/packaging for everything that customers will need for the conversion (article lists, packaging units, etc.). This Internet address also provides a list of answers to frequently asked questions.

The new Simrit packaging concept takes effect June 1, 2012 and focuses on the needs of industrial customers and distributors.

ANOTHER AWARD FOR SIMRIT The US technology company United Technologies Corporation (UTC) has awarded its “Supplier Gold Award” to Simrit. With its Pratt & Whitney and Sikorsky brands, UTC is a global player in the aircraft industry. Among the Simrit products used by UTC are seals for Pratt & Whitney jet engines manufactured in Canada. These seals, which are manufactured in Tillsonburg, Ontario, offer high temperature resistance, excellent compatibility with synthetic 04 Simrit insight 01|2012

oils and low combustibility. The four most important criteria for receiving this award are excellent service, ontime delivery, unmatched quality and lean structures in all operating areas —all continuously achieved over the course of the last 12 months.

Simrit was selected from among nearly 10,000 UTC suppliers. It is the third year in a row that it has received the award. Vinay Nilkanth, Vice President Global Sales Aerospace at Simrit, was

pleased with the award: “This award shows that Simrit, with its quality strategy and lean operating structures, is also one of the world’s leading sup­ pliers of sealing components in the aerospace industry.

Simrit now has three production sites that are specifically certified for aerospace sealing components: Tillsonburg in Ontario, Canada, Santa Ana in Cali­fornia, USA, and Lutterworth in the UK.

+ + + Innovative method for surface treating elastomers + + +

Cover Story

Long live small differences With sealing components, the devil’s in the detail: minuscule differences that make all the difference between a solution that is merely acceptable and one that is really outstanding.

Just how small are these details? Incredibly small: between the width of a single atom and minuscule structures a few nanometers in size. The secret behind this devilishly critical detail is RFN® (Reduced Friction by Nanotechnology), an innovative

process developed by Simrit for surface treating elastomers. When RFN® is used in combination with the right material, the surface characteristics of O-rings, solenoid armatures, U packings or custom seals can be optimized for the given application. The result is sealing elements that have precisely tuned surface properties. In addition to static friction, parameters like kinetic friction, wear and wettability can be carefully

designed in to the product. Changes in surfaces at the nano level are not visible with the naked eye. But their positive consequences are readily apparent: longer service life, more precise operation, easier installation, and much more. A small difference has a big impact because with quality the devil is in the detail. Honeywell’s building technology experts found this out. More about this on the following pages.

Simrit insight 01|2012 05

Cover Story

+ + + Innovative method for surface treating elastomers + + +

Strong together: The surfaces of Simrit sealing products are optimized in close cooperation with various analysis methods and

The chemical composition of the surface is uncovered using X-ray photoelectron spectroscopy.

A high-speed contact angle meter is used to determine wettability.

Topological differen- visible using X-ray

CUSTOM Made Surfaces The reliability and performance of entire machines can be improved by systematically optimizing the surface characteristics of sealing elements. Simrit’s innovative RFN® treatment is based on nanotechnology. It impacts such key parameters as friction, wear and wettability.

Continually bigger and better? It was not too long ago that superlatives always had something to do with physical size. Things are different today. Hi-fi systems no longer fill up the whole wall.

An MP3 player the size of an old-fashioned audio cassette can now hold the same amount of music as a 10 meterhigh stack of vinyl LPs! Today, it’s small size, performance and efficiency that count. Nanotechnology, which utilizes the characteristic properties of the very smallest structures, has played an important role in this trend toward miniaturization. That’s because the rules of the game are different at the nanostructure level. The mechanical, electrical, optical, magnetic and chemical properties of nanostructures do not depend on the material. Instead, it is the size and configuration of the structure that count.

The range of applications for nanotechnology extends from the development of increasingly smaller data storage devices with increasingly larger capacities 06 Simrit insight 01|2012

to the development of innovative materials that offer completely new properties. Simrit uses the unique capabilities of nanotechnology in its RFN® process to systematically treat sealing element surfaces. Substantial process improvements can be achieved by optimizing individual parameters such as the surface topographies of the materials used. In addition to static friction, kinetic friction, wear and material wettability can be modified. For example, using nanotechnology a hard-to-wet nonpolar elastomer like FKM can be modified to achieve good wettability with polar media—a huge advantage in lubricated systems.

for a certain time, the elastomer can adhere to the valve seat, an undesirable effect that occurs when machines stand overnight or over the weekend.

When the equipment is restarted, high breakaway forces must be applied.

Over the long term, this can cause damage. When the RFN® process is used, the sealing surface can be modified by means of nanotechnology in such a way that friction and adhesion forces are minimized and a low-wear surface results. But it gets better. Simrit has improved upon its patented RFN® process, so that now additional surface characteristics of elastomer seals can be optimized.

In top shape, even on Monday mornings When elastomers are used as materials in sealing solutions, high adhesion and high coefficients of friction can occur.

These two factors are responsible for the so-called “Monday morning effect.”

For example, after a valve has rested

Drinking water, forward march!

The U packings and O-rings in Honeywell backflow preventers show the huge impact of modifications at the smallest (nano) level. Backflow preventers are used when drinking water systems need to be protected from backflow, siphon-

+ + + Innovative method for surface treating elastomers + + +

Cover Story

In brief testing processes ●

●

ces at the nano scale are made electron microscopy.

The tribological properties of RFN®-optimized surfaces are measured in special friction test stands.

ing effects or process water back-pressure. This is the case with hot-water heating systems, for example.

According to DIN EN 1717, heating water falls into liquid category 4 and is considered to be highly hazardous to human health. Therefore, residential installations must be designed to ensure that water that is tapped from the drinking water system for use as heating water cannot find its way back into the drinking water system. This task is performed by backflow preventers. Since Honeywell backflow preventers are used in drinking water systems, the sealing products that are used in them must meet the highest standards. The basic requirement is that all drinking water approvals, such as KTW, W270, WRAS and ACS, must be obtained. To ensure that the water systems are reliably isolated, the positioning or controlling forces of any system components that are equipped with Simrit dynamic seals must not exceed 2 N. This is guaranteed when the “devilishly small details” referred to above come into play in order to distinguish a truly customized solution from one that is merely usable.

Less friction for uniform control characteristics If the friction in the system is too high, backflow preventers that must compen-

sate for pressure variations in the plumbing system can exhibit inconsistent control characteristics and functional problems. This challenge cannot be satisfactorily met with conventional seals. Specialists in Honeywell’s product development department collaborated with Simrit to find the solution: A low-friction seal designed using FEM and having an optimized RFN® surface. Since 2011 a U packing made of the material 70 EPDM 291 has been used in standard production of backflow preventer BA295. Its surface was optimized to minimize friction. In addition, O-rings made of the same RFN®-modified material are used.

Minuscule changes in the surface structure in the nanometer range now ensure that the backflow preventer operates reliably with uniform control characteristics.

This year Honeywell will also equip its model CA295 backflow preventer with a U packing of 70 EPDM 291 enhanced with the RFN® effect. Based on the positive results that have been obtained, a new pressure regulating valve using Simrit seals will also go into production. A U packing and a washer made of a hydrolysis-resistant polyurethane material that is approved for drinking water applications will be used.

Using the RFN® process, the sealing surface is altered in such a way that friction and adhesion forces are minimized, resulting in a low-wear surface FN® treatment relies on nanotechnology to R fine tune central parameters such as friction, wear and wettability

Do you have questions or suggestions? Please contact achim.loell@simrit.de

Honeywell backflow preventers for drinking water systems

Model BA295 backflow preventers are suitable for protecting drinking water systems from backflow, including that caused by pressure and vacuum build­ ups. Depending on their specifications, they can be used for various residential buildings and industrial and commercial purposes.

Model CA295 backflow preventers are suitable for protecting drinking water systems from backflow, including that caused by back pressure and vacuum buildups. Liquids up to and including liquid category 3 per DIN EN 1717 are protected.

Simrit insight 01|2012 07

Applications

FULL SAIL

The special crane hoisting vessel INNOVATION, put into service in the summer of 2012, has revolutionized the construction of offshore wind turbines. The rack-and-pinion gears used here, made by Siemens Mechanical Drives (MD), and the gears‘ sealing components play an important role in this technical advancement.

Offshore wind turbines are at “full sail”. The German government’s energy plan has established a target output of 10,000 MW for 2020; this output is to be generated through these kinds of coastal wind turbines. In 2030, the plan assumes an output of 25,000 MW. In order to achieve this ambitious goal, powerful hoisting vessels will no doubt be required; they bring the huge parts to the installation site, but they also serve as a construction platform.

Last but not least, the hoisting vessels serve to house the installation personnel and the crew at sea. With its strong partners, HOCHTIEF Solutions and GeoSea n.v., HGO InfraSea Solutions, with its crane hoisting vessel, has

developed a new ship model which enables the installation and maintenance of coastal wind turbines having heights of greater than 120 meters and water depths of up to 50 meters (see box). It’s pretty obvious that component suppliers for this super-class of ships must themselves be technically elite world-class suppliers: the rack-and-pinion gears for the hoisting mechanisms of the ships are supplied by Siemens MD and the sealing components for the gear systems come from Simrit.

Maintenance-free operation

Siemens MD supplied all 96 gears for the hoisting vessel by the end of 2011. Type BA 600x640x20 and

type Radiamatic R35 600x650x22 radial shaft seal rings are being used for the gear wheel shaft seals. The BA seal rings seal the oiled parts of the gear shafts, whereas the Radiamatic R35 prevents penetration of sea water. Since the special crane hoisting vessels must be flexible and must be capable of operating around the clock every day of the year, maintenance downtime is unacceptable to the operator.

Maintenance-free operation over the entire life cycle of the gear system is therefore absolutely required. Therefore, for years Simrit has designed its sealing components for life cycle times of greater than 10,000 operating hours. The cost savings for the system manufacturer and for the crane hoisting vessel builder, thanks to this quality guarantee, is quite obvious.

Butt-joint-vulcanized O-rings

Hoisting vessels for offshore wind turbines The special crane hoisting vessel INNOVATION, manufactured by the consortium of HOCHTIEF Solutions and GeoSea and which was put to sea for the first time in 2012, brings a new technical quality to the construction of offshore wind turbines.

The ships have 8,000 tons of loading capacity, 1,500 tons of crane capacity and a speed of 12 knots.

They are so-called „floating cranes“ which are jacked up when they arrive at the site. In contrast to platforms, which must be towed, the hoisting ships are self-­ propelled and have a large working range, offering housing capacities up to 180 persons. The ships have a helicopter landing pad for flying installation personnel in and out.

08 Simrit insight 01|2012

Other technical highlights in the sealing of Siemens MD rack-and-pinion gears for the INNOVATION are the size 1160x4 and 510x4 O-rings. The O-rings have particularly large diameters of over a meter and over a half meter, respectively. Nevertheless, they are butt-joint-vulcanized and not glued. This reliably prevents the ends of the seal rings from coming apart at the seam: In this regard, Simrit’s superior material competence and highly reliable production know-how contributes decidedly to the high stability and long life span of the entire system. Moreover, the O-rings are manufactured in an extrusion process, making specially-manufactured molding tools unnecessary, which further optimizes the cost-benefit ratio of the seal rings.

Applications

The rack-and-pinion gears in the special crane hoisting vessel INNOVATION enable a lifting speed of up to 1m/min.

Up to 7 wind turbines (output class 6 MW) can be transported.

In brief More installation capacity

With the special crane hoisting vessel INNOVATION, the installation capacities for construction coastal wind turbines has increased fourfold in a single blow. Siemens MD, as the central gear supplier, and Simrit as the sealing specialist, have certainly helped to make the ambitious goals set out by the German government, for energy production through wind energy, reachable.

●

●

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pecial INNOVATION type crane S hoisting vessels provide an enormous boost to the construction of offshore wind turbines imrit delivers important sealing S components for the rack-andpinion gears built by Siemens MD for the lifting mechanism -rings with diameters of greater O than one meter are manufactured

in the extrusion process with buttjoint-vulcanization ●

T he development partnership extends from construction planning to large-scale production

Do you have questions or suggestions? Please contact robert.podgorschek@simrit.de

Simrit insight 01|2012 09

Applications

Simrit test capabilities allow new and innovative designs to be validated in real life applications.

Testing tailor made Comprehensive tests are indispensable when it comes to ensuring the quality of products. That is why Simrit have always had diverse, state-of-the-art test stands and testing equipment. Now the sealing specialist is going a step further and is, for example in cooperation with Eaton Hydraulics, making test stands available which are tailored to the actual customer applications.

+ ●

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●

In brief

ew testing equipment for radial N shaft seals is designed to perfectly match the customer‘s individual application specifications T ogether with their customer Eaton Hydraulics, Simrit have now developed such „application-optimized“ test rigs and have put them into operation The new equipment shortens the product development cycle at Simrit and therefore helps the customer to reduce the product’s time-to-market Do you have any questions or suggestions? Please contact chuck.white@simrit.us

10 Simrit insight 01|2012

Detailed knowledge of how a seal behaves in the real customer application is becoming an absolute must in many areas of industry. Together with their long-standing customer Eaton Hydraulics, Simrit have therefore developed several new test stands in order to test products with various inputs and test criteria. These trials are geared to specific customer requirements and applications and allow Simrit to prove and adjust seal designs simultaneously with the development of the application. This saves the customer vital time in the product development cycle.

Partnership make the difference Eaton was looking for a new and innovative design that would improve

the oil seals’ performance. Due to the diverse operating conditions that Eaton’s products are exposed to, a shaft seal was needed that could reliably operate both in low- and high-pressure situations for a longer period of time.

To address these concerns, Simrit developed a sealing design that combines the above named characteristics. Parallel to this, the sealing specialist invested in new testing equipment, based on Eaton’s established test stands, that allows the complete hydraulic motor to be tested with various inputs and test criteria.

This means that completely new ap­ plication tests can now be carried out in addition to the usual test stand

Applications

A better understanding of Eaton products enables Simrit to effectively fulfill the customer’s needs and to verify his concepts. That accelerates the market launch.

trials. It is, for example, possible to replicate pressure spikes and rotational speeds, allowing the Simrit specialists to gain a more accurate understanding of inputs (side load, pressure spikes, shaft interface, etc.) and to obtain key data regarding life expectancy of the seal. The collected data forms the basis for the development of new seal designs that improve durability and performance.

Testing for customer needs These types of trials are typically conducted on the customer’s equipment, not by the seal developer. Also here, Simrit is breaking new ground, offering its customers immense advantages. The improvements made to the rigs at Simrit’s Plymouth, Michigan Technical Center, significantly decrease the testing cycle from more than 80 days to approximately 45 days, which shortens the product development cycle considerably. This means that customers such as Eaton can be provided much more rapidly with seals of the highest quality which are also fully tailored to their appli­ cation.

In order to test the oil seals which Eaton Hydraulics receives from Simrit, a test rig which had originally one pump was fitted with a further pump and combined with a second copy of the new configuration. This test configuration and the testing procedures which are now possible are of significant importance to Eaton and it there-

fore comes as no surprise that Simrit is already working on three new sealing profiles, targeting specific applications from Eaton. „These hands-on tests were a great learning experience which will lead to even better seal designs for these types of applications. For example, as a result of the hydraulic motor testing, we’ve gained a much better understanding of pressure to speed interactions and how system inputs are critical to maintaining proper operating conditions for the seal,” concludes Simrit Application Engineer Chuck White.

Moving Forward The increased understanding gained from the cooperation with Eaton provides a further boost to Simrit’s innovativeness. The involvement of customers in the extension and improvement of testing facilities leads to the continuous development of new testing capabilities.

Whether you want to maintain a technological lead with innovative solu-

tions or want to optimize existing applications – Simrit is your partner.

Together we will meet your needs.

Innovative controls allow for products to be subjected to various application inputs such as shaft side loading. Simulating end use conditions of the equipment is key.

Simrit insight 01|2012 11

Applications

360° ROTATION

Things can really get hot inside robots from KUKA Roboter GmbH when they are doing their thing.

Continual changes in direction, temperatures of over 100 °C and the use of synthetic lubricants make it necessary to use absolutely top-quality rotary shaft seals. These seals have to be stocked in standard inventory worldwide so that they are available fast when needed.

In clean rooms, humans are a potential source of problems. So it’s best if they stay outside. Robots usually meet the rigorous standards for cleanliness in such facilities far better than humans, and they also work more reliably and accurately. Round the clock.

Robots that are suitable for use in clean rooms, such as the KUKA KR 180-2 CR, are multi-talented: they load and unload, mount and install parts, or perform measurement, testing and quality control operations.

A robot like the model KR 180-2 CR can carry loads up to 180 kg, has an

Robot clean room with wafer box during the cleaning process.

12 Simrit insight 01|2012

operating radius of up to 2700 mm, and performs its tasks with an accuracy of within ± 0.06 mm. Industrial robots like those manufactured by KUKA are veritable acrobats that can perform rotational, pivoting, and turning movements with great precision.

Fast movement, high temperatures

The great variety and complexity of these movements place high demands on the components installed in robots, and seals are no exception. In particular in the case of pivoting movements, with their continual changes in the

direction of rotation, the hydrodynamic lubricating film that is required must be reestablished continually. The planetary gearbox that is used in robots like the KUKA KR 180-2 CR experiences severe heating due to the high intensity of the work it performs. The sealing components that are used in this gearbox must withstand temperatures over 100 °C. In addition, highadditive synthetic oils are used. These oils demand the use of materials like FKM that are especially resistant to aggressive media. Moreover, these robots are in use nearly 24 hours a

Applications

Robots like the KUKA KR 180-2 CR can be used for a wide range of activities: loading and unloading, mounting and installing, measuring and testing.

day. So the loads on the seals that are used, especially rotary shaft seals, are enormous.

The process reliability that is achieved in the clean room is highly dependent on the seal supplier, in particular since the extended product life cycles that are required today mean that com­ ponents must be able to operate for 20,000 hours and more. Type BA and BAUM (even higher thermal and chemical stability) rotary shaft seals, as well corresponding types having additional dust lips (BASL and BAUMSL) were the only real alternative for KUKA.

KUKA values Simrit’s broad line of standard products, which guarantees that even relatively specific application-related requirements can be met worldwide from standard warehouse stock. Another advantage is the detailed understanding of the interactions between seal and fluid that Simrit’s experts have. This is because the synthetic lubricants that are increasingly being used today are critical to the development of production equipment with long service lives.

Small but effective design modifications

In addition to the advantages of a wide range of parts available in stock throughout the world and deep materials technology know-how, Simrit offers broad expertise in design and designrelated details. For example, sometimes the design details of drives that are used for particular high-performance applications in robots need to be modified slightly. Since these drives, which are often outsourced, are manufactured in high volumes, it often does not make economic sense for the drive manufacturers or KUKA

to make these small modifications.

So making small but effective design modifications is a job for Simrit. An example of such a modification for very specific high-performance applications might be to add a nonwoven washer to an existing rotary shaft seal to prevent lubricant from escaping between the seal’s lubricant sealing lip and the dust lip.

In such cases it becomes completely clear why Simrit and KUKA have been working together closely for 30 years.

In brief ●

Rotary shaft seals used in the planetary drives in KUKA robots have to be able to handle high temperatures and more.

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modern robots, seals must In withstand high temperatures and aggressive media

Simrit can meet KUKA’s performance requirements with its standard range of rotary shaft seals

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Simrit‘s specialists are an important resource for KUKA for small but effective design modifications

Do you have any questions or suggestions? Please contact hans.kettl@simrit.de

Simrit insight 01|2012 13

Applications

Not seen, but essential to the performance of the TGM planetary gears are the BAUM type seal rings.

VIRTUALLY MAINTENANCE-FREE Brazil is one of the world’s leaders in the use of ethanol and biofuel mixtures. Adequate domestic ethanol production capability is a key factor in the Brazilian economy. Since ethanol refineries work round the clock, only top-quality components can be used. This applies to the planetary gearboxes used by TGM and the seals in them.

Brazil’s TGM Group, with headquarters in Sertaozinho in the state of São Paulo, is one of the leading manufacturers of steam turbines and planetary gearboxes used in ethanol refineries and biomass power plants. With 15 million vehicles now running on 100% ethanol or flex fuel in Brazil (see box), there is a big demand for ethanol and biofuels. So TGM products play an important role in maintaining a reliable transportation system in this South 14 Simrit insight 01|2012

American country. Ethanol refineries mainly consist of giant drums in which sugarcane is converted to ethanol through the addition of enzymes. TGM in collaboration with Perkun has developed special planetary gearboxes for the power trains used to operate these drums. These gearboxes must be able to operate maintenance-free and round-the-clock for months on end during the sugarcane harvest season.

They must be able to withstand high

torques, large load differences, high temperatures and aggressive process fluids. This in turn places high demands on sealing products. “In terms of the overall cost of the planetary drive, seals play a relatively minor role; but they cause high costs when they fail,” says Aristides Mattar, Junior, engineering coordinator at TGM. Mattar continues: “That’s why we decided to go with Simrit as our sealing products supplier. Compared

Applications

with other suppliers, Simrit offers seals that are clearly superior. And there’s no competition when it comes to the price/performance ratio. Plus, their technical support is excellent and is oriented toward meeting TGM’s needs.

Minimum maintenance Simrit supplies two different rotary shaft seals of the BAUM type with dia­ meters from 80 to 800 mm for the drive shafts on TGM’s new RPZ/RPS 3 planetary gearboxes. In order to meet the requirements for minimum maintenance, the rotary shaft seals were optimized by a team of Simrit specialists from Brazil and Germany. Being virtually maintenance-free is critical because ethanol refinery sites usually are situated in isolated locations and because the planetary gearbox is only a small component within a very large mechanical complex. Moreover, it is often very difficult to access. If maintenance became necessary, the entire production facility would be shut down, resulting in lost time for the entire refinery team. The material used in the rotary shaft seals is also optimized because the environmental conditions that are present at the shafts are extreme and the components nevertheless must not release oil, and dirt, and

Brazil: Ethanol for 15 million vehicles Brazil has focused on biofuels for decades. 15 million vehicles run on 100% ethanol or a mixture of ethanol and conventional gasoline (flex fuel). The ethanol is produced from sugarcane. Sugarcane grows well in the São Paulo region, so that only an extremely small amount of agricultural land is needed to produce fuel, and food production is barely affected. In order to meet the demand for 15 million vehicles, the ethanol refineries operate round the clock for about eight months a year (during harvest season). An ethanol refinery prod­ uces an average of 20,000 tons ethanol daily.

moisture must not penetrate into the components. Therefore, highly temperature- and media-resistant FKM is used as the material. “We subjected Simrit seals to comprehensive visual inspection, testing with measurement instruments, and chemical testing. We found that these seals are superior to all competing products in terms of design, materials used, and resistance to temperature and media,” reports Julmar Gersely, Quality Manager at TGM. Global technological partnership TGM became sold on Simrit because of the quality of its services as well as the

quality of its products. A local Simrit team is available for technical support and logistics. Merkel Xpress Services is a big advantage to TGM in Brazil.

This service allows customer-specific sealing rings to be manufactured and delivered within 24 hours. TGM is not only a strong player in Brazil; it is now active in 30 different countries.

Internationalization continues to expand. As a globally oriented sealing components specialist, Simrit is also the ideal partner for TGM in this regard. This also applies to new technological areas in which TGM plans to become involved in the near future.

In brief “Seals are a miniscule part of the overall costs for planetary gears, but can result in high costs when they fail”, says Aristides Mattar Júnior, technical coordinator for TGM.

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thanol refineries operate round E the clock during the 8-month-long sugarcane harvest otary shaft seals for components R used in ethanol production must, above all, be extremely lowmaintenance T GM and Simrit plan to expand their technological partnership throughout the world imrit offers TGM fast local prodS uct replacement parts service Do you have any questions or suggestions? Please contact andre.borghi@simrit.com.br

Simrit insight 01|2012 15

Applications

Close Cooperation The construction machinery manufacturer Sany Heavy Machine Co., Ltd. is not only one of the market leaders in the People’s Republic of China, but also the only Chinese company listed in the FT Global 500.

Global orientation and premium quality were deciding criteria in selecting our technology partner.

With construction machinery, extreme operating conditions are standard: Abrupt starting and stopping, extreme rotary motions around its own axis and higher vertical accelerations cause high temperatures and pressures. In addition, there is dust and dirt in the work environment. These factors place high demands on the hydraulic components and their seals. Both in terms of design and material quality, they must be ideally suited to tough environmental conditions. Suppliers of seals should be able to respond with a wide product range and extensive design know-how to the modification requests of the construction machinery manufacturer. Integrating the supplier of seals in the development process as early as possible therefore is particularly indispensable in the construction segment, in order to increase the serv-

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In brief

NOK Simrit as part of NFGC has had a close technology collaboration with Sany Heavy Machine Co., Ltd. going back to 2003 I t uses a large number of standard products from the catalogue program NOK Simrit is the preferred technology specialist of Sany Heavy Machine Co., Ltd. in the development of new business areas, such as gear assemblies and components for wind energy

Any questions or suggestions?

Please contact ChristineWunderlich @nok-freudenberg.com

16 Simrit insight 01|2012

ice life of machinery. The smooth cooperation of the Chinese construction machinery manufacturer Sany Heavy Machine Co., Ltd. with NOK Simrit (part of the NOK Freudenberg Group China) in optimizing these fields for the hydraulic components of the 5.5T – 13T and 20T – 33T as well as 40T – 46T excavator lines is an example of a successful technology collaboration.

Optimization with design and materials

Sany faced the challenge of performing major design and material modifications to four hydraulic cylinders at the same time, in order to be able to achieve an even higher level of thermal stability and resistance to pressure. Specialists of NOK Simrit were consulted right away to analyze requirements in the actual work environment and contribute their experience in the adaptation of specifications.

NOK Simrit specialists performed various design and material modifications on Sany hydraulic cylinders. The polyurethane at the rod seal was replaced by a high-temperature HNBR material, and the design has been optimized as well. The dust lip seal design was also changed and the seal around the buffer was replaced by particularly heat-resistant high-performance polyurethane. Furthermore, the NBR material at the piston seal was replaced by high-performance HNBR material that is designed for a temperature range from -30°C to +120°C. Dai Qinghua, Vice President of the Sany Group and General Manager of Sany Heavy Machine Co., Ltd. praised the cooperation: „NFGC with its NOK Simrit market specialists plays a major role in development for Sany Heavy Machine Co., Ltd., which, both in terms of design and product quality, are cutting-edge worldwide“.

Cooperation will be intensified

Sany‘s Guiding Principles include the aim to be among the world‘s leading companies and to have the by far best-known brand in the country. This requires the best possible employees and the best possible suppliers, such as, for example, NOK Simrit.

We require employees who are interested in developing further in an independent and target-oriented manner to guarantee the company‘s success.

And we also require suppliers whose high level of quality effectively improves the value of the products and thereby that of the Sany enterprise.

Through research and development (R&D), Sany has developed a new generation of excavators. NOK Simrit was thereby able to assist with all its available expertise.

For other components of its product spectrum, such as hydraulic pumps or gear assemblies, NOK Simrit are also Sany‘s preferred technology specialist for sealing solutions. These components use oil seals (model Simmerring BABSL) and TCZ seal rings that reduce torque and are designed for pressures in excess of 2 MPa. And over 90 percent of the sealing components actually are Simrit catalog products, which Simrit offers worldwide together with its Japanese partner NOK. Dai Qinghua considers there to be great development opportunities for cooperation between Sany and NOK Simrit. „The continued consolidation of the technology collaboration between our two companies has considerably helped Sany Heavy Machine Co., Ltd. to improve its standing with its customers even more. I envision excellent future prospects for both companies due to our cooperation.“

Applications

Impressive dimensions: The excavator weighs 20,000 kg, its blade has a capacity of almost 1.45 cubic meters and the engine provides 190.5 kW at 2000 rpm.

Sany Heavy Machine Co., Ltd.: The construction machinery giant from the People‘s Republic of China Sany Heavy Machine Co., Ltd., which was founded in 1989 in Changsha, Hunan Province, is the world‘s largest cement machinery manufacturer and is the only company in the People‘s Republic of China which is listed in the FT Global 500. The company has around 70,000 employees worldwide and six production sites in the People‘s Republic of China, as well as four other production sites in the USA, India, Brazil and Germany. In Germany, since 2010, Sany has invested around €100 million in its Bedburg site, which, apart from production, also has a research and development department. In addition to construction machinery, Sany now also produces gear assemblies and is active in wind energy.

Simrit insight 01|2012 17

Products

AIR AND OIL TIGHT

The long service lives and reliability of tire pressure control systems are improved substantially by the CTI (Central Tire Inflation) rotary shaft seal.

This component reliably seals the rotating wheel hub from air on one side and from oil and grease on the other side.

The primary sealing lip system used on the CTI rotary shaft seal has the task of providing an air seal and simultaneously limiting pressure.

The tire pressure of agricultural and construction machinery that is used in difficult terrain must be matched precisely to the ground and soil characteristics. In modern machinery, this can be controlled by the driver with a touch of a button. However, rotary shaft seals are frequently a weak point in such tire pressure control systems because the seals must be tight relative to oil and grease and high air pressures.

In contrast to conventional seals made of PTFE, which do not seal reliably against oil and grease, the patented CTI rotary shaft seal offers high reliability at high pressures and a long service life. The core of this Simrit innovationis a two-component solution utilizing two sealing lips. The primary sealing lip system, which is constructed

of a highly wear-resistant PTFE, has the task of providing an air seal and simultaneously limiting pressure. Therefore, the secondary sealing lip is never subjected to full pressure, so it can seal against normally occurring air leakage throughout its long service life. A pressure-stable FKM oil sealing lip then takes over the function of lubricant sealing. The PTFE sealing lip is bonded to the actual oil seal using state-of-theart adhesive technologies.

Do you have any questions or suggestions? Please contact rene.dauphin@fst.com

ACTIVE FLUID RETURN High oil levels or even flooded applications can now be sealed reliably. The Radiamatic速 HTS II 9541 with its dynamic helix function now handles this task without a sweat.

This function is achieved through a machining operation (turning) so that no molds are required and the component is also suitable for small-volume applications.

18 Simrit insight 01|2012

Whether it is used in heavy-duty transmissions on agricultural machinery, in vacuum pumps used for fluid handling, or in construction machinery, the Radiamatic HTS II 9541PTFE rotary shaft seal with dynamic helix function guarantees operation in all of these units, extremely long service lives, unsurpassed low coefficients of friction and highly rugged design, even under extreme operating conditions.

The Radiamatic HTS II has been optimized further using a machining operation (turning), which eliminates the

need for molds. This is particularly advantageous for applications in which oil and fluid reservoirs must be sealed.

A spiral-shaped groove that is machined into the sealing lip on a lathe causes the fluid to be fed back into the source when the shaft is rotating. The direction of rotation is already engraved on the seal in the manufacturing process. The unique advantage of a mold-free manufacturing process is the flexibility with which various customer requests can be met. Even very small quantities can be easily supplied

Products

AN ALLROUNDER IN RUGGED TERRAIN

The High-Performance Protection Seal combines the lowest possible frictional torque and optimized space requirements with high resistance to dirt, ice and water.

Sealing component solutions for dirty environments are a real challenge for seal manufacturers when it comes to design and material know-how. Rotating parts must be reliably protected from dust, sand, or corrosion particles, and the seal must be optimally designed with respect to friction and space requirements. With its High-Performance Protection Seal, Simrit performs a real engineering high wire act with a seal that not only protects perfectly over the long haul against dirt and contamination but also achieves sensationally low frictional torque. The design optimization is based on a sealing lip of PTFE-­ impregnated nonwoven material. In a patented manufacturing process, highperformance fibers capable of achiev-

within short lead times. More than 60 standard dimensions are listed for the HTS II in the basic version of Simrit’s e-catalog (http://www.simrit. de/web/public/products/eCatalog).

In addition, numerous product options are available to increase machine performance and give the customer a competitive market advantage.

ing very high mechanical and thermal resistance are processed into an impregnated and a laminated specialty non­ woven. The high-speed performance and energy efficiency of the High-Performance Protection Seal significantly extend the performance limits of equipment in which the seal is installed. In addition, the seal’s low frictional torque and an optional conductive material version allow the seal to be used in ATEX environments. The High-Performance Protection Seal is available as a readyto-install single seal or as an individual sealing lip as part of a modular system.

The High-Performance Protection Seal can be used as an individual seal in many applications: The spectrum extends from electrical motors and gene­

An optional conductive material version makes it possible to use the HighPerformance Protection Seal in ATEX potentially explosive atmospheres.

rators to blowers and machine tool equipment and conveyor belts. The component is also available as a modular sealing lip that can be used as an auxiliary element for oil, grease, and labyrinth seals. This makes it possible to install an additional dirt and contamination-preventing element in gearboxes, rolls, pumps, axles and bearings.

Do you have any questions or suggestions? Please contact bianca.wolf@fst.com

The direction of rotation is already marked during the manufacturing process.

Do you have any questions or suggestions? Please contact bianca.wolf@fst.com

Simrit insight 01|2012 19

simrit.com

LEADING IN ALL AREAS

„CLAAS combine harvesters with TERRA TRAC track roller units are the fastest on the road world-wide, with speeds up to 25 mph, but still gentle in the field.

An innovative Linear Compensator from the Simrit brand has helped achieve these advantages. Above all, the intelligent integration of functions and design simplifications allow us to substantially reduce the number of conventional components, minimizing the potential for system failures.

In this way, our CLAAS combine harvesters also set new standards with regard to operational reliability.“ Robert Obermeier-Hartmann

Rüdiger Mohr, Head of Corporate Purchasing, Claas

Robert Obermeier-Hartmann, Project Manager TERRA TRAC, Claas

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Simrit Linear Compensator with innovative accumulator technology