Date post: | 29-Dec-2015 |
Category: |
Documents |
Upload: | sivakumar118 |
View: | 7 times |
Download: | 0 times |
Less Fuel. More Drive.Röchling Automotive Profile
Benefits for Customers Across the Globe
The Röchling Group, established in 1822, has operated in the field of plastics processing for over 90 years. Our globally positioned group of small and medium-sized companies is characterized by its innovative applica-tions for a broad spectrum of industries.
Our customers value the quality of our products, a result of a close partnership, a high level of innovation, and expertise in product and process solutions. They benefit from global standards as well as the power of a strong group.
Röchling Automotive aims to provide vehicle manufac-turers and their customers with future-oriented techno-
logy in the fields of air flow management and acoustics, lightweight construction, and thermal management.
Over 3,500 employees working at development centers and production sites in every world market help reduce CO2 emissions and noise pollution, lower air resistance and friction, and keep the total costs of producing a vehicle as low as possible.
Our uncompromising slogan is:
Less Fuel. More Drive.
Get There Quickly with Röchling
Competence. Quality. Innovation.
Competence: Air Flow Management
Directing the Flow
On Point: Quickly and Efficiently
- Optimized engine performance with the help of aero-dynamic flow simulations (CFx) in single and multi-channel systems
- Reduced weight by integrating the charge-air cooler in the intake manifold, simplifying component designs and substituting metals
- Reduced resistance through intelligent air flow guidance at the front and underbody of the vehicle
- Enhanced driving enjoyment with the design of complete air intake systems built for durability, performance, and the perfect sound
- Increased customer benefit by taking a holistic approach to development and validation
Competence: Acoustics
Bringing Silence to Life
Pitch Perfect
- Integrated acoustic features in lightweight materials
- Noise damping and absorbing components for under-bodies, engine compartments and passenger compart-ments
- Engine simulations with GT Power for that extra performance boost and customer-specific intake acoustics
- Sound designs with or without low and high-frequency resonators
- Acoustic and aeroacoustic calculations for both far and near-field with FFT Actran and other software solutions
- Stationary and mobile measurement devices for verifying acoustic improvements
- Specialists with knowledge on the correlations between material composition, acoustic properties, and their effects
0807
System: Engine Air Intake
Less Weight, More Performance
Simulate Reality AccuratelyThere are many ways to achieve goals. With complete intake systems, technology and costs are the major hurdles to overcome. Simulation expertise, innovative spirit, and engineering commitment are the keys to developing a system successfully and time-saving.
Another important factor is the experienced team of specialists who develop and produce the system‘s individual components. Strong in the details, yet remaining flexible: That‘s how Röchling Automotive has made a name for itself as a system supplier.
Campbell diagram before and after acoustic optimization
Tracking down pressure losses Determining air flow speeds
A new topology of the intake section, with the charge-air cooler integrated in the intake manifold, saves 40 percent on air volume and installation space as well as 20 percent on components, weight, and costs.
Downsizing by Integration
Intake section, developed and produced by Röchling Automotive
Air filter housing made from 99 percent Plantura biopolymers
1009
Air filter cartridges manufactured in-house Optimizing acoustics Air flow analysis
- Great range of vertical manufacturing and flexibility from producing our own paper filters
- Fleece filters for greater durability and improved filtration results
- Various pre-filtration designs - Maximized filter dust capacities through optimal
particle distribution - Forecasted filter service life - Quick presentation and evaluation of options due to
high-performance system development
- Targeted optimization according to customer wishes - Integration of noise dampers in the air intake system - Helmholtz and quarter wave resonator tubes as well
as high-frequency resonators - Use of acoustic cones - High precision 1D and 3D acoustic simulations - Great freedom in construction thanks to modern
manufacturing technology and clever material selection
Reliability Starts with the Filter
Air Filtration Sound Design
The Art of CoordinationIntake systems are characterized by excellent filtration, long maintenance intervals, and a minimal loss of pressure. Numerous requirements for hot or cold regions need to be observed. Acoustics are playing an increasingly important role.
From simple air filters to multi-level filtration designs: The air flow management and acoustic expertise of the developer represents a benefit to the customer. As do the various manufacturing techniques. The end result is satisfied drivers pleased with their vehicles‘ low maintenance costs, driving enjoyment, and great sound. The environment also benefits from the quieter outlet noise.
High performance solutions for sports cars
Air filter – Twins for the premium class
Functionally optimized air filter housing Radiation cross-linked clean air tube with Helmholtz resonator
1211
Flexible, wrinkle-free 3D lightweight charge-air tube
- Flexible piping using one-component and two- component blow molding technology
- Resistant to aggressive substances - Plastic return pipes for temperatures up to 230°C - Mounting elements attached with high cohesiveness
thanks to Jectbonding™ - Intelligent injection molding solutions - Unique test stands and validation facilities
- Built-in shifting mechanisms and flaps - Charge-air cooler integrated in the intake manifold - Multi-channel solutions - Optimized and harmonized air flows thanks to high-
performance software - Constructed according to acoustic requirements - Comprehensive testing technology - Joining shell over injection
Intake ManifoldsCharge-air Tubes
From Turbo to Combustion Chamber
Two-channel intake manifold
SPE-Award
Pre-intercooler duct, up to 230°C
Pressure in the SystemAir tubes and intake manifolds are designed almost completely digitally. This greatly aids in ensuring that high temperatures combined with major fluctuations in pressure do not lead to mechanical failure – even after extensive periods of operation. To accomplish this, air flows, acoustics, and material selection need to be optimized.
Time invested in design and technical engineering features often result in elegantly simple and innovative solutions. The spectrum of applications stretches from small suction and turbo engines to large-volume high-performance engines, from compact cars to luxury sport sedans.
Precision is our focus Intake manifold, made in PolypropylenJoining by overinjection
1413
Thermoacoustic Engine Encapsulation
Engine Isolation on the Sides-- Various-approaches-for-sound-absorption-- Thermally-insulating-materials-- Temperature-resistant-lightweight-construction-
Composite-materials-- Full-body-and-partially-placed-aluminum-heat-shields-
for-lightweight-reinforcement-materials-- Blow-molded-solutions-- Integrated-seals-and-brackets
Databases-holding-characteristic-values-collected-from-our-acoustics- laboratory-help- in-design-planning.-Ther-mal- imaging- data- provides- insights- into- the- thermal-loads- of- various- components.- Thermal- conductivity-values-are-crucial-for-heat-dissipation-and-thermal-isola-tion.-Every-design-is-custom-tailored-to-meet-customers‘-specific-needs.
-- Air-and-water-tight-separation-of-the-engine-compartment-from-the-air-intake
-- Sound-insulated-feed-through-of-steering-column,-cabling,-and-supply-wires
-- Constructed-to-meet-pedestrian-impact-requirements-- Various-materials-available-with-filled-plastics-- Solutions-with-or-without-foam-absorbers-- Broad-spectrum-of-manufacturing-approaches
Partition walls
Sound and EnergyWith- clever- engineering,- engine- noise- emissions- can-be- brought- to- lower- levels- without- having- to- sacrifice-much-installation-space.-The-keyword-here-is-acoustic-integration-in-lightweight-construction-materials.-Here,-Röchling- Automotive- offers- a- unique- spectrum- of-various-material-and-production-approaches.
Engine-side-second-front-wall,-sound-insulating Second-firewall,-sound-absorbing
CO2-management:-Thermoacoustic-insulation
Heat-stays-in-the-engine-compartment-with-encapsulation
Drive-by-sound-level-measurement Engine-compartment-–-Partition-wall-made-with-SMC Thermal-imaging-data
1615 Less CO2
Benefit-for-the-customer:-many-aerodynamic-advantages-as-well-as-engines-that-warm-up-faster-and-stay-warm-longer.- Röchling- Automotive- develops- and- validates-component-designs-for-customers-throughout-the-entire-world:- For- both- passenger- and- commercial- vehicles- –-independent-of-the-drive-system.
Smart Cooling Air Controls
Controlled Shutter Systems
Competence: Actuators
-- Improved-drag-coefficient-- Fuel-savings-of-approximately-1%-in-average--
European-driving-cycle-- Lowers-emissions-- Shortens-cold-starts-- 1dB-noise-reduction-for-diesel-engine-cold-starts-- Accelerated-warm-up-times-for-passenger--
compartment-- Shortened-windshield-defrost-times-- Electric-auxiliary-heater-can-be-downsized-- Protects-the-cooler-pack-- Can-be-used-with-any-drive-system-- Especially-effective-for-frequent-drivers
-- Complete-solutions-- Customer-specific-validation,-wind-tunnel-testing,-
LIN-conformity-tests-and-error-diagnostics-within-the-vehicle-using-vector-software
-- Integrated-FailSafe-functionality
Controllable- air- flap- systems- lower- fuel- consumption-and- CO2- emissions.- One- reason- for- this- is- reduced- air-resistance- with- the- flaps- closed.- These- flaps- close- or-remain-closed-when-greater-cooling-capacities-are-not-needed- or- desired.- The- movement- of- the- air- flaps- is-usually-controlled-with-a-sophisticated-actuator-system.
Open-/-closed-according-to-customer-wishes Active-air-flap-system
Modular-solutions-for-various-vehicle-models,-with-and-without-ornamental-grill
Modules-with-multiple-rows-of-flaps,-centrally-controlled
Deflectors-for-further-optimization-of-aerodynamics Deflector-frames-with-up-to-99-percent-organic-materialActuator-development-
Flap-open
Air high-cooling-capacity
Flap-shut
improved-aerodynamics
Radiator-grill unprotected protected
Cold-start normal accelerated
Interior/glass warms-up-normally accelerated-warm-up
Noise-level normal lower
1817
Aeroacoustics for the Interior
-- Multi-functional-windshield-cowls-and--water-collectors
-- Secure-drain-pipe-- Various-sealing-designs-- Optimized-separation-of-air-and-water-- Integrated-mounting-devices-- Experience-with-various-designs-- Single-and-multi-piece-variations
Detailed- flow- analysis,- advanced- manufacturing- tech-nology,-and-acoustically-effective-lightweight-construc-tion- materials- represent- the- foundation- for- product-ideas-that-make-driving-more-enjoyable.-Special-measu-ring-techniques-and-testing-methods-round-out-the-ser-vice-offer.
Air/Water Separation Climate Control-- Flow-analyses-for-individual-components-and--
complete-systems-- Optimized-flows-- Minimal-loss-of-pressure-- Absorbing-materials-- Thermally-insulating-materials-- Integrated-switch-flaps
More ComfortPassengers- of- vehicles- with- Röchling- Automotive-products- should- travel- with- peace- of- mind.- Con-sidering- the- effective- separation- of- air- and- water,-optimized-channel-air-flow,-and-noise-reducing-meas-ures,-innovation-is-redefining-the-state-of-the-art.
Windshield-cowl-with-integrated-pedestrian-impact-protectionHollow-profile-soft-seals-produced-using-projectile-injection-technology
SPE-Award
Acoustic-climate-channels-made-of-lightweight-materials
Seals-are-mechanically-and-acoustically-optimized Acoustically-effective-housings-for-A/C-units
Air-intake-with-filter
Complete-air-distribution-system
Competence: Lightweight Construction
Developing Top-class Models
-- Acoustic-lightweight-construction-using-multi-layered-material-compositions
-- Perfect- balance- of- strength- and- stiffness- using-targeted- fiber-alignments-and-optimized-fiber/matrix-adhesion
-- Broad- spectrum- of- modern- innovative- processing-technology
-- Sophisticated-joining-and-mounting-techniques
-- Material-and-process-technology-in-close-coordination
-- Lightweight-construction
-- Integrated-solutions
Save Weight without Sacrificing Safety
2221
System: Underbodies
Light, Acoustically Active Absorption SurfacesVehicle-manufacturers-know-the-consumption-reducing-effects- a- shielded- underbody- can- offer.- They- are- also-aware- of- the- safe- and- powerful- driving- dynamics- it-provides- along- with- high- acoustic- comfort- for- both-passengers-and-environment.-Röchling-Automotive-sup-ports- this- efforts- through- extremely- light- composite-materials-with-various-porous-cores-and-coatings.-
With-a-minimum-of-installation-space,-underbody-shields-manufactured- with- the- Softlofting™- process- achieve-excellent-acoustical-values-at-the-lowest-possible-weight-per-unit-area.-The-process-also-allows-mechanical-values-to-be-set-to-the-highest-requirements.
Lightweight Design, Solid Performance
Perforated-aluminum-foils,-which-are-applied-to-generally-multi-layered-underbody-materials-during-the-manufacturing-process,-reliably-dissipate-the-heat-radiated-from-the-exhaust-system.-
Alternatively,-Röchling-Automotive-offers-its-customers-high-temperature-resistant-underbody-materials-–-a-novelty-that-enhances-integration-in-the-vehicle-floor.
High-temperature Solutions
Modularly-constructed-underbodyLightweight-underbody-with-textile-and-injection-molded-wheel-arch-liners
Aero-acoustic-underbody-with-molded-cooling-channels-and-large-surface-perforated-aluminum-foils-applied
Interior road noise in the back of a luxury-class sedan measured at 100 km/h
without underbody
Hard plastic underbody + additional absorber on the upper side
Seeberlite 2
dB
Hz31,530
40
50
60
100 315 1k 3,15k 10k
overall level [dBA]
69.168.568.1
23 24
Working Together to Reduce Emissions
Wheel Arch Liners and Ram Air Lips-- Single-and-multi-part-injection-molded-solutions-in-
one-component-and-two-component-constructions-- Stable-textile-solutions-for-lower-weight-and--
improved-noise-damping-- Various-designs-for-aerodynamic-improvements--
using-ram-air-lips-- Built-in-cooling-slits-- Various-sound-absorbing-materials
Engine and Body Undershields-- Substantial-reduction-of-interior-and-exterior--
noise-levels-- Best-in-class-lightweight-construction-with-
Softlofting™-- Proven-mechanical-integrity-- Especially-chipping-resistant-solutions-- Large-surfaces-with-few-mounting-points--- Covers-for-the-exhaust-system-with-and-without-
aluminum-sheets-- Thermally-insulating-effect
Functionality in Tight SpacesThe- product- solutions- developed- for- our- customers-around- the- world- need- to- conform- to- various- speci-fications.-Close-cooperation-with-our-customers-during-development-and-internal-testing-facilities,-such-as-the-water-track,-allow-for-streamlined-development-times.
The-decisive-element-next-to-feature-integration-is-the-choice- of- the- right- material.- Acoustic- and- strength-parameters-can-be-adjusted-as-can-the-water-absorption,-flammability-properties,-and-temperature-stability.
Chipping-resistant-engine-undershieldcomes-in-various-models
Side-body-undershields-with-area-densities-of--less-than-1,000-g/m²
Exhaust-system-cover-with-cool-air-openings-molded-into-the-material
Textile-wheel-arch-liner
Insulator-in-D-LFT-with-built-in-maintenance-flap Preparations-for-vehicle-testing 2-component-solutions
weight per area
glass content tensile stregth
tensile E-module
thickness (compact grouted)
thickness (acoustically)
Seeberlite DLFT
Competence: Thermal Management
Transporting Heat
-- Concepts-and-components-for-quick-heat-transfers--in-tight-spaces-
-- Thermally-insulating-materials-
-- Solutions-for-thermal-decoupling-
-- Calculating-and-designing-venting-processes-
-- Targeted-cooling-and-thermal-conduction-
-- Knowledge-of-sensors
Because All Energy Is Useful
27 28
Piping-- First-series-use-of-projectile-injection-molding-for-
plastic-pipes-in-the-automotive-industry-- Consistent-inner-diameter-- Benchmark-for-weight-savings-through-reducible-wall-
thicknesses-- Minimal-pressure-drops-- Generally-enough-standard-materials-- Homogenously-structured-inner-surfaces
Controlled Fluids
-- Multi-chamber-solutions--- Controlled-integrated-ventilation-- Built-in-level-sensor--- Strong-expertise-in-joining-- Guaranteed-sealing,-up-to-40bar-for-extreme-cases-- Highest-purity-grades-- Production-under-clean-room-conditions--- Integrated-corrosion-and-scalding-protection-- Solutions-for-shortened-heat-up-time
Tanks
Stable Supply SystemsPhysical- and- chemical- specialist- knowledge,- high-performance-simulation-programs-and-a-refined-testing-infrastructure-are-the-requirements-for-developing-com-ponents- that- work- in- fluid- environments.- Automated-production-with-highly-productive-and-flexible-systems-is-a-further-challenge.
Röchling-Automotive-offers-its-customers-this-specialist-knowledge-for-both-high-quality- tanks-and-piping-with-extremely-thin-wall-thicknesses.-Fluid-management-also-leads- to- other- specialist- fields- when- developing- new-drive-systems.
SPE-Award
Expansion-tank-with-level-sensor-made-of-conductive-plastics
Expansion-tank-with-ion-exchanger-for-fuel-cell-vehicles
A-cooling-water-pipe-with-built-in-mounts-formed-using-projectile-injection-molding
Rapid-prototyping Laser-welded-oil-tanks- Heated-windshield-washer-fluid-module
Fluid-pipe-by-PIT
29 30
Lightweight Structures
Lightweight Supports-- Weight-reduction-through-substitution-of-metal-
solutions--- Low-warpage-injection-molding-solutions-- Many-years-of-experience-in-back-injecting-and-back-
foaming-components-- New-composites-with-thermoplastic-matrix-- Varying-porous-reinforcement-materials-with-low-
thicknesses-for-lightweight-interior-applications
Housings and Pans-- Structural-and-thermal-protection-for-batteries-- Airbag-functions-remain-intact-in-crash-situations-- Larger-pans-come-with-optionally-integrated-material-
reinforcements-- Highly-automated-processing-of-long-glass-fibers-- Compounded-injection-molding-solutions-for-
optimized-strength-in-short-glass-fiber-reinforced-components
-- Spare-wheel-trays-in-hybrid-designs-- Special-solutions-for-spare-tire-storage
From Kilogram to GramSustainable- resources- represent- a- central- economic-and-ecological-focus-of-the-automotive-industry.-There-is-still-much-unrealized-potential-in-the-area-of-avoiding-unnecessary- materials- as- well- as- in- substituting- thick-materials-with-thinner-alternatives.
The-knowledge-gained-at-Röchling-Automotive-through-years- of- designing- and- producing- lightweight- appli-cations- is- greeted- with- ever- increasing- demand.-Sustainable-applications-are-the-object-of-intensive-pre-development- work- and- are- supported- by- the- New-Business-Green-Car-development-team.
Door-module-support-made-of-plastic,-coordinated-to-door-panel--and-frame
Acoustic-side-panel-with-laminated-lightweight-reinforced-materials-Multifunctional-tray-for-vehicle-tool-kits-and-more
Load-bearing-interior-floor-made-of-STRATURA,-thermally-and--acoustically-insulating
Material-analyses-in-the-scanning-electron-microscope
Battery-tray-in-luggage-compartment
GermanyMannheimGernsbach
PeinePeineIngolstadt
WackersdorfWolfsburgWormsWorms
BelgiumGijzegem
ItalyAbbiategrassoCollegno
TrentoLaivesLaives
SpainAraia
Czech Republic
LatviaMilzkalne
Koprivniceˇ
GermanyMannheimGernsbach
PeinePeineIngolstadt
WackersdorfWolfsburgWormsWorms
BelgiumGijzegem
ItalyAbbiategrassoCollegno
TrentoLaivesLaives
SpainAraia
Czech Republic
LatviaMilzkalne
Koprivniceˇ
The World Is Our Home
MannheimGernsbachPeineWackersdorfWolfsburgWorms
GermanyAbbiategrassoLaives-Trento-Volpiano
Italy
PitestiRomania
-AraiaSpain
MilzkalneLatvia
GijzegemBelgium
Czech RepublicKoprivniceˇ
Headquarters
Research & Development
Production
São-Paulo
Duncan,-SCDetroit,-MIAkron,-OH
Changchun,-JilinSuzhou,-ShanghaiChengdu,-Sichuan
Brazil
USAChina
www.roechling.com
Further commercial information by: Röchling Automotive AG & Co. KG Richard-Wagner-Straße 968165 MannheimGermany-Phone : + 49 621 440 55 – 335Fax : + 49 621 440 55 – 355E-Mail: [email protected]
Further technical information by: Röchling Automotive AG & Co. KG Floßhafenstraße 40 67547 WormsGermany Phone : + 49 6241 844 – 118Fax : + 49 6241 844 – 316E-Mail: [email protected]