0 WITH 201 ESULTS R G IN C A R
NO. 91/42 I DECEMBER 2010 I www.motorex.com
REPORT
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Swiss high-tech automotive engineering Packed full of high-end hybrid technology, the SWISSAUTO POLO REX is headed straight for the international automotive market. Fredy Barth drove it for us. TOPIC
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LowSAPS technology FOCUS QTM for clean snowcats.
INSIDE
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MOTOREX laboratories State-of-the-art infrastructure at your service.
INDUSTRY
18
Medical engineering Innovative production for precision forceps.
IN MOTOR SPORT, YOU CAN’T AFFORD TO MAKE COMPROMISES, HE SAYS. UNLESS YOU DON’T WANT TO WIN.
Winfried Kerschhaggl, Motor Sport Director KTM / WP
WHY DO YOU THINK HE SWEARS BY US? Being successful in motorcycle racing is like winning a marathon of 100-metre sprints. Because only if eve-ryone on the team is performing at peak level can the rider do his best. That’s why Winfried Kerschhaggl,, Motor Sport Director KTM / WP, is so uncompromising when it comes to quality. “Promises aren’t enough.. I need to know that I can rely on someone absolutely.” Making the most exacting demands: that’s some-thing MOTOREX also stands for. And why we are precisely the right partner for KTM. Find out more aboutt m how our oils are helping companies from a wide range of industries to reap success: www.motorex.com
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EDITORIAL
CONTENTS
NEWS 4
MOTOREX in the news
TOPIC 6
LowSAPS motor oil for snowcats
MOTOREX creates value HYDRAULIC OIL 8
Winter sport regions turn to OEKOSYNT HEES
Dear customers, partners, readers, dear colleagues,
REPORT 10
Swiss high tech on the international
As early as the first century B.C., the Roman poet Publilius Syrus wrote that
automotive market
“money alone sets all the world in motion.” In recent years these words have proved all too true. The world was ruled by unbridled financial markets; there was speculation and juggling of fantasy products. The equilibrium between capital and labor vanished altogether. There was more fast money to be made with financial investments than with honest, value-generating work. What remained was a dismaying heap of rubble for the government,
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INSIDE
and thus for all of us, to clean up. Without real added value there is no benefit
The latest from the MOTOREX lab
to the economy. One person’s speculative gain is another’s loss. It’s as simple as that in this zero-sum game!
EXPORT 16
Storm Motor storms Finland
Our company too has struggled with the global economic crisis during the past year. But we have never lost sight of our full responsibility as a Swiss
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INDUSTRY
family business. In keeping with our founder’s philosophy, in nearly 100
Innovative production processes for
years we have not lost a single franc to speculation. We have kept our
precision forceps
honestly earned profits in the company, reinvesting for sustainable growth and to keep our 240 jobs secure. We are pleased and thankful to have had no layoffs during the difficult times. And now, as the times get better, we know we can still depend on our loyal employees. Precious people with potential, initiative and ideas put to use every day through the work of their hands and minds for MOTOREX. This issue of MOTOREX magazine presents more about all the things we’ve created, started and
PRACTICE 20
For heavyweights: GREASE 219
Please join us today and in the future in celebrating the many win-win
BOX 22
invented for and with our customers.
Cool ideas/Did you know…/Comic
propositions we’ve created for our customers, employees and MOTOREX businesses. And please accept my sincerest thanks.
Peter Regenass-Bucher Chairman of the Board, BUCHER AG LANGENTHAL
IMPRESSUM Editor: BUCHER AG LANGENTHAL I MOTOREX Lubrication I Bern-Zürich-Strasse 31 I CH-4901 Langenthal I Tel. +41 (0)62 919 75 75 I Fax +41 (0)62 919 75 95 I Customer service by phone. Advice and problem solving also in German, French and Italian I Design, redaction and art direction: AESCHLIMANN, Advertising Concepts and PR GmbH, Muri/Berne I Translation: BMP Translations AG, Basel I Graphics and prepress: Burki & Scherer AG, Oftringen I Printing: Dietschi AG, Druck & Medien, Olten I Text contributions may be used when source is indicated. I Cover photo: Racer (WTCC series, SEAT SWISS RACING Team) and test driver Fredy Barth with SWISSAUTO POLO REX I MOTOREX® and all employed product names are internationally protected trade marks. No responsibility is accepted for printing errors or changes in the technical data.
MOTOREX MAGAZINE
I DECEMBER 2010
3
MOTOREX IN THE
NEWS UTTO POWER PACKAGE FOR CONSTRUCTION EQUIPMENT The new MOTOREX UTTO CF (Universal Tractor Transmission Oil) in SAE 10 W/30 viscosity is specially designed for use in heavy-duty construction machinery and heavy hauling vehicles. It is ideally suited for filling axles (especially with self-locking differentials), transfer case shifters and transmissions with wet brakes. It also boasts remarkable thermal stability and high wear protection and reduces noise from wet brake/ self-locking differential systems. MOTOREX UTTO CF meets API GL-4 / ZF TE-ML 03E, 05F, 17E / KOMATSU AXO-80 / VOLVO WB 101 / Allison C-4 specifications.
BIOGARD CHAIN OILS REFORMULATED The trend toward rapidly biodegradable chainsaw lubricants is advancing steadily. MOTOREX’s BIOGARD and BIOGARD PLUS products are the result of over ten years’ experience with chainsaw oils based on renewable raw materials. The latest formula further improves the speed (10-day window) and biodegradability within 28 days (based on OECD 301 B), to 87 % for BIOGARD PLUS and no less than 99% for BIOGARD! The all-important wear protection properties, excellent adhesion and anticorrosive and viscosity-temperature characteristics are also enhanced,
RACING PRO 4T NOW AVAILABLE IN SAE 5W/30 The recently introduced RACING LINE racing lubricants for motorbikes have been a big hit with many motor sport teams. Now MOTOREX has added semi-synthetic RACING PRO 4T SAE 5W/30 to the existing lineup of two full synthetic four-stroke motor oils, RACING PRO 4T SAE 0W/40 and SAE 15 W/50. The new oil was developed especially for off-road racing by the MOTOREX Racing Lab in collaboration with KTM. RACING PRO 4T SAE 5W/30’s special formula and additives are the perfect answer to the conflicting goals of withstanding the extreme demands on wet clutches in motocross and providing lubrication for very high-RPM one-cylinder fourstroke engines. The result is maximum racing performance combined with optimum clutch action.
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guaranteeing ideal lubrication for all chainsaws all the year round.
OVER 25,000 DIESEL ENGINES EVERY DAY P.S.A. Peugeot Citroën produces over
years. When the time comes, a
25,000 diesel engines a day at its
trained maintenance team (photo)
Douvrin and Trémery engine plants.
changes the fluids during the sum-
The world’s largest diesel engine
mer break.
producer’s customers are not only French automakers; BMW, Ford, Volvo and others also have their engines built here. Countless machining centers grind, mill, turn and bore the various aluminum and cast iron engine components in three shifts. MOTOREX COOL-X spindle coolant is used in the spindles with great success: there have been no spindle downtimes due to cooling problems since the switch to COOL-X. And COOL-X can stay in the system for two full
KTM 350 SX-F WITH A MOTOREX EXTRA
FOCUS FE SAE 5W/30 COMBINES FUEL ECONOMY AND LOW SAPS
“Efficient, maximum transmissible power from smaller engine volumes, tailored to the rider’s needs” was the vision guiding KTM and Stefan Everts (ten-time MX world champion and KTM Race Director) in developing the KTM 350 SX-F. With a completely new four-stroke fuel injection gasoline engine, new body work and a chassis with a linkage-equipped rear suspension system, KTM is revolutionizing the MX-1 class, capturing the world championship in its first season. Like all KTMs, the new SX-F is filled with MOTOREX motor oil, in this case with race-tested CROSS POWER 4T SAE 10W/60. And now KTM and MOTOREX are giving customers one more reason to smile when they take delivery of their new 350 SX-F, by including a free two liters of the pioneering fully synthetic www.ktm.com
Photo: KTM
Photo: Mercedes-Benz
motor oil. That way buyers can start their first ride right.
This modern LowSAPS motor oil meets the stringent requirements for the latest generation of trucks (Euro 4 and 5) with de-NOx catalytic converters, diesel particulate filters and SCR (selective catalytic reduction). With its special FM (friction modifier) additives, FOCUS FE at viscosity 5W/30 also yields up to 3% fuel savings compared to conventional SAE 15W/40 motor oils. It also meets leading truck manufacturers’ stringent requirements with regard to extended oil change intervals, wear protection, engine cleanliness, etc. Always observe manufacturers’ recommendations. Contact your MOTOREX partner for more information.
SUCCESS FOR SWISSCOOL TRESOR A world first from MOTOREX has
provide unparalleled cost-effec-
met with great interest in the press
tiveness. The powerful advantages
and among many leading metal
of the new MOTOREX technology
processing companies. SWISSCOOL
and the strong positive response in
TRESOR coolant-lubricant concen-
the press have persuaded many
trate now uses new technology
renowned companies to progressi-
which protects the emulsion effec-
vely switch to SWISSCOOL TRESOR
tively against bacteria. The product
in their machining centers.
is free from problematic substances and there is no need to add any “chemical bludgeons” in the form of bactericides, fungicides, boron, amines, etc. SWISSCOOL TRESOR also guarantees top cutting performance and the highest human and environmental safety characteristics. Together these properties
MOTOREX MAGAZINE
I DECEMBER 2010
CLEAN WINDSHIELD WITHOUT VOCS Available immediately, MOTOREX offers a VOC-free all-year windshield wiper fluid concentrate and a VOCfree winter ready-mix fluid (–20 °C). An ultramodern formula containing a wide range of highly effective cleaning components keeps the solvent concentration low. Another major advantage is easier storage since the new generation of wiper fluids is non-flammable. MOTOREX VOC-free wiper fluids keep windshields crystal-clear and, at the right concentration, prevent spray systems from freezing in low temperatures. The all-year concentrate can be mixed with water at any ratio (a 50:50 winter mix offers antifreeze protection down to –20 °C).
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Photos: Prinoth AG
TOPIC
Snowcats with diesel particulate filters need a modern LowSAPS motor oil to run at their best.
THE RIGHT MOTOR OIL
FOR LOWER EMISSIONS Future emissions limits will also apply to diesel engines in utility vehicles like snowcats. Technical innovations in engine construction are also redefining the boundaries for motor oils. Ever-stricter European emission standards are obliging
A DELICATE BALANCE
engine and vehicle manufacturers to think years ahead,
In a joint declaration of intent with the DETEC (Swiss
and technology is advancing steadily. To meet EU
Federal Department of Environment, Transport, Energy
exhaust gas levels III B (in effect from 2011) and IV (from
and Communications), the Swiss Cableway Association
2014), engine manufacturers are turning to
has recommended purchasing only snowcats with
• Exhaust gas treatment and recirculation systems • Electronically controlled high-pressure common rail injection systems • Improved surfaces and stricter manufacturing tolerances • High-lubricity technology and state-of-the-art materials • Special valve seals and piston rings • Innovative compound turbocharger systems • Improved combustion chambers for more complete combustion • More efficient engine cooling systems and much more.
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diesel particulate filters (DPFs) since the start of 2010. Keeping the latest generation of engines with innovative exhaust gas treatment systems running economically and smoothly requires not only low-sulfur (below 10 ppm) diesel fuel, but also a low-SAPS motor oil (with very low sulfate ash, phosphorus and sulfur content). Why is that, exactly? To keep the diesel particulate filter functioning smoothly during snowcat operation, the exhaust gas temperature must remain above 250 °C. Exhaust gas pressure must not exceed about 200 mbar, since higher pressures can reduce performance and raise the engine temperature. Besides the fuel’s sulfur content and completeness of
The latest diesel engines wouldn’t run without electronic assistants. Future engine management systems will use even more electronics.
Exhaust gas treatment systems require a LowSAPS motor oil to function at full efficiency. FOCUS QTM meets these requirements as well as the ACEA E9/E6 standards.
combustion, formation of sulfate ash in the exhaust
• Allows filter systems to function at optimum
gases is also affected by contamination from ash-contai-
efficiency and durability
ning additives in earlier motor oils. In response, MOTOREX
• Provides outstanding protection against wear
invested in the development of its FOCUS low-SAPS
• Enables extended service intervals
motor oils several years ago.
(follow manufacturer recommendations!)
LOW-ASH ADDITIVES AND SULFUR-FREE BASE STOCKS
Your MOTOREX partner will be glad to answer any
High-performance FOCUS QTM SAE 10W/40 motor oil is
for your vehicle fleet.•
questions you may have on choosing the right motor oil
built on quality base fluids and features MOTOREX’s integrated low-SAPS technology. The combination of an innovative additive package with low-ash ingredients and a specially produced sulfur-free base stock makes it ideal for vehicles equipped with exhaust gas treatment systems such as de-NOx catalytic converters, diesel particulate filters (DPFs) or selective catalytic reduction (SCR)
SPECIFICATIONS
systems. It is ahead of its time in its compliance with the
ACEA E9, E6 API CI-4, CH-4, CG-4 MB approval 228.51 MAN M 3477, MAN 3271-1 VOLVO VDS 3, CNG DAF E6 Renault RXD, RGD Deutz DQC III-05 Global DHD-1, MTU 3.1 CAT ECF-1-a Deutz DQC III-05
strict ACEA E9/E6 standards, clearing the way for practical implementation of the latest technologies. This makes MOTOREX FOCUS QTM ideal for use in modern snowcats, with the following compelling benefits: • Already meets ACEA E9/E6 standards • Ideal for the latest engines with exhaust gas treatment systems
MOTOREX MAGAZINE
I DECEMBER 2010
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HYDRAULIC OIL
Perfectly conditioned ski trails depend on 100 liters of hydraulic fluid flowing through a complex system. Willi Tremp of BEST AG tells us about his experience with MOTOREX’s OEKOSYNT HEES biofluid.
GREEN ON
WHITE SKI TRAILS The annual process of preparing winter sport areas demands a great deal of work from snowcats and their drivers alike. The demands placed on lubricants are equally extreme. As a rapidly biodegradable hydraulic fluid, MOTOREX OEKOSYNT HEES also sets new performance standards. Speaking for the many snowcat operators who use
MOTOREX magazine: “Has OEKOSYNT HEES made it
OEKOSYNT HEES, Willi Tremp, operating technician for
possible to extend fluid change intervals compared to
Bergbahnen Engadin / St. Moritz AG (BEST AG) tells us
the mineral-based hydraulic oil you used to use?”
about his experience with MOTOREX’s pioneering
Willi Tremp: “Yes, significantly. In our region we operate
biofluid.
24 snowcats. Kässbohrer, for example, prescribes a fluid change interval of 1,200 hours for mineral hydraulic oil. With OEKOSYNT HEES, we’ve been operating certain
“Extended change intervals and high environmental compatibility are important factors for us”
machines for 4,200 hours already without changing the fluid! That means that machines can go an entire season without an oil change even with extremely heavy use.” MOTOREX magazine: “What are your maintenance routines like?” Willi Tremp: “We stick to the manufacturers’ re-
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MOTOREX magazine: “Your region uses only rapidly
commendations. Change the filter and top up
biodegradable hydraulic oils. Why is that?”
the fluid where needed. We perform a visual
Willi Tremp: “As a region that depends on tourism, un-
inspection of all hoses at regular intervals.
spoiled nature is our most important asset. That’s why,
We also send samples to the MOTOREX
in keeping with our corporate vision, we use environ-
lab for analysis when necessary. The
mentally friendly technologies wherever possible. That
results tell us if it’s time to change
includes lubricants and other consumables.”
the fluid or microfilter it.”
Photos: Bergbahnen Engadin / St. Moritz AG
Willi Tremp regularly takes hydraulic fluid samples and sends them to MOTOREX for analysis.
Over 1,000 snowcats are in use for conditioning ski trails in Switzerland. In the Engadin they are exclusively filled with HEES hydraulic fluids.
MOTOREX magazine: “That means you use MOTOREX’s customer and laboratory services?” Willi Tremp: “Yes. To me that’s an important part of the product and one that provides security for us as users.”
OEKOSYNT HEES PASSES SAUER-DANFOSS TEST Official approvals and successful testing by the leading hydraulic component supplier further underscore the superiority of MOTOREX OEKOSYNT HEES. The biofluid based on liquid saturated esters meets
MOTOREX magazine: “How long does it take to flush the hydraulic system and change the oil in a snowcat?” Willi Tremp: “By yourself it can take a day or a day and a half. Nowadays you can order snowcats with factoryfilled biodegradable HEES hydraulic oil. That’s what our region does.”
• DIN ISO 15380 environmental and technical standards for HEES fluids • VDMA 24570 non-ferrous metal compatibility (Linde test) • DIN 51524 HLP and HLVP performance levels • the Sauer-Danfoss H1P078 and H1B110 tests • and holds Bosch Rexroth A4VSO125, KAISER AG Fahrzeugbau, Prinoth AG and other manufacturers’ approvals. Photo: Sauer-Danfoss
MOTOREX magazine: “What product benefits were foremost in your choice of OEKOSYNT HEES?” Willi Tremp: “The product is 100% in line with our vision. So far we’ve had nothing but good results with it. It’s also quite a bit more economical than what we were using before. We work three or four times longer with one and the same fluid fill.” MOTOREX magazine: “In your view, what is the main benefit for St. Moritz as a ski area?” Willi Tremp: “That’s got to be how economical it is thanks to the extended service intervals, and naturally the assurance of working with a biofluid that’s absolutely safe for the environment. This is also something our guests appreciate a great deal and it’s an important image factor.” Do you have questions about hydraulic oil in snowcats? Just contact your MOTOREX partner for technical advice. •
MOTOREX MAGAZINE
I DECEMBER 2010
High-performance hydraulic pump on test equipment at Sauer-Danfoss.
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REPORT
The SWISSAUTO POLO REX engine compartment with electric motor, power electronics and range extender – this Swiss technology is drawing lively interest from auto manufacturers.
SWISS HIGH TECH FOR
the automotive world of tomorrow Switzerland, land of mountains, watches, chocolates… and cars! Automobiles may not be mass-produced here, but few if any new cars in the world roll off the assembly line these days without parts from Swiss suppliers. And highly innovative Swiss companies are taking a leading role in shaping the future of the industry as technology suppliers. Over 300 companies in Switzerland, mostly small and
AUTOMAKERS AS PRODUCTION PROS
medium-sized enterprises (SMEs), are involved in pro-
Automakers purchase most of the 20,000 or so parts that
duction for the international automotive industry. They
go into a typical car from suppliers, manufacturing only a few key components such as the engine and body
“New technologies in the automotive industry”
themselves. Practically everything else is purchased on the global market, enabling the automakers to focus on
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manufacture parts out of various metals and plastics as
optimizing production costs. Nowadays all leading manu-
well as electronic components in large series. But Swiss
facturers offer outstanding quality at competitive prices.
companies also supply production equipment as well as
Total production volume in 2010 is again expected to
molds and tools for automotive manufacturing.
reach some 70 million vehicles.
Photo: Swissauto Wenko AG
The battery pack is installed space-efficiently beneath the trunk cover. No trunk room is sacrificed.
Successful research and development depends not only on brilliant ideas, but also on quality resources and specialized staff.
KNOWLEDGE CHANGES HANDS
leading engineering studios for combustion engines and
Research and development continue to play a very special
turbochargers. The company’s technological back-
role in auto manufacturing. Without the requisite tech-
ground was developed through many years of working
nologies, automakers can’t set new trends or keep up
with reduced-displacement and highly turbocharged
with the evolving market. For this reason, innovation and
gasoline engines and involvement in various aspects of
know-how in the following areas is often acquired from
auto and motorcycle racing. So it is no surprise that
outside the company:
SWISSAUTO has repeatedly supplied new technologies to major corporations in the automotive industry, many
• Alternative propulsion systems
of which are now used in series production.
(hybrid, electric, fuel cell, etc.) • Smaller internal combustion engines optimized for fuel efficiency and performance • General reduction in weight and rolling resistance
“The team has gathered a number of innovations into one winning technology package!”
• Aerodynamic optimization • Emission reduction concepts with the ultimate goal of “zero emissions”
In the SWISSAUTO POLO REX (REX = range extender), the team from Burgdorf has gathered a number of innovations into one winning technology package. This
In their efforts to integrate as many of the components
“electrified” vehicle based on a VW Polo is equipped
that embody the hottest new trends into production
with a Brusa hybrid synchronous electric motor deliv-
vehicles at the lowest cost, many automakers turn to
ering 85 kW (115 hp) of output and 220 Nm of torque.
engineering studios in Switzerland.
The REX is powered by electricity in all operating modes. A one-cylinder, 0.3-liter four-stroke engine de-
SWISSAUTO COMBINES TECHNOLOGIES
veloped by SWISSAUTO, along with energy recovered
For years, SWISSAUTO WENKO AG in Burgdorf has been
from the braking system, charges the lithium ion poly-
seen by many international automakers as one of the
mer battery (14 kWh).
MOTOREX MAGAZINE
I DECEMBER 2010
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Photos: Swissauto Wenko AG
REPORT CONTINUED
The one-cylinder, 0.3-liter internal combustion engine supplies 26 kW of power and is directly connected to the 30-kW Brusa generator.
The crankshaft (left) and camshafts of the 300-cc range extender engine are equipped with lowfriction roller bearings. Turbocharged reduced-displacement gasoline engines also have great potential for the future. The photo shows a combustion chamber test bench built by SWISSAUTO in collaboration with AVL.
REX PROVIDES 800 KM RANGE
about 800 km and the car can accelerate its 1,245 kilo-
The range extender directly addresses a weakness of
grams from zero to 100 kph in just 8.5 seconds.
electric vehicles. Although the battery’s 100 km range is enough to meet the average driver’s daily mobility
HIGH EFFICIENCY, LOW EMISSIONS
needs on electric power alone, the vehicle must be capa-
The extremely compact fuel injection intake manifold
ble of longer trips as well. When necessary, the SWISS-
engine boasts an efficiency of 37%, which is astonish-
AUTO POLO REX uses the range extender to generate
ingly high for a gasoline engine. Its specific consumption
electric power for recharging its own batteries.
values are comparable to those of a modern direct-injection engine. The mini-motor will also run on ethanol.
“The SWISSAUTO team worked closely with the specialists at MOTOREX to minimize engine friction”
This means that, depending on the source of electricity and fuel, the POLO REX can be operated on a completely CO2-neutral basis. The REX always runs on electric power; the range ex-
The newly designed one-cylinder gasoline engine was
tender’s one-cylinder gasoline engine is used only to
engineered for maximum fuel efficiency right from the
charge the batteries. This means that the combustion
outset. This was primarily achieved by using roller
engine continuously runs within its optimum operating
bearings rather than slide bearings throughout and
range. This clever design, with no constantly changing
employing a special dry sump lubrication system to
loads, yields outstanding engine efficiency. The combus-
reduce friction. The SWISSAUTO team worked closely
tion engine’s catalytic converter is also pre-heated after
with the lubrication technology specialists at MOTO-
the electric motor starts. Once the converter has reached
REX to minimize engine friction.
operating temperature, combustion can start and continue with low emissions from the first turn of the
The SWISSAUTO engine consumes only the equivalent of
crankshaft. This feat of engineering lowers pollution
about three liters of fuel per 100 km, fully meeting SWISS-
emissions by as much as 80% compared to a conven-
AUTO’s goal of charging the batteries with a small and
tional modern gasoline-powered passenger car!
economical 26 kW (35 hp) range extender. This achieve-
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ment is proof that the combustion engines used in today’s
SWISS HIGH TECH IS IN DEMAND
mass-market hybrid vehicles are still too large. The REX’s
In conventional automotive engineering, Swiss precision
quick-filling 27-liter fuel tank gives it a total range of
is in especially high demand when it comes to safety and
Photo: BRUSA AG
BRUSA Elektronik AG supplied the high-efficiency performance electronics for the POLO REX; testing on the electric motor test bed.
dependability. Examples include components for highpressure fuel injection systems (common rail systems) in the latest generation of economical, low-emission diesel engines, safety features such as airbag igniters and ABS sensors, dependable locking systems, noise-muffling in-
Fredy Barth took the SWISSAUTO POLO REX for a test run for MOTOREX magazine and clearly enjoyed himself.
HOW THE POLO REX DRIVES Fredy Barth, racer (WTCC series, SEAT SWISS RACING Team) and test driver, drove the SWISSAUTO POLO REX exclusively for MOTOREX magazine.
terior linings and corrosion-resistant chassis.
A COMPACT BUNDLE OF INNOVATION The SWISSAUTO POLO REX combines a number of futuristic features. For once, the expression “high tech” is apt. The POLO REX offers • a full-featured, highly comfortable electric drivetrain
Fredy Barth: “It looks almost like a normal VW Polo, aside from the wheel covers, modified front end and rear spoiler. The SWISSAUTO POLO’s zippy performance compared to other alternative propulsion systems is an absolute highlight given its range. In D gear, the electric motor’s 50 kW output sends it gliding along effortlessly. In the sporty S position, the front wheels receive a full 85 kW (115 hp) from standstill. The perfectly tuned power electronics function without jolts and in just the right dosage.
• sophisticated engineering • extremely high efficiency • low emissions • everyday practicality In building the POLO REX, SWISSAUTO received support from the Swiss Federal Office for Energy and worked closely with Brusa Elektronik AG (www.brusa.biz). The Sennwald-based electronics company supplied the lithium polymer battery (135 kg), the electric motor and the power electronics. The POLO REX was converted, tuned and tested by SWISSAUTO (www.swissauto.com). Remarkable how Swiss inventors and manufacturers, after the many automotive achievements of the past hundred years, are now playing a pioneering role in
In stop-start mode, the REX range extender can be activated manually or electronically. The driver would have to listen very closely to hear any difference in noise levels from having the REX on or off. The SWISSAUTO one-cylinder engine is perfectly well-behaved; it produces absolutely no vibrations and runs smoothly even at a full 7,000-rpm load. When the range extender is on, the combustion engine switches off below 25 kph and back on at around 50 kph. Power is transmitted by a one-gear continuously variable transmission. Top speed is limited to about 130 kph for optimum energy efficiency. But when braking, you first have to get used to the response and feedback from the brake pedal. The energy recovery system in the brakes gives them a significantly different feel from conventional brakes. The fine-tuning of the vehicle and the successful redesign of the drive train make SWISSAUTO’s POLO REX not only extremely good for the environment, but also a lot of fun to drive!”
alternative mobility technologies. •
MOTOREX MAGAZINE
I DECEMBER 2010
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INSIDE
The Atom Emissions Spectrometer (AES) rapidly and precisely identifies trace elements such as wear components (metals) and additives.
RESEARCH, DEVELOPMENT AND ANALYSIS
FOR OUR CUSTOMERS MOTOREX is continually expanding its laboratory capacity. Additional staff and state-of-the-art equipment guarantee the MOTOREX lab’s capacity. For our customers, this means cutting-edge products, guaranteed quality and fast analytical services. As an independent lubricant company, MOTOREX has
stantly inventing new analytical methods and inge-
a tradition of ongoing investment in research and
nious equipment, often developed in-house. The lab also
development and has made R&D a key factor in its
has close relationships with technical institutes for
success. The laboratory in Langenthal, with its expert
farther-ranging investigations and test bench trials.
staff and innovative infrastructure, exemplifies this commitment.
MOTOREX performs some 120 types of analysis and investigation in its own facilities (see chart on page 15).
“New analytical methods”
RAPID ANALYSIS The emphasis in the MOTOREX labs is not only on pure
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AUTONOMOUS AND FORWARD-LOOKING
science, but also on practical results. Countless customer
MOTOREX is currently capable of conducting over 95%
samples are analyzed every day. The objective is to
of analysis and development processes in its own labo-
conduct the analyses as rapidly, but also as precisely as
ratory. This is especially important for technologies that
possible. In recent months, many analytical methods
have not yet been patented. Tribology experts are con-
have been automated. This lets customers know in a
timely fashion whether a lubricant needs changing or if it’s safe to keep using it.
A TYPICAL ANALYSIS The following scenario gives a clear picture of the lab’s day-to-day work in analysis of raw materials, finished products and customer samples from actual use. This specific analysis can be used to determine the condition of the machine and the medium, which in turn makes it possible to predict the remaining service life of the fluid. For hydraulic fluids, the relevant examination methods
Every day the MOTOREX lab receives a large number of customer samples for quick, high-precision analysis.
are combined in a set of tests. In most cases a representative view of the condition of the lubricant is not provided by a single test value, but rather a number of test results and the way they are interpreted.
HYDRAULIC FLUID ANALYSIS 1. Visual inspection of incoming sample: The specialist can often recognize certain problems by sight (color, water, wear) or smell (burnt). 2. Viscosity at 40 °C/100 °C and the viscosity index calculated from these figures: This is where test values are compared with specification tolerances. This phase provides information on shear stability, lubricity, etc. 3. Infrared readings: By comparing with reference samples, IR spectra can be used to identify even minor variances from fresh oil. 4. Aging stability by measuring total acid number: The TAN increases as oxidation products accumulate during operation – the concentration of acidic oxidation products rises. If the concentration exceeds a critical point, a deterioration in the lubricant’s tribological properties may result.
Rapid, precise analysis of incoming raw materials and production batches saves time and enhances productivity.
Equipment
Analysis
Viscosimeter
Dynamically/kinematically determining viscosity
IR spectrum (infrared spectroscopy)
Determining identity and divergence from reference values, lubricant composition analysis
Cold cranking simulator
Low temperature resistance to starting
Karl Fischer titrometer
Water content of lubricants
pH titration
Measurement of acidic components, determining changes in concentration of acidic compounds, for example due to oxidation processes. Determining alkali reserves of oil formulations
RFA/spectroscopy
Determining elemental content of oils
Pour point test device
Automated low-temperature flow characteristics of oils
NOACK test device
Evaporation loss of base oils and final formulations
7. Determining cleanliness class (ISO 4406): Hydraulic fluid cleanliness classes are growing in importance as microfiltration systems are becoming more widespread in modern hydraulic equipment. Particles should also be prevented from circulating within the hydraulic system to avoid a large increase in wear.
Flame point measuring device
Fuel contamination, quality characteristics / deviations
BOSCH pump
Shear stability, viscosity loss during lubricant use
Particulate measuring device
Particulate contamination through wear and foreign matter
The MOTOREX laboratory team and the services it
Filterability measurement device
Determining filterability
5. Measurement of elemental content: This measurement enables conclusions about changes in concentrations of additives and wear elements such as chromium, molybdenum, copper, etc. Modern alloys and composite materials have made additional elements such as silicon and tungsten a focus of testing. 6. Measurement of water content: Water content is particularly critical in hydraulic fluids, since water evaporation can lead to failure of hydraulic systems. Moisture content is measured using the Karl Fischer titrometer (DIN 51777).
performs will always be a key success factor in compelling products and well-received services from MOTOREX. •
MOTOREX MAGAZINE
I DECEMBER 2010
See also Tribology A–Z at www.motorex.com for explanations of technical terms.
15
EXPORT
For its 40th anniversary in 2008, Storm Motor Oy moved to a new headquarter with central warehouse and an impressive retail shop.
STORM MOTOR OY:
MOTOREX IN FINLAND Turku-based Storm Motor Oy has been an importer and distributor of the MOTOREX MOTO LINE in Finland for many years. The family business is popular among dealers and consumers alike – a balancing act that is the sign of true professionals. Storm Motor was founded in 1969 by current CEO Jyrki
QUALITY AND DEPENDABILITY PAY OFF
Storm. A top-level European Motocross Championships
Storm Motor built a reputation as a reliable partner in
racer at the time (including a 5th place in the 250 cc
the motorcycle market in record time, serving customers
Motocross World Championship in 1967), Mr. Storm
with a broad assortment of parts, accessories and equip-
used his international connections to start an import
ment ranging from top brands to affordable alterna-
business for motorcycle parts and accessories. During
tives. Although the company operates its own stores
the following years the business would grow to reach
and maintains an active catalog sales operation, it also
motorcyclists throughout Finland through mail-order
serves a network of dealers who have rewarded Storm’s
catalogs and a growing dealer network. Starting with
commitment to quality and high dependability with
one retail store at its headquarters location, Storm
exceptional loyalty.
gradually added new outlets over the years. A second
16
store was opened in Helsinki in 1978, and today there
THE MAGIC NUMBER 5
are company-owned Storm Motor shops throughout
Storm Motor has opened five company-owned retail
Finland.
outlets to date, at its headquarters in Turku, in the
Finnish capital of Helsinki, in Tampere in the country’s interior, in Oulu in the north, and the newest in Lahti in the Finnish Lake District. Together these stores cover an area of over 5,000 square meters, supplied from a 5,500-square-meter central warehouse in Turku. Storm’s retail stores serve motorcyclists directly and act as a fast delivery point and large-order depot for local dealers and repair shops. In its business-to-business operations, Storm Motor’s satisfied clientele comprises 500 dealers. All customers can also use Storm’s state-of-the-art website to purchase products and exchange information.
TOP BRANDS LIKE MOTOREX Storm represents the top brands in the industry – including MOTOREX, Nolan, EBC and Michelin – and is committed to exceptional quality. In 2009 the company recorded sales of EUR 7 million. Since the motorcycle market appears to have reached a saturation point, Storm is constantly working on new products and
A strong team (l. to r.): Sirkka Storm (Vice President) and Jyrki Storm (founder and CEO) in front of their “favorite products” from Switzerland.
ways of doing business at the company’s headquarters in Turku. The company places a special emphasis on caring for existing customers to their complete satisfaction. Storm markets and advertises extensively and is one of the leading advertisers in Finnish motorcycling publications. Within the company, MOTOREX is frequently cited as an outstanding example of innovation and quality. Partnering with KTM has proven to be a great way to raise the MOTOREX brand’s international profile, creating a strong association with success in motor sports. Motor racing has long been among the most popular sports in Finland!
READY FOR THE FUTURE
The spacious sales floors at each Storm retail outlet provide the ideal surroundings for a perfect shopping experience.
Storm Motor’s management team and product managers keep their eyes and ears open and are constantly thinking of the future. In the highly contested parts and accessories market, discovering new products and developing innovative services quickly and at the right time are key success factors. Storm is continually improving logistics and delivery services and has significantly cut both costs and average delivery times. This approach keeps the company open to new opportunities and ready to face any challenge. The company’s 34 employees throughout Finland have made Storm Motor a name to be spoken with pride. •
Active promotion is a must in Finland too – Storm Motor delivers up to 75,000 catalogs directly to consumers each year.
www.stormmotor.fi
MOTOREX MAGAZINE
I DECEMBER 2010
17
INDUSTRY
Alligator and biopsy forceps are available in diameters from 1 to 5 mm and in flexible or rigid versions in lengths up to 200 cm.
INNOVATION IN MEDICAL DEVICE PRODUCTION:
PRECISION FORCEPS FOR ENDOSCOPIC SURGERY For many years Bacher Medizintechnik of Tuttlingen, Germany has specialized in the manufacture of alligator and biopsy forceps for use in endoscopes. The company relies on Swiss technology to produce these mechanical masterpieces. All turned parts are manufactured on a Tornos Micro 7, and high-performance MOTOREX ORTHO NF-X cutting oil is used for all machining processes. In the German-speaking world, Tuttlingen is regarded as
in a universal fluid, any compromise on performance
a major center for medical engineering, a status reflected
was out of the question. MOTOREX’s recommendation
in its leading role in manufacturing. Continuous
to switch to its ground-breaking, high-performance
improvement in production processes is as much of a
ORTHO NF-X cutting oil offered several advantages at
given in this sector as ever-more specialized materials
once for the user: All machining processes, including
and tools. So it was no surprise when Bacher turned to
turning, drilling, milling and threading, could now be
the lubrication specialists at MOTOREX in its search for
carried out with one and the same fluid. And thanks to
ways to optimize its production processes.
the fluid’s integrated Vmax technology, both production quantities and Ra (surface roughness) values improved.
ADVANTAGES OF MULTIPURPOSE CUTTING FLUID
18
Certain production steps have always had to be per-
TOOLS IN LIQUID FORM
formed on machines filled with the “right sort” of cutting
Machining the materials used in medical engineering
oil, but lately the company had been looking for a cutting
requires extremely high cooling, lubrication and rinsing
fluid that could be used anywhere. Of course, even
performance from the medium. Nowadays, rinsing
The results of milling with MOTOREX ORTHO NF-X can be seen in the arms of the forceps – and in the tool service life of the HSS milling cutter.
The forceps jaws are connected by joints with a pull mechanism. Here, a wire is laser-welded to the mechanism under optical magnification.
As important as a high-performance machining center: the choice of machining fluid has a significant impact on the production process and costs.
pressures of up to 120 bar are not uncommon, and out-
working conditions. This not only has a positive effect on
standing high-pressure characteristics are a must. To
the atmosphere in the workplace, but also helps reduce
withstand these extreme pressures, the lubricating
maintenance and disposal costs.•
film must exhibit extraordinary temperature and pressure stability. SWISSCUT ORTHO NF-X meets all these requirements with aplomb. Through ongoing develop-
“THE TECHNOLOGY HAS MADE A BELIEVER OUT OF ME”
ment of this high-performance cutting oil and the MOTOREX Vmax technology, MOTOREX has made a significant contribution to innovation in the industrial manufacture of medical device components. The fluid is also free of chlorine and heavy metals and easily cleaned away.
“MOTOREX ORTHO NF-X really surprised me! I didn’t expect it to have much impact on production results, but this innovative cutting oil began showing its full performance potential with the very first series of tests. Here are just a few of the things I’ve found using ORTHO NF-X:
• Allows machining of all materials It is generally understood in component manufacturing that the whole process is only as efficient as the weakest link in the chain. Accordingly, the four success factors of
• Guarantees top performance in all processes, such as drilling, turning, milling, spinning, etc.
Mate Bekavac
machine, tool, machining fluid and operator are all
• Reaches working temperature quickly and provides outstanding cooling characteristics
equally important. A company has little to gain by
• Removes swarf without foaming at pressures up to 120 bar
investing in the latest generation of machinery if it
• Provides ideal lubrication
skimps on staff training or uses an outdated cutting oil.
• Helps to significantly increase tool life
CUTTING COSTS – PROTECTING THE ENVIRONMENT The data from the machine reports show that switching to innovative MOTOREX cutting oil has paid off in terms of output, tool service life and quality. The current generation of ORTHO products is also risk-free for human health and the environment and thus helps create better
MOTOREX MAGAZINE
I DECEMBER 2010
• Easily removed from the workpiece • Free of undesirable critical substances I’m glad we’ve switched to the Swiss cutting oil. It makes our day-to-day production work here noticeably easier.” Mate Bekavac, machine operator Bacher Medizintechnik, Tuttlingen, Germany www.bacher-medizintechnik.de
19
PRACTICE
To keep equipment operating with low wear, automatic lubrication systems have to be refilled regularly with the right grease.
TECHNICAL GREASE 219
KEEPS CONSTRUCTION EQUIPMENT FIT The capabilities of the ever-more powerful construction equipment used in earth-moving work are astonishing. And the loads on greaselubricated components are just as imposing. That’s why MOTOREX developed heavy-duty lithium grease 219.
20
Anyone who faces the extremely harsh conditions in
HANDY SOLID LUBRICANTS
which heavy earth-moving and construction equip-
The new heavy-duty GREASE 219 is a semi-synthetic lithi-
ment operates every day knows all about constant
um complex grease. The formula contains lithium (Li),
heavy loads. Wheel loaders, excavators, cranes, convey-
which together with other solid lubricants including
or belts, shredders, mills, crushers and screening units
PTFE (polytetrafluorethylene/TeflonÂŽ) provides a number
are all expected to work perfectly in all temperatures
of beneficial properties in the innovative new GREASE
and weather conditions. Keeping them running
219 product. The EP (extreme pressure) grease has good
smoothly requires skilled operators and the right heavy-
adhesive properties and provides effective protection
duty grease to protect all lubrication points reliably.
against wear and corrosion. A special additives package
GREASE 219 is available in 400g cartridges and 17 kg containers and can be easily loaded into mobile greasing systems.
Regular application of lubricant to lubrication points that are not connected to an automatic lubrication system prevents unpleasant surprises.
The four-ball apparatus is used to test the lubricant’s pressure resistance up to the point at which the balls weld together.
with a high solid lubricant content gives the technical
grease 9900. The new product also meets the specifica-
grease the following benefits:
tions of other major construction equipment and vehicle
• Extreme pressure resistance
manufacturers such as Caterpillar, Komatsu, Akerman-
(four-ball tester welding load >6000)
Volvo, O&K, Volvo and Scania. GREASE 219 is an NLGI
• Outstanding emergency running properties
Class 2 product and meets the strict KPF 2 P-20 specifica-
• Good protection against corrosion and oxidation
tions under DIN 51502.
• Wide range of operating temperatures • Good water resistance • High fulling stability
A WIDE RANGE OF APPLICATIONS
“This grease can withstand almost any climatic challenge”
GREASE 219 is suitable for lubricating heavily loaded roller and slide bearings as well as sprocket gears and any
DETERMINING WELDING LOAD
lubrication points that require high pressure resistance.
Welding load is tested using a four-ball extreme pressure
It is ideal for use in automatic lubrication systems. The
(EP) testing device. The grease is tested in a four-ball system
grease can also be applied manually with a grease gun.
consisting of one rotating ball in contact with three identi-
With an operating temperature range of –20 to +150 °C
cal stationary balls. Test loads are gradually increased until
(or even +200 °C for short periods), this grease can with-
the four-ball system welds together (see photo above).
stand almost any climatic challenge.
Torque or friction torque can also be measured. At the end of the test, the weld point of the lubricant is calculated.
FOR LIEBHERR AND OTHERS The new MOTOREX GREASE 219 can be used in Liebherr
MOTOREX’s new GREASE 219 has added a new heavy-
machines in place of the manufacturer’s recommended
duty option to the company’s range of technical greases.•
MOTOREX MAGAZINE
I DECEMBER 2010
21
BOX COOL IDEAS Since 2007, a team of specialists from Gasser Felstechnik AG has been regularly traveling to Maarmorilik in Greenland, where the northernmost passenger cableway in the world is being built. The construction site of the planned Black Angel zinc mine is located some 400 km north of the polar circle. It is just about accessible by sea from June to October; for the rest of the year the ice-choked fjords are impassable.
COMPRESSOR OIL TESTED ABOVE POLAR CIRCLE The courageous team from Switzerland is providing securing elements, rock fall restraining systems and explosives work at the upper terminus, situated 600 m above sea level on a vertical cliff face. Specially prepared compressor oil from MOTOREX makes it possible to work on the cliff wall even in extreme below-zero
Camp Maarmorilik with the future upper terminus of the planned cableway (circle).
temperatures. So spectacular is this project that BBC
For a first impression of the construction site, visit this link:
World has even made a film about it. •
http://www.youtube.com/watch?v=Gt_mja_uDCE
DID YOU KNOW THAT KWC FAUCETS ARE PRODUCED WITH MOTOREX? KWC AG is a leading producer of high-quality Swiss kitchen and bath faucets. The product line ranges from traditional, utilitarian products to highly innovative, design-oriented fittings. The standards KWC sets for its suppliers are correspondingly high. For example, a number of KWC fittings are machined by a supplier with MAGNUM UX 500 universal coolantlubricant from MOTOREX. Turning and milling operations with this efficient and highly economical coolant-
Photo: KWC AG
lubricant result in flawless surfaces. Its high lubricating
OTTOREX
22
effect has resulted in a 14.5 % reduction in tool down times. More performance with lower production costs: MOTOREX MAGNUM meets customer needs to the maximum! •
www.kwc.ch
A CUT ABOVE THE REST!
Swiss army knife
Officer’s knife
Swiss army knife in MOTOREX green and engraved with a logo.
Everything at hand – for both small and major trips. You always have
With this small Swiss army knife you always have the right tool to
the right tool to hand with this “Officer‘s Knife”. Large blade, small
hand. Version with large blade, small blade, corkscrew, tin opener
blade, corkscrew, can opener with small screwdriver, cap lifter with
with small screwdriver, bottle opener with screwdriver, wire strip-
screwdriver and wire stripper, reamer, punch, key ring inox, tooth-
per, reamer and punch, ring, stainless steel toothpick, tweezers.
pick, tweezers.
Article No: 450338
Article No: 450630
For your order, please use the card in the center of this magazine. Please ask your MOTOREX importer about the availability, price and delievery time of the above article. Thank you.
MOTOREX MAGAZINE
I DECEMBER 2010
23
THERE ARE THOSE WHO MAKE COMPROMISES, AND THERE ARE THE OTHERS. HE’S ONE OF THE OTHERS.
Peter Julen, Technical Director Zermatt Bergbahnen
WHY DO YOU THINK HE SWEARS BY US? Not many people have more responsibility than Peter Julen. As Technical Director of Zermatt Bergbahnen,, he has to ensure that ten million passengers are conveyed safely to altitudes of up to 3880 metres everyy year, a challenge that allows no compromise. Setting radically new quality standards, never settling for the e s first solution that comes along, but always insisting on the best: that’s something MOTOREX also stands for. And why we are precisely the right partner for Zermatt Bergbahnen. Find out more about how our oils s m are helping companies from a wide range of industries meet their ambitious targets: www.motorex.com