bosch common rail 2015

The Innovations ReportThe International Suppliers Fair (IZB)14 th 16 th October 2014

Allerpark | Wolfsburg | Germany

www.izb-online.com

Including

28 world

premieres

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the innovations report | izb 2014 3

The Innovations Report of the IZB 2014. The 8th International Suppliers Fair (IZB) will take place in the German city of Wolfsburg from 14th to 16th October 2014. Over 820 exhibitors from 29 different countries will present their latest developments and products at the showcase event for the automotive supplier industry. As the partner region of the IZB 2014, the countries that make up the Association of Southeast Asian Nations (ASEAN) will form the focus of this years trade fair and its programme of accompanying events.

The automotive industry has been considered to be a driving force behind innovation for a long time. Back in the 1970s, plastics transformed the automotive market before the focus switched to innovations such as vehicle safety systems, aerodynamic car body designs and catalytic converters. The vehicles of the future are now defined by their alternative drive technologies, increasing digitalisation and lightweight materials. At the IZB, exhibitors from Germany and abroad showcase their latest products, systems, technologies and services in and around the field of automotive manufacturing.

The Innovations Report provides a summary of some of these new exhibits. The informative publication also contains a number of important facts and figures concerning the IZB.

You can find an online version of the report at www.izb-online.com/neuheitenreport.

We hope that you will enjoy reading this Innovations Report and have an interesting time in Wolfsburg.

Julius von IngelheimSpokesman of the Board of Wolfsburg AG

FOREWORD


CONTENTS

The IZB

The Showcase Event for the International Automotive Supplier Industry 13

IZB 2014 Facts & Figures 14

IZB Programme of Special Events 15

Layout of the Exhibition Grounds 16

The Press Team at the IZB 2014 17

Innovations Presented by Exhibitors:

Using the Refractive Index to Record AdBlue Quality* 19

AB Elektronik GmbH

Proven Improvements to Ambient Air Quality 20

AB-Polymerchemie GmbH

Optical Tracking Technology for Design Centres* 21

AICON 3D Systems GmbH

An AMV System with Maximum Data Protection Standards* 22

AMV Networks GmbH

A Drawer Cabinet with a Magnetic Bolt Lock 23

Bedrunka+Hirth Gertebau GmbH

Going Far Beyond Simple Coating and Painting 24

BENSELER Beschichtungen Sachsen GmbH & Co. KG

An Additive with Outstanding Dissolving Power 25

Bio-Circle Surface Technology GmbH

* World premiere


CONTENTS

Excellent Resistance to Media and Flame Resistance 26

BIW Isolierstoffe GmbH

Using Android Applications* 27

Blaupunkt Malaysia Sdn. Bhd.

Lightweight Materials* 28

Borealis AG

Innovative Leather Solutions for an Extremely Light and Resilient Interior 29

BOXMARK Leather GmbH & Co. KG

Software for the Digital Factory 30

CENIT AG

The Worlds Biggest Laser Metal Melting Machine 31

Concept Laser GmbH/Hofmann Innovation Group

Improved Multiple Injection Thanks to Injectors 32

Delphi Automotive Systems

Increasing Efficiency for the Mobility of the Future* 33

Diehl Metall Stiftung & Co. KG

Cost-Effective Lightweight Construction in the Field of Vehicle Interiors* 34

Drxlmaier Group

Industrial Laser Colour Printing without Sunburn 35

DSP-PRINT-TEC GmbH

Optimal Forced Induction with a Variable Engine Speed* 36

Eaton Germany GmbH

* World premiere

An Impact Splinter Protection Concept for Door Trims 37

Eissmann Group Automotive

A Multi-Functional Pick-up Turning Machine* 38

EMAG Group

A Compact Oxygen Sensor Element with a Rapid Response Time 39

E+E Elektronik Ges.m.b.H

Expert Teams Where Needed 40

Espacio Subconmeeting (MMB Gadestic, S.L.)

Silent Operation and Bidirectional Control* 41

E-T-A Elektrotechnische Apparate GmbH

Less Weight and Improved Performance 42

Evonik Industries AG

Lightweight Cast Iron Steering Knuckles 43

Fagor Ederlan S. Coop.

A Secure Hole Sealing Concept and Automated Film Coating* 44

FAIST ChemTec Group

Better Surface Quality and Leak-Tightness 45

Felss Shortcut Technologies

Increasing Service Life and Resilience 46

Frauenhofer-Institut fr Schicht- und Oberflchentechnik IST

Efficient, Emission-Neutral and Embedding People* 47

Frauenhofer-Institut fr Werkzeugmaschinen und Umformtechnik IWU

An Urban Mobility Vehicle* 48

From Concept to Car

* World premiere


CONTENTS

An Urban Mobility Vehicle* 49

GKN Driveline

3D Measuring Machines for Automated Quality Control 50

GOM Gesellschaft fr Optische Messtechnik mbH

Fibre-Reinforced Plastic Components in a Single Processing Step 51

HBW-GUBESCH Kunststoff-Engineering GmbH

Individual Control of Every LED* 52

HELLA KGaA Hueck & Co.

New Opportunities Thanks to Innovative Processes 53

HEWI G. Winker GmbH & Co. KG

An Extremely Precise Measuring Device for Production Areas 54

Hexagon Metrology GmbH

Equipped for the Large-Scale Production of Elastomer-Micro Bonded Parts 55

Hoffmann GmbH Gummi- und Kunststoffformtechnik

Precise Pressure Control Thanks to a Servo-Driven Valve Gate 56

HRSflow c/o Inglass S.p.A.

An XXL Vacuum Distillation System* 57

H2O GmbH

A Test Bench for Multiaxial Vibration Tests 58

IABG mbH

A Management System for Vehicle Testing 59

ICT Software Services GmbH

* World premiere

Better Handling Combined with Easier and More Flexible Operation* 60

Inficon GmbH

Real-Time Thermography in HD Quality* 61

InfraTec GmbH Infrarotsensorik und Messtechnik

A Connection Point for Production Activities 62

item Industrietechnik GmbH

A Lowerable Exterior Door Handle 63

ITW Release & Trim

Lightweight Construction with State-of-the-Art Technologies 64

KIRCHHOFF Automotive Germany GmbH

A Special Lubricant for Plastic 65

Klber Lubrication Mnchen SE & Co. KG

SmartWave A 3D Hybrid Featuring Electronics and Plastic* 66

Kunststoff Helmbrechts AG

Protection and Ease of Assembly Combined 67

Langendorf Textil GmbH & Co. KG

High-Performance Energy Storage Components 68

LSIS Co., Ltd.

Duplex Coating for Maximum Corrosion Protection 69

Metob Beschichtungen GmbH

Reducing Vehicle Weight 70

Muhr und Bender KG

A Mirror-Inverted Fan Design* 71

NMB-Minebea GmbH

* World premiere


CONTENTS

The Best Possible Screw Connection Behaviour 72

NOF METAL COATINGS EUROPE

Protection against Scratches and Impact Damage 73

Norddeutsche Seekabelwerke GmbH

puremaxLED The Modern and Energy-Efficient Surface Control Optic* 74

OLIGO Lichttechnik GmbH surface controls

Management Software Displays Expiry Dates and Remaining Service Times 75

Perschmann Calibration GmbH

System Components with High-Performance Surfaces 76

plastic-design gmbh

Manufacturing Tubes from High-Strength Steels 77

Prinz Mayweg Gruppe

Profile Pictures for Project Work 78

Projektron GmbH

A Sprayed Metallic Effect for Decorative Surfaces and Garnish Mouldings 79

RECTICEL Automobilsysteme GmbH

Connectivity in Vehicles 80

Robert Bosch GmbH

Small-Series Products at Mass-Production Prices* 81

rpm rapid product manufacturing GmbH

A Weight Reduction of 30 Percent* 82

Somboon Advance Technology PLC

* World premiere

Achieving a Large Measurement Volume Whilst Maintaining a

High Level of Precision 83

Steinbichler Optotechnik GmbH

Enabling Users to Check Soldering Results and Positioning Accuracy* 84

Sumida flexible connections GmbH

Leather Covering as an In-Mould Decoration Process 85

Tecnocad Progetti SPA

Multi-Bus Data Loggers in a Mini Format 86

Telemotive AG

Making Dashboards Easy to Pack and Unpack 87

THIMM SCHERTLER Verpackungssysteme GmbH & Co. KG

An Electronic Switch for Micro Interruptions 88

TOELLNER Electronic Instrumente GmbH

Extensive Colour Matching with a New Standard Light Concept* 89

TORSO-VERLAG e.K.

Innovative Fuelling Systems and Quick Connectors 90

WEH GmbH Verbindungstechnik

A Docking Station for Smartphones 91

Continental AG

A Special Multimeter that Now Features Interturn Short-Circuit Detection* 92

GMC I Messtechnik GmbH

Determining the Position of Car Gears 93

Hartmann-exact KG

A Robot with a Camera System for Spatial Monitoring* 94

YASKAWA Europe GmbH

* World premiere


In line with the events motto of Connecting Car Competence, the 8th International Suppliers Fair (IZB) will provide supplier companies with an excellent opportunity to present their industry and to establish business contacts.

Over 820 exhibitors ranging from global players through to small and medium-sized enterprises will attend Europes leading trade fair in the Wolfsburg Allerpark. These exhibitors will include more than 50 companies from this years partner region, the Association of Southeast Asian Nations (ASEAN). Both the exhibition itself and its programme of accompanying events are focusing on the opportunities and potential of the ten member countries of ASEAN.

The IZB was first hosted in 2001 as a Volkswagen in-house trade fair with 128 exhibitors from six nations and attracted 13,500 visitors. It has since established itself as an important business platform for the industry, attracting as many as eight of the worlds ten highest-volume supplier companies as exhibitors to Wolfsburg. The high-quality exhibitors and large number of key decision-makers and trade visitors that attend the IZB make it an important communication and business platform.

For more information on the IZB and the accompanying programme of events, please visit www.izb-online.com.

THE IZB THE SHOWCASE EVENT FOR THE INTERNATIONAL SUPPLIER INDUSTRY


Dates: 14th 16th October 2014 | daily from 10am to 6pm

Venue: The Allerpark in Wolfsburg

Organiser: Wolfsburg AG

Patrons: Mr Stephan Weil Prime Minister of the German Federal State of Lower Saxony Mr Francisco J. Garcia Sanz Member of the Board of Volkswagen AG Mr Klaus Mohrs Mayor of the City of Wolfsburg

Exhibition area: 7 halls covering an exhibition area of around 36,000m

Exhibitors: 821 exhibitors from 29 different countries

Partner region: The Association of Southeast Asian Nations (ASEAN), (Brunei, Cambodia, Indonesia, Laos, Malaysia, Myanmar, the Philippines, Singapore, Thailand and Vietnam)

Most-represented countries: Germany (around 530 exhibitors, 80 of which come from Lower Saxony), Spain (46), Italy (29), Portugal (27), Canada (17)

Key areas: Electrics | Electronics | Mechatronics Vehicle Interiors Vehicle Exteriors Metal Powertrain

Admission fee: Day ticket: 18 Euros | 3-day ticket: 48 Euros Free admission for school pupils, students and OAPs upon presentation of a valid ID card

You can find more information online at: www.izb-online.com

IZB 2014 FACTS & FIGURES

The International Automotive Congress ASEAN 13th October 2014 | Forum AutoVision of Wolfsburg AGwww.izb-kongress.com

China Symposium14th October 2014 | IZB exhibition grounds, Mobility Forumwww.chinasymposium.de

30th VDI/VW Joint Congress on Driver Assistance Systems14th to 15th October 2014 | Forum AutoVision of Wolfsburg AGwww.vdi-wissensforum.de

Resource-Efficient Automotive Production Symposium 15th October 2014 | IZB exhibition grounds, Mobility Forumwww.izb-ressourceneffizienz.com

The Lightweight Construction Forum Expert Discussions16th October 2014 | IZB exhibition grounds, Mobility Forumwww.izb-leichtbau.com

Other Events:

Mobility Talk of the Metropolitan Region14th October 2014 | IZB exhibition grounds, Mobility Forum

Automotive Cluster Meeting15th October 2014 | IZB exhibition grounds, Mobility Forum

IZB Job Fair16th October 2014 | IZB exhibition grounds, Mobility Forumwww.izb-online.com/jobboerse

IZB PROGRAMME OF SPECIAL EVENTS


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The press accreditation stand in Hall 1 in the main entrance area is the main port of call for media representatives attending the IZB 2014. You can visit this stand in order to pick up your accreditation documents and your press pass.

This year the IZB press stand where you can receive more information material, the exhibitor catalogue, exhibitor press kits and where workstations with internet access are available can be found in Hall 1, in the passage from the entrance area.

The stand also provides an overview of visual material relating to the IZB that is updated on a daily basis.

Opening hours of the Accreditation | Press Stand:10am to 6pm

Press contact:

Ms Anke HummitzschTelephone: +49 53 61.8 97-11 56Fax: +49 53 61.8 97-78 [email protected]

Ms Susann NagelTelephone: +49 53 61.8 97-11 55Fax: +49 53 61.8 97-78 [email protected]

THE PRESS TEAM AT THE IZB 2014


AB Elektronik GmbHWerne | GermanyHall 4 | Stand 4209

The AdBlue quality sensor (see image) from the company TT Electronics AB Elektronik Sachsen GmbH meets the requirements for systems in car, lorry and off-road applications. Its compact cost-optimised design is robust and able to withstand both environmental impacts such as dirt and temperature fluctuations and ageing processes. The sensor, which works as a refractometer, measures the refractive index of AdBlue and provides temperature-compensated information according to the media concentration. It is able to immediately detect unauthorised fillings or additions and as a result, guarantees a consistent level of AdBlue quality in the SCR system and the AdBlue tanks. The sensor can be installed in the base of the AdBlue tank or as an in-line solution between the tank and the dosing system. This solution is not only designed for implementation in new applications, but also for upgrading existing systems.

USING THE REFRACTIVE INDEx TO RECORD ADBLUE QUALITY

Press contact: Ms Sandra GroTelephone +49 23 89.78 81 [email protected]

The AdBlue sensor

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AICON 3D Systems GmbHBraunschweig | GermanyHall 3 | Stand 3405

AICONs 3D Arena tracking system enables vehicle designers to determine the absolute position of processing machines or measuring devices in working space. This in turn enables them to work flexibly with mobile machines that can be freely moved around the working space. When the machines are not needed, designers can make the most of a completely undisturbed view of the model, which they can observe and process from all possible angles. The 3D Arena features up to 15 MoveInspect cameras mounted on a frame above the working space. The camera system captures the position of a mobile milling machine, white light scanner or another device and continuously determines its absolute position in the working space in reference to the vehicle model. If the machine is put aside and then brought back to the model at a later point in time, the tracking system is able to recognise it and set up the processing programme according to its coordinates, thus enabling the machine to continue its work without any problems. The breuckmann naviSCAN white light scanner is particularly suitable for use with the 3D Arena (see image).

OPTICAL TRACkING TECHNOLOGY FOR DESIGN CENTRES

Press contact: Ms Regina Marszalkowski-WulfTelephone +49 5 31.58 00 05 [email protected]

The breuckmann naviSCAN

AB-Polymerchemie GmbHAurich | GermanyHall 4 | Stand 4418

The company AB-Polymerchemie GmbH specialises in the manufacturing and sales of ESD and industrial flooring and claims to be the first full-service provider of practically emission-free floor coating systems for recreation rooms and production areas. Its AB-ZEROPUR comfort flooring and AB-ZEROPOX industrial flooring meet the criteria stipulated by the Committee for the Health-Related Evaluation of Building Products (AgBB) and have been granted technical approval by the DIBt, the Deutsche Institut fr Bautechnik (German Institute for Civil Engineering) The innovative systems are based on benzyl-alcohol-free coating materials (VOC < 1%) and are proven to improve ambient air quality for processors and users. The flooring emits virtually no unpleasant odours, even during installation, and can therefore also be laid during ongoing production activities. The products have been intensively examined and approved by the Safety Chemistry team at Volkswagen AG and have already been successfully used to cover an area of 28,000m2 at the companys factory in the German town of Emden (see image).

PROVEN IMPROVEMENTS TO AMBIENT AIR QUALITY

Press contact: Mr Edward SandersTelephone +49 49 41.60 43 [email protected]

A floor coating in the Volkswagen factory in Emden

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AMV Networks GmbHRanshofen | AustriaHall 2 | Stand 2205 K

The company AMV Networks GmbH, which is based in the Austrian village of Ranshofen, was recently awarded the EuroPriSe certificate (see image) for its innovative telematics technology, the AMVSystem. The AMVSystem is therefore the first and currently the only telematics system in the automotive industry to comply with the highest certifiable data protection standard in the world. The AMVSystem technology, which was developed in accordance with automotive OEM standards and EU directives, seamlessly incorporated the Security & Privacy by Design / Information Security and Data Protection Principle at an early stage, namely during the development of its basic concept. As an immediately available retrofit solution, the system enables users to record vehicle data in real time, across different platforms and in accordance with data protection regulations and to make these data widely available for different areas of use.

THE AMVSYSTEM WITH MAxIMUM DATA PROTECTION STANDARDS

Press contact: Mr Raimund WagnerTelephone +43 77 22.64 32 [email protected]

The AMVsystem with the European Privacy Seal

Bedrunka+Hirth Gertebau GmbHBrunlingen | GermanyHall 3 | Stand 3406

The Tool Server Modular (TSM, see image) is an electronically controlled tool cabinet with a magnetic bolt lock. The storage system is not only ideal for small components, but also for bulky items up to 600mm long. It can be used for a wide variety of applications requiring access control, for example for storing expensive tools, confidential files, valuable articles or medical items. The TSM is constructed like a normal tool cabinet and contains a number of individual drawers. Unlike a normal tool cabinet, however, each of these drawers is secured with a magnetic bolt lock. This patented locking mechanism does not require any cables and is therefore less susceptible to faults because frequently opening and closing drawers puts a lot of strain on cables and often leads to breakdowns and disturbances. The access authorisation process for the drawers in the TSM requires users to either enter a pin code or use a screen installed on the side of the cabinet to provide their fingerprint.

A DRAWER CABINET WITH A MAGNETIC BOLT LOCk

Press contact: Ms Lea KellnerTelephone +49 7 71.9 20 [email protected]

The Tool Server Modular

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BENSELER Beschichtungen Sachsen GmbH & Co. KGFrankenberg | GermanyHall 3 | Stand 3205

The BENSELER Group is a specialist for coatings, decorative paint finishes, corrosion protection, deburring and electrochemical shaping. As an innovative, reliable and efficient partner, above all in the automotive industry, the company offers a wide variety of different individual processes and professional combinations of processes. When it comes to light metals and plastic materials, the exhibitor offers a vast spectrum of new and unique combinations of coatings and uses mixtures such as a combination of PVD and UV coatings (see image) to give plastic substrates an elegant and robust metallic appearance. BENSELER also uses high-pressure water jet deburring, thermal deburring and electrochemical shaping to process components of different shapes and sizes. It offers highly automated processes for the treatment of large quantities, with new procedures meaning that individual deburring techniques can also be better combined in this area.

GOING FAR BEYOND SIMPLE COATING AND PAINTING

Press contact: Ms Ines KblerMs Martina HnekoppTelephone +49 7 11.94 76 [email protected]

A curved line of UV coating

Bio-Circle Surface Technology GmbHGtersloh | GermanyHall 3 | Stand 3301

The company Bio-Circle Surface Technology will present a number of innovations for the world of cleaning and maintenance at the IZB 2014. Nature Boost-Green Corner, for example, is an innovative additive based on renewable raw materials. It stands out due to its outstanding dissolving power designed especially for heavy greases, oils, adhesives and paints and is also incombustible, VOC-free, exempt from labelling regulations and renewable. The BIO-CIRCLE GT Compact cleaning system (see image) is being launched on the market as the successor to the well-established BIO-CIRCLE Compact system and features a contemporary design, while the parts washer boasts an impressive compact construction and flexibility. The BIO-CIRCLE Clean Box Flow is a flexible cleaning system that is suitable for a wide range of applications and the ideal solution for degreasing components. CB 100 is an alternative to petroleum and perfect for removing the toughest stains occurring throughout the industry. The VOC-free cleaner is environmentally and user-friendly and suitable for applications such as motor servicing.

AN ADDITIVE WITH OUTSTANDING DISSOLVING POWER

Press contact: Ms Mirela CindricTelephone +49 52 41.9 44 39 [email protected]

BIO-CIRCLE GT Compact


Blaupunkt Malaysia Sdn. Bhd.Seberang Prai Tengah | MalaysiaHall 1 | Stand 1301

Cape Town 945 (see image) is the new flagship of the company Blaupunkt and offers much more than conventional car radios. Alongside a high-end tuner for excellent sound, the ability to play CDs or DVDs, Bluetooth streaming, USB stick ports at the front and back and an SD slot, Cape Town 945 also facilitates the use of Android applications. On top of all this, Cape Town 945 also boasts a new operating concept in which it is not only controlled by its 6.8-large touchscreen, but can also mirror the displays of a large number of Android smartphones or iPhones on its screen so that it can be operated via these devices. This Mirror Mode is made possible by a free Blaupunkt app for connected smartphones. The new Blaupunkt model can also access the Internet without a smartphone thanks to the WiFi USB dongle supplied with the device.

USING ANDROID APPLICATIONS

Press contact: Mr Duong Tran NgocTelephone +49 51 21.9 98 13 [email protected]

Cape Town 945

BIW Isolierstoffe GmbHEnnepetal | GermanyHall 6 | Stand 6205

The tried-and-tested self-sealing PES abrasion resistance tubes in the Flextex series (see image) from BIW Isolierstoffe GmbH, which are heat-resistant up to a temperature of 150 degrees Celsius, have already been approved by leading OEMs and are now being used as cost-effective protection for pre-assembled power trains. These highly flexible tubes are ideal for fast and subsequent installation. They are also available with double-sided adhesive tape (Flextex SK) and cover the entire nominal diameter range from 5 to 50mm. An orange version of the tubes is available for hybrid electrical applications and is already in use in series production. Soft edges guarantee that the tubes can be used safely and without injury. On top of this, the tubes boast excellent resistance against fuels and lubricants, water, cleaning agents and salt spray and are flame-resistant in accordance with the class C FMVSS302.

ExCELLENT RESISTANCE TO MEDIA AND FLAME RESISTANCE

Press contact: Mr Dirk HolsteinTelephone +49 23 33.8 30 [email protected]

Flextex SK in black and orange

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Borealis AGWien | AustriaHall 2 | Stand 6220

The new hybrid polypropylene material Fibremod WE380HP from Borealis has a glass-fibre content of 20 percent and a mineral-filler content of ten percent. It is suitable for use in structural and visible car parts such as bonnets, window frames and armrests (see image). The lightweight material helps to reduce both fuel consumption and CO

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emissions without making any compromises when it comes to performance. Alongside its high mechanical resistance, the material also stands out due to its excellent processability, dimensional stability, low warpage, thermal resistance and extraordinary surface aesthetics. Daplen EE158AIB, a TPO material with a mineral-filler content of 13 percent, was selected by Volkswagen for its VW up! model. The material helps VW to achieve its weight reduction targets and additionally offers a balanced mechanical performance in terms of UV and scratch resistance, low emissions and fogging, as well as outstanding aesthetic properties.

LIGHTWEIGHT MATERIALS

Press contact: Ms Karin SchoberTelephone +43 1.2 24 [email protected]

Interior components made of Fibremod WE380HP

BOXMARK Leather GmbH & Co. KGFeldbach | AustriaHall 6 | Stand 6120

BOXMARK aims to use its leather innovations XLIGHT and XTREME to set trends for the vehicle interiors of the future and make a valuable contribution towards sustainability. XLIGHT weighs just 600g/m including lamination and is therefore able to reduce the overall weight of every vehicle while at the same time achieving reductions in the emission of harmful substances and cost savings. XTREME stands out due to its longer than average service life, high abrasion resistance and outstanding strain, ductility and tear strength properties. A multitude of test certificates additionally act as proof of its extraordinary resistance against mould, bacteria, disinfectant agents, sun radiation, dirt, chlorine and salt water, oil, alcohol and water. XLIGHT and XTREME meet all international standards and are also available combined in a single leather product (see image). The leather innovations from BOXMARK can be used for all interior components.

INNOVATIVE LEATHER SOLUTIONS FOR AN ExTREMELY LIGHT AND RESILIENT INTERIOR

Press contact: Mr Eduard KatholnigTelephone +43 31 52.41 [email protected]

A leather seat

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CENIT AGStuttgart | DeutschandHall 3 | Stand 3103

With its FASTSUITE Edition 2 (see image), the IT software and consulting company CENIT from the German city of Stuttgart has created an independent platform that reliably covers the entire process from the validation of process planning through to the virtual commissioning of production facilities. The software is based on an approach that is suitable for a comprehensive range of different manufacturers, processes and technologies. It therefore enables robotic, mechanical, human or logistics components to be integrated in just one simulation environment without any problems. The IZB exhibitor aims to use FASTSUITE Edition 2 to fill a gap in the market that existed between PLM-based and manufacturer-specific systems. The strengths of the software solution from CENIT include aspects such as simple and innovative operation, efficient and technology-specific programming functions for robotic applications and the complete openness of the system.

SOFTWARE FOR THE DIGITAL FACTORY

Press contact: Ms Maren StierleTelephone +49 7 11.78 25 34 [email protected]

FASTSUITE Edition 2

Concept Laser GmbH / Hofmann Innovation GroupLichtenfels | DeutschandHall 6 | Stand 6320

According to its supplier, the X line 1000R (see image) is the worlds largest generative laser metal melting machine, with a building area of 630 x 400 x 500mm3. It was developed for the tool-less manufacturing of large functional components and technical prototypes with identical material properties to series-production parts. One of the main aims in the automotive industry is to replace cost-intensive casting applications in early stages of development. This machine not only meets this aim, but also enables users to produce lightweight structures with a high rigidity that facilitate the use of weight-optimised forms with virtually no constructional limitations. The X line 1000R was even used to create the largest metal component ever to be produced using a powder-bed-based laser melting process, namely an aluminium gear part with impressive dimensions of 474 x 367 x 480 mm3. On top of this, the machine concept also features a multitude of positive environmental effects. By avoiding the use of casting applications and casting furnaces, it enables users to save a significant amount of energy and produce much less waste.

THE WORLDS BIGGEST LASER METAL MELTING MACHINE

Press contact: Mr Daniel HundMs Susanne PfadenhauerTelephone +49 95 71.1 67 92 51Telephone +49 95 71.94 91 [email protected]@hofmann-mod.dewww.concept-laser.dewww.hofmann-innovation.com

X line 1000R


Delphi Automotive SystemsBascharage | LuxemburgHall 3 | Stand 3600 (IZB Delphi TV lounge)

The new family of Diesel Common Rail Systems produced by Delphi features a variety of different components for fuel injection, including solenoid valve injectors, high-pressure pumps (see image), control devices (ECUs) and rails. The special combination of these components helps to improve performance by increasing injection pressure to up to 2500 bar and provide more effective multiple injection thanks to injectors that can carry out up to nine injections per cycle. These innovations result in better injection control and improved combustion, which in turn lead to a reduction in fuel consumption, carbon dioxide emissions and other emissions. The innovations therefore clearly represent a step forward in terms of environmental protection. They also open up opportunities to reduce combustion noise or improve the sound of engine noise.

IMPROVED MULTIPLE INjECTION THANkS TO INjECTORS

Press contact: Mr Thomas AurichTelephone +49 2 02.2 91 21 [email protected]

A high-pressure pump

Diehl Metall Stiftung & Co. KGRthenbach | GermanyHall 5 | Stand 5122

Three business units of the company Diehl Metall will use the IZB 2014 to present their product innovations for the automotive industry. Diehl Metall Messing will showcase its newly developed and extremely wear-resistant high-tensile brass alloys, which form a basis for power trains and ancillary units such as turbochargers and gear elements. Diehl Metall Schmiedetechnik will present its multi-cone synchroniser ring package made of brass and steel, which guarantees optimal thermal efficiency in mechanical manual gearboxes. Diehl Metal Applications offers customer-oriented solutions thanks to the integrated added value provided by services such as the in-house production of semi-finished products, pressing technology and electroplating right through to metal-plastic compound systems. New additions to the units product portfolio include the Schempp+Decker press-fit zone EE04, which follows the trend of miniaturisation, and the whisker-reduced surface coatings S+D Advanced Indium and S+D Advanced SnAg for press-fit zones. New developments such as contact systems for electromobility (see image) are already being used by a German OEM.

INCREASING EFFICIENCY FOR THE MOBILITY OF THE FUTURE

Press contact: Ms Taina TemmenTelephone +49 9 11.5 70 [email protected]/metall

Contact systems for lithium-ion batteries

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Drxlmaier GroupVilsbiburg | GermanyHall 4 | Stand 4305

Up until now, a high level of lightweight construction potential and low costs have always been in strong conflict. At the IZB 2014, the Drxlmaier Group will use its new X-Mittelkonsole centre console concept (see image) to show that both advantages can indeed be combined. This innovative concept for vehicle interiors enables the production of a centre console that is on average more than 30 percent lighter and over 30 percent more cost-effective than the conventional centre consoles currently installed in middle-class vehicles. The automotive supplier company aims to achieve these reductions by using a new and unique bracket architecture with an integral construction that intelligently combines the benefits of the well-known cover and bracket construction methods. As a result, the X centre console offers users maximal design freedom, variability, modularity and sustainability. It also boasts an additional advantage by being the first centre console that can be installed in vehicles without requiring the use of tools. A multitude of patents have already been granted and several analyses aiming to confirm the concepts suitability for series production are now as good as complete.

COST-EFFECTIVE LIGHTWEIGHT CONSTRUCTION IN THE FIELD OF VEHICLE INTERIORS

Press contact: Mr Dr. Tobias NickelTelephone +49 87 41.47 47 [email protected]

The X-Mittelkonsole centre console

DSP-PRINT-TEC GmbHGntersleben | GermanyHall 1 | Stand 1108

Laser Colour Coating (LCC) is a newly developed printing technology that uses a standard industrial laser to mark different surfaces in a production line in a cost-effective and variable process using different colours (RAL chart). LCC (see image) uses the advantages of inkjet printers (contactless printing, variable texts and different colours) and laser technology (high availability, low maintenance) whilst eliminating their disadvantages. Conventional laser printing technology burns surfaces or, in the case of plastics, leads to foaming. The LCC process, on the other hand, uses a thin coating to produce a colour print with a laser. Laser Colour Coating avoids the use of additives in the product material and is suitable for both labelling and high-resolution printing.

INDUSTRIAL LASER COLOUR PRINTING WITHOUT SUNBURN

Press contact: Mr Karl-Heinz PrstlerTelephone +49 93 65.89 06 [email protected]

Innovative laser colour printing

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Eaton Germany GmbHRastatt | GermanyHall 3 | Stand 3107

Electrically Assisted Variable Speed Technology (EAVS) from Eaton is a new electrically assisted system that enables forced induction with a variable engine speed on the basis of Eatons TVS superchargers (see image). Alongside forced induction, the technology also offers a number of benefits when it comes to optimising power and consumption, for example its regenerative mild-hybrid mode. It additionally enables starters and alternators to be replaced with an integrated start/stop module. A planetary gear in this module connects superchargers, electric motors and vehicle engines and facilitates extremely flexible operating modes. When used with a relatively small vehicle battery, it therefore enables optimal forced induction at all engine speeds whilst avoiding the delays in the build-up of pressure that occur with other superchargers. Vehicle engines equipped with EAVS develop more torque and a perfect vehicle response, especially at low engine speeds. This enables aggressive downsizing and optimises the mileage of the vehicle in question. The combined properties of EAVS offer a significant amount of fuel-saving potential without any compromise in terms of performance.

OPTIMAL FORCED INDUCTION WITH A VARIABLE ENGINE SPEED

Press contact: Ms Orsolya EsztervaryTelephone +49 72 22.15 99 86 [email protected]

The Eaton EAVS supercharger

Eissmann Group AutomotiveBad Urach | GermanyHall 6 | Stand 6204

The company Porsche AG has joined forces with the Eissmann Group Automotive to develop a multitude of visible and structural components made of CFRP and fibreglass for the interior of the Porsche 918 Spyder hybrid model (see image). This joint development partnership has resulted in the launch of an innovative splinter protection concept for carbon door trims in the case of side impact that is suitable for series production. The corresponding product portfolio available from the Eissmann Group contains door trims (visible components), glove compartments, support frames and several other components (some of which are visible components) that can be assembled together to form an instrument panel. The visible components in this portfolio are coated with a layer of either gloss or matt protection paint in order to ensure that their high-quality surface finish can withstand exposure to the elements. The company Eissmann Cotesa GmbH, which is responsible for the carbon fibre and glass fibre segment, is a joint venture that was created in 2010 in cooperation with the company Aerospace Experten Cotesa GmbH. The aim of this joint venture is to meet the growing requirements concerning lightweight construction in the automotive industry and to constantly expand the product portfolio available in this area.

AN IMPACT SPLINTER PROTECTION CONCEPT FOR DOOR TRIMS

Press contact: Ms Stephanie ConzmannTelephone +49 71 25.9 37 [email protected]

A Spyder interior

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EMAG GroupChonburi | ThailandHall 1 | Stand 1308

According to EMAG, an IZB exhibitor from Thailand, the company is the worlds first manufacturer to produce a turning machine with a pick-up work spindle with main axes that move while the tooling systems remain stationary. EMAG claims that this concept has completely transformed the turning procedure used up to now. Every machine in the VSC series is a manufacturing cell. The pick-up spindle enables the machine to load itself very quickly at virtually no extra cost. Nowadays, these machines act as multi-function production centres that can also be used for drilling, milling, grinding, gear cutting and other associated processes. The machines all feature the same design but contain different tooling systems. The VL 2:12 pick-up turning machine (the machining area of which can be seen in the image below), for example, can be used for turning or for driven drilling and milling tools in order to carry out a large number of processing activities.

A MULTI-FUNCTIONAL PICk-UP TURNING MACHINE

Press contact: Mr Uli KaiserTelephone +66 87.1 46 88 [email protected]

The pick-up turning machine VL 2: 12

E+E Elektronik Ges.m.b.H.Engerwitzdorf | AustriaHall 2 | Stand 2205 E

The new O2 sensor element (see image) from E+E Elektronik enables

oxygen concentrations of between 0 and 100 percent in combustion processes to be precisely measured and monitored. One of the main advantages of the E+E sensor element in comparison with the lambda sensor is its rapid response time of less than a second. Another highlight is its particularly compact design, which results in less heat dissipation and, as a result, lower case temperatures. Its sensor characteristics stand out due to its linear O

2 dependence through the

entire measurement range, as well as its low voltage and temperature dependency. The sensor element is calibrated with a fixed O

2 content

and can be electrically connected with wires or clip contacts. It is suitable for operating temperatures of up to 800 degrees Celsius.

A COMPACT OxYGEN SENSOR ELEMENT WITH A RAPID RESPONSE TIME

Press contact: Mr Johannes FraundorferTelephone +43 72 35.60 52 [email protected]

The oxygen sensor element

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E-T-A Elektrotechnische Apparate GmbHNrnberg | GermanyHall 4 | Stand 4095

The electronic ESR10 Micro 10 A standard relay (see image) from the company E-T-A Elektrotechnische Apparate GmbH is a solid-state relay for 12V DC vehicle applications. It stands out due to its silent operation, bidirectional control, low current consumption and long lifespan. The ESR10 Micro 10 A can be used to replace an electromechanical relay because control polarity plays no role. The solid-state relay is suitable for switching resistive, inductive and capacitive loads, as well as lamp loads. It also offers users the option of frequency control. E-T-A is a manufacturer of circuit breakers, automatic cut-outs and electronic fuses. Its range of products also contains relays, power distributors and complete control cabinet solutions. The products manufactured by the IZB exhibitor, for example its circuit breakers for equipment, offer maximum reliability against the effects of overcurrents and short circuits in areas such as automation and automotive engineering.

SILENT OPERATION AND BIDIRECTIONAL CONTROL

Press contact: Mr Patric GroTelephone +49 91 87.1 05 [email protected]

The ESR10 Micro 10 A standard relay

Espacio Subconmeeting (MMB Gadestic, S.L.)Madrid | SpainHall 2 | Stand 2204

The Spanish company Espacio Subconmeeting will use the IZB 2014 to showcase its new concept for the supplier industry. This new concept is based on being able to provide a team of experts in every industrial supply sector where needed. It enables manufacturers to work on the development of their products and components hand in hand with a group of research, development and production experts. In doing so, they not only benefit from shared synergies, but also from many years of experience and a high level of expertise. According to the IZB exhibitor, this new approach to dealing with the production and improvement of industrial processes enables manufacturers to achieve a significant amount of savings.

ExPERT TEAMS WHERE NEEDED

Press contact: Mr Mario LobatoTelephone +34 6 70.30 97 [email protected]

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Fagor Ederlan S. Coop.Eskoriatza | SpainHall 7 | Stand 7225

In accordance with the OEM strategy of using weight reduction to improve fuel efficiency and lower exhaust emissions, the Fagor Ederlan Group has now developed lightweight cast iron steering knuckles (see image). The manufacturer, which develops products, materials and processes, was also able to achieve a weight saving of 15 to 25 percent in real commercial applications as a result of its multi-technology innovation programme. The function-oriented structural optimisation of the steering knuckles enables users to design thin-walled products whilst achieving a tolerance reduction of 75 percent. According to the exhibitor, the expansion of the companys industrial model resources was made possible by its experience, advanced engineering, investments in next-generation facilities and the use of its own expertise in its in-house processing activities. For strength-driven applications, Fagor Ederlan plans to release new high-yield ductile grades of cast iron without patents. It has succeeded in improving the yield strength of these metals by 60 percent with no loss of elongation.

LIGHTWEIGHT CAST IRON STEERING kNUCkLES

Press contact: Ms Inmaculada Rodriguez LizarraldeTelephone +34 9 43.71 90 [email protected]

Lightweight cast iron steering knuckles

Evonik Industries AGDarmstadt | GermanyHall 3 | Stand 3500

At the IZB 2014, EVONIK Industries will use an automotive CFRP monocoque (see image) to present a variety of innovative material solutions in the specialty chemicals sector with a special focus on lightweight car body manufacturing. The components used in the CFRP monocoque were mostly manufactured using an RTM process and the matrix is epoxy-based, in this case on the basis of the VESTAMIN resin/hardener system. EVONIK additionally used NANOPOX in order to specifically improve the strength properties of certain components by adding silica nanoparticles to the matrix. The floor area and tunnel use a sandwich structure with a core made of ROHACELL structural foam to achieve further weight reduction whilst also improving performance. The fact that the sandwich layers are easy to shape in component manufacturing processes with short processing times means that this material solution is an interesting option for selected series components. The windscreen is made of PLEXIGLAS and therefore offers advantages such as a weight saving of 50 percent compared to mineral glass, excellent transparency and outstanding malleability.

LESS WEIGHT AND IMPROVED PERFORMANCE

Press contact: Mr Dirk ReinhardTelephone +49 61 51.18 43 [email protected]

The CFRP monocoque


FAIST ChemTec GroupWorms | GermanyHall 6 | Stand 6123

FAIST ChemTec has developed a new adhesive pad that can be used to seal holes during the painting process and joined forces with the company SAR to produce a concept for automated assembly. The adhesive pad stands out due to its secure and durable hole sealing properties, the fact that it provides increased corrosion protection by sealing the punching burr and the fact that its automated application requires less time and effort, enabling 50 adhesive pads to be fitted in a cycle time of under 60 seconds. The application equipment is also able to check that the pads have been fully applied in exactly the right positions (see top image). FAIST ChemTec has also joined forces with the company alpha-tec to develop a system for the automated application of damping films (see bottom image). This system enables damping films with hot-melt adhesive and magnetic damping films to be applied in conveyor cycles and significantly reduces the high costs involved in manual film coating or LASD systems. It also minimises the number of different items involved. The FAIST Akustikzentrum is currently developing the coating concept for the automatic application of damping films in preparation for the implementation.

A SECURE HOLE SEALING CONCEPT AND AUTOMATED FILM COATING

Press contact: Ms Kristin EmmerichTelephone +49 62 41.30 12 [email protected]

The adhesive pad application equipment and damping film application

Felss Shortcut TechnologiesKnigsbach-Stein | GermanyHall 5 | Stand 5118

Strong vibrations, severe fluctuations of temperature and high and variable system pressures are disadvantageous conditions for injection tube connections that need to be permanently secure. The rolling processes used by the company Felss help to significantly improve the quality of surfaces and, in turn, their leak-tightness. The Felss common rail line (see image) is able to withstand injection pressures of more than 10,000 bars and stands out due to a multitude of different advantages. These benefits include the fact that in comparison to similar lines, the Felss common rail line is 25 percent stronger thanks to its surface finishing in the sealing area (calculated on the basis of the increase in injection pressure), 400 percent more precise due to the improvement of surface quality (calculated on the basis of the evaluation of the RZ values for forming vs. forming and rolling) and 44 percent better in terms of resource efficiency as a result of the elimination of additional components/solder joints (calculated on the basis of the number of components involved in forming vs. the assembly of rotary components). Other special features include an increase in geometric accuracy and material hardening in essential areas.

BETTER SURFACE QUALITY AND LEAk-TIGHTNESS

Press contact: Ms Lauretta OjukwuTelephone +49 72 32.40 [email protected]

The Felss common rail line: stronger thanks to autofrettage

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Frauenhofer-Institut fr Schicht- und Oberflchentechnik ISTBraunschweig | GermanyHall 5 | Stand 5109

The IZB exhibition stand run by the Fraunhofer Institute for Surface Engineering and Thin Films (IST) will showcase a variety of different components from the fields of automotive manufacturing, tool making and mechanical engineering. DLC coatings can increase the service life and resilience of these parts and minimise friction losses. The staff at the institute are significantly involved in the development of such DLC coatings and also continue to work intensively on adapting an extremely wide variety of DLC modifications to suit customer-specific applications and optimising tribological systems. The main focus of their work is the evaluation of component surfaces, wear analyses, the selection of the most suitable coatings and the adjustment of the entire substrate and layer assembly process with the aim of achieving the best possible performance. Particular emphasis is placed on combinations of different coatings and coating technologies. Users of these coatings include the automotive industry (see image), the aerospace industry, tool manufacturers and users and the entire field of mechanical engineering.

INCREASING SERVICE LIFE AND RESILIENCE

Press contact: Ms Dr Simone KondruweitTelephone +49 5 31.2 15 55 [email protected]

The functional coating of engine componentsImage: Fraunhofer IST, R. Meier, BFF Wittmar

Frauenhofer-Institut fr Werkzeugmaschinen und Umformtechnik IWU Chemnitz | GermanyHall 1 | Stand 1211

Industrial production is the backbone of Germany as a business location. In order to maintain the locations high level of innovative power and competitiveness, we need to use comprehensive approaches and technology, for example by using resources in a more sustainable manner, saving energy, making better use of materials and more efficiently recycling limited resources. At the new E Research Factory for Resource-Efficient Production (see image), scientists from the Fraunhofer Institute for Machine Tools and Forming Technology (IWU) work to develop solutions for these central challenges and synergistically combine these different problem-solving approaches. These researchers work together with partners from industry and science to explore how resource, energy and information flows can be networked and controlled in such a manner that they create an efficient and emission-neutral factory in which people play an important role as central innovation leaders and knowledge holders. The E Research Factory uses this approach to develop solutions for the production activities of the future in the competence areas of Car Body Construction, Powertrain and Energy Management.

EFFICIENT, EMISSION-NEUTRAL AND EMBEDDING PEOPLE

Press contact: Mr Hendrik SchneiderTelephone +49 3 51.53 97 14 [email protected]

The transparent glass control centre at the E Research Factory for Resource-Efficient Production

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From Concept to CarTorino | ItalyHall 3 | Stand 3403

From Concept to Car is currently working on the development of a L6e and L7e as well as a last-mile small delivery e-van with advanced properties. One of these properties is the fact that the open-source modular vehicle supports the design and allocation of seats, while its modular power train architecture supports REX and FEV. Other features include the vehicles simplified and cost-effective E/E architecture, its wireless connection to mobile devices on the basis of available standards, torque vectoring for the parking assistant and the use of thermoplastic recyclable material to replace metals. The use of new materials helps to improve both thermal and acoustic comfort. The vehicle has an efficiency target of 40 Wh/km. It uses a combination of green REX (biofuels) and e-traction (ZEV) e-motor technology with a low rare-earth content to have a low impact on the environment. The aim is to develop a new LEV concept. The design phase is fully oriented towards cost-effective product development.

AN URBAN MOBILITY VEHICLE

Press contact: Ms Linda NegroTelephone +39 0 11.6 70 06 [email protected]

The UMV project logoGKN DrivelineLohmar | GermanyHall 5 | Stand 5208

The company GKN has now developed a new high-performance version of its electric drive axle (eAxle) for plug-in hybrid supercars. The eAxle technology (see image) provides high-performance cars with an optional pure electric mode, increased fuel efficiency, excellent acceleration and extremely good handling. The company has already supplied all-wheel drive eAxle systems for more than 250,000 vehicles. Two manufacturers of luxury vehicles have also chosen to use the GKN technology in their hybrid supercars. When developing its technology, GKN uses its very own state-of-the-art simulation and analysis tools to meet its own high standards and its growing customer demands with regard to weight, power density, NVH and durability. GKN is certain that these programmes will help to increase public acceptance of plug-in hybrid drives. Its technology provides vehicles with all-wheel drive characteristics combined with significant reductions in harmful emissions and fuel savings, even in the case of cars with front-wheel drive.

MORE ALL-TERRAIN MOBILITY AND FUEL SAVINGS FOR SUPERCARS

Press contact: Ms Sigrid Schulte-BeckhausenTelephone +49 22 46.1 00 22 [email protected]

eAxle technology

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GOM Gesellschaft fr Optische Messtechnik mbHBraunschweig | GermanyHall 3 | Stand 3308

GOM will present three different models of its optical 3D measuring machine ATOS ScanBox (see image) at the IZB 2014. These standardised measuring cells are fully automated, from the entire measurement and inspection processes right through to the inspection report. They therefore enable the completion of unmanned quality control checks in the production environment, for example checks carried out on cast, plastic and sheet metal components and assemblies. The different models of the ATOS ScanBox are suitable for different sized components. GOMs 3D measuring machine does not have to be installed in a permanent location, but instead can be assembled and put into operation in just one or two days. The main element in all of the measuring cells is a robot-controlled 3D scanner from the ATOS series that is used to measure components using a three-dimensional and contactless method. The ATOS ScanBox models have been specially developed for production-related inspection and quality assurance activities and are already being used by a multitude of different companies such as Daimler, VW, Rolls Royce, Bosch, Honeywell, Samsung, Automotive Lighting and ZF.

3D MEASURING MACHINES FOR AUTOMATED QUALITY CONTROL

Press contact: Ms Katrin StenebergTelephone +49 5 31.39 02 [email protected]

The ATOS ScanBox series

HBW-GUBESCH Kunststoff-Engineering GmbHEmskirchen | GermanyHall 6 | Stand 6110

Twin-O-Sheet is an energy-efficient procedure that is suitable for series production for the cost-effective manufacturing of large-volume, functionalised and highly resilient hollow objects made of fibre-reinforced plastic (FRP), for example organic sheeting, in a single processing step. The area of application of the procedure covers the production of structural items such as strut braces and seat shells. The Twin-O-Sheet procedure involves heating two sheets of fibre-reinforced plastic, using gas pressure to form them and subsequently using the residual heat to weld the component halves together in the same step. Injection moulding can then be used to functionalise the components where necessary. The precise positioning of the heated sheets of fibre-reinforced plastic in the tool plays an important role in the Twin-O-Sheet procedure in order to guarantee the required gas seal on the mould parting surface. The procedure is the first approach to enable the production of closed hollow FVK structures in one step or with one tool. Its combination of lightweight construction in terms of both design and material enables users to increase the rigidity of components without increasing their costs.

FIBRE-REINFORCED PLASTIC COMPONENTS IN A SINGLE PROCESSING STEP

Press contact: Ms Jasmin RedelbergerTelephone +49 91 04.8 27 [email protected]

Components made of fibre-reinforced plastic


HELLA KGaA Hueck & Co.Lippstadt | GermanyHall 4 | Stand 4107

The companies Audi and HELLA are currently celebrating the introduction of a world premiere in the new Audi A8, which was recently launched on the market. Audis flagship model is available with the worlds first ever Matrix LED headlights with glare-free high beam (see image). The technical implementation of this function involves dividing the high beam up between five reflectors, each of which contains a 5-chip LED. For the first time ever, the lighting expert HELLA has succeeded in individually controlling each LED on the 5-segment chip and is therefore able to turn up or dim a total of 25 LEDs per headlight as and when required. The use of this Matrix technology enables several tunnels to open simultaneously for the first time, for example in the case that a number of oncoming vehicles are driving one behind the other. The technology is able to mask out these vehicles whilst enabling the high beam to continue to fully illuminate all of the areas between and to the left and right of the oncoming vehicles. The system then returns to its full high-beam function as soon as all vehicles have left the drivers field of vision.

INDIVIDUAL CONTROL OF EVERY LED

Press contact: Mr Dr Markus RichterTelephone +49 29 41.38 75 [email protected]

Matrix LED highlights from the AUDI A8

HEWI G. Winker GmbH & Co. KGSpaichingen | GermanyHall 7 | Stand 7200

Cold forming processes enable users to have a specific influence on the properties of their materials and components. According to the IZB exhibitor HEWI, it is able to produce optimal benefits for its customers by taking an integrated approach to the parameters of materials, design and technology. HEWI uses its comprehensive expertise and the incorporation of state-of-the-art developments to tackle new challenges. In the field of design, for example, the company combines numerical analyses of the sub-disciplines of forming and structural mechanics to predict the ultimate properties of components. According to HEWI, the constant modernisation and expansion of its machinery (see image) enables the company to offer its customers a cost-effective substitute for hot-pressed and turned parts in the form of cold-formed parts in net-shape quality. The exhibitor demonstrates its expertise in the field of connecting elements and cold-formed parts with a customer portfolio containing all well-known OEMs, as well as joint patents with Volkswagen AG and Daimler AG.

NEW OPPORTUNITIES THANkS TO INNOVATIVE PROCESSES

Press contact: Mr Daniel SchmidTelephone +49 74 24.70 42 [email protected]

The HEWI workshop

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Hexagon Metrology GmbHWetzlar | GermanyHall 5 | Stand 5214

Hexagon Metrology recently announced the market launch of TIGO SF (see image), a precise and compact 3D coordinate measuring machine (CMM) specifically designed for use in production areas. TIGO SF is the ideal measurement solution for a broad spectrum of small and medium-sized parts from all industrial sectors. With a measuring volume of 500 x 580 x 500mm (X/Y/Z), the device boasts a volumetric accuracy and is therefore, according to its manufacturer, the most precise production CMM in its category. A number of functions help to ensure that the device provides extremely precise measurements, even under demanding production conditions. Its improved structural thermal compensation guarantees precise measurements in a temperature range of 15 to 30 degrees Celsius. Passive damping protects the machine against the common vibrations involved in production activities and active dampers are also available as an option for extra protection. The machine is additionally equipped with covers and bellows to prevent contamination of its moving parts.

AN ExTREMELY PRECISE MEASURING DEVICE FOR PRODUCTION AREAS

Press contact: Ms Melanie StutzTelephone +41 44.8 09 35 [email protected] www.hexagonmetrology.de

TIGO SF

Hoffmann GmbH Gummi- und KunststoffformtechnikKirchheim | GermanyHall 6 | Stand 6118

In cooperation with a manufacturer of rubber injection moulding machines, this IZB exhibitor has developed a new concept for the large-scale production of rubber-metal and rubber-plastic micro bonded parts using 50-ton injection moulding machines (see image). The aim of this development was to keep the idle time of the machines down to an absolute minimum. The option of connecting an industrial robot to the process in order to fill and empty the vulcanisation moulds was also factored into the concept development process. The micro bonded parts are manufactured in the companys new production facilities for industrial process measurement and control components to be installed in proportional valves, 2/2-way valves, non-return valves and pneumatic and hydraulic actuators and sensors. The requirements for highly-resistant materials are just one of the challenges faced by the company alongside tolerance demands concerning linear measures, evenness, perpendicularity, rotation and surface quality in a range of 0.02mm.

EQUIPPED FOR THE LARGE-SCALE PRODUCTION OF ELASTOMER-MICRO BONDED PARTS

Press contact: Mr Jochen KuglerTelephone +49 70 21.9 50 10 [email protected]

An injection moulding machine for micro bonded parts


HRSflow c/o Inglass S.p.A.Torino | ItalyHall 3 | Stand 3403

HRSflow, an international supplier of hot runner systems, offers a multitude of advance technological solutions for sequential injection moulding. One of these solutions is the FLEXflow, a Servo-Driven valve gate that assures accurate, easy and flexible control of pressures and flow rates during the whole injection process. It is a step forward the sequential injection molding thanks to its high flexibility in adjusting the process parameters. Among the various benefits, FLEXflow allows to improve part quality and perform the most challenging of applications. The HRSflow FLEXflow controller grants accurate setting, control and monitoring of the valve pin position, velocity, acceleration and stroke. Controllers are available in 7 different configurations: 4, 6, 8, 10, 12, 14 and 16 zones. Furthermore HRSflow Mold Flow department can provide customers with an optimized nozzle opening sequence for a minimized numbers of shots for color changeover. This sequence can be recorded in the FLEXflow control unit to be easily recalled whenever needed.

PRECISE ADjUSTMENT OF EVERY PIN POSITION

Press contact: Mr Stephan BerzTelephone +39 04 22.75 01 [email protected]

Avoiding pressure jumps

H2O GmbHSteinen | GermanyHall 5 | Stand 5131

The new VACUDEST XXL vacuum distillation system (see image) from the company H20 is nearly 7.6 metres long and 6m high and can process an impressive 30,000m3 of wastewater per year: The system is a new addition to the exhibitors existing high-performance XS to XL series and will be presented to trade visitors from the global automotive industry for the first time at the IZB 2014. This extraordinary system boasts a distillation performance of up to 5000 litres per hour and is above all interesting for the field of automotive production due to its large processing capacity and patented H20 innovations. Plans are in place for the VACUDEST XXL to go into production at the company, which is based in the town of Steinen in the German Federal State of Baden-Wrttemberg, at the beginning of 2015. According to the exhibitor, the experts for wastewater-free production at H20 GmbH are the worlds technology leaders when it comes to efficient and reliable evaporators for the processing and management of industrial wastewater.

AN xxL VACUUM DISTILLATION SYSTEM

Press contact: Mr Thomas DotterweichTelephone +49 76 27.9 23 [email protected]

The new VACUDEST XXL

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Press contact: Ms Monika PetersTelephone +49 89.60 88 20 [email protected]

IABG mbHOttobrunn | GermanyHall 3 | Stand 3402

IABG has been testing products and components from the automotive and aerospace industries and the fields of energy and transport for more than 50 years. In August 2014, the company will add yet another test bench to its range of services in the area of multiaxial vibration testing: the LiMAS (Light Multi Axis Shaker, see image). This will enable IABG to carry out multiaxial vibration tests in a frequency range of 0.5 to 200 Hz and with an acceleration of up to 13g with a maximum test object weight of 1t, as well as under simulated environmental conditions. The bench also enables the company to examine product behaviour in combined tests in a temperature range of -40 to +95 degrees Celsius and with a relative humidity of up to 95 percent. The services available from the exhibitor are oriented towards customer-specific demands and requirements. The IABG Fatigue Strength Laboratory (IBL) is accredited in accordance with the standard DIN EN ISO 17025 in the field of vibration testing and is therefore subject to regular quality surveillance by the German Accreditation Council (DAkkS).

A TEST BENCH FOR MULTIAxIAL VIBRATION TESTS

The Light Multi Axis Shaker

ICT Software Services GmbHKarlsruhe | GermanyHall 3 | Stand 3312

Vehicle Circuit Test OpeRation (VICTOR, see image) is a management system that supports the testing process used for vehicles on an automotive test track. The basic version covers all stages of the process. The control centre is used to plan tests, define test parameters and coordinate the execution of test programmes. The electronic unit in the vehicle instructs the driver as to how to conduct the test and records the test data. After the testing is complete, the test data are transmitted to the control centre, where they are stored and evaluated. Test reports can then be produced in accordance with customer-specific requirements. Optional system extensions enable garage staff to be provided with instructions on how to configure the test vehicles, an automated driving manoeuvre recognition function, danger warnings and audio recordings of drivers comments and observations. The main advantage of VICTOR is that it enables paperless, reliable and secured test operations that can be used to achieve reproducible test results.

A MANAGEMENT SYSTEM FOR VEHICLE TESTING

Press contact: Mr Alexander Dotzler Telephone +49 7 21.93 27 61 [email protected]/de

The VICTOR management system


Press contact: Ms Sandra SeitzTelephone +49 2 21.56 78 81 [email protected]

Inficon GmbHKln | GermanyHall 3 | Stand 3311

The company INFICON will present a special innovation for the very first time at the IZB 2014 in the form of its HLD6000 leak detector (see image). The refrigerant leak detector is able to quickly and reliably detect leaks in air conditioning systems and is suitable for detecting substances such as CO2 and even R1234yf. When compared with its well-established predecessor, the HLD5000, the HLD6000 features a multitude of improvements. The servicing devices optimised ergonomic design and lighter probe, for example, make it easier to use over long periods of time, while LEDs in the probe help to optimally light up the inspection area. Control of the device is highly simplified by the new intuitive HMI, which reduces operating errors and requires less training, as well as making the Inficon HLD600 easier to set up and service. The leak detectors manufactured by the IZB exhibitor are used in challenging industrial processes with a wide range of different applications in the fields of production and quality control.

BETTER HANDLING COMBINED WITH EASIER AND MORE FLExIBLE OPERATION

The HLD6000 leak detector

InfraTec GmbH Infrarotsensorik und MesstechnikDresden | GermanyHall 3 | Stand 3105

A maximum level of quality, unique performance characteristics and excellent handling are the outstanding features of the new VarioCAM High Definition camera series (see image) from InfraTec. These camera models are now available for use as mobile equipment in the research and inspect lines and as stationary alternatives in the head range, with the individual properties of each type of camera enabling it to meet the requirements for optimal use in all areas of application. Two different high-definition microbolometer detectors of the latest generation with a resolution of 1024 x 768 or 640 x 480 IR pixels make up the heart of the VarioCAM High Definition series. These work in combination with the cameras innovative optomechanical MicroScan technology to quadruple the native detector resolution and provide real temperature measurements. The cameras also boast a multitude of equally innovative useful functions such as the permanent autofocus supported by the integrated laser rangefinder and the unique EverSharp function.

REAL-TIME THERMOGRAPHY IN HD QUALITY

Press contact: Ms Anja ScheibeTelephone +49 3 51.8 71 86 [email protected]

The mobile and stationary versions of the VarioCAM High Definition series

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Press contact: Mr Maik Rico y GomezTelephone +49 2 12.6 58 04 [email protected]

item Industrietechnik GmbHSolingen | GermanyHall 1 | Stand 1103

The item installation column (see image) can be used to connect production areas with power, compressed air and data network access. The stable column contains two spacious cable conduits and sockets, switches and jacks can be directly plugged into place in the openings. Once they are finished and ready for use, all open conduits can be neatly covered with an aluminium profile so that the installation column securely seals all supply lines. Each of the four sides features two Line 8 grooves that can be used to connect lamps, pivot arms and other accessories, meaning that the installation column can be productively used for several different purposes. Two aluminium ducts inside the column can be used to supply compressed air, while the pneumatic connection set provides outlets for compressed air tools at any height. On top of this, partition profiles divide each cable conduit into two separate areas in order to ensure that high and low-voltage lines are kept safely apart.

A CONNECTION POINT FOR PRODUCTION ACTIVITIES

The item installation column

ITW Release & TrimRttingen | GermanyHall 6 | Stand 6107

This door handle meets market demands by completing a virtually linear movement as it extends out of its basic position, which lies flush with the bodywork. It can then be used rotationally in the normal manner. Intelligent kinematics have enabled the company to significantly scale down the package compared to existing solutions without having a detrimental effect on the robustness of the system. The lowerable exterior handles (see image) particularly come into their own when combined with keyless technology, which automatically moves them outwards when needed and then returns them to their basic position once they have been used. The manual release of the handles in an emergency is also possible at all times. The component assembly features a closed case and also provides users with an integrated seal between the handle and the bodywork. Its visible surface can be coated using an online painting method or chrome plated and users can also choose to give it an even more elegant appearance with lighting options.

A LOWERABLE ExTERIOR DOOR HANDLE

Press contact: Mr Markus SchubertTelephone +49 93 38.8 [email protected]

A lowerable exterior door handle


Press contact: Mr Andreas HeineTelephone +49 23 71.21 12 [email protected]

KIRCHHOFF Automotive Germany GmbHAttendorn | GermanyHall 7 | Stand 7105

As a development partner, KIRCHHOFF Automotive uses a wide variety of different materials and state-of-the-art technologies to transform function-integrated designs into successful products. These lightweight products, which are optimised for every area of application, are individually tailored to meet the demands and requirements of each individual customer. The fact that the company uses partial press hardening enables it to achieve customised component properties. This procedure also facilitates the production of car body components, for example A-pillars and B-pillars, with weight and crash-optimised designs. When making hybrid structures of metal and plastic or steel and aluminium, KIRCHHOFF Automotive uses joining technologies such as adhesive bonding, clinching, tox clinching, riveting and screwing. The company additionally uses a variety of welding and soldering procedures and laser technology (see image) when joining and assembling structures made from mono-material. This laser technology also enables KIRCHHOFF to join sheet metal that is extremely thin-walled and light.

LIGHTWEIGHT CONSTRUCTION WITH STATE-OF-THE-ART TECHNOLOGIES

Laser welding

Klber Lubrication Mnchen SE & Co. KGMnchen | GermanyHall 5 | Stand 5100

The use of plastic components in the automotive industry is becoming increasingly frequent. The risk of potential interaction between plastics and lubricants (see image) means that the involvement of a lubricant expert at an early stage of the new development of safety-relevant components is an important requirement. In its intensive research activities, the company Klber Lubrication develops and tests lubricants designed to meet its customers needs and requirements. When it comes to achieving failure-free operation, a made-to-measure lubricant is essential, especially in the safety-relevant automotive sector. Unsuitable lubricants may damage plastic components by causing swelling, stress cracks, thermo-oxidative ageing and chemical corrosion, which in turn may change the plastics mechanical properties. The systematic investigations carried out by the company so far have identified a multitude of lubricant components, especially base oils, additives and thickeners, that cause specific damages to plastic.

A SPECIAL LUBRICANT FOR PLASTIC

Press contact: Ms Kirsten BuschTelephone +49 89.7 87 67 [email protected]

Lubricant


Langendorf Textil GmbH & Co. KGMarktrodach | GermanyHall 6 | Stand 6331

The convoluted tubing GAFMIL (see image) combines the protection of a non-slit tube with the ease of assembly of a slit tube. It protects wires against dirt, abrasion, excessively short bending radii and wire damage. The main benefits of GAFMIL are its reduced assembly time, weight reduction, high mechanical protection of wires, fill ratio of up to 100 percent and the fact that it is easy to use. On top of all this, it does not require any wrapping tape. Different versions of the tubing are available for different requirements. Waterproof replaces non-slit corrugated tubes and wrapping tapes and provides protection against liquids, dust and harsh environments. Silent protects wires and wire harnesses in seats, dashboards, vehicle pillars, doors and boots. So-Kool protects wires and wire harnesses placed near sources of heat such as exhaust manifolds and pipes, engines, turbo compressors, brakes, catalysers and radiators and Low Abrasion protects wires and wire harnesses against the effects of vibration.

PROTECTION AND EASE OF ASSEMBLY COMBINED

Press contact: Ms Nicole HempflingTelephone +49 92 61.967 [email protected]

GAFMIL convoluted tubing

Press contact: Ms Dr Sabine KobTelephone +49 1 75.3 35 06 [email protected]

Kunststoff Helmbrechts AGHelmbrechts | GermanyHall 6 | Stand 6105 A

Flat but full of technical highlights: the SmartWave (see image) produced by the company Kunststoff Helmbrechts AG (KH) integrates electronics into a three-dimensionally moulded plastic component that is just 8mm high and is a prime example of the impressive range of functions of contemporary hybrid components. The possible applications of such components, for example in car interiors, will increase rapidly over the next few years. The SmartWave, which is manufactured using an in-mould labelling (IML) process, combines a decorative film with a glossy black finish with a functional film in a sandwich construction. This construction features conductive tracks applied using a screen printing process and is fitted with resistors and other electronic components that are adhered with anisotropic conductive film. These processes are carried out by the companys project partner MID-TRONIC in the German town of Wiesau. The IML technology enables SmartWave to boast a completely closed surface with a black-panel effect. By touching this surface, users can control several programmes and functions with capacitive buttons and sliders. RGB LEDs enable colour changes, luminous fields follow the movement of users fingers and the KH logo is lit up.

SMARTWAVE A 3D HYBRID FEATURING ELECTRONICS AND PLASTIC

SmartWave

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Metob Beschichtungen GmbHMichelau | GermanyHall 7 | Stand 7110

The combination of suitable lacquer coating systems from pre-treatments right through to topcoats guarantees reliable corrosion protection. The composition of these coating systems can be precisely defined on the basis of guidelines produced by automotive manufacturers. When it comes to corrosion protection, a tried-and-tested combination of applications of zinc phosphate (pre-treatment, 5 to 10 m), EPD dipping paint (undercoat, 25 m) and polyester powder coating (topcoat, 80 m) has proven to be an excellent solution. By using modern coating systems, manufacturers can ensure that they comply with the strict EU directives on VOC emissions both now and in the future. Volatile organic compounds (VOC) are classified as precursors of ozone together with nitrogen oxides. In combination with sunlight, they support the production of ground-level ozone, which is a key ingredient of so-called summer smog. The company Metob already produces environmentally friendly duplex coatings (see image) at two sites in Germany. Its main customers are well-known automotive manufacturers and their suppliers.

DUPLEx COATING FOR MAxIMUM CORROSION PROTECTION

Press contact: Mr Uwe BauchTelephone +49 95 71.89 [email protected]

An EPD coating as part of duplex coating systems

Press contact: Ms Kate Jeeshun YeonTelephone +82 10.50 49 64 [email protected]

LSIS Co., Ltd.Gyeonggi-Do | Republic of Korea Hall 5 | Stand 5306

The international automotive supplier LSIS will present its innovative products and systems at the IZB. According to the exhibitor, the company has established a proven track record of providing its customers with high-quality xEV solutions since 1993 with its national G7 EV project. LSIS provides future technology for electric devices and electric protection whilst focusing on the automotive megatrends of the dual battery system and vehicles with engines powered by alternative energy. The LSIS stand at the IZB will present the companys high-performance energy storage components (relays and a battery disconnection unit, see image) as part of the double battery system, as well as showcasing its power electronics (a DC/DC converter) and charging product (Cordset). Where safety is concerned, these products were designed and manufactured on the basis of the ISO26262 and ASIL standards. The South Korean exhibitor works in close cooperation with its customers to develop advanced xEV solutions and bring new and innovative products to the market.

HIGH-PERFORMANCE ENERGY STORAGE COMPONENTS

The LSIS BDU plug-in type


Muhr und Bender KGAttendorn | GermanyHall 7 | Stand 7306

Mubea works to support the challenging objectives set by automotive manufacturers in order to lower fuel consumption and emission values on a long-term basis by continuously developing new solutions for reducing vehicle weight. The use of flexibly rolled flat steel, for example, helps to significantly reduce the weight of twist-beam rear axles without causing any limitations in terms of their function and robustness (see image). The companys current development projects in the B/C segment use this approach to achieve a weight reduction potential of over ten percent. Mubea will also use the IZB as an opportunity to showcase its innovative power in a number of other product areas. Its CFRP wheels, which are a world first, for example, can achieve weight savings of 20 to 30 percent compared to forged aluminium wheels, with a weight reduction of 9.4kg per vehicle in the case of a 7.5J x 20 hybrid wheel (spoked alloys and a CFRP rim bed) and nearly 13kg per vehicle in the case of full CRFP wheels. These wheels have already successfully passed all important relevant tests.

REDUCING VEHICLE WEIGHT

Press contact: Ms Kirsten EntrupTelephone +49 27 22.62 93 [email protected]

A TRB twist-beam rear axle

NMB-Minebea GmbHLangen | GermanyHall 4 | Stand 4412

Fans for LED headlights have now been available for quite some time. The solution recently launched by NMB-Minebea, however, boasts a new feature in the form of a mirror-inverted fan design. This new design makes it easier to cool headlights on both the left and the right. Unlike axial fans, the mirror-inverted fan uses a laminar airflow and is therefore able to dissipate the heat towards the LEDs cooling element in a targeted and effective manner. This high level of effectiveness also means that the fans are smaller and lighter and can operate at lower rotational speeds. The new and reliable NMB-Minebea fan for LED headlights (see image) not only cools down headlights, but also prevents mirrors, lenses and cover plates from fogging up. Both fans meet the required standards for use in the automotive industry NMB-Minebea GmbH, a subsidiary of the Minebea Group, has been a qualified supplier of electromechanical components such as DC motors, brushless DC motors and DC gear motors for OEMs in the automotive industry and as a first-tier supplier for many years.

A MIRROR-INVERTED FAN DESIGN

Press contact: Mr Gerhard LangnerTelephone +49 2 11.63 61 [email protected]

Fans for LED headlights

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NOF METAL COATINGS EUROPEMarkgrningen | GermanyHall 5 | Stand 5130

The NOF METAL COATINGS GROUP has adapted its PLUSVL topcoat, which it claims forms part of the most frequently used zinc flake system in Europe when combined with GEOMET321. This approach meets the new requirements in the automotive industry with regard to the avoidance of stick-slip and multiple screw connections. The PLUSVLh finish prevents problems on EPD-coated surfaces and in the case of screw connections on or in aluminium. The parameters of this new topcoat, for example its application temperatures, are identical to those of its predecessor. The coating also has the same IMDS number due to the fact that the optimisation only involved subtle amendments to the product. All of its properties, for example its nominal friction coefficient, corrosion and dimension tolerance, remain unchanged, meaning that the new topcoat can be used as a full replacement for previous solutions without any problems. Fitting attempts at the companies Volkswagen and Daimler have proven the usability of the product, its suitability for the most critical fitting cases and its significantly lower amount of variance in the case of torque/angle tightening.

THE BEST POSSIBLE SCREW CONNECTION BEHAVIOUR

Press contact: Mr Ludger FuchsTelephone +49 71 45.9 63 [email protected]

Testing heat-induced loosening behaviour

Norddeutsche Seekabelwerke GmbH Nordenham | GermanyHall 5 | Stand 5317

The production of vehicle components is a high-precision process and even the smallest of scratches can impair the function of such parts. It is therefore important that components with sensitive surfaces are sufficiently protected during transportation. POLY-NET surface protection nets and grids (see image) are the ideal solution for meeting this requirement. These soft and flexible polyethylene nets and grids can be placed around or between components in order to provide effective protection against scratches or impact damage. They enable parts to be placed close together, either on top of each other or next to each other, thus ensuring an optimal use of transportation and storage areas. POLY-NET products boast a high level of resistance to mechanical stress and are also resistant to oils and greases. They are therefore reusable and offer users a number of technical and economic benefits. The surface protection nets and spacer grids are available in different sizes and structures and can be supplied as rolls or ready-cut. The company also manufactures special spacers for the washing processes used to clean parts during production.

PROTECTION AGAINST SCRATCHES AND IMPACT DAMAGE

Press contact: Mr Wilfried ReimannTelephone +49 47 31.82 12 [email protected]

Surface protection


OLIGO Lichttechnik GmbH surface controlsLenzen | GermanyHall 3 | Stand 3205

The company OLIGO Lichttechnik GmbH surface controls has been developing, designing and installing customer-specific lighting systems for indust

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