Rába Axle Ltd.
Transcription
Rába Axle Ltd.
Rába Axle Ltd. Member of the Rába Group – Hungary CONTENTS RÁBA AXLE LTD. FORGING PLANT AND OPERATIONS 1 3 6 PRODUCTS PRODUCTION OF AXLE COMPONENTS 7 COMPLETE AXLES 10 Axles for Trucks - Rába MAXSTM 11 Axles for Buses and Trolley Buses 13 · Midibus and its drive line with angle drive 14 · Front axles for buses 14 · Single reduction rear axles for buses 15 · Double reduction rear axles for buses and trolley buses 16 · Portal rear axles for buses and trolley buses 17 Axles for Agricultural and Construction Equipment 18 SPARE PARTS HOW TO CONTACT US? 19 21 RÁBA AXLE LTD. Rába Axle Ltd. was founded by Rába Automotive Holding • Engineering activity: Plc. in 1999 when the Axle Business Unit of the company - Products are designed with Pro/Engineer 3D software became an independent legal entity; however, Rába was - Complete product validation – from designing through testing and simulation to the starting of the serial production founded more than one hundred years ago. Rába Axle Ltd. is specialized in producing mid-series complete axles and high-series axle components for commercial vehicles. Its products are primarily installed in: - Technological process- and quality planning - Forging part deformation simulation in the die using Simufact software • Forging capacity - Maxima presses 2500/4000/6300 t • medium- and heavy duty trucks - Hot extruders 800/1000 t • military trucks - I-beam production line (400 kJ counterblow hammer) • specialty vehicles: tractors and construction equipment • buses and trolley buses • Foundry producing nodular iron (joint venture) • Tool manufacturing • Heat treatment (isothermal annealing, normalizing, hardening and tempering equipments) Although Rába is traditionally a Hungarian company, it is present on the international market, year by year more than 80 % of the sales revenue comes from export. 1 • Machining capacity • Surface treatment • Test and measurement laboratories Our main customers are well-known and recognized • Assembly plant companies, such as Marmon-Herrington, ArvinMeritor, • Parts supply in painted, packed condition Dana, John Deere, Claas, Scania, Volvo, BPW, ZF, the GAZ • Logistics solutions Group, KAMAZ, and Isuzu. VERTICAL INTEGRATION The vertical integration of Rába Axle Ltd. is a great advantage in meeting customers needs the fast and flexible way. The strength of the Rába Axle Ltd. is in the vertically integrated production process which makes Rába Axle Ltd. capable of offering complex package to its customers including: VALUE CREATION COOPERATION As a market player specialized in axle and axle components The design engineers of the company have been production, Rába Axle Ltd. creates value to OEMs with its cooperating with experts of the international automotive cost-efficient, high quality products that are designed to companies for a long time. Rába Axle Ltd. designs and tests meet specific customer needs. The company has a the products in close cooperation with its automotive certificate of ISO/TS 16949. The ISO/TS 16949 Quality partners and is ready to satisfy the most unique customer Assurance System applicable in automotive industry requirements. provides guarantee for steady and reliable quality. Our company obtained the Certificate of Approval of ISO 14001 Environmental Management System Standards as well. 2 FORGING PLANT AND OPERATIONS MAIN DATA Year of establishment: 1907 Area: 20,000m2 Annual total capacity: 40,000 t Basic material used: · Alloyed and unalloyed steels · Micro-alloyed steels Rába Forging Plant was established in 1907 so we have more than a hundred years of experience in making forged products. Continuous developments allowed constant increase in production capacity. As a result, the Forging Plant has become one of the significant forges in the region. Details of the Rába Forging Plant: • Up-to-date design methods Main pillars of designing: CAD-CAE-CAM system, controlled by up-to-date PDM (Product Data 3 Management) and PLM (Product Lifecycle Management) systems • Certificate of ISO/TS 16949 • R&D within the frame of the Regional University Knowledge Center for Vehicle Industry. The science serves the production. • The relevant production lines are robotized and heat measurement tests with thermal camera are also applied. The main profile of the forging plant includes the forgings of components for the automotive industry (trucks, buses, specialty vehicles), which are installed either into Rába designed front and rear axles, head assemblies or are delivered for axle and transmission manufacturers worldwide. THE FOLLOWING PRODUCTS CAN BE PRODUCED IN OUR FORGING PLANT: 0,5-10 kg weight range Bracket, diff. side pinion Shift yoke, Differential spider Steering arm Gear, Planet gear, Shoulder ring 10-20 kg weight range Steering arm Pinion gear, Spindle Tie rod arm Ring gear, Companion flange 4 20-50 kg weight range Spindle Integral steering knuckle Steering knuckle, Planetary carrier Ring gear, Diff case halves 50-140 kg weight range I-beam In addition to forging operation, the following processes are carried out in the forging: heat treatment, isothermal annealing and normalizing of forgings as well as, hardening and tempering, straightening, crack inspection, shot peening and surface cleaning and hardness measurement of forgings. MACHINES, PRODUCTS AND MACHINE CAPACITY DATA Machines Lasco counterblow hammer (400KJ) Product weight (kg) Typical products Forging capacity (3 shifts) in thousand pcs/year 50-145 I-beam 150 Steering knuckle, 63 MN Maxima mechanical forging 20-35 presses Ring gear, Diff. case halves, 300 Planetary carrier 5 2-8 Steering arm, Tie rod arm, Gear, Planetary ring gear, Companion flange, Diff. case halves 666 1-8 Differential spider, Sun gear, Planet gear, Shoulder ring, Shift fork 700 40 MN Maxima Mechanical forging press 25 MN Maxima mechanical forging press LASCO I. (8 MN) hot-extruding 8-20 production line Pinion gear, Spindle 300 LASCO III. (10 MN) robotized hot extruding production line 15-30 Spindle 300 PRODUCTION OF AXLE COMPONENTS PRODUCTION OF AXLE COMPONENTS Recently, besides the production of complete axles, the The forged pinion and ring gears are turned and then production and direct sales of front and rear axle machined on Gleason CNC gearing machines. Besides components to the largest axle, transmission and vehicle traditional lapping (matching), these pinion and ring gears manufacturers all over the world, like ArvinMeritor, Volvo, can be ground on Gleason Phoenix tooth grinder in John Deere, DANA Corporation, ZF, Caterpillar, Scania, increasing volumes in order to get more precise tooth MAN, BPW have played a significant part in the activities of profile, better contact patterns and lower noise levels. Rába Axle Ltd. The company's competitiveness has been Rába Axle Ltd. is able to produce a total of 60,000 sets, out increased by vertical integration within the company of which 20,000 are ground, while 40,000 lapped pinion (forging and tool plants, and foundry has been operating as and ring gears, annually. Rába-Busch joint venture from the beginning of 2008) as well as by the development and test capacities and competence suitable for the development of complete axles and their subassemblies, too. Axle components are machined on machining centers, high-capacity specialpurpose machines and automatic production lines in the company's plants. HOUSING TYPE PARTS These parts (differential carriers, differential cases, planetary carriers, axle housings, suspension beams and centre sections) are elements in the drivelines of drive 7 axles. The castings and forgings are produced in the joint venture foundry or forging plant or they are purchased STEERING KNUCKLES from external foundries (especially gray iron). The internal Rába Axle Ltd. has been supplying light and heavy-duty production range covers fabricated axle housings, too. knuckles to the largest axle producers of heavy-duty trucks Production base for machining these parts consists of CNC all over the world. For several years our company has been lathes and machining centers that are capable of producing a supplier of integral knuckles that are forged as one piece – among others – 100,000 differential carriers, 20,000 with the tie rod arm. For the largest volumes, the knuckles welded and 20,000 off highway transmission housings are machined on automatic production lines, in other cases annually. they are produced in flexible production lines built of machining centers. Production capacity of the knuckles is close to 100,000 per year. I-BEAM The production of forged axle beams is one of the strengths of Rába Axle Ltd. Annually, a maximum of 150,000 beams can be produced. I-beam forgings are made on counter blow hammers with automatic material transfer, and they are machined on lines of special-purpose machines and in PINION AND RING GEAR SETS Rába Axle Ltd. has a very wide production range of these products. Our company is ready to produce ring gears from 200 mm up to 500 mm with spiral and hypoid gearing used in heavy-duty trucks. increasing number on special Unisign CNC machining centers. The majority of these products is supplied to our customers or they are also installed into our own products, namely into low-floor front axles. PRODUCT GROUP MACHINING CAPACITY Gear set 60,000 pcs/year Spur gear 220,000 pcs/year Axle shaft 90,000 pcs/year I-beam 150,000 pcs/year Knuckles 100,000 pcs/year Axle housing (welded) 20,000 pcs/year 8 HEAD ASSEMBLIES In order to meet the customers' requirements, Rába Axle Ltd. produces single- and double reduction head assemblies on lines developed specially for this purpose. OTHER COMPONENTS Production capacity of Rába Axle Ltd. involves some further axle and driveline components like spindles, brake spiders, wheel hubs, tie rod and steering arms of steer axles, companion yokes and axle shafts. NEW INVESTMENTS Important investments and upgrading - Improvement of cutting technologies - Extending the capacities in the assembly plants - Updating the blank parts and machining processes - Updating forging blanks and finishing processes (robotization, Lasco III) - Robotization has been introduced in the cold-forming areas, too (plasma cutting, welding robots) - Development of logistics - Updating additional technologies (heat treatment equipment, renewal of shot peening equipment) The aim of this development was to further boost the company's market presence and to strengthen its competitiveness through efficiency improvement. TESTING, MEASURING Our company is continuously testing and inspecting its 9 products. In the company's own test laboratory new products are tested for performance, strength, lifetime, vibration and noise. Also the customers who purchase parts and subassemblies frequently utilize this opportunity. Up-to-date measuring equipments (including several 3D measuring devices) support the good and stable quality of production. COMPLETE AXLES AXLES FOR TRUCKS - RÁBA MAXS™ off-road and military vehicles is MAXS double reduction RÁBA MAXS™ DOUBLE REDUCTION MODULAR AXLE SYSTEM off-road axles applicable in all-wheel-drive, off-road FLEXIBILITY, ROBUST DESIGN, QUALITY AND GOOD vehicles intended for use in heavy terrain, which – thanks VALUE/PRICE IN AN AXLE The main strength Rába Axle Ltd. has in the area of axles for to their modular system – provide unique possibility to the users. Rába MAXS™ off-road axles - Axles for 4x4, 6x6 and 8x8 applications. - It is developed for high mobility off-road vehicles with high dynamic axle load (5X) - CW and CCW input options - Optional „Limited Slip” differential lock for the front and conventional differential for the rear axles - Ratio range 4.250 – 8.52, Normal Duty 30 mm planetary - Ratio range 4.87 – 10.048, Heavy Duty 40mm planetary - - The total ratio range can be covered with less than 5 % steps - The axles can be serviced or adapted even in a simple workshop 11 - Variable full length - Variable center offset - Left-, right- or symmetrical steering arm Rába has been producing double-reduction axles from the 1970'ies. Initially, the main markets were the domestic market (Ikarus) and the CIS region. Since 1984 Rába has been supplying complete truck axles to the USA, too, which has already become one of our strategic regions by today. Our large experience is supported not only by the long years of production, but also by the fact that by now the quantity of the rear axles Rába sold has exceeded 1 million, dominated by the double-reduction axles. - CTI system for the 10 t and 11.3 t axles - Due to the double reduction axles the differential is relatively small - The small differential provides high ground clearance on off-road AXLE FOR TRUCKS Axle type GAW (t) Ratio range Engine performance kW/HP Output torque (Nm) Ring gear dia/ face width (mm) Planetary ratio/ face width (mm) Remark RÁBA MAXS™ Double reduction steering axle 739/639 7.5 4.25-8.52 - 30,000 883/783 10 11.3 4.87-10.048 - 30,000 40,000 255/41 (45) 255/41 (45) - 30,000 3.4615/30 3.4615/30 3.958/40 optional CTI, 5X* 255/41 3.4615/30 optional CTI, 5X* RÁBA MAXS™ Double reduction tandem front axle 783/783 2X10 4.25-8.52 RÁBA MAXS™ Double reduction rear axle 739 7.5 4.25-8.52 206/280 30,000 250/41 3.4615/30 884 10 11.3 4.25-8.52 7.17 206/280 276/375 30,000 40,000 250/41 3.4615/30 3.958/40 955 13 4.25-8.52 276/375 40,000 250/41 3.4615/60 optional CTI, 5X* RÁBA MAXS™ Double reduction tandem rear axle 739/739 2X7.5 4.25-8.52 294/400 30,000 250/41 3.4615/30 884/884 2X10 2X11.3 4.25-8.52 7.17 324/440 30,000 40,000 250/41 3.4615/30 3.958/40 965/955 2X13 4.25-8.52 324/440 70,000 250/41 3.4615/60 optional CTI, 5X* Single reduction steering axle 060 (061) 062 5.9 (6.6) 4.111-7.17 17,000 336/45 061: optional CTI 5.45 4.111-7.17 17,000 336/45 disc brake 26,000 375/57 optional CTI Single reduction rear axle 063 7.1 5.57 205/275 * Max. dynamic loading capacity of the axle is five times higher than the static one. 12 13 AXLES FOR BUSES midi medium up to 10.3 t up to 15 t heavy up to 19 t up to 28 t front rear rear front rear front middle rear 3.3t I-beam 3.8t IFS 6.5t SR 6.5t AD 9t SR 11.5t SR 7.5t I-beam 7.5t I-beam portal 11,5t SR 13t SR 13t DR 13t portal 7.5t I-beam 7.5t I-beam portal 10 t non-driven 11.5t non-driven portal 11.5t SR 13t DR for low-entry 13t driven portal IFS: Independent Front Suspension AD: Angle Drive SR: Single Reduction Axle DR: Double Reduction Axle MIDIBUS AND ITS DRIVE LINE WITH ANGLE DRIVE APPLICATION Low floor midibus Length: 8 m GVW: 9,500 kg Max. engine performance: 125 kW The „Z” arrangement of the drive line provides extremely compact design of the rear part of the bus. FRONT AXLES FOR BUSES 14 12 GAW (t) Track (mm) King pin distance (mm) Wheel disc size Brake Remark 270 3.3 (3.3), 3.8 2016 1793.5 17.5” air disc Rigid IFS 932 7.5 2005 2054 1749.7 1779.7 22.5” air disc 752 7.5 2041 1784.5 22.5" - 20.0” S-cam drum 702 7.5 2101 1825 22.5” air disc portal type 703 7.5 2101 1825 22.5” S-cam drum portal type Axle type DETAILS OF THE AXLES: - Forged I-beam or swinging arms - King pins with seals providing long lubrication intervals and long lifetime - Tie rods are maintenance-free or can be greased, as required - High turning angle 15 SINGLE REDUCTION REAR AXLES FOR BUSES Axle type GAW (t) GWV (t) Ratio range Hypoid offset (mm) 360 6.55 10 3.58-6.14 35 125/170 17.5” not available air disc bus 361, 362 Angle drive for Z-drive 6.55 10 3.72-5.25 35 125/170 17.5” not available air disc bus 106 9 14 3.58-7.17 35 176/240 19.5", (22.5”) not available S-cam drum bus 306 9 14 3.58-7.17 35 176/240 19.5" not available air disc bus 209 11.5 19 25* 3.07-5.875 35 235/320 206/280* 20” or 22.5” Optional S-cam drum coach city bus 309 11.5 19 25* 3.07-5.875 35 235/320 206/280* 22.5" 19.5” Optional air disc coach city bus 311 13 23 30* 2.80-5.86 35 330/450 235/320* 22.5” not available air disc coach city bus * for city bus application DETAILS OF THE AXLES: - Noise minimized ground pinion and ring gear set - Axle housing welded from high-strength pressed plate - Robust bearing support in the carrier, allowing retarder service mode, too - In the models 360, 361, 309 and 306 there are compact wheel bearings not requiring maintenance - Precision forged (with ready-made toothing) differential gears Engine performance kW/HP Wheel disc size Diff.lock Brake Application area DOUBLE REDUCTION REAR AXLES FOR BUSES AND TROLLEY BUSES Axle type GAW (t) GWV (t) Ratio range Hypoid offset (mm) Engine performance kW/HP Wheel disc size Diff.lock Brake Planetary face width (mm) Application area 618 13 30 5.11-7.13 10.67-14.39* 0 20* 220/300 20.0" or 22.5" optional drum 40 city bus trolley bus 718 13 30 5.11-7.13 10.67-14.39* 0 20* 220/300 20.0" or 22.5" optional drum 60 city bus trolley bus * Specially designed for trolley bus application DETAILS OF THE AXLES: - Only 344 mm banjo diameter for low-entry application - Strong driveline to meet the 1,000,000 Miles Lifetime concept - More than 500,000 axles in the field with an accumulated milege of more than 300,000,000,000 - Well optimized manufacturing processes for example: broached and ground planetary gears, broached planetary ring gear, etc. 16 17 PORTAL REAR AXLES FOR BUSES AND TROLLEY BUSESS Axle type GAW (t) GWV (t) Track (mm) Ratio range Hypoid offset (mm) Engine performance kW/HP Wheel disc size Brake Application area Portal driven rear axles 138 13 28 1826 4.46-6.85 20 260/353 22.5” drum city bus APT 28 13 28 1888 6.25; 9.63 20 260/353 22.5” drum city bus BPR 28 13 28 1836 4.43-6.51 20 260/353 22.5” disc city bus Portal non-driven rear axles 038 13 28 1826 drum city bus APT10 10 28 1888 drum city bus DETAILS OF THE AXLES: - Wider and lower boarding bridge in the application - Driveline system for heavy duty application - Noise minimized - ground hypoid ring gears and pinion set, helical gears in the side drive AXLES FOR AGRICULTURAL AND CONSTRUCTION EQUIPMENT Rába has a great experience in this type of axles because it - The Rába wet brake is installed with „retrainer” Due to has been producing them for more than 40 years. The axles this solution the speed of the equipment can be over 50 for agricultural and construction equipments are designed km / hours neverthless no cooling system is used. with a modern and unique technical solution, wet brake. - The agricultural axles are installed with differential lock Rába has been producing these axles since 1991. which can be operated at any speed. - Axles for construction equipment have such diff. lock Main units are designed so that we can provide the most mechanism, which – in addition to the basic locking suitable axle to the vehicle by means of some new parts torque – provides locking torque increasing in proportion after getting familiar with the customers' requirements. with loading in order to reliably meet the requirements in the most various applications. AXLES FOR AGRICULTURAL EQUIPMENT Engine performance kW/HP Output torque (Nm) GAW (t) Ratio range 576 10-16 t 20.80026.000 235/320 88,000 integrated steering, wet brake, patented diff.lock 577 10-16 t 20.84824.296 280/380 88,000 integrated steering, wet brake, patented diff.lock Axle type Remarks AXLES FOR CONSTRUCTION EQUIPMENT Axle type GAW at transport (t) 575 16.4 576 21.8 GAW at breaking (t) 26.7 34 Ratio range Engine performance kW/HP Output torque (Nm) Remark 20.8-26.0 153/208 120,000 Non-steering, automatic diff. lock, wet brake 20.8-26.0 196/267 168,700 Non-steering, automatic diff. lock, wet brake 18 SPARE PARTS When producing spare parts, we have the same outstanding expertise and attitude as in making common developments with the vehicle producers or even in producing our complete axles day by day. Our experience gained in vehicle production, our team consisting of more than 30 engineers, the continuous developments guarantee that our customers will always receive the most excellent quality and reliability in our spare parts. Our most significant spare parts are: • Brake lining sets • Brake drums / discs • Brackets • Slack adjusters • Brake chambers/ brake systems • Wheel bolts / nuts /bolts • Bearings / seals / rings • King pins / bushings / king pin sets 19 • Gears (R/P, planetary gear, sun gear, differential pinion, differential gear) • Planetary ring gear, ring gear support • Differential spider • Tie rod • Tie rod arms / steering arms • Axle shafts • Knuckles / spindles • Carrier assemblies / differential assemblies • Planetary carrier assemblies • Wheel hubs • Suspension elements (swinging arms, air springs, shock absorber) • Ball joints Etc… SPARE PARTS DISTRIBUTORS Company DINARA A.D. Location Serbia Bus Center Kft. Hungary Prim Vol. Trade Kft. Hungary Rába Spol. s.r.o. Address Phone nr. E-mail address 11000 Beograd Save Maskovica 3. Serbia 9071 Gönyû, Rákóczi Ferenc u. 60, Magyarország 4030 Debrecen, Ozmán u., Magyarország +381 11 2 468 629 [email protected] +36 96 600 200 [email protected] +36 52 470 212 [email protected] +420 2 3332 1828 [email protected] Address Phone nr. E-mail address 113452, Moscow, ul. Azovskaya, 35. 127410, Moscow, Altufeyevskoe shosse, 79 A 107014 g.Moscow, 2-aia Boiebskaia ul. 6a +7 495 318-1638 [email protected] +7 495 439-7856 [email protected] +7 495 651 9504 [email protected] +380 56 770-0235 [email protected] +7 855 239 31 17 [email protected] +380 56 296 2661 [email protected] Czech Republic, Slovakia, Poland, Latvia, Lithuania, 160 00 Praha 6, Starodejvická 4, Estonia, Germany, Czech Republic Western Europe, USA SPARE PARTS DISTRIBUTORS – CIS Company Location OOO "Profcar” Russia ZAO MTCO "GROUS” Russia OOO „Interdetal” Russia AO "LITAN” Ukraine, Moldova, Georgia, 49008 g. Dnepropetrovsk, Azerbaijan ul. Krivorozhskaia, 20 Armenia, Turkmenistan OOO STFK „KAMAZ” Russia UP “Belelektrotransservis” Belarus 423800 Naberezhnye Chelny, B-r Akademika Rubanenko, 4 220070 g. Minsk, ul. Perehodnaia, 64 20 Rába Axle Ltd. - Member of the Rába Group H- 9027 Gyõr, Martin Str. 1. Tel: +36 96 622 600 Fax: +36 96 624 069 E-mail: [email protected] URL: www.raba.hu In case demand exist for • new businesses either with existing or with new customers • receiving quotations, drafting and creating frame contracts • leading the project when introducing new products please do not hesitate to turn to any of the colleagues of Business Development Name Phone nr. E-mail address Position Dr. SZÕCS Károly +36 30 444 95 01 [email protected] Director, Business Development ASZTALOS Péter +36 96 624 341 [email protected] Head of Technical Sales ANDRÁSI Mátyás +36 30 444 95 13 [email protected] Product Planning Expert MIKE Lóránt +36 96 624 363 [email protected] Technical Sales DÖBRÖSI Balázs +36 96 624 349 [email protected] Marketing Specialist Our Sales Department is the first and main contact point for the customers and is to focus on • customer satisfaction, continuous customer contracts • collecting and confirming customer orders • handling short and mid term capacity utilization issues • dealing with product modifications and actual pricing Name Phone nr. E-mail address Position FARKAS Ákos +36 96 624 943 [email protected] Director of Sales TÓTH Zsuzsanna +36 96 624 954 [email protected] North-South America Regional Sales Manager KOZMA Balázs +36 96 624 637 [email protected] ROW Regional Sales Manager REPRESENTATIVE OFFICES AND REPRESENTATIVES Name Phone nr. E-mail address Location KÕVÁRI Pál +1 630 682 3559 [email protected] Chicago, USA GERENDAI László +7 495 232 3894 [email protected] Moscow, Russia Dr. Chen Xin +86 10 8719 7168 [email protected] Beijing, China Published with the support of: 2009 ITD H U N GA RY INVESTMENT AND TRADE DEVELOPMENT AGENCY WWW.ITD.HU