HARSEWINKEL, GERMANY: In 1936, the Westphalian agricultural

The LEXION 770 in action. It is part of the latest generation of combine harvesters from CLAAS. PHOTO: CLAAS
HARSEWINKEL, GERMANY: In 1936, the Westphalian agricultural machinery
manufacturer Gebrüder CLAAS introduced the first European combine harvester, the
reaper-thresher-binder (MDB). It was a mechanical marvel. Today, harvester-threshers are
high-performance machines boasting sophisticated drive technology and comprehensive
on-board electronics. Through modern testing technology, HOERBIGER ensures that the
complex electric systems operate flawlessly on delivery. (Page 26)
014
015
HARSEWINKEL, GERMANY [51° 58’ N, 8° 14’ E]
www.claas.com
A constant
CLAAS combine harvesters have
been valued for generations.
CLAAS Combine Harvesters
026
027
Seed Green
is more than just a color
CLAAS combine harvesters: for 75 years, they have been an indispensable implement in
agriculture. With the MDB reaper-thresher-binder in 1936, CLAAS successfully launched
the first European harvester-thresher. This laid the foundation for the combine production
operation of CLAAS.
TEXT: Ludwig Schönefeld · PHOTOS: CLAAS; Peter D. Hartung
T
oday, the company is one of the most successful manufacturers
of agricultural machinery worldwide, generating sales of 2.5 billion
euros (2010). More than 9,500 employees in 14 locations
supply the world market. The trademark of all machines is the
seed green paint: CLAAS Green—around the globe, it is
synonymous with high productivity and maximum reliability.
Despite the outstanding success, the CLAAS Group has preserved the
character of a family-operated enterprise: value-oriented management is
their leadership maxim. Coupled with ingenuity, intrinsic value and partnership, CLAAS has become a driving force in agriculture.
“To us, it’s not just important to continuously optimize machinery and
service. We also want to steadily boost the benefit for our customers,”
says Dr. Theo Freye, Spokesperson of the CLAAS Management Board.
You can see this endeavor to consistently improve in the people of
CLAAS: “A passion for agriculture is the basis of our success.”
Thinking Outside the Box
The development and production of combine harvesters, forage harvesters
and large XERION tractors continue to be concentrated at the headquarters in Harsewinkel. The plant employs approximately 3,000 people, and
the production facility covers almost 100 acres.
The company values Germany as a business location. In 2010, a new
Technology Center was opened in Harsewinkel. This was a key impetus
for the small Westphalian town which is home to 24,000 inhabitants.
CLAAS thinks outside the box—for example, when it comes to conserving natural resources by transporting brand-new combine harvesters by
rail. In addition, it is the objective of the CLAAS Foundation established in
1999 to promote training and education in the fields of agricultural
engineering and farming around the world.
LEXION—Pure Innovation
With the LEXION 600 and 700, CLAAS presented a new generation of
powerful large combines in 2010. In 1995, the first LEXION model was the
most powerful combine in the world, harvesting up to 40 tons of grain per
hour. The current top product, the LEXION 770, easily manages twice this
amount under the right conditions. When processing corn, it even clearly
surpasses the 100-ton-an-hour mark.
Innovations in every respect: the new combine harvester sets standards in
the drive, cutter bar and threshing unit, and in particular driving and
operating comfort. One of the key new developments is the cab: even
more spacious than the predecessor, the cockpit of the new LEXION
affords the driver more freedom of movement, well-organized controls and
excellent all-round visibility. Comfortable air-conditioning, a particularly low
noise level, and a three-position adjustable steering column create firstclass working conditions.
“A passion
for agriculture is the
basis of our success.”
But there is another innovation, which is not apparent to the farmer or
agricultural contractor. Not only is the design of the CLAAS LEXION cab
a new development—the assembly of the cab also underwent major
changes at CLAAS Selbstfahrende Erntemaschinen GmbH. HOERBIGER
Elektronik GmbH was able to significantly contribute to the development
of the cab. HOERBIGER Elektronik GmbH from Ammerbuch, Germany, is
considered a Hidden Champion in the development of test consoles and
testing software.
028
029
One Testing System for all Functions
All electric components of a combine harvester are controlled and monitored
from the cab. Previously, during the final inspection CLAAS tested all
electric circuits and the interfaces to performance-defining functions of the
combine to ensure flawless operation. Subsequent rework of parts due to
malfunctions entailed high costs for the required work.
Gl ob al M ar ke t Le ad er
wi th We stp ha lia n Ro ots
s back
The history of the CLAAS Group date
Franz
to the year 1913. At that time, August,
er
and Bernhard Claas founded Gebrüd
ment
CLA AS company. Their first develop
which
was a mechanical straw binder, for
the
series production started in 1919 at
y.
man
Ger
l,
inke
sew
Har
in
tion
new loca
The young enterprise spurred on the
eld:
mechanization in the agricultural fi
the
elop
dev
to
an
beg
hers
brot
the
in 1930,
the
first har vester-thresher. Even before
on,
combine was ready for series producti
rst
fi
CLA AS started to manufacture the
rs.
bale
w
stra
mechanical
Combine harvesters from the first generation of 1936 (top) and 1953.
comIn 1936, CLA AS launched the first
.
bine har vester built in and for Europe
a
The initial types were still pulled by
tractor—until in 1953 CLA AS launched
vester.
the first self-propelled combine har
continFrom then on, the family business
lian
tpha
Wes
its
uously evolved from
roots into a global player. The combine
uct:
har vester became a top export prod
erPad
in
t
plan
new
a
after the opening of
Ger
of
ide
outs
site
rst
born in 1956, the fi
2.
196
in
ce,
Fran
z,
many followed in Met
estiOther locations followed, both dom
was
ge
ran
uct
prod
cally and abroad. The
elled
prop
selfThe
ed.
continuously expand
ge
fora
by
wed
follo
was
combine har vester
e
can
ar
sug
-up
pick
s,
har vesting machine
veshar
ge
fora
ed
pell
har vesters, self-pro
ses.
ters, round balers, and large bale pres
stake
In 2003, CLA AS acquired a majority
its
ing
and
exp
,
ture
in RENAULT Agricul
.
tors
product range by trac
➸ ww w.claas .com
Inn ov ati ve
r, in
CLAAS sets standards in the drive
and
unit,
hing
thres
and
bar
the cutter
in driving comfort.
PART
Once a driver’s cab has been completed, the
manufacturer performs a final and exhaustive
test run. Here, HOERBIGER test stands show
their full potential: they inspect all electric components and controllers and document the results.
HOERBIGER Elektronik GmbH supplies comprehensive tailor-made solutions—optimized to the
respective field of application and the individual
task, and capable of expanding to accommodate
future requirements. Professional engineering
assures the customer turnkey solutions and
enables the start of production without delay.
The newly developed cabs offer maximum comfort.
030
To avoid these costs, HOERBIGER Elektronik GmbH developed a new
cab test stand for CLAAS. The new testing system allows all electric
components to be checked as early as on the assembly line under
simulated real-life conditions. The benefit: the early detection of defects
avoids costly surprises during the final inspection.
Ideal Development Conditions
The partnership between CLAAS and HOERBIGER began in February
2010. “The cooperation was successful right from the start. From the
very beginning, HOERBIGER tuned in to CLAAS’ requirements and this
was the only way that we were able to implement the project in just eight
months,” says Stephan Dohmann, Head of Production Scheduling,
System and Testing Technology at CLAAS in Harsewinkel. For the
development of the testing system and the testing software, HOERBIGER
Elektronik GmbH was provided with the original cab of a LEXION
combine harvester. “Of course, these were ideal development conditions
for us,” Gerhard Marquardt explains, Head of Test Stand Development
at HOERBIGER. “In designing the cab contacts and the related test
flows, we were able to draw on real-life conditions.”
Well-Engineered Testing Technology
The number of interfaces alone demonstrates just how multifaceted the
scope of testing in a combine is: the cab test stand developed for
CLAAS has 136 digital and 18 analog inputs, 32 digital and 24 analog
outputs, as well as 16 frequency outputs and 6 CAN bus connections.
The contact between the combine cabs and the test stands is established
by adapter cable sets. This allows the HOERBIGER test console to be
used for more than the cabs of the brand-new LEXION combine.
Additionally, the electric functions in the cabs of the mid-range TUCANO
combines and the compact AVERO combine harvesters as well as in
the cockpit of the JAGUAR forage harvester and the large XERION
tractor can also be tested with HOERBIGER technology. It goes without
saying that all HOERBIGER test stands are network-compatible: USB
interfaces, LAN and WLAN, and high-speed CAN are standard features.
To make the work of the assembly staff easier, the cab test stand can
be operated not only via the 19-inch touch screen, but also from the cab
using the wirelessly coupled “SmartControl” remote. This is a considerable
benefit, in particular when performing quality controls of large machines such
as combine harvesters.
Partnership on an Equal Footing
“The design and procurement of the cab testing technology was a part of
the overall project aimed at redesigning the cab assembly at the Harsewinkel
site. With production in full swing, the testing technology had to be prepared
so that it was possible to install and begin testing inside of only two weeks,
during the plant shutdown in fall,” reports Stephan Dohmann. To achieve
this goal, it was of crucial importance that the project teams of CLAAS and
HOERBIGER worked together smoothly. “The cooperation on both sides
was marked by a pronounced openness: everyone knew their respective
contact person when questions arose,” says Stephan Dohmann. HOERBIGER,
so it seems, performed admirably for CLAAS. HOERBIGER Elektronik
GmbH developed the know-how regarding modern testing systems through
years of working with leading truck manufacturers. “This experience helped
us to understand today’s demands on the electronics systems in modern
agricultural machines, which are considerably more complex,” says
Gerhard Marquardt, Head of Test Stand Development at HOERBIGER.
“Many functions of agricultural machinery were uncharted territory for us.
The proximity to our customer and the continuous exchange with our
discussion and development partners were especially important during the
joint project.”
Another important aspect was the confidence that CLAAS had in
HOERBIGER: “The customer and supplier were very much alike in this
project,” says Gerhard Marquardt. “Both companies are medium-sized
businesses and innovation- and technology-oriented. We at HOERBIGER
always want to improve a good product a little more. This constant endeavor
to achieve Product Excellence convinced CLAAS.”
PART OF
031
Within the HOERBIGER Group, HOERBIGER
Elektronik is the specialist for testing and diagnostic technology, control technology, and industrial electronics. The company was founded
in 1985 and presently employs a staff of
60 people. The majority of the hardware and
software is produced in-house. The best-selling
products are flash, testing and diagnostic
systems for the vehicle industry. In addition to
stationary testing systems, such as the cab test
stand developed for the CLAAS Group, the
product portfolio includes mobile testing
devices, such as the HOERBIGER Porty EVO III
used in truck manufacturing for quality
assurance purposes.
PARTNERSHIP
HOERBIGER supplies comprehensive tailor-made
solutions—optimized to the unique field of application and the individual task, and capable
of expanding to accommodate future requirements. Professional engineering assures the
customer turnkey solutions.
HOERBIGER Elektronik GmbH developed a new cab test stand for
CLAAS that checks all electrical components already on the assembly
line. This avoids unpleasant surprises during the final inspection.