EQUIPMENT SEGMENT – DEVELOPING AND OPERATING MACHINERY IN A SUSTAINABLE MANNER
All products have a life-cycle – from the basic idea and the development phase, through production and use, to replacement and end-of-life disposal or recycling. The machinery and plant manufactured by Bauer is of course no different.
In order to meet the basic requirements for a sustainable product right from the development phase, eco-checklists are used to guide project managers in planning for the complete product life-cycle. In the subsequent design phase, too, environmental guidelines exist which must be followed not only in-house but also by third-part contractors. They include the requirement that hydraulic and fuel systems should be designed to use biodegradable oils. Other considerations include conformance to guidelines regarding noise emission. Some of our drilling rigs feature an optional eco-mode in which cooling can be reduced or shut off altogether at low power. This also improves the efficiency of the engine in the part-load range, which in turn markedly reduces power consumption.
A key factor in operation of our equipment is efficiency. Measurements over recent years have proved that Bauer machines are much more efficient than comparable products from other manufacturers. Thanks to the detail work which goes into ensuring the perfect interaction of individual components, both in the systems engineering process and in optimal setup during component production, customers are able to enjoy the benefits of a more efficient machine, delivering lower fuel consumption and reduced emissions.
Legal requirements in relation to emissions have been rising in recent times. The Tier IV standard in the USA and the corresponding Stage IIIB in Europe which came into force at the end of 2010
significantly lowered pollutant emission limits further. We buy the motors and hydraulic components for our equipment from a range of different manufacturers. The new standards have also brought about a change in motor dimensions. The Bauer Equipment segment companies have utilized this trend to undertake general updates of their various machine models. As a result, we are today already able to offer many machines featuring Tier IV motors as standard. However, in order to comply with Tier IV the new motors do need low-sulphur diesel or urea for exhaust gas cleaning. Both are available only in the USA, Europe and a few other countries. This means that for several years we will have to produce and sell two motor variants.
Bauer machines which have worked on site for many years are regularly to be encountered on projects all over the world. Some of them have even been in use for more than 20 years. It is one of our core aims to produce machines which are robust and durable – primarily because of the benefit to our customers, of course. Over such a long service life, it is only natural that consumables occasionally need to be replaced or complete rigs have to be overhauled. Our plant in Singapore specializes in carrying out such overhauls and selling the reconditioned machinery. We operate production facilities and workshops worldwide in order to respond rapidly and flexibly to the needs and wishes of our customers.
At the end of a machine's life-cycle, it can be recycled without causing major environmental impact. Our machinery is for the most part made of pure steel; we are able to avoid using composite materials almost entirely. After draining off the oils, lubricants and fuels, the machines can be recycled almost in their entirety, and the raw materials recovered can be utilized in a new product life-cycle.
RESEARCH AND DEVELOPMENT IN THE BAUER GROUP
| 2009 | 2010 | |||||||
|---|---|---|---|---|---|---|---|---|
| Construction | Equipment | Resources | BAUER Group | Construction | Equipment | Resources | BAUER Group | |
| Total Group revenues (in EUR million) |
581,920 | 530,605 | 165,805 | 1,278,330 | 598,530 | 533,439 | 172,048 | 1,304,017 |
| Expenses for R&D (in EUR million) |
2,300 | 22,448 | 1,603 | 26,351 | 2,678 | 23,062 | 1,925 | 27,665 |
| as % of total Group revenues | 0.4% | 4.2% | 1.0% | 2.1% | 0.4% | 4.3% | 1.1% | 2.1% |
| Group employees | 5,308 | 2,493 | 656 | 8,674 | 5,055 | 2,775 | 1,019 | 9,094 |
| R&D employees | 44 | 180 | 19 | 243 | 48 | 184 | 20 | 252 |
| Patent series | 250 | 260 | ||||||
| Applications, patents etc. | 1,050 | 1,080 | ||||||
COOPERATIONS
In 2010, BAUER Maschinen GmbH intensified its cooperation with universities and research bodies. The Development and Construction department intends to commit even more financial and human resources to such cooperation in future. As one example, it is engaged in a federal government-sponsored project being run by the German Construction and Construction Machinery Research Federation (FVB). The aim of the research project is to develop a benchmark for mobile machines in order to classify their energy efficiency and to improve the operating efficiency of drilling rigs. As part of the project, as many as 15 different construction techniques are being analyzed in terms of their CO2 balance.
NEW DEVELOPMENT
In 2010, a pilot project for a customer produced a trench cutter driven by an electric motor. This enabled various measures to be implemented which significantly reduced emissions compared to a diesel engine. Savings were also made on motor oil, filter components and maintenance, as well as fuel. A further positive effect was the major reduction in noise emission. The trench cutter was delivered on time, and is now running successfully in customer operations.
THE BAUER CAB
Sustainability in the development of drilling rigs is largely about efficiency, emissions and environmental compatibility – but not just that. Another important factor is that the operators, who spend much of their working day in the machine's cab, should feel comfortable and at ease there. The development of the BAUER cab represents a major step in achieving that. The main considerations in the development were the ergonomics of the seat and the appeal of the interior design. As well as enhancing the seat design, the joystick was moulded more closely to the contours of the hand so as to provide the closest possible feel and enhance direct control. Alongside the basic features of a cab, such as heating and cooling, additional storage facilities were installed for food, drinks and the like. The new sliding doors make it easier for operators to get in and out, and are also safer than swing doors. The energy loss from the air-conditioning system has also been significantly reduced thanks to the easier door opening. Another key feature is the "B-Tronic" – the visualization system presenting operators with a wide variety of data including the drilling depth, drilling rate, etc. The display has been made more visually appealing, and clearer.