fluidInternational news & information of the fischer group

Technology for people and the environment.A new addition to the group: fischer eco solutions

Technology for people and the environment.A new addition to the group: fischer eco solutions

1 | 2011

fischer Hydroforming:Rotary swaging as a new forming technology in Chemnitz

fischer eco solutions:On a great journey with Aida

fischer Edelstahlrohre:Many new sizes, tailored to customer requirements

2 3fluid 1 | 2011 // fluid 1 | 2011 //

Publisher: fischer group, Gewerbegebiet 7, 77855 Achern, Germany

Editor: Peter Hils (responsible)

Contributors to this issue: Hans Fischer, Hans-Peter Fischer, Roland Fischer, Christian Behrle, Brigitte Antal, Dr. Stefan Geißler, Erich Kotzenmacher, Thomas Prell, Hans Wolfgang Szymanek, Jens Helmbrecht

Contact: Phone: +49 7841 6803-0, E-mail: sales@fischer-group.com

Design: Frank & Konsorten Werbeagentur, Lahr, Germany

Print: Straub Druck+Medien, Schramberg, Germany

Photo credits: fischer group, Aida Cruises, Udo Loster, Jörg Wilhelm

Editorial

Greeting

fischer China

Quality management certified

News

Effective October 2010, fischer Tubetech (Taicang) Co. Ltd. in Taicang ,

China, is now also certified according to DIN ISO EN 9001:2008.

With this step, the young Chinese fischer branch office becomes part of

the internationally uniform quality standards within the fischer group.

You will read a detailed report on that topic in the next fluid. ‹‹

fischer eco solutions

TÜV approval for flue gas desulfurization

fischer group has had the quality of its weld seams tested and

confirmed by TÜV. Now laser-welded fischer tubes made of particularly

high-quality materials such as NiCr23Mo16Al (2.4605) can also be used

in sensitive areas such as flue gas desulfurization for example. ‹‹

Title themefischer eco solutions: Technology for people and the environment . . . . . 4Trigeneration: On a great journey with Aida . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Companyfischer eco solutions at IFAT ENTSORGA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6fischer Hydroforming & fischer Maschinentechnik:

Internal group teamwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Team Talkfischer South Africa: Computer training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8fischer South Africa: Action Cricket Team . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8fischer South Africa: Soccer team on the path to success . . . . . . . . . . . . . . . 9fischer Canada: Longtime employees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8fischer Canada: Thomas Prell turns 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9fischer Germany: Congratulations on qualifications . . . . . . . . . . . . . . . . . . 16

Tech TalkMechanical rotary swaging at fischer Hydroforming . . . . . . . . . . . . . . . . . . 10Automated press cuts for special section tubes . . . . . . . . . . . . . . . . . . . . . . . . 14

CustomersMEIKO: Revolutionary rinsing technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15REMUS-SEBRING: Great sound from fischer tubes . . . . . . . . . . . . . . . . . . . 15

fischer AquaDesalt

Minister visits trade fair stand Saudi Water & Power Forum 2010

Last year, fischer AquaDesalt again participated in the lar-

gest conference and trade fair for energy and water which

was held in Jeddah, Saudi Arabia. The company presented its

seawater desalination competence from 2 – 6 October. In additi-

on to many other interested parties, the Saudi minister for water

and electricity, Abdullah Al-Hussayen, also visited the fischer

trade fair stand and was impressed by the company‘s innovative

technology. ‹‹

With an ear to the market

Under a new flagDear Customers,

Dear Employees,

We have been the specialists for welded stainless

steel tubes for decades. We made our name with

the production and processing of such tubes. With

the continuous expansion of available tube sizes,

new materials and processing methods, we have

gradually developed our expertise in our core

segment. So we are especially happy to see that a

new project has achieved a surprising amount of

success in a very short time period: the formati-

on of fischer AquaDesalt. With the establishment

of this company, we entered a new direction in

2009 – with a subsidiary that specifically took up

the issue of seawater desalination on an applied

basis. The creation of this company has set in mo-

tion dynamics which led to significant demand

in adjacent application areas. Therefore the focus

was no longer just on seawater desalination but

also refrigeration equipment and evaporators.

Or, to put it more generally, methods in which

highly corrosion-resistant heat exchangers play

a key role. In this context, fischer group was able

to combine its processing competence with this

newly gained process competence for the first

time. This created entirely new perspectives in

a promising market segment. To reflect the new

direction of the company, we quickly decided on a

new name: fischer AquaDesalt became fischer eco

solutions. The name is encompassing enough to

combine a number of different applications under

one roof. In addition, it also signals the direction

of the company: fischer eco solutions develops

and promotes highly-efficient methods of thermal

energy conversion that offer not only economic

but also considerable ecological benefits.

Personally, I am very happy and proud of what

the committed employees and partners of the for-

mer fischer AquaDesalt and current fischer eco

solutions have already achieved in such a short

time period. A big thank you to all who played

a part in this development. To a successful and

energy-efficient future.

Sincerely yours,

Hans Fischer

Founder and Chairman of the fischer group

High-profile visitor: the Saline Water Conversation Corporation (SWCC) from Saudi Arabia at the fischer trade fair stand.

Dear Customers,

Dear Employees,

In addition to product and process competence,

outstanding customer orientation has also long

been an important success criteria for fischer

group. This competence was again proven last

year, as we have taken a market-oriented ap-

proach and expanded our product range for the

production and processing of welded stainless

steel tubes according to in-house market studies.

With respect to the products, we have ex-

panded the fischer Edelstahlrohre delivery

program in key segments. These include

larger tube diameters, small thick-walled

tubes and laser-welded thin-walled tubes

with small diameters.

In the case of processes, fischer group has in-

troduced rotary swaging as the forming tech-

nology at fischer Hydroforming Chemnitz.

The order situation and customer reactions have

already provided positive confirmation of the

decision to invest in new areas. We are pleased

to be able to engage in continuous further

developments together with our customers –

towards ever new possibilities for fluid shapes

from welded tubes.

Sincerely,

Hans-Peter Fischer

Managing Director of the fischer group

4 5

Technology for people and the environmentfischer eco solutions follows fischer AquaDesaltOne and a half years ago, fischer group

established fischer AquaDesalt – the first

group company specializing in one indus-

try. But sometimes success has a way of

overtaking your plans. The developments

and contacts of this special company

were so successful, that they soon led to

a demand for new application areas. To

address this demand, the business area

of the new company has been expanded:

refrigeration machines and heat distil-

lation have now been added to seawater

desalination. To reflect this natural de-

velopment, management has decided to

transfer fischer AquaDesalt GmbH into

fischer eco solutions GmbH.

Continuity in all business areasThe new company therefore becomes the legal

successor to the previous company and will

continue all of the business operations of its

predecessor. The sole purpose of the transfer

process was to lend adequate expression to the

new alignment and expansion of this business

segment. “With the new company fischer eco

solutions we are setting a clear signal of where

the journey is headed”, says the former and now

also new Managing Director Christian Behrle.

For the first time in fischer group‘s history, the

group company has developed a special compe-

tence in plant construction in a very short time.

“Until now, we always supplied our customers

with high-quality products and components

and thus displayed our excellent production

competence. With fischer eco solutions, we are

also providing proof of our solution competence

for complex and highly innovative thermody-

namic processes”, says Hans Fischer, founder

of the fischer group, about the new quality.

The product spectrum of fischer eco solu-

tions also includes highly corrosion-resistant

heat exchangers. They represent an important

component of different applications, such as

seawater desalination, refrigeration and heat-

ing systems, equipment for the beverage and

process industry, power plants and more.

Added to these are special solutions such as

the modular multi-effect distillation systems

(MED), absorption refrigeration units (ARU)

and systems with combined processes – the

so-called “trigeneration” – for combined heat,

Products and solutions by fischer eco solutions

power and refrigeration facilities. This process

involves the production of mechanical energy

from a heat source, e.g. for electricity genera-

tion, cold water and drinking water. ‹‹

On a great journey with AidaTrigeneration for more energy efficiency On the new AIDA 6

cruise ship, fischer

eco solutions is

showing how ef-

ficient energy uti-

lization can work

in practice. This

is where trigen-

eration is being

tested in a pilot

facility. The cool-

ing water of the

diesel engines is used to generate elec-

tricity, cooled water and drinking water

on board of the cruise ship. The facility

can achieve a cooling capacity of up to

1300 kW and produces up to 150 m³ fresh

water every day. The project was imple-

mented in close cooperation with INVEN

Absorptions GmbH and the shipbuilders

of the Meyer Werft

i n P a p e n b u r g

(Germany) .

By using a MED

facility for desali-

nat ion purposes

and an absorption

cooling facility for

cooling purposes,

instead of reverse

osmosis and me-

chanical compressor cooling , it is possible

to achieve a noticeable increase in the pro-

duction of valuable electrical energy on the

ship. ‹‹

AIDA cruise ship: More on-board energy efficiency in the future – thanks to fischer eco solutions.

4 5

Energy conversion comparison

Conventional: Trigeneration:

Diesel /Gas

Electricity

Heat

Losses

Freshwater

Cooling

Diesel /Gas

Electricity

Heat

Losses

Freshwater

Cooling

The heat added to the cooling water of the diesel engines is used to desalinate seawater and produce refrigerated air for air-conditioning purposes.

This principle can also be used in the port. The desalination (MED) and refrigeration machines

(ARU) consume much less electricity as compared to reverse osmosis systems and refrigeration compressors.

The systems consist of compact and removable modular components.

Maintenance requirements are very minimal The operating temperature of the MED system is

max. 44° C. Both systems are based on the same design

principle: namely modular components. Optimized heat recovery ensures that waste heat is

better utilized. Attractive ROI (Return on Investment)

Advantages at a glance

fluid 1 | 2011 // fluid 1 | 2011 //

fischer AquaDesalt becomes fischer eco solutions.

Consistently modular: the MED seawater desalination system for Aida.

Title theme

A U-flow heat exchanger up close.

Compact and efficient: heat exchanger modules by fischer eco solutions.

6 7fluid 1 | 2011 // fluid 1 | 2011 // 7

News

fischer Edelstahlrohre

Larger diameters:168.3 – 203.2 mmCustomer satisfaction plays a key role at

fischer group. After the company‘s own mar-

ket studies showed an increased demand for

larger pipe diameters, activities in the large

tube segment increased accordingly. Invest-

ments in existing tube profiling systems mean

that longitudinal seam welded stainless steel

tubes can now be produced up to a diameter

of 203.20 mm (8 inches) since the second half

of 2010. The first completed orders for this size

segment have shown that this was the right in-

vestment to make, and that the expanded range

is accepted by customers. ‹‹

News

fischer group know-how for the production

of longitudinal seam and welded stainless

steel tubes has been transferred to the small

tube segment, resulting in the development

of an entirely new market segment focus-

ing on small thick-walled tubes with diam-

eters ranging from 6.00 to 12.00 mm. While

Achern mainly produces tubes for the automo-

bile industry with diameter tolerances of D4

pursuant to DIN EN ISO 1127 (+/- 0.5 % min.

0.10 mm), fischer Edelstahlrohre Austria in

Griffen now rounds off the product portfolio

in the small pipe segment with its WIG welded

and inline bright annealed stainless steel tubes

all the way to high-precision tubes (HP tubes)

with displayable diameter tolerances beyond

existing standards at +/- 0.05 mm.

Of course fischer is also active in the small

EGR round tube segment, with one produc-

tion line dedicated to producing small lon-

gitudinal welded stainless steel tubes with

diameters ranging from 5 – 10 mm and a

wall thickness of 0.10 – 0.50 mm.

To achieve maximum efficiency, fischer

relies on the proven welding method for the

production of thin-walled stainless steel tubes.

It is particularly in the EGR segment that

welding can exhibit its strengths due to its

continuous and constant process. ‹‹

Existing tube profiling systems for this seg-

ment reached their capacity limits a mere 18

months after the completion of this portfolio

extension at the Achern site. Another reason

to continue to invest in this area. One example

is the state-of-the-art profiling system for

small thick-walled stainless steel tubes (6 x 1.0,

8 x 1.0/1.5, 10 x 1.5/2.0, 12 x 2.0) which has been

in operation since November 2010. The system

produces both fixed and production lengths (in

technical coordination with our customers). It

can also produce stainless steel tubes wound on

coiling stands. This program is mainly directed

at customers wishing to reduce transport, ware-

housing and production costs by minimizing

cut-offs. ‹‹

fischer Edelstahlrohre

Small thick-walled round tubes: 6 x 1.0, 8 x 1.0/1.5, 10 x 1.5/2.0, 12 x 2.0 mm

fischer Edelstahlrohre

Small thin-walled round tubes: welded!

6fluid 1 | 2011 //

IFAT ENTSORGA 2010 in Munich

Core competence: Heat exchanger modulesfischer eco solutions impresses with innovative thermo-dynamic applications

Company

The environmental technology industry

met at its new major global trade fair IFAT

ENTSORGA between September 13 – 17,

2010 in Munich. And in the middle of it all:

fischer eco solutions. The new fischer heat

exchanger modules were the centerpiece of

the trade fair stand. They play a key role in

a variety of different applications: in ther-

mal seawater desalination, refrigeration

machines and heat pumps, and as an inno-

vative heat exchanger concept for creameries

and breweries. “IFAT ENTSORGA is the ideal

platform for our new technologies”, says a

happy Christian Behrle, Managing Director

of fischer eco solutions. “We have made a lot

of interesting contacts and have shown that

fischer eco solutions will consistently pursue

the path started by fischer AquaDesalt.” ‹‹

8 9

Long-time Managing Director of fischer

Canada – Thomas Prell – celebrated his

50th birthday last year. Of course this was a

reason for celebration, which took place on

Friday, 13 August.

The evening event, which included many

fischer Canada

Happy 50th Managing Director Thomas Prell celebrated his birthday

9

Team Talk Team Talk

Thomas Prell with daughters Sabrina, Kristina and Sarah

8

fischer South Africa

Silver at first tryNewly formed Action Cricket Team reaches finale

Great interest in computer training

fischer South Africa has been imple-

menting a program for improving

the computer skills of its employ-

ees for almost a year. The initiative

is evidence of fischer group‘s com-

mitment to opening up professional

development opportunities for its

employees – and not just in South

Africa.

The voluntary and free com-

puter courses are managed by Cedric

Kotzenmacher , who has a Bachelor

degree in information technology from

Bond University in Australia. The

courses are held every Saturday, in

two-hour blocks. Each course takes four

weeks and ends with a written exam.

To date, two course cycles consist-

ing of a basic and advanced course

have been completed. Course topics

range from basic PC knowledge and

Office applications to using the Inter-

net. More than 35 percent of employees

have attended the courses – and an

increasing number of employees have

expressed their interest. ‹‹

fischer South Africa

From the World Cup to the Industrial League The fischer soccer team on the path to success

When the 2010 FIFA World Cup was held in

South Africa, employees of fischer South

Africa decided to host their own “fischer

World Cup”. The teams that were formed

represented the various football soccer

nations. fischer’s “Germany Team” was the

overall winner.

The “German” team consisted of young

players who were very quick on the ball. They

were as creative as the stars of the real German

national team, such as Müller, Podolski and

Klose. The “fischer South Africa World Cup”

was greeted with enthusiasm by all employees,

and was very well attended.

Following the success of this idea, col-

leagues formed a fischer group South Africa

team, which includes all of the good players of

the “fischer World Cup”. Fired up by the World

Cup spirit, the fischer selection played its first

official game against a customer team on

14 August. The fischer team won 6:2.

Now fischer South Africa is in the process

of registering the team for the “Industrial

League”. With the great support offered by

management, the players are confident that

they will reach the top of the league standings.

Finally, these activities also aim to create an

inspiring and healthier work environment for

all fischer employees. At the same time, rela-

tionships with current and future customers

and suppliers are also strengthened, according

to Henry Free, the “fischer South Africa Soccer

Manager”. ‹‹

“Gemuetlichkeit” at the Concordia Club

In attendance (from left to right, front): Stanislaw Wawrzaszek, Birgit Prell, Jan Twardus, Al Loft, Jaroslaw Michalak, Kim Lizun, (back row) Thomas Prell, Kris Bulawa, Jerzy Walczyk, Uta Prell and Nelson Gow.

guests, friends and family, took place at the local

Concordia Club, a traditional club for German

immigrants in Ontario. They were also joined

by several international Managing Directors of

the fischer group as well as group founder Hans

Fischer and his son Hans-Peter.

We would like to take this opportunity to

send congratulatory greetings to Thomas Prell

in Canada. ‹‹

On 11 July 2010, fischer Canada hosted an

anniversary event for all employees who

have been with the company for

more than 20 years. At this event,

the company also said good-bye

to Nelson Gow, who retired.

On this occasion, fischer Canada

Managing Director Thomas Prell

personally thanked all employees who have

stayed loyal to the company during the

good and not so good times.

The celebrations took place at the

Charcoal Steakhouse. The “good old

times” were remembered with many an-

ecdotes and stories, which also made for an

entertaining and successful evening. ‹‹

fluid 1 | 2011 // fluid 1 | 2011 //

“Team building” and the promotion of good

relationships among employees forms an

integral part of a good work environment.

This is why fischer South Africa recently

formed an Action Cricket Team.

Action Cricket is the faster indoor version of

conventional cricket. The new team has already

played its first season in a local league with five

other teams. It got off to a slow start with two

consecutive losses. But thanks to its excellent

team spirit, the fischer South Africa team was

able to turn things around and made it all the

way to the finals.

While the new team was not yet able to win

“Gold”, it proudly returned with a silver medal

– proving that teamwork and persistence do

indeed pay off. And the fischer team is com-

mitted to consistently improving its game. But

just the fact that the team made it all the way to

the finals after only one season and without any

previous competitive experience is an achieve-

ment to be proud of. ‹‹

fischer Canada

A part of the team for more than 20 yearsAnniversary celebrations for long-standing employees

10 11fluid 1 | 2011 // fluid 1 | 2011 //

Rotary swaged series components: Gearbox locking sleeve I (1 – 3), gearbox locking sleeve II (4 – 6), exhaust manifold six-cylinder (7 – 8), exhaust inlet tube (9 – 10)

fischer Hydroforming

Mechanical rotary swaging Now under the fischer group umbrella

fischer Hydroforming Chemnitz has added

rotary swaging to its processing activities.

Rotary swaging refers to a chipless form-

ing method. It reduces the cross section

of rods, tubes and wires. It involves two to

four, and in exceptional cases eight, tool

segments which perform radial upward

and downward movements at the same

time, in very quick succession. A part of the

tool is reformed at every downward move-

ment of the toolset. Rotary swaging is an

incremental forming method, as the tool

gradually achieves its desired shape. fisch-

er Hydroforming Chemnitz has been suc-

cessfully using this processing method as

the pre-forming stage for the Hydroform-

ing process for almost a year. Previously,

these processing steps were performed

outside of the plant. The project was imple-

mented with hmp Maschinenfabrik GmbH

(Heinrich Müller Maschinenfabrik in

Pforzheim), which had already been sup-

plying services in the past. The companies

concluded a cooperation agreement to en-

sure that the corresponding know-how for

the tools and process could be integrated

into the fischer group.

At this time, approximately 600,000 com-

ponents are formed on the system every year

Tech Talk Tech Talk

10 11

for a total of four series products, in three-

shift operations. Rotary swaging is used as a

pre-stage to Hydroforming so that the Hydro-

forming process can be started with the largest

possible starting cross section. This reduces

the number of required Hydroforming steps.

A locally occurring restriction, which is due

to the component design, is already included

before, using the process of rotary swaging.

Depending on the task at hand, the pro-

cess can also be supplemented by a pin that is

placed inside. This allows for internal geom-

etries to be mapped to the precise tolerance

level, and also enables internal contours.

New rotary swaged components

fischer Hydroforming views rotary swaging

as the ideal method to achieve an economical

pre-stage to the Hydroforming process, which

can be supplied at both the Chemnitz as well as

Menden sites.

In addition to serving as a Hydroforming pre-

stage, however, the method also has the potential

of producing specific finished components – and

thus continue to expand the fischer group port-

folio. To this end, the group is developing the

required know-how through external training,

joint feasibility studies with cooperation partner

hmp and other internal training courses.

Typical applications outside of the pre-stage for

the Hydroforming process include:

Hollow steering columns

Hollow axle drive shafts

Eyeglass temple pieces

Tube fittings

“We are pleased to have added rotary swag-

ing as another reforming method to our own

processes. Another piece of the puzzle in the

increasing customer orientation of the entire

fischer group”, says Hans-Peter Fischer, Man-

aging Director of fischer group, who is very

satisfied with the new machine-based swaging

method. ‹‹The principle behind rotary swaging The illustration shows the main process principle. The tool that is placed on the inside is machined using rotating segments, which perform axial strokes for the reforming process, which reduce the circumference of the corresponding piece of the tube. This process results in a radial and axial material flow in the entire cross section of the component.

Rotary swaging in detailThe axial preparation to the desired final diameter is carried out by wedges, which are moved in accordance with the process stage. They allow for a high degree of forming. For one, a cross section of the machine has been illustrated in the figure to the left; the red elements drive the tool segments to the inside in a circular manner. The right figure shows how a continuously progressive diminution can be achieved for the component cross section with the use of wedges.

A summary of the advantages of rotary swaging:

Production that achieves close to final contours, installation-ready precision:

The tolerances that must be adhered to are so close that subsequent machining (involving cutting) is not usually necessary. This saves on material grades and shortens the process chain. The result – lower unit costs.

High form representation potential, weight optimization: Rotary swaging allows for the implementation of a very

diverse form spectrum both outside and inside of the tool. Average weight savings for rotary swaged components range between 30 and 50% as compared to conventional production.

Good component quality: Rotary swaging allows for an uninterrupted fiber flow in

the tool. The cold working of the tool that occurs due to the reforming process can be utilized for component stability. The surface quality achieved by rotary swaging is at the level of ground surfaces.

High degree of formation, processing of brittle materials: Rotary swaging can achieve high degrees of formation with-

out heat treatments. The method is suitable for the forming of brittle material grades. This is due to the favorable stress state during the forming process and the homogeneous forming process.

High degree of flexibility: Rotary swaging equipment can be converted very quickly.

The replacement of tools and adjustments for a new part usually only takes a few minutes.

Short cycle times, high availability: Due to the horizontal configuration and relatively low space

requirements, rotary swaging machines are combined into effective transfer systems which are used to produce larges series in several shifts. A robust and maintenance-friendly design warrants a high level of availability.

1 4 72 5 83 6 9 10

12 13fluid 1 | 2011 // fluid 1 | 2011 //

process technology into a new component

of the customer. The task now was to imple-

ment the process optimization and new series

component at the same time. At this point,

fischer Maschinentechnik was included in

the project as a tool supplier and special ma-

chinery builder. Led by the Achern site, the

following individuals became active in the

project: Viktor Kimmig with responsibil-

ity for the development of the series tool,

Roland Moser for the construction of the se-

ries tool, and Dirk Müller for the linking of a

supplementary compression unit to the rotary

swaging system. The compression unit was

integrated into the process chain to achieve

an ideal transition between the swaging area

and the unformed tube. To this end, prototyp-

ing experience – with Markus Niebecker (fH,

Menden) responsible for design – was also in-

cluded in the considerations. The project has

now been successfully implemented, and the

new components, which feature an improved

switch function, have been approved by the

customer. ‹‹

mization project, under the leadership of Theo

Ostermann (fH, Menden) and Peter Juraschek.

In the new process, the starting material is

also designed as a double part, but is formed

in the middle using plunge rotary swaging.

This allows for a better stamping of switch

geometries through the subsequent feeding of

material grades using the ends of the compo-

nents during the Hydroforming process. In ad-

dition, the stamping of final switch geometry

has been integrated into the Hydroforming

process, doing away with the repeated addi-

tion to another stamping machine.

New process chain in prototyping

Initially, the new process chain was investi-

gated in a prototyping tool and successfully

mapped. In addition, this process was also

supported through a forming simulation, as

implemented by Thorsten Junge (fH, Men-

den). At the same time, Andreas Gräve (fH,

Menden) was also able to integrate the same

1312

Company Company

Almost three years ago, the former hde So-

lutions GmbH, with sites in Menden and

Chemnitz, was added to fischer group as

fischer Hydroforning GmbH (fH). It was also

the start date for the cooperation between

fischer Maschinentechnik (fMT) and the

new group member. fischer Maschinentech-

nik became an important supplier for the

tool manufacture segment and special solu-

tions in machine and equipment engineer-

ing. Hence fischer Hydroforming became an

important customer of fischer Maschinen-

technik. In this context, the two Managing

Directors, Roland Fischer (fMT) und Stefan

Geißler (fH), can look back not just on the

sales figures that have been achieved, but

also on the technical developments that have

created enormous benefits for the two com-

panies – and of course also the customers of

fischer group.

On the one hand, fischer Maschinentech-

nik experience was used to further develop

issues related to the automation and linking

of machines, which was not a strong focus of

the former hde Solutions. For the coming year,

additional investments for the automation of

Hydroforming systems and bending machines

are already being planned in addition to already

implemented projects. On the other hand, fMt

benefitted from the long-standing know-how

and extensive series experience of the new

Menden and Chemnitz colleagues in the area of

Hydroforming. The synergy of this knowledge

together with already existing knowledge re-

lated to fischer group‘s own Hydroforming proj-

ects made it possible to combine the advantages

and good ideas into optimized design concepts,

which contain different tool configurations

depending on the series application.

Another step towards ideal teamwork consist-

ed of the introduction of the Pro/Engineer devel-

opment platform, which is already used by fischer

group, at fischer Hydroforming. It makes it pos-

sible to work together on different projects without

problems and version difficulties. Design data is

administered and backed up in a central database.

fischer Hydroforming & fischer Maschinentechnik

Working together for our customersInternal group teamwork

From practice: Process optimization of locking sleeve production

One example of good cooperation: Process

optimization for locking sleeve production in

Chemnitz. Peter Jurascheck from the Chem-

nitz site is the project manager responsible for

implementing this process optimization.

In the original process, the starting mate-

rial (as a double component) was reduced at

both ends using rotary swaging (see also the

article on this technology on pages 10 / 11 of

this fluid edition). This process is following by

Hydroforming. This Hydroforming step mere-

ly preforms the switch geometry. The next

process step involves the separation of the

component. At the end, the final switch geom-

etry for the two resulting individual parts is

generated as part of a final stamping process.

The problem with this sequence of processes

is the repeated addition of components to dif-

ferent processing units, frequently resulting in

inaccuracies associated with the exact forma-

tion of the functional geometry – with the cor-

responding reject volumes. A new production

concept was developed as part of a joint opti-

Simulation results for the new locking sleeve process

Wall thicknesses Forming limit curve and stress distribution in the component

Feasibility analysis

FEM simulation

Hydroforming component development / design

Process development

Tool construction

Prototype / Pre-series production

Series production

ZSB / Assembly production

Tool design

The development process at fischer Hydroforming

Step by step to a new component.

Designed at fischer Maschinentechnik: Series tools (left) and compression unit for the new process.

14 15fluid 1 | 2011 // 1514

Customers

The system combines these work steps for the fuel rails:

Separation of the tubes to the required

length.

Trimming for clean cut edges.

Weld seam positioning using a camera.

Calibrating the ends for true-to-size

connections.

Leakage test: The entire component is

tested for leakages.

Eight punching stations: This is where

tube parts are exactly positioned and

punched as required. Standard punching

forms are round or oval, but other

forms and special forms can also be

implemented.

Testing of punching results: A sensor

checks the final product.

Automated rejection of parts that do not

correspond with specifications.

Final visual inspection: Following a

final visual inspection, components are

degreased and packaged according to

customer specifications.

Additional quality assurance measures by

testing random samples on the 3D measure-

ment device are carried out by trained ma-

chinery personnel at regular intervals.

“In a way, the punched precision com-

ponents could be viewed as pieces of art”,

according to Peter Hils, manager at fischer

Rohrtechnik. “At the same time, with the ex-

tended workbench of our partner companies,

we can offer our customers even more.” fisch-

er specialists are also looking at correspond-

ing components related to sanitary, heating,

air-conditioning and solar technology. ‹‹

fischer Rohrtechnik

Automated press cuts for special section tubesFor fuel rails and other precision components

Another example of fischer Rohrtechnik’s

processing competence is the company’s

tube processing system, which impresses

with its eight punching stations. This is

where openings are punched into tubes at

very high precision levels; at this time, the

tubes are further processed into vehicle fuel

rails. “This process hinges on very clean and

error-free work. Chips or cuttings in the tubes

can lead to engine damages in the finished

vehicle. For this reason we are subject to very

high requirements, which we are able to meet

fully”, says Frank Schneider, production man-

ager, who is very proud of the machine – and

the qualified and diligent employees who op-

erate the precision device.

There are eight fully automated work steps

and the visual final inspection. It starts with

a round tube (currently at 18 x 1 mm) or a

16 x 13 mm square tube. The tubes may fea-

ture an edge length or diameter of up to ap-

prox. 50 mm. Up to now, they were smaller

however. The length of the part can be up to

approx. 500 mm.

Tech Talkfischer Germany

Revolutionary rinsing technology MEIKO guarantees cleanliness with fischer tubes

MEIKO, the Offenburg dishwasher special-

ist, has garnered a lot of market attention

with a new machine – and

fischer stainless steel tubes

and components are also

playing a part. The new

dishwasher series „M-iQ“

contains different models of

rising pipes and connecting

pieces as well as stainless

steel tubes from fischer.

30 % savings in operating

costs, no need for direct ex-

haust air connections, flexibili-

ty due to a modular design – all of these are inno-

vations that do not compromise quality. Experts

agree: Anyone looking for a modern dishwasher

will eventually be looking at a MEIKO M-iQ.

With its revolutionary filter technology, innova-

tive ventilation technology and state-of-the-art

operating and control concept with Bluetooth or

GSM/GPRS interfaces, the M-iQ is the new stan-

dard for all professional rinsing applications in

the food service and large kitchen segment.

Based on this innovation, MEIKO

has once more defended its position

in the market. The company slogan

“Meiko – The clean solution” not only

refers to “clean” as a characteristic but

also a value. This includes fresh ideas,

orderly structures, hygienic results,

ecological and economical technology,

perfect quality, sustainability and fair

treatment of customers.

fischer group is proud to be assist-

ing MEIKO with this unique innovation by

supplying sophisticated components. ‹‹

fischer Germany

Great sound from fischer tubes Sport mufflers by REMUS-SEBRING

“Sound Design is one of our most impor-

tant product features”, knows Ing. Otto

Kresch from REMUS-SEBRING. The group

produces high-quality sport mufflers and

exhaust equipment for the world market –

and fischer group supplies the appropriate

stainless steel tubes for this purpose.

REMUS Innovation Forschungs- und

Abgasanlagen Produktionsgesellschaft m.b.H.

was founded in September 1990. In only five

years, it made a name for itself among manu-

facturers of sport mufflers. Another milestone

occurred in 1997 with the purchase of SE-

BRING and the construction of the SEBRING

Technology Center in Voitsberg, which opened

in June 1998. The new research and develop-

ment center opened in the summer of 2002.

In 2006, the company expanded its production

space by 5,000 square meters and established

a modern logistics centre. Today, the REMUS-

SEBRING group has a production area of over

33,000 square meters.

State-of-the-art processing and process

technologies guarantee products with the

highest dimensional and fitting accuracy. Raw

material is cut mainly with laser cutting tech-

nology and sometimes in automated mechani-

cal sawmills. The bending processes for the

stainless steel tubes are only performed with

computer-controlled and hydraulically oper-

ated tube bending machines. Thin sheet weld-

ing processes, consisting of both manual and

robot welding processes, form an essential part

of the production of high-quality exhaust sys-

tems. Muffler units are produced in a partially

automated muffler production line.

The centerpiece of the REMUS-SEBRING

Technology Center is the acoustics measure-

ment room, where the sound that is typical

for the brand is created and optimized. This is

where measurements of vehicle and idle noise,

sound quality and sound intensity for locating

sound sources are conducted in compliance

with the strictest confidentiality requirements.

Everything so that car enthusiasts are able

to identify their car by its individual sound. ‹‹

fluid 1 | 2011 //

fluid 2 / 2010:

Fiery moments with Blomus stainless steel garden torches

Your opinion is rewarded!

A big thank you to all who have

sent us their opinions. The lucky

winners below can now keep the

flame using their new Blomus stain-

less steel “ORCHOS ” garden torch:

Stefan Heinrich, Herrmann Haas,

Klaus Wessel, Michael Elabor,

Dr.-Ing. Franz Rückert

Congratulations!

Team Talk

O u t s t a n d i n g

quality can only

be achieved with

qualified person-

nel. This is why

fischer group has

always emphasized

its commitment to

apprenticeships

and professional

development. We would like to provide com-

mitted people with development and creative

opportunities. Of course, this also benefits

every one’s work, as a company culture can only

be built with loyal and motivated employees – a

company culture that makes it possible to work

together even during difficult times.

At the Achern headquarters site, seven em-

ployees successfully completed their appren-

ticeships and six the professional development

programs (6) this year. Today, all of them hold

full-time positions at the Achern-based fischer

companies.

The spectrum

of work completed

is as diverse as the

work areas of the

group companies.

For example, Mario

Rummel and Bernd

Waltersbacher –

former laborers

– took the opportu-

nity to complete successfully conversion train-

ing for industrial mechanics while on reduced

work hours. Another special feature of this

year: Isabell Schmälzle was the first employee

to complete the material inspection appren-

ticeship, who now works in the quality assur-

ance department of fischer Edelstahlrohre.

Of course, congratulations are also due to

those employees who have not been specifically

mentioned in this context. Hence we would like

to say it once more: Congratulations to all

2010 graduates. ‹‹

2010 graduates at a glance

Apprentices:

fischer Maschinentechnik

Stefan Fuchs, Industrial Sales Representative

Mario Rummel, Industrial Mechanic

Daniel Schmidt, Industrial Mechanic

Bernd Waltersbacher, Industrial Mechanic

fischer Edelstahlrohre

Pascal Huber, Industrial Mechanic,

Specialization: Production Technology

Isabell Schmälzle, Material Inspector

Andreas Pillin, Bachelor

(Applied Informatics)

fischer Rohrtechnik

Corina Hund, Industrial Sales Representative

with additional qualifications

Professional development:

fischer Edelstahlrohre

Christian Zink, SPS expert

Daniel Wonsik, Foreman (Metal)

Ralf Panther, Master Electrician

fischer Rohrtechnik

Klaus Riehle, Technical Business Graduate

Konrad Fallert, Technical Business Graduate

Thomas Jörger, Technical Business Graduate

fischer Germany

Congratulations on qualificationsSeven apprenticeships and six professional development diplomas in 2010

Ms. Isabell Schmälzle, the first quality inspector trained by fischer, at work.

We mean it: Tell us what you think, so we can ensure that fluid

remains an interesting magazine.

To express our thanks, we will be drawing for 10 x 8 GB sticks

in a trendy stainless steel design from all responses. Now you

can carry your most important information with you at all times.

All e-mails to sales@fischer-group.com with the subject line

“fluid” will be entered into the draw for the memory sticks.

Thank you very much for your opinion and good luck in the draw!

Carry your important information with you Win one of ten 8 GB USB sticks!