All about winches, capstans and winch systems 22/07

Contents ROTZLER System in Recovery Vehicles

Steam train nostalgia in Winches and CAN Bus Technology for UK Support Vehicle Program

2 Master Control panel

How to fold up a bridge using A further important element of HK winches Rotzler’s solution for monitoring all system functions is an integrated master control panel with a touch screen that can be operated from outside the vehicle. This panel sup- ports the operator and service personnel during trouble shooting operations by providing important technical data in real time. This During an on-site presentation at the A CAN bus-based communication makes it possible to quickly locate 3 Steinen plant, the Rotzler workforce system connects all individual and solve any possible problems, gathered information about an un- subsystems. These include Rotzler more rapidly prepare the vehicle for Greater efficiency at the usual project involving an impressive winches as well as further recovery operational deployment and increase construction site recovery vehicle which is being equipment such as the EKA recovery vehicle availability in general. tested at Rotzler as part of a major device and a Terex Atlas crane. The Coupled with excellent hardware contract. The recovery vehicle is one specialized pulling winches TREIB- components, all of which are variant of a bigger vehicle contract, MATIC TR 200 and TREIBMATIC TR perfectly integrated into an won by MAN ERF UK Ltd. The UK- 080 have been integrated to act as outstanding truck, the advanced based company EKA Ltd. is respon- recovery and self recovery winches operation concept of this vehicle, sible for the recovery vehicle based and the rope pay out of the main which is supported by the consistent on the MAN chassis. EKA developed recovery winch (TREIBMATIC TR use of CAN Bus technology in and designed the top hamper, but 200) is supported and accelerated combination with a second-to-none will also be responsible for building by a Rotzler HZ 010 pulling winch. software management and support 4 the vehicles. In addition EKA pro- The recovery crane features a concept, make it the most advanced vides one of the core components of Rotzler TITAN TC 5 hoisting winch. recovery truck worldwide. Training course at the Carinthian this truck, i.e. the recovery device. The subsystems have been fitted State Firefighting School The presentation involved a demon- with Rotzler’s new digital controller, Scope of supply stration of Rotzler’s scope of supply which was specifically developed to and functions for this vehicle. The suit such and similar demanding Main winch integrated recovery, lifting and applications in harsh environments. ROTZLER TREIBMATIC TR 200 auxiliary winches as well as the CAN All the recovery equipment can be winch – 250 kN bus-based digital controllers and easily operated using Rotzler’s Recovery winch operating panels represent core ergonomically designed RCP-MS ROTZLER TREIBMATIC TR 080 components of the truck. For this 2/6FP multifunctional remote con- winch – 80 kN project, the scope of which covers trol. The RCP-MS 2/6FP differs Auxiliary winch 5 fitting a large number of vehicles, from conventional control panels ROTZLER HZ 010 winch – Rotzler has developed a tailor-made mainly due to its low weight, a large 8 kN (on top layer) Exhibition calendar 2008 system concept that takes the LCD display and its clear, menu- Crane winch 5 complex hydraulic, electronic and supported navigation. These features ROTZLER TITAN TC 5 winch application-specific requirements of bring many user benefits and (on TEREX ATLAS crane) – Farewell after 50 years these recovery vehicles into account. make the RCP a highly useful tool. 43 kN (on top layer) at Rotzler Rotzler digital controller 6 Rotzler remote control High-octane job starters Rotzler monitoring system 6 with NEXUS II Software Hydraulic main manifold with integrated sensor equipment and safety valves

TREIBMATIC TR 200 and TITAN TC 5 TREIBMATIC TR 080 and HZ 010 ReportReport

Steam Train Nostalgia in the Swiss Alps Furka Cogwheel Steam Railway

landscape left in the glacier’s place quickly changes its appearance and provides a new habitat for Alpine flora and fauna.

History of the

The exhibition at the historical Hotel Belvedère near the shows photographs that chart the history of the Furka railway, which was found- ed in 1913. The construction of the bridges, via- ducts and tunnels was considered to be a pio- neering feat of railway technology at the time. The line was electrified in 1942 and the Swiss steam engines found a new home in Vietnam. However, a number of them were subsequently fetched back to Switzerland and are now in operation again on the Furka steam railway line. When the was finally opened, it enabled year-round operation of the line. As a result, the Furka Pass route lost importance and was finally discontinued. Thanks to the effort of numerous steam train enthusiasts, a registered society and public company dedicated to saving the Furka mountain steam railway were founded in 1983. The impassioned commitment of a large number of volunteers is continuing to ensure that white steam clouds can still be seen billowing over the The steam trains run on the Furka mountain line from June till September – crossing the Steffenbach bridge. tracks today. Due to the risk of avalanches, the steam railway is only open for passenger trips Switzerland is a country of many attractions and Bridge” on the following page.) The train continues from the end of June to September. The Furka this issue of INFORM features a report about very its ascent through blossoming Alp meadows right cogwheel steam railway company (Dampfbahn special Swiss treat: the Furka cogwheel steam up to the highest station in Furka (at 2,160 meters Furka-Bergstrecke AG) provides many interesting railway (DFB) in the Swiss Alps. above sea level). The Furka Pass connects the offers and further attractions for anyone who Swiss cantons of Uri and and also forms the interested in going on this unforgettable steam train Retracing James Bond’s Steps on route along which the European watershed runs adventure. Detailed information can be obtained from: a Steam Train between the North and the Mediterranean Seas. Coincidentally, the fantastic landscape also im- If you’re keen on getting a first-hand impression of pressed the film industry and a number of scenes Dampfbahn Furka-Bergstrecke AG a magnificent landscape with ravines, glaciers and in the James Bond movie, ‘Goldfinger’, were shot P.O. Box 141 breathtaking panoramas, a ride on one of DFB’s at the Furka Pass in 1964. Today, these scenes are 6490 Andermatt, Switzerland nostalgic steam trains is a must. With a blow of considered to be classics of Bond film history. Yet Phone: + 41 (0)848 000 144 the whistle, the steam train begins its back to the Furka steam train. After a Fax: + 41 (0)55 619 30 39 journey at station in Urn, which brief stop, the trains steams through E-mail: [email protected] is situated 1,420 meters above sea the 1,874-meter Furka Tunnel towards www.furka-bergstrecke.ch level. At a leisurely pace, the train Valais. As the train makes its way then climbs up to one of the highlights along the down the mountain on a gradient of up to 118 ‰, 18 kilometer route: the famous bascule bridge passengers enjoy a clear view of an incredible over the fast-flowing Steffenbach stream. Due to spectacle of nature and technology in between the the prevailing danger of winter avalanches, this snow-covered peaks: the Rhône glacier. Some bridge is taken down, or rather ‘folded up’, in 10,000 years ago, the Rhône glacier was the October of each year. In May, during the spring longest Alpine glacier at more than 300 kilometers snowmelt, the bridge is then ‘unfolded’ again. The in length. However, this has changed dramatically folding mechanism of the Steffenbach bridge is in the course of time. In the last 400 years alone, probably unique in the world. (Read more about the glacier has melted over a stretch of more than it in “How to Fold Up a two and a half kilometers. However, the barren

Inauguration of Realp’s new station in the summer of 2007 The Steffenbach bridge is “folded up” during the winter (1,420 meters above sea level). months due to the danger of avalanches.

2 How to Fold Up a Bridge ROTZLER HK 075 winches used on the famous Steffenbach bridge

Bridges fascinate people all over the world. There avalanche damage after the first two conventional are countless famous examples of outstanding bridge designs (1913 and 1915) actually collapsed bridge designs like the Golden Gate, Rialto, or were damaged so badly that the became Öresund, Pont Neuf, and Bosporus I – names that unusable. The Swiss civil engineer Rudolf Dick just about everyone is likely to have heard or read therefore designed a broadly spanned steel at some point in their lives. A further example of construction without any pylons to be constructed Folded down middle section of the Steffenbach bridge. consummate bridge building to add to the list is in the streambed. The design was intended to give the Steffenbach bridge on the Furka cogwheel avalanches the smallest possible area of attack. steam railway line in Switzerland. INFORM found The three-section bridge was constructed so that Technical Data: Technical Data: out just what makes this bridge so special. it could be dismantled in autumn and re-erected Steffenbach bridge HK 075 winch in spring. When the bridge is dismantled, the Year of Year of Folding mechanism protects against middle section is folded down and lowered at construction: 1926 construction: 1990 avalanche damage the edge of the ravine on large hinges attached Length: 36.24 m Pulling force: 62 kN to the end of the fixed bridge section. The upper Gradient: 110 ‰ Rope length: 153 m The Steffenbach bridge is famous worldwide section and the lower bridge section with the Steel weight: 32 m.t. Rope Ø: 16 mm because of its unique folding mechanism. This attached middle section are pulled back to firm was developed to protect the bridge against ground. The bridge then ‘hibernates’ in this position from October until May. When the snow is cleared on the line in spring, the bridge is feature a 153-meter, 16-mm wire rope. The ropes re-erected. Depending on the prevailing weather are used with a pulley system to move the bridge conditions, it takes between 12 and 15 techni- sections. The smoothness and reliability of cians about 5 to 8 hours to complete the deman- Rotzler winches are of key importance for the ding task. construction team – after all, the bridge sections have to be positioned very accurately. After HK pulling winches precisely position the 17 years of unfailing service, the winches were bridge sections taken to the Rotzler plant in Steinen for a general overhaul this year prior to the bridge dismantling Two Rotzler HK 075 winches have been moving operation in October. The winches were inspected and positioning the several-tonne bridge sections by Rotzler’s expert After Sales Service and sub- since 1990. This has proved to be a considerable sequently overhauled to ensure their continued convenience in comparison to the former manual safe operation at the Steffenbach bridge. winches, which took 20 men and a lot of hard Rotzler HK 075 winches in use for dismantling the bridge. work to operate. The hydraulic winches each

During dismantling and re-erection of the bridge, the HK winches are positioned on the track (left) and then pull the several-tonne General overhaul of the winches at the Rotzler plant. bridge sections into place (right).

3 MiscellaneousMiscellaneous

Greater Efficiency at the Construction Site TITAN TC 1 hoisting winch plus Putzmeister concrete pump

ROTZLER Hook Connector/ Weight for attaching the wire rope and swivel hook. ROTZLER Top Roller is used to deflect the rope.

The winch is spooled off, the hook is lowered from the mast and then engaged in the lifting harness of the tube feeder.

The company Putzmeister from Aichtal in Ger- work involved for the pump driver while loading many is headed for lofty heights: concrete pumps and unloading containers with tube feeders for ROTZLER Swivel Hook securely holds the load. made by Putzmeister are currently being used in cleaning. A fully loaded container can be lifted the construction of the tallest building in the world, to a practical working height or deposited using the Burj Dubai. However, for slightly less spec- the TITAN hoisting winch. This hoisting function tacular construction sites, the fleet of pumps has enables the machinist to position the loaded been supplemented by the new BSF 20 4.09 H container in a 4-meter radius of the vehicle. The auto-concrete pump with a loading function. This Rotzler hoisting winch is approved for loads of feature consists of a Rotzler TITAN TC 1 hoisting up to 1 tonne in weight, which makes it a useful winch plus Rotzler’s MCD electronic monitoring handling device for the machine-specific acces- system as well as winch accessories made up of sories of the concrete pump. This removes the a deflection roller, weight and lifting hook. The need for the machinist to manually unload the compact design of the TITAN TC 1 winch was container or tube feeders. The advantages are decisive for it being chosen for the job as it plain to see: greater efficiency at the construction enabled optimum integration into the existing site, time savings and lower costs. device. The loading function lightens the physical

The winch is used to lift the tube feeder.

ROTZLER TITAN TC 1 hoisting winch with MCD electronic monitoring system.

The tube feeder is lifted into the desired position using the hoisting equipment with the Rotzler TITAN TC 1 winch.

4 Hands-on Winch Training Courses in Austria Technical workshop at the State Firefighting School in Klagenfurt, Carinthia

Rotzler held two-day training courses in winch Practical training then culminated in the partici- operation at the State Firefighting School in pants working with the winch systems fitted to Klagenfurt, Carinthia. 46 participants from 20 fire their own vehicles. The State Firefighting School brigades in the Austrian state of Carinthia were very kindly put their entire premises plus decom- given theoretical and practical instruction in the missioned cars and trucks at our disposal for operation of winches, followed by hands-on train- training purposes. Thanks to the creativity of the ing in using winches in emergency situations. firefighters who took part, countless application The firefighters brought their own vehicles featur- scenarios that could occur in real-life recovery ing TR 030 or TR 080 TREIBMATIC winches along operations were practiced for winches, attaching to the course. Safe winch operation and compe- devices and deflection rollers. The breaks in the tent use of attaching devices were some of the course work gave the workshop instructors, Bernd main topics comprising the theoretical part of the Bünning and Hartmut Wagner, an opportunity workshop. The practical part then began with the to talk to the participants from the various fire participants working on the demonstration trailer brigades and provide them with valuable tips that Rotzler provided specifically for this purpose. and advice regarding their specific winches or This gave the participants an opportunity to put entrained attachment parts. We were pleased to their new-found theoretical knowledge into direct receive positive feedback from the participants winch-operating practice. A further advantage across the board at the end of the course. Realistic recovery situations were practiced during hands-on was that the TREIBMATIC recovery winch fitted to Further events of this kind are under discussion training using winches and recovery equipment. the demonstration trailer was easy to access and and a refresher course is planned for the autumn thus afforded a clear view of how the winch works. of 2008.

Introduction to the theory of winch operation. TREIBMATIC and HZ pulling winches on Rotzler’s The participants came to Rotzler’s training course with a number of their own training trailer. vehicles and TREIBMATIC winches. Exhibition Calendar 2008 International trade fairs and exhibitions featuring Rotzler

Exhibitions/ Place Dates Topic Trade Fairs

CONEXPO-CON/AGG Las Vegas, USA 11. – 15.3.2008 Construction exposition

EUROSATORY Paris, France 16. – 20.6.2008 Defence exhibition

AUSA Washington, D.C., USA Autumn 2008 Specialist military exposition

SAIE Bologna, Italy Autumn 2008 Building and construction exhibition

5 InternalInternal

Farewell after 50 Years at Rotzler Günter Sturm retires

It really is a rather special occasion when some- duction lines could rely on.” He also remarked one reaches his 50-year employment jubilee. For how much he had always enjoyed working at Günter Sturm, this moment arrived in May of this Rotzler. “I was allowed to work independently and year. He began his machine fitter training at given lots of leeway.” That was also why Günter the age of 14 and then remained a loyal Rotzler Sturm never thought of changing his place of employee for the rest of his working life. In the work. After all, it is not easy to find a good job that course of these 50 years, he worked on milling is close to home and can sustain an entire working machines at which he machined individual and career nowadays. From August 2007 onwards, serial parts for the production of winches. “My Günter Sturm will be able to fully dedicate himself precision parts were always spot on.”, he said to his hobbies and grandchildren, who are likely to Günter Sturm’s colleagues presented him with a model of a proudly. “That was something all downstream pro- ensure life never gets boring during his retirement. milling machine as a retirement gift.

In Brief: High-Octane Job Starters 125 years at the service of winches Rotzler apprentices on top form

Jürgen Rotzler, managing director, and Thomas Rotzler apprentices once again finished the past effort on the part of the trainees as they found Wagner, chairman of the works’ council, con- training year with top grades, much to the pleas- themselves climbing through the tree tops. The gratulate Rotzler ‘veterans’ Günter Sturm, Uwe ure of their instructors. Having passed their final day was finally brought to a close with a delicious Wössner, Rolf Braun and Armin Lauer on their examinations, a number of job newcomers were meal of Alsatian specialties. 50- and 25-year employment jubilees. taken over in the fields of After Sales Service, Proj- ect Construction and Product Management and are now providing these departments with plenty of fresh, enthusiastic support. In September, five new apprentices began their training at Rotzler. All in all, 14 young people are either undergoing vocational training at Rotzler to become industrial mechanics, technical draughtspeople and mecha- tronics technicians or are studying at the Univer- sity of Cooperative Education. Joint activities like the last excursion to the Alsatian high-wire climb- ing park also ensure the trainees have lots of fun after work. The trip also required real ‘high-octane’ Imprint New apprentices in 2007

Publisher: ROTZLER GMBH + CO. KG Winches, capstans and winch systems What’s Your Opinion? Robert-Bosch-Strasse 4 79585 Steinen, Germany Phone +49(0)76 27/701-0 Dear Reader, Fax +49(0)76 27/701-166 E-mail: [email protected] In each issue of the INFORM, we try to Internet: www.rotzler.com put together an informative mix of arti- cles about Rotzler products, applications Responsible, editorship: and innovations. To make INFORM even Bettina Stillich, Marketing Manager more attractive for your in the future, we Creation: Thomas Hecht, hecht visuell are interested in hearing your opinion. Translation: Francesca Deakin What do you like? What do you think we could improve on? Are there any Circulation: subjects about which you’d like to know 2.500 german, 1.500 english more? If there are, which subjects inte- Reprints or summaries require the advance rest you? In addition, we would be happy approval of the publisher. to publish guest contributions about your experience in working with Rotzler Photographs courtesy of/ Copyright: products. Perhaps you might even have p. 2/3: Furka Cogwheel Steam Railway/ a photo of a particularly spectacular Gottfried Benz winch operation? Whatever the case p. 6: Putzmeister AG, Aichtal ROTZLER GMBH + CO. KG may be, we would love to hear from you p. 2, 5, 6: Cartoons, Markus Olivieri Editorial Office INFORM / Marketing by surface mail, fax or e-mail. other pictures: ROTZLER GMBH + CO. KG Robert-Bosch-Strasse 4 The INFORM editors are looking forward 79585 Steinen, Germany Technical data are subject to change to receiving your suggestions, wishes Phone + 49 (0) 761 70 1-195 without notice. and ideas. All entries will be rewarded Fax + 49 (0) 761 70 1-198 with a small thank-you gift. E-mail: [email protected]