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Issue June 2016

Developing proactively

The latest newsletter is again a testimonial to our continuous commitment to innovation and technological improvement. Our central engineering and the technical designers in our subsidiaries make the demand and needs of the customer the central measure of their efforts.

But we do not stop there. Sometimes we develop solutions, which may not be needed now, but will be for the next generation of technologies. In other cases we develop ways to achieve a level of precision and performance in our products that generate a “wow effect” for the customer and allow us to serve new applications.

Being active in many different markets and applications has the benefit of being abreast of most of the latest technological trends in the industries using our products. Be it the latest generation of diesel technology, high pressure direct injection for gasoline engines, electric drives or any number of niche applications in different industries: Poppe + Potthoff has a contribution to make.

In a world of rapid change and uncertainty this is a key element in our effort to secure the future of our company for the next generation. We can analyze trends and developments and identify new opportunities.

Enjoy the news; there will be more to come.

Profile shape around the line interface; the optimized design on the left, the classic design with round profile on the right.

New development: lightweight rail

Currently, two trends dominate the design of components for common rail systems in passenger cars: The increase in pressure up to 3,000 bar to optimize the combustion process and the weight reduction to lower fuel consumption.

A new development for reducing component weight is represented by the lightweight rail by Poppe + Potthoff. For example, it allows for a weight saving of more than 20 percent for a four-cylinder-rail depending on the application.

The analysis of the designs using FEM shows a slight increase in stress on the rails. This increase occurs in non-critical device areas. Verification by high pressure impulse testing is planned in the short term.

Starting point of the study is a tube made of highly tensile steel PP1100 with an outer diameter of 28 mm. This material has excellent properties to meet the highest pressure requirements.

Design-technically, material is dispensed where it is not functionally relevant. This particularly concerns the interspaces between the line interfaces, but also the subsections facing away from the interfaces.

The areas which are relevant to the strength of the interfaces with the injector and pump line retain their contour which has proven to be best for very high pressures. Thus the sealing cone has a 90° opening with a reduced sealing diameter.

Design of the weight-optimized four-cylinder rail, also a visual highlight.

The interfaces to sensors and the holder connections for the mounting on the engine are located at the ends of the rail. Here, it has to remain with the proven outer diameter to meet the functional criteria of the screwing of the pressure regulating valve, and to ensure the necessary receiving for processing the rails in production.

Specifically, the following weight savings are achieved in a passenger car application compared to the conventional technique:

weight reduction
absolute
weight reduction
relative
4 cylinder railG > 250 gX > 22 %
6 cylinder railG > 500 gX > 25.6 %

Summary: With the new lightweight concept, Poppe + Potthoff has managed to reduce the weight of the common rail significantly. It also offers further advantages for customers, such as more space and a more compact design.

At the Tube 2016, Poppe + Potthoff showed its comprehensive skill profile around tubing.

Experts around the Tube 2016

The Wire & Tube has led the global pipe community to Düsseldorf for the 15th time. From April 4 to 8, a total of 69,500 trade visitors from 130 countries came to learn more about the latest machinery, equipment and products shown by 2,600 exhibitors.

"Being present is very important to our customers. Who counts, is here", says Beáta Ferenczi, Sales Manager at Poppe + Potthoff in Ajka, Hungary. At the booth, the visitor’s attention was drawn to precision steel tubes, high-pressure lines and test systems.

A plus of over 50 percent in qualified talks compared to the fair in 2014 particularly delighted Thorsten Ellersiek, Head of Sales at the tubing facility. "We now offer welded in addition to seamless precision steel tubing with an outer diameter of up to 100 mm. This led many prospects to us.”


About half of the requests came from industry and mechanical engineering. The high flexibility and quality that Poppe + Potthoff not only proves in the automotive field or with its commitment in the areas of innovation and industry 4.0, open up new market segments.

With over 65 percent, the share of international trade fair visitors was very high at the Tube. Among others, customers from Asia used the fair to discuss on long pipes for injection lines and rails or equipment for testing the quality and pressure resistance of materials and components.

"As a Group, we were able to show a broad skill profile which was perceived very positively by interested parties. This opens versatile connection points for new and existing contacts and positions us in a unique way", says Stefan Dreyer, CEO at Poppe + Potthoff Maschinenbau.

Poppe + Potthoff has developed a compact impulse testing system with a safety chamber for tests in gasoline at pulses of up to 2,000 bar. Optionally, tests in oil can simultaneously take place in a second chamber at a frequency of up to 10 Hz.

Impulses for gasoline injection

Otto engines shall become more efficient and cleaner. Direct gasoline injection is an important contribution. It helps to reduce fuel consumption as compared to conventional intake-manifold injection by about 15 percent. The pressure in the system is significantly higher.

Extensive tests are needed to prove the continuous loading capability of the common rail, injection lines, injectors, pumps and other metal and plastic components for the fuel injection system. These can now be implemented efficiently using a new impulse test system.

"The pressure cycling tests should be carried out under realistic conditions in gasoline with varying bio-ethanol content," says Johannes Montag, Head of Sales at Poppe + Potthoff Maschinenbau. "Special precautions need to be taken to prevent the development of an explosive fuel-air mixture."

Johannes Montag, Head of Sales at Poppe + Potthoff Maschinenbau GmbH in Nordhausen (Germany) together with CEO Stefan Dreyer (left) and CTO Frank Baudler (right).

Poppe + Potthoff’s new impulse test stand is extremely compact. It has a safety chamber with nitrogen flushing for safe testing in gasoline and optionally a second chamber with a separate test circuit for simultaneous pressure-testing with oil.

At a pulse frequency of 2 Hz to 10 Hz (depending on the pressure unit), metal and plastic components are validated with up to 2,000 bar. All test procedures and data can be collected, visualized, stored and exported with LabVIEW applications from National Instruments.

Coupling series with a high precision fit

Precise disc pack couplings compensate shaft misalignments while offering high torsional stiffness. To provide superiorly fitting and weight-optimized solutions for a great variety of requirements, R+W has now added new serial models to its family of LP-couplings.

“With our extended portfolio, design engineers are able to optimize the power train very precisely”, says Sascha Markert, project engineer at R+W. “Without having to use custom-designed solutions, the finely graduated LP series allows for achieving weight and cost advantages.”

In twelve instead of previously six different sizes, R+W now offers the single and double flex precision disc pack couplings LP1 and LP2 with keyway mounting for a nominal torque ranging from 350 to 12,000 Nm.

In addition, models with a conical clamping ring (LP3) as well as variants according to the API 610 standard (LPA) with keyway mounting are available. R+W also delivers customized solutions, such as in extra lengths, upon request.

Compact and completely made of steel, R+W precision disc pack couplings are designed for an extreme temperature range from -30 to +280 degrees Celsius. They are used worldwide in the most varied systems such as test stations, steel plants, conveyor equipment and pumps.

R+W has extended its series of precision disc pack couplings. Besides variants with single and double flex, models in accordance with the API 610 standard are also available.