Innovations
Innovations play a central role in ThyssenKrupp's strategy – including in times of economic crisis. In the 1st half of the current fiscal year our researchers and developers came up with numerous new and improved products and processes to meet the requirements of the market. Many projects focused on making more efficient use of resources and energy. A key task was to seek out potential synergies within the Group.
Steel: New material for hybrid and electric vehicles
Researchers from the Steel segment have developed the new material 330-30 AP specifically for electric motors in cars. The non-oriented electrical steel is tailored to the limited packaging space, high revs and high temperatures of high-speed electric motors. The material is suitable both for hybrid cars, in which the internal combustion engine is supported by an electric motor, and for all-electric drives. Drives of this type can sustainably reduce CO2 emissions from cars.
Non-oriented electrical steel is a soft magnetic material with a silicon-aluminum content of up to 4.5% and low carbon contents. It is used in electrical machines as an iron core to concentrate and strengthen the magnetic flux. In particular the microstructure of the new material – i.e. the size and orientation of the grains – was optimized for use in electric cars. 330-30 AP is characterized by low core losses, high polarization values and good thermal conductivity. This combination of properties makes the new material better than other soft magnetic materials currently available for hybrid and electric drives.
Stainless: Innovative wire for the energy sector
An increasing focus of research in the Stainless segment is the development of new wire materials made from nickel alloys. A new heating conductor material, the nickel-chromium alloy Cronifer® 40B, has already been successfully positioned in the market. Heating conductors made from wire are used in heating elements for domestic appliances. The new material is highly durable and offers outstanding shape stability. It is also lower in cost than the material previously used.
Current research is also focused on enhanced weld filler metals. For applications in highly corrosive conditions such as in waste and biomass incineration and natural gas production, steel materials are generally overlaid with a corrosion-resistant nickel alloy. After the overlay is welded on, the surface must be bright and defect-free. In a research project we developed a filler metal for this hardfacing application which meets all the requirements for a bright, defect-free weld deposit. Even after several layers have been applied, the surfaces generally require no machining. The benefit for our customers is enormous: Hardfaced components can be produced 10% - 30% faster with the new filler metal Nicrofer® S6020.
Technologies: Camshafts for reduced fuel consumption
For the commercial vehicle industry our engineers have developed an assembled camshaft which is 35% lighter and up to 10% lower in cost than conventional products. With this innovative camshaft, the raw material required for production can be significantly reduced – in some cases by 25 kg per camshaft. This saves material and energy in the manufacturing process. Once fitted, the camshafts significantly cut fuel consumption and increase engine life thanks to the reduction in moving mass. To meet demand for these innovative camshafts, the first fully automatic assembly line has now been commissioned. With it we can produce low-cost camshafts in lengths of up to 2,200 mm under standard production conditions with full monitoring of all requisite quality parameters.
Elevator: World's fastest double deck elevators
After three years of planning, production and installation, the Elevator segment has created a particularly fast method of passenger transportation in the new Shanghai World Financial Center, the tallest building in China. The four double-deck elevators each comprise two cabs attached one on top of the other, each with a capacity of 2,000 kg, and serve a sky lobby at a height of 240 m. Visitors can get there at a record speed of 10 meters per second (36 km/h), which makes these systems the fastest double-deck elevators in the world.
To achieve these high speeds in the elevator shaft, our engineers developed aerodynamic cladding for the cabs and doors. In addition, electronically controlled active roller guides ensure low-vibration travel. The guide rails were installed in the shaft using advanced laser technology to ensure extremely high precision and thus guarantee maximum ride comfort even at high speeds.
Services: High-temperature heat accumulators for modern power plants
In the Services segment we have initiated a project to develop a high-temperature heat accumulator for combined-cycle power plants. The aim is to incorporate ThyssenKrupp expertise into a pilot plant to be built by RWE Power in Dortmund. The integration of this type of accumulator in the power generation process will allow electricity and heat to be provided at separate times. Heat produced during the day in excess of customer requirements can be "parked" in the accumulator and distributed again at night time when the gas turbine is switched off. This has never before been possible in combined-cycle power plants, producing both heat and power.