140354_atworkengl

8/12/2019 140354_atworkengl

http://slidepdf.com/reader/full/140354atworkengl 1/24

1/09

How to secure a 15 m

tall rock devouring giant – heavier

than a dozen jumbo jets

Read more on page 18 – 21

O f f i c i a l L o c t i t e ® C u s t o m e r M a g a z i n e no.

8/12/2019 140354_atworkengl


10The next generation of gasketing.Providing more flexible solutions.Read more on this topic on page 10

at work | no. 1/09

8/12/2019 140354_atworkengl


4 6 14 1

4 14

6 1811 2212 23

Dear Readers,

Have you ever wondered how to drill a hole into a mountain? If so, the story of Martin Herrenknecht and his

rock-eating submarines might interest you. Maybe you were the kind of child who took grandpa’s mechanical

alarm clock apart to see how it works? In this case, Rudolf Neumayer and his Tear Down Centre could be just

what you are looking for.

What we would like to do in the first issue of “Loctite® at work”, our new customer magazine, is to take you on a

journey behind the scenes of some of the world’s most successful and sophisticated high-tech companies. This is

why we gave this issue the title “Reliability at work” . We want you to share our fascination when we look over the

shoulders of engineers constructing the world’s largest tunnel boring machines destined to drill the way through

the Alps or building propellers that move tankers and cargo ships through the ocean.

We believe that curiosity and an interest in how things work are the basis for creativity and innovation, two values

that Henkel and the brand Loctite® stand for. That’s why in the first issue of “Loctite® at work” we are putting the

spotlight on two out of the many companies that embody those values, to show how they can impact on the

practice and the success of a business.

In our Trend Report, we will track the evolution of energy over the last 150 years and give an outlook on how the

future of this most important resource of all might look like. And of course, with Henkel and Loctite ® you'll ride

shotgun in the Dakar Rally with the Loctite® brand.

So, lean back and enjoy the ride.

Yours sincerely,

Highlight: Dakar 2009Come along to the bivouac and learn moreabout the heroes of the Dakar.

Side GlanceEnergy – the breath of civilisation.

Reliability Report 1: Berg Propulsion

Marine propulsion systems. High tech andmaximum precision, hand made. Breathtakingtechnology from Sweden.

Reliability Report 2: Herrenknecht Tunnel boring technology from Germany.How does Loctite® provide design support?

RD&E insights Adhesives aren't invented. They are carefullydeveloped. Read more to find out how.

Handy HintsInsights online – the new web-platform fromtechnicians for technicians.

Advanced Technologies The Tear-down process provides insights andcreates new options.

OutlookSome of the topics for the next issue of Loctite® at work.

Content

Vice PresidentLoctite Industrial GroupHenkel Adhesive

Technologies EMEA

Cédric Berthod

Cédric Berthod

at work | no. 1/09

Editorial |

8/12/2019 140354_atworkengl


A cloud of dust on the horizon. A VW Touareg

approaching at breathtaking speed. The towering

mountains and dunes of the Atacama desert rising up

all around Copiapo, in the northern part of Chile. The

Copiapo – Copiapo special is a pretty tough challenge:

476 kilometers of the steepest dunes, deep sand and stonytracks. According to the drivers it‘s the toughest one in thehistory of the Dakar.

The Touareg whizzes by only a metre away at top speed,the air filled with the powerful roar of the new turbo-dieselengine, a sound that makes every off-road fan‘s heart beatfaster. Next the field of competitors arrives hot on the heels,in rapid succession: the great Mitsubishi, Hummer and

BMW X-Raid desert racers. And then, following a short

distance behind, the monster trucks rumbling by, makingthe ground shake. Thick clouds of dust have engulfed theterrain. The Atacama desert is said to be the driest in the

world, with places where it hasn‘t rained for 400 years.

Conditions for the drivers are tough: Rough terrain, difficultnavigation, extreme temperature differences and, most ofall, the dry and dusty conditions, push all competitors tothe limit. Vehicles are continually subjected to hard shocksand flying stones, the steep dunes demand the highest

level of performance from the engines. That day the stage finishes at the Copiapo bivouac, thenorthern most point of the rally. The “Desert Knights” –

Henkel engineers, better known as the “Loctite® Charlies”,

are also ready for action: Jean Gaborit from France,

Célio Renato Ruiz and Demetrio Santos from Brazil. TheDakar Service Center, set up as a common platform forEuromaster, BF Goodrich and Loctite® /Pattex, is easily

visible from a long distance. Loctite® banners are snappingin the wind – and the red Renault truck is parked in its

slot. It is fully loaded with products for repairing all kinds ofvehicle damages: Teroson plastic repair and window glazingadhesives, Pattex Power Tapes, and the indispensable

threadlockers, sealants, retaining compounds and instantadhesives from Loctite®, used for maintenance and overhaulof the mechanical assemblies on engine and gearbox.

Just now, as dusk is falling, the Henkel Team is busy,

working at full steam: many of the drivers coming “home” – mainly the private competitors not accompanied by a

service armada of their own – urgently needing supportto get their vehicles going again for the next day. “ There

were several difficult situations during this rally wheremy machine was quickly back in shape thanks to the

Loctite® Team‘s professional repair service. This

helped me save valuable time when every minute

counts”, says Miran Stanovnik, a Slovenian KTM

rider in the top 20, sponsored by Loctite® since 2005.Right now there are three bikersdragging their fairings to the

Loctite® service tent, where

Célio Renato Ruiz and

Live from the 2009 Dakar Rally

Meeting the Loctite®

“Desert Knights” in the

Copiapo bivouac

at work | no. 1/09

Highlight|

8/12/2019 140354_atworkengl


Demetrio Santos are busy doing a plastic repair on a BMWbody part. Their daily work and many exciting insights intothe heart of the rally are documented on the Loctite® live blogwww.dakaradventure.com

Chief Charlie Jean is nowhere in sight. I finally discover himwith the Hummer team! Robby Gordon‘s box-shaped racevehicle is almost completely disassembled, sitting on therepair stand like a skeleton. Jean is explaining to the chiefmechanic how to use Loctite® 243, a medium strength

threadlocker that is capable of withstanding severe

vibration but allows parts to be dismantled whenever

required. “ You need only a few drops to make sure that

VW – The new Dakarwinner

Innovative solutions for racingchampions

Hummer H3 in action Loctite® repair area in thebivouac

threaded assemblies such as motor mounting bolts remainsafely and reliably locked – all the way to the finish line ”,is Jean Gaborit‘s expert advice. This is truly “Reliability atwork ”, or, using rally parlance: “Dakar proven!”

The rally finished successfully on 18th January, with a greatwinners‘ ceremony in the heart of Buenos Aires. A double victory in the car category makes VW the newhero of the Dakar: Both Giniel de Villiers and Mark Millermaintained their lead after Carlos Sainz‘ withdrawal fromthe race, and they were more than enthusiastic: “For sure:this is the toughest rally in the world - and we had the

best marathon team in the world! I am overwhelmed bythe surge of feelings at the finish line”, as de Villiers put it inmoving words, “I am proud to be part of it, proud of whatthe team has achieved”. And his team colleague, secondplaced Mark Miller, adds: “De Villiers is a great champion.He deserved to win! For me as an American it‘s a dream

to finish the rally in second place, and finish as thebest American. Our team did a fantastic job.

We will gather new strength from this

victory!” Third position was claimed

by Robby Gordon driving

a Hummer, the eye

catching race car

from USA withrear mounted,

7.0 liter V8 engine. He lost ground to VW as a result ofseveral roll-over crashes during the rally. In the interviewhe stated: “Our only goal was to make it safely across thefinish line. And we did. The rally was an incredibly toughchallenge. We will now work on improving the chassis toget an even better result next year”.Marc Coma secured victory in the motorcycle class

Second and third positions went to Frenchmen CyrilDespres and David Fetigne. Chilean motorcycle rider

Francisco Lopez finished fifth and was celebrated as a

national hero by his compatriots and ardent local fans.Loctite® KTM bikers Miran Stanovnik, Annie Seel and

Norman Kronseder successfully mastered the tough

challenge and reached positions 13, 76 and 82.Loctite® triumphed in the truck category! Another doublevictory was achieved in the truck competition with Russia‘s Team Kamaz , supported by Loctite® since 2007. The twofront runners fought a spectacular fight, finally decided by

Vladimir Chagin‘s tire damage. Firdaus Kabirov finished just30 seconds ahead to win overall victory.

The Dakar winners

Henkel – OfficialPartner to the

Dakar Rally

First timeparticipation: 2005

Team: "LoctiteCharlies": Service teamwith 3 – 6 internationalengineers

Brands: Loctite®, Teroson, Pattex

Products: Adhesives,Sealants, Surface

Treatment

Major applications:

Threadlocking,Gasketing, Sealing,Retaining, PlasticRepair, WindscreenReplacement, GlassRepair, Instant Bonding

at work | no. 1/09

Highlight |

8/12/2019 140354_atworkengl


High-tech from

Sweden The rays of the morning sun reflect on the calm surface of the sea, before they

reach the white lighthouse that has been operating for more than a hundred years.

The small sai ling boats are quietly bobbing up and down in their moorings, wooden

houses with the characteristic low roofs line the waterfront and the cries of the

seagulls are the only sounds that the wind carries.

oduction in Öckero Berg Propulsion headquarters Propel ler blades ready for assembly High precision meets h igh-tech

at work | no. 1/09

Reader recruiting Reader|| Reliability Report 1

8/12/2019 140354_atworkengl


What sounds like the beginning of a bad novel or a holidaybrochure for travellers with a taste for maritime nostalgia,

actually describes the location of a modern production plant: The island Öckerö, off Sweden‘s West coast, is home to theship propeller manufacturer Berg Propulsion, one of Sweden‘sleading high tech companies.

Ensuring reliability with Loctite®

at work | no. 1/09

Reader recruiting Reader |Reliability Report 1 |

8/12/2019 140354_atworkengl


eaning the hydraulic pipes withoctite® 7063

octite® 243 – securing the

opeller s steering mechanism

Locking & sealing the threads with –Loctite® 638

End cap fixing on hub shaft with

Loctite® 243

A dowel pin controls the propeller

blades. Secured by Loctite® 243

The hydraulic system is embeddedinto the shaft

After only one hour the system ha

to withstand 70 bar of oil pressure

All the blades are

assembled and the

propeller is ready

for use

Assembly of the pipes – securing itwith Loctite® 243

No room for errorFrom modest beginnings, the company was founded asa shipyard for fishing vessels in 1912, Berg Propulsion

has developed into a multinational company constructingpropellers for all kinds of vessels. Tankers, containers,

cargo ships and luxury yachts, to name just a few, all rely onthe experience and the craftsmanship of Berg Propulsion.

The demands placed on the reliability and durability of

Berg‘s CP (Controllable Pitch) propellers are enormous:

Once the propeller is fitted to the vessel, alterationsbecome extremely difficult and the propellers are in usefor 25 years or more. There is no room for error, becausethe safety of the ship and the vessel depend on the qualityof the product. Money is another aspect; every day that aship has to remain in the dock for repairs costs the ownerbetween $15 and $20,000 a day, explains Berg‘s ManagingDirector Anders Christoffersson. (see interview)

Family businesses gone global Technological progress has made its

mark on every aspect of life, and the

manufacturing process at the plant on theidyllic island of Öckerö is no exception

to this rule. A lot has changed sinceJohann Wiktor Berg manufactured

the first CP Propeller for a

wooden fishing vessel in 1929;

one of those changes is the useof Henkel‘s Loctite® products.

Berg Propulsion and Henkel, the

global leader in adhesive technology, have a lot in common:Both started as family businesses with an emphasis

on high-quality products and both have developed into

successful companies operating on a global scale.

Henkel had the opportunity to observe the production

process at Berg‘s island plant. The gigantic propeller,

with a diameter of more than 9 metre, dwarfs the men

standing next to it. The shining bronze propeller blades

appear almost menacing in their shining perfection. At every

stage of the manufacturing process Loctite®

products havean important role to play: The threads of hydraulic pipesresponsible for controllingthe individual

b lades

Customer:Berg Propulsion,Sweden

Task:Securing hydraulicsystems to assurereliability for 25 yearsand more

Products:Loctite® 243Loctite® 638

Reliabilityat work

at work | no. 1/09

| Reliability Report 1

8/12/2019 140354_atworkengl


What is your position at Berg Propulsion? I am Vice President of our

technical division Berg Propulsion Technology. And we are developing Berg’s

products of tomorrow.

You use Loctite® threadlockers and thread sealants to secure assemblies inthe hydraulic system and in the propeller hub. Can you tell us more about thespecific requirements applicable to these areas? The requirements which oursystems must meet are that they have to be sealed, and this applies especially

for our hydraulic systems, they have to be pressure resistant. Then in our threadedassemblies we have to lock the bolts and screws against vibration loads.

In which way can Loctite® be of help in those situations? Loctite® increases

reliability of our products.

Why do you use Loctite® products in this application? This gives us a quick andeasy assembly.

Which products do you mainly use? We use threadlockers 243 and 2701, for

retaining it is 638 and 603.

Which benefits do you get, besides the technical reliability? We can reduceinventories for mechanical locking devices and we have fewer item numbers, whichgives us big savings in warehousing

Why is reliability so important for Berg Propulsion? Reliability is important as Berghas safe and dependable products. Our customers expect ship propulsion systemswith highest availability at all times. If there is some failure in the propulsion system,

the boat can no longer earn money. And in this case, we talk about high amounts ofmoney. This varies from 15 – 20 thousand US Dollars per day. This is not unusual.

Do you make use of Loctite‘s technical service today? Yes, we use Loctite® technical support daily in the form of calculations and application solutions. Then, wealso get ongoing product training for our technicians and engineers.

Do you know more about the brand Loctite®, e.g. the history or the other

product ranges? Yes, concerning the history I know that it is a company from the50's, and we’ve started to use Loctite® in 1964. It was a colleague, Erik Berg, son ofthe founder of Berg Propulsion. He was in England and came home with a Loctite ® product as replacement for the locking washer. And it worked. Since then we haveused Loctite® products and other products; those we know among others are yourlubricants and flexible adhesives and instant adhesives.

What do you think are the most important characteristics and benefits of

Loctite® products today? Loctite® products have a lot of benefits. But the mostimportant one for us is reliability and the technical support which Loctite® gives us.

are retained with Loctite® 638. They have to withstand

pressures of more than 70 bar, which equals twice the

force the blades will have to bear on the ocean.

Developing tailor-made solutions The adhesive sealing has to create a hermetic seal

after an hour, because then the hydraulic pipes are

embedded into the shaft. Another example for applied

technological progress is the production of the

spacer that protects the propeller‘s control units. The

spacer is fitted to the units with 4 screws, locked with

Loctite® 243. “Loctite® increases the reliability of our

products. We co-operate closely with Loctite‘s technicaldepartment during the development and the productionprocess” says Christofferson.

Lars Andreasson, from Loctite‘s Industrial Engineering

department explains: “We can assist the customer by

calculating the pressures the product has to withstand, forexample. It‘s a form of team-work. Our goal is to assist thecustomer by developing tailor made solutions.”

The manufacturing process of ship propellers has comea long way. What is interesting to note about it, is the factthat there is something like a conspiracy theory about

the origin of the technology. There is a possibility that theEnglishman Francis Smith, who took credit for the inventionwas actually preceded by the Austrian enthusiast Josef

Ressel. Unfortunately, however, that issue wasn‘t resolvedin Ressel‘s lifetime and he never received the credit that inretrospect appears to be due to him. While technologicalprogress is unstoppable, like the co-operation of Berg

Propulsion and Henkel on idyllic Öckerö shows, issues withintellectual ownership seem to be here to stay.

Anders Chr istofferson, Managing Director Berg Propulsion Technology AB

at work | no. 1/09

Reliability Report 1 |

8/12/2019 140354_atworkengl


The stories behind invent ions tend to have

something romantic, something co-incidental about

them: Archimedes allegedly had his big idea in the bath

tub and Einstein is said to have been sunbathing in the

park when the special theory of relativity occurred to him.

If you listen to Martin Smyth and Peter Wrobel from the Henkel Technology Centre in Dublin, however, there seems to be little roomfor the picturesque co-incidents that make for a good urban myth aboutinventions.

No room for mythsIt rather seems to be an efficient, well-organised process that leaves very little to chance.“We have something called Single Customer Project, which allows us to react very quicklyto customer needs,” says Smyth. In this particular case, a customer needed an adhesivethat cured on nickel-plated substrate with an extreme speed. The initial screening phasetook about a month. After another month, during which three employees of the centre inDublin devoted themselves full time to the project, the first prototype was ready. “I t met 90%of their requirements, but it needed some fine-tuning,” says Smyth. By that point, marketresearch had already shown there was a broader market for Loctite® 276, the new additionto the Loctite® product family.

Co-adapting to industrial evolutionPeter Wrobel’s story is an example for a more long term project. It was a 2 year

process that led to the development of Loctite® 5188, a flange sealant aimed primarily at theautomotive industry. “We are basically co-adapting to the evolution of car engines,” saysWrobel. “There is a shift from steel to aluminum in the industry, and accordingly, we

constantly improve Loctite® sealants in order to work well with that material.” Before Mr. Wrobeland his team embark on such a project, though, there needs to be a solid business case. “If asuccessful commercial application seems less than probable, we don’t go into the lab,

because that’s very cost-intensive,” explains the team-leader. Wrobel is a trained chemist, buthe has acquired a good feeling for the business side of things through customer visits. Whilethere is still a place for the coincidence and the power of the subconscious, after all successand failure is still down to people, individuals with their strengths and weaknesses, innovationdepends today on to a large extent on exact planning and efficient use of resources.

Peter Wrobel, Senior Development Scientist, Automotive Product Development Dept.Henkel Technology Centre Europe

RD&E insights The evolution of new adhesives

at work | no. 1/09

| RD&E insights

8/12/2019 140354_atworkengl


Achieving fast fixture on passive metal substrates – such as nickel- & other plated

surfaces – is quite a challenge for an anaerobic threadlocker, especially if requirementsalso call for good sealing performance and high strength, as well as very good thermal and

shock resistance.

Finding the optimal solution: Loctite® 276, one of the latest innovations to come out of the Henkel

R&D labs, meets all of these requirements. Originally developed in as little as two months within the scopeof Henkel's so-called Single Customer Project in reaction to an urgent customer need, the product was fine-

tuned to give an optimal combination of characteristics for the market environment. And, there could be no compromisewhere performance was concerned, because a high production output is one of the key criteria. Mission accomplished: Loctite® 276 is a high-strength anaerobic threadlocker that achieves fast fixture even on

passive metal substrates. It provides locking and sealing of threaded assemblies. It cures reliably even at low

temperatures but can withstand up to +150 °C. Loctite® 276 carries the European gas approval according to EN 751-1. Available in 50 ml and 250 ml bottles.

Flexibility – a challenge in gasketing

High-speed threadlocker

Loctite® 5188, the first anaerobic gasketing material

offering excellent flexibility even after heat aging, can beused for many applications in the automotive and industrialarea. Typical applications include metal-to-metal flange

assemblies such as gearboxes, housings, covers, etc.

Anaerobic gasketing technology has revolutionised flangesealing of rigid flanges in the automotive industry, and theassembly of heavy equipment. Anaerobic sealants remain

liquid when exposed to air, but cure when the metal partsare assembled and the adhesive is confined between

mating flanges. OEMs and subsuppliers have long beenenjoying the technical and economic benefits of anaerobicgasketing materials, and Loctite® 5188 takes this

technology to a new level. The use of alumin ium to produce light-weight

automotive castings has gained wide acceptance, and

Loctite® 5188 meets the flexibility requirements

of these modern concepts. The product

is designed to function in the most

demanding applications.It has very

good

adhesion to metal surfaces, especially to aluminium,

and provides immediate low pressure sealing.

Resistance of the cured product to thermal and

chemical stress is excellent. It provides elongation

to compensate for micro-movements resulting from

vibration, pressure and temperature changes. Because

Loctite® 5188 allows flanges to come together with

metal-to-metal contact, tolerances can be more

accurately maintained, and the correct clamp load

is ensured throughout the life of the assembly.Loctite® 5188 has improved oil tolerance, allowing

it to seal through slight oil contarmination. To suit

all needs, the product is available in three sizes:

2 l bag-in-box, 300 ml cartridge, and 50 ml accordion.

Reliabilityat work

Reliabilityat work

Benefits – Overview:

Provides locking and•

sealing

Ideal for gas pipes,•

valves & connectors

Allows higher•

production output

Benefits – Overview:

Suitable for light-•

weight design

flanges

Can tolerate•

micromovements

on highly stressed

flanges

Ideal for engine•

compartment

applications

at work | no. 1/09

RD&E insights |

8/12/2019 140354_atworkengl


Have you ever felt the urge to take a washing machineapart to see how it works? Or an oven? A fridge, maybe?If your answer to any of the above questions is yes, youwill probably envy Rudolf Neumayer: Because that’s whathe does for a living. The friendly Bavarian lights up whenhe starts talking about taking things apart.

“Taking things apart” is not his official job description, ofcourse. Rudolf Neumayer is Manager of European TechnicalService and Engineering for Henkel in Munich. He worksout of Henkel’s Innovation Centre in Munich and is part ofan interdisciplinary team of specialists that is responsiblefor what Henkel calls the “Teardown Analysis”, also knownas taking things apart.

Tearing it downWhat is the rationale behind such an analysis, apart fromthe sheer joy it seems to bring to the people involved in theactivity? A Tear Down analysis is a form of Value Engineering,

i.e. the attempt to look at eachcomponent of a

finished

product, to see whether the value of the product can beenhanced or the cost of manufacturing can be cut.

“Value Engineering or Value Analysis was conceived in theearly 1940s by Lawrence D. Miles while he was employedby General Electric, a major defense contractor which

was facing the scarcity of strategic materials needed toproduce their products during World War II, according to apaper published by the International Value Society in 2007.

From those humble beginnings, Value Engineering has

come a long way. One of the paths the development ofthe method has taken is the Tear Down Analysis practicedby Neumayer and his team. “In the last 3 years, we haveworked on over 60 projects with a broad range of majorinternational companies,” explains Neumayer. Since the

customers enter a very confidential relationship with Henkel,giving access to manufacturing sites and construction

plans, it is understandable then Neumayer guards theiridentities very carefully and refuses to even hintat them during the interview.

Tear Down analysisimproving industrial processes

Rudolf Neumayer

Manager of European Technical Service andEngineering, Henkel, Munich

at work | no. 1/09

Advanced technologies|

8/12/2019 140354_atworkengl


Dreaming of windmillsWhat he does talk about is in what way

he and his team have achieved some quitestunning results on some of the projects: Adhesives,aka glue, are something else that Rudolf from Bavaria

seems to feel passionate about. “It is a problem that in

many vocational trainings, people aren’t taught enough

about the possibilities that modern adhesives open up,”he says in English. Surprisingly, his English sounds a lotmore polished and difficult to place than his German. Thefact that he is responsible for the whole European area

and speaks English most of the time seems to have takenits toll.

“To give you an example: For a major customer (we onlydeal with customers that do mass-production, otherwise

our process wouldn’t make any sense) we managed toreplace a step in the production process of his washingmachine by using Loctite. That way, the production hasbecome cheaper and the customer was able to fit a

larger drum inside the washing machine. So, it’s good foreverybody: Good for us because we have a new customerfor Loctite, good for the manufacturer because they raisetheir margin, and good for the consumer because they geta larger drum,” he explains enthusiastically and it is hardto disagree with him.

And it doesn’t stop here, at least not for Rudolf:

“We have only just started, we have just scratched the

surface of what’s possible,” he says and his eyes gleam.

Team play and interplay of our various technical specialists at the ETS in Munich brings all relevant facts and figures on the table.

And what kind of machine would he like to tear down

next? “A windmill would be nice,” he says, with a dreamy

look in his eyes…

Value

engineering

Enhanced

product

value

Tear Down

analysis

Lower

production

costs

at work | no. 1/09

Advanced technologies |

8/12/2019 140354_atworkengl


Energy – the breath

of civilisation With every breath we take, according to Traditional Chinese Medicine, we receive

our share of Chi, the universal energy keeping us alive. Normally we are not aware of

breathing. Normally we are also not aware of the energy, equivalent to 120,000 TWh,

produced and used each year around the world to keep our society alive, except

when our cit ies stay dark, oil becomes too expensive or there is no gas for heating.

at work | no. 1/09

Side Glance|

8/12/2019 140354_atworkengl


Watt – the man who brought the dawn of endless

opportunity In 1776 James Watt installed the first industrial standardsteam engine. This was the dawn of our modern,

technology-driven society that soon became inseparablylinked to and dependent upon a continuous and growingsupply of energy. From these very first days, energy

production and transport became a global network, as

unobtrusive as it was reliable, always available and readyto work. The impact energy has on daily life, the way

energy characterises society becomes apparent when

malfunctions occur; only when cities remain dark, or whenoil, gasoline or natural gas run short or become unavailabledo we fully understand our lifestyle’s dependence on

energy. Without an energy supply there is no mobility, nomedia, no information technology, no commodities nor afood supply; medical care and hygiene is reduced instantly,and in the worst-case-scenario there is iciness.

Sources and uses of energy For more than a hundred years, the world’s energy

consumption has increased rapidly. Today the demand

for energy is nearly twenty times greater than in 1900

and twice as big as in 1970. Of the energy consumed

globally, 58 % is produced by oil and coal, 24 % by naturalgas, and 18 % by biomass, renewable energy and atomicpower plants. In the distant past, coal was a less-than-ideal solution for those who could not afford wood and

had to use these putrid, smoking stones for cooking andheating. But the growing demand for metal, and JamesWatts’ steam-engine paved the way to a coal-driven era.Soon large cities like London, Boston, New York and Berlinwere illuminated by coal-produced town gas. From 1800 to1850, coal consumption grew from 10 million tons (mt) to76 mt. In 1900, 760 mt of coal were used in a single year.In those days, coal covered 90 % of global fuel needs.

Share of world energy

consumption 2007,

percentages.

Source: BP

Timeline of energy demand

by sources.

Source: Exxon

Others

Africa

India

Middle East

Latin America

Japan

Russia EU

China

USA

oil

gas

nuclear power

hydropower

firewood

coal

(Mtoe)

(Year)

2118

17

1665

5

5

43

10,000

9,000

8,000

7,000

6,000

5,000

4,000

3,000

2,000

1,000

1860 1880 1900 1920 1940 1960 1980 2000

at work | no. 1/09

Side Glance |

8/12/2019 140354_atworkengl


The rise of industrial nations would not have been

possible without the combined power of coal and the

steam engine. Even today, coal production is still rising.Due to the increasing demand for energy, especially in

China, coal production was at an all time high of 5.4 bntons in 2007 – equivalent to a 1.4 kilometre cubic blockof coal, and an increase of more than 30% within only

five years.

The rise in demand for crude oil started with an ingeniousmarketing campaign. To sell more petroleum, J.D.

Rockefeller gave away free oil lamps. So people boughthis oil instead of expensive and rare whale oil. Some yearslater, refined oil played a key role in developing the newlyinvented motorcar, and oil became the basis of mobility.From then onwards, a global distribution network was

introduced that included drilling rigs, pipelines, crude oilvessels, refineries and gas stations. Since 1960, crude

oil has been the most important fossil fuel, covering onethird of world energy consumption. A 60% share of oil

production is used for traffic and transport. In 2008 theaverage daily production and use of crude oil was 85 millionbarrels (one barrel =159 litres) a day or 31 bn barrels a year,which is 4933 bn litres or 4.9 cubic kilometres – this wouldmake a cube with sides 1,68 kilometres long.

Natural gas has been available since the beginning of oilproduction, was mainly considered as an unimportant

and dangerous by-product. In the 1980s, natural gas

became established as a basic energy resource for

industrial production, the production of electricity, and forhouseholds. This economic breakthrough was founded

on the convenience, warmth and cosiness that natural

gas offered as a replacement for coal-produced town

gas. Today, natural gas is still a major fuel for generatingelectricity and for residential domestic use. The total

worldwide amount of natural gas extracted in 2007 was2940 bn m3 – this time enough to make a cube with 14kilometre-long sides.

However, progress was followed by adverse effects. In

total, burning oil, coal and gas produces 26.100 bn tons(13.300 bn cubic kilometres) of carbon dioxide a year –imagine a cube with sides 23.7 kilometres long. This is theproblem of growing energy consumption – nature cannotrecycle all the man-made CO2 and so the atmosphere

is becoming overloaded with this gas. In addition, fossilresources are limited but in the future there will be a vitalneed for these precious raw materials – for synthetics aswell as for life-saving pharmaceuticals and hundreds of

other products derived from crude oil. Dependency onfossil resources has also become an economic and a

political source of crisis. The Cold War as well as powergames with and between main oil-producing countries

has led to economic imbalances. Long-distance transportroutes, volatile prices, geopolitical instability, trouble spotsand economic dependency on a few energy providing

countries are causing a worldwide re-evaluation of energysystems.

The breath of the sun – light, heat, windIn contrast to fossil energy production, atomic energy,

hydro power, biomass and renewable energy represent

only one fifth of world energy production. Nevertheless, the

A 1.7 kilometre cube in

New York, equivalent to

the world oil consumption

each year.

Source: SDI-Research

at work | no. 1/09

Side Glance|

8/12/2019 140354_atworkengl


hope for an enduring and stable energy supply dependson renewable resources such as the wind, sun, biomassand water. The reason is obvious; in only three hours thesun sends as much energy as the whole world needs ina year.

Therefore only 3 % of the Sahara‘s land area would be

enough to cover the world’s usage of electricity. Only a

fraction of available solar energy is used now even though

solar power capacity increased from 2 Petajoules (Pj) to 13Pj in the period from 2004 to 2008. In 2008, wind energyplants, mainly in Germany, the USA and Spain, produced94.000 MW of electricity. A huge potential remains

untouched. The overall potential of renewable energy

also depends on technical as well as geographical and

economic conditions. Only a fraction of the solar energy wereceive is usable but the figures are still impressive:

Type of Energy Amount ofworld energyconsumptioncovered

Solar Energy 3,8x

Wind 0,5x

Biomass 0,4x

Geothermal Energy 1,0x

Tidal Power 0,05x

Hydrogen Power 0,15x

Less is more – power efficiency The largest power plant does not produce any energy;

it is designed to save energy by intelligent and efficientusage. On the road from power production to the end-

user there are often losses of up to 90% measured againstenergy input. There are losses within the power-plants,

losses of transmission and distribution, and losses in powerconversion, for example:

A bulb converts only 3 % of electric energy into visible•

lightOnly 13 % of gasoline energy reaches a car’s wheels.•

80 % of heating and climating losses in buildings could•

be avoided by efficient thermal insulation.

The reduction of losses is multiplied as the energy travels

back to power plants. If losses cause a reduction of energyfrom say 100 produced units to 10 units output, an increaseof efficiency from 1 unit on the output side will save 10 unitson the input side. Therefore energy efficiency is the mostpromising power source of the future.

The Evolution of Technology For more than 150 years the increasing availability of energyhas improved access to resources and the production andsupply of food. It has enabled unprecedented mobility,

information availability, communication, and the usage

of sophisticated technical devices. New technologies

evolve whenever existing applications turn out to be

too costly to resolve new problems. Old technologies

will either be optimised or gradually substituted by their

successors, unless the problem itself is altered or changedby new perspectives and solutions. It is obvious that

an environmental and socio-economic driven changein energy-technology lies ahead. It is also obvious that

essential technologies already exist or are in development,ready to compete to provide useful and practical solutions.Even now there are numerous inventions and innovations,such as new technologies to produce and save energy orefficient production solutions to preserve natural resources.New materials, components and drives are steadily

reducing the energy demands of industry and transport.New concepts of mobility will evolve to a essential criteria. The final goal should be, as Traditional Chinese Medicineadvises, to keep the flow of energy alive – with every breathwe take.

Dr. Oskar Villani, SDI-Research

A fraction of the area of the Sahara could cover theworld’s energy demands Source: TREC

Only a fraction of primary

energy is used.

Source: Paeger

Primary energy 100 %

transport

Conversionin power plants,

refineries etc...Conversion loss

22.5 %

Private consumtion,

loss of power5 %

Non-energeticconsumption

7.5 %

Consumerconsumption

36 %

Final energy 65%

Usefulenergy

WorldEU 25 D

Reliabilityat work

Technical Glossary

bn:billions 1 billion =1,000,000,000 =1x109

barrel:1 barrel = 159 litresor 42 US Gallons

CO2:

Carbon Dioxide

PJ:Petajoule1,000,000,000,000,000 J~ 278,000,000 kWh,

unit of energy

MW:Megawatt = 1,000,000Watt

Mtoe:million tons (of) oilequivalent, unit ofenergy. 1 Mtoe =11,630,000,000 kWh

Km:Kilometre, 1 Km ~ 0.62Miles

kWh:kilowatt-hour = 1,000Wh, unit of energy

at work | no. 1/09

Side Glance |

8/12/2019 140354_atworkengl


A German

masterpieceImagine a 82 m long, rock-eating submarine with four floors, as

tal l as a high rise building with 20 f loors lying on its side.

This monster is heavier than a dozen 747 jumbo jets and creeps

forward through the ear th behind a more than 9 m tal l rotating

cutting face. Sounds a little outlandish to you? Product of a

hyperactive imagination? If you thought that, you were wrong.

This is not Hollywood, this is the Discovery Channel.

gineering Know-How fromermany for the whole world

Every mm counts – even when 9t ofsteel are waiting at the hook

82 m of pure power – ready for action This threaded fitting has to resist to 350 bar oil pressure

at work | no. 1/09

Reliability Report 2|

8/12/2019 140354_atworkengl

http://slidepdf.com/reader/full/140354atworkengl 19/24at work | no. 1/09


8/12/2019 140354_atworkengl


The main drive of a tunnel boring machine is an assembly of no less than four large gear units that are bonded and bolted together.Flange faces are coated with Loctite® 586 using a roller, which increases friction 2 to 2.5 times.

Insane pieces of engineeringIf you are the kind of person that doesn‘t like science-

fiction, because you are interested in reality, Allmannsweierin Baden-Württemberg is the place for you.

Allmannsweier in Baden-Württemberg is one of the morepleasant regions of Germany, famous for its good food andthe friendly locals. It‘s also the home of Herrenknecht, theworld‘s leading manufacturer of tunnel boring machines. And it‘s those machines which dwarf the imagination ofyour average Hollywood screen writer. It’s not surprisingthat the company and its charismatic founder, Dr MartinHerrenknecht has attracted a lot of attention from the

global media lately.

“ An insane piece of engineering” is how the American

Discovery Channel describes the Herrenknecht machinethat drilled a 5.4 and a 3.9 kilometer tunnel in Kuala Lumpurin 2006.

The defining project of Herrenknecht‘s career and one ofthe greatest public works of any kind is the Gotthard Base Tunnel. The tunnel, which has been under construction

since 2002, will run from the village of Erstfeld, in centralSwitzerland, to Bodio, in the southeast, a distance of morethan 57 kilometers. When completed, in 2017, it will bethe longest traffic tunnel in the world; it is also one of themost geologically challenging, The Gotthard crosses ninegeological zones. It cuts through granite and quartz, alongfault lines and beneath a sugar like layer of dolomitic marble

– a challenge to anything going through it.

No rock too hard, no mountain too high:Loctite® and Herrenknecht

Herrenknecht has been growing ever since its foundationin the 70s. It now employs around 3000 people worldwideand sales reach 1 billion Euro for the first time in 2008. This impressive success story is partly due to the fact

that Herrenknecht took advantage of the opportunities

offered by globalisation. China is one of the countries whichHerrenknecht focused on early and in 2008 they were ableto celebrate the delivery of the 100th machine to the power-house of the world economy. Completed main drive waiting

for the assembly into the

machine.

Forget Star Wars, forget Star Trek, forget the Matrix.

Wherever one of the machines operate, Malaysia, China,Switzerland or Brazil, Henkel‘s Loctite® products alwaysplay an important role during the construction of those

insane pieces of engineering. Loctite® threadlocker 243 isused to lock all the screws in the machine, which has towithstand enormous pressure while it eats its way throughthe rock.

Another application which makes good use of the

reliability that Loctite® stands for, is the machine’s rotatingcutting head. The cutting head's power unit relies on a

variable number of single engines. The superstructural

part's flange ring and main bearing as well as transmissioncase and main bearing are cemented repeatedly in a

laminary fashion, using Loctite® 586. This process allows

to transmit more than twice the turning movementthat would be possible otherwise. The cementing with

Loctite® enhances the reliability and allows the power

unit to withstand the forces that can come to bear on itunderneath the earth.

Loctite® Sales Engineers are also involved in the planningprocess of the machines, liaising with the various

Herrenknecht departments in order to meet the customer’sconstruction needs as early as possible. Henkel and

Loctite® are ideal partner for Herrenknecht’s tunnel-boringmachines, which never quite know what kind of rock theywill have to taste next. Loctite’s Rapid Response Process(see Product Development Article), allows us to

respond to new requirements in a matterof weeks.

The next stop for the tunnel

boring machines is Paris,

where the new tunnel for theMetro 12 has to be drilled.

Reliabilityat work

Customer:Herrenknecht,

Germany

Task:Securing flanges on

the main drive with a

2 to 2.5 times higher

friction coefficient

within it.

Products:

Loctite®

7070Loctite® 586

Loctite® 243

at work | no. 1/09

Reliability Report 2|0

8/12/2019 140354_atworkengl


Interview

Wolfram Lais, Head of SubassembHerrenknecht AG

Christian Draeger, Traffic Tunnelling SalesDepartment, Herrenknecht AG

You're using Loctite® products for a wide variety

of applications in the manufacturing process of

your equipment. What Loctite® products do you

use in the manufacture of tunnel boring machines?Mr. Lais: In our department we mainly use Loctite® 586for bonding flanges and 577 for thread sealing, 243 for

threadlocking and Loctite® 7070 as a cleaner.

Where do you use Loctite® adhesives on your

machines? Mr. Lais: We use Loctite® mainly on the

cutting wheel drive. We apply product 586, to increase

friction.

In general, what parts of a machine are most severely

stressed during operation of the equipment? Mr.

Draeger: The cutting wheel and the main drive are

subjected to very high loads. Just imagine that the cuttingwheel is moving through the ground, encountering a varietyof soil types and loading conditions. There may be hardrock or loose rock. In the case of hard rock it's mainly the

pressure and the force to be transmitted by thecutting wheel when it's carving away the rock.

With loose rock, it's mainly the torques, therotating or twisting forces that act there and

cause very high stresses.

How does such a tunnel boring machine get from this

production facility to its final destination ?Mr. Draeger: The tunnel boring machine is fully assembledright here in the factory. But, to move the machine to theconstruction site, it must be disassembled again. That's why the machine is completely modular in design,and modules are assembled with bolts. We will disassemblethese bolted joints to get accurate structures which we

can transport to the construction site. Once they have

arrived at the construction site, these structures are thenre-assembled, tightened with bolts or welded.

at work | no. 1/09


8/12/2019 140354_atworkengl


Insights online

The new web platform designed by engineers for engineers!

Ready for more action? Watch full-length videos of our most exciting

application stories and get inspired for your own professional tasks on

www.loctitesolutions.com/uk

Get connected and order the next issue of the magazine.

Benefit from the latest

technology trends

Witness

fascinating

real life

application

stories

Get entertained with

captivating video features

Get insightful

application tips

WIN

amazing prizes

at work | no. 1/09

Handy Hints|2

8/12/2019 140354_atworkengl


Discover reliability in the most extreme racing conditions.Learn more about the Porsche Mobil 1 Supercup and Loctite'stechnology partnership with the fastest one make cup in the world.

... coming soon

Come along and visit the “kings of earth”.

Discover the plant of TEREX in Scotland.Get insights into the production of 100 ton rigid trucks.

at work | no. 1/09

Outlook |

8/12/2019 140354_atworkengl


Imprint

PublisherHenkel AG & Co. KGaA

Adhesive TechnologiesHenkelstraße 67

40191 Düsseldorf

Germanywww.henkel.com

Editorial DepartmentMarketing Department EMEA:Christian Scholze

Andreas Engl

Beate SchneiderIsabelle Feix

Erik Edelmann

Frank Fischer

Contact Andreas Engl (Project lead)

Phone: +49-211-797-6758

[email protected]

Creationblösch.partner

Werbeagentur GmbHwww.bloesch-partner.de

Henkel LimitedWood Lane End

Hemel Hempstead

Hertfordshire HP2 4RQTel. 01442 278100

Fax 01442 278071

140354_atworkengl

Documents