all solutions from one single source

CENTER OF COMPETENCE | HIGH-PERFORMANCE AND LIGHTWEIGHT SOLUTIONS
ALL SOLUTIONS FROM ONE SINGLE SOURCE
A Member of the Eberspächer Group
2 | CENTER OF COMPETENCE
CENTER OF COMPETENCE | 3
PERFECT DIVERSITY
For 25 years we have been developing innovative solutions with and for our partners. As members of the
Eberspächer Group, we can now add other areas of expertise to supplement the experience we have gained in
development, prototype production, special series production and motorsport, and we can pass this all on to
o u r c u s t o m e r s . To p u t i t i n t o a s h o r t c o n t e x t , w e o f f e r a c o m p r e h e n s i v e r a n g e o f e x h a u s t t e c h n o l o g y c o m p e t e n c e.
CENTER OF COMPETENCE:
MOTORSPORT:
As a centre of competence for high performance applications and light-
Motor racing activities include the 24 hour race in Le Mans and the FIA
weight systems, Prototechnik’s main focus is on the areas of develop-
European Truck Racing Championship, the DTM and the WTCC, but also
ment, prototype production and special series production for intake and
a wide variety of other formula series. International teams depend on
exhaust systems. Working with the Eberspächer Group, Prototechnik
the innovative solutions from Schwäbisch Gmünd. Thin-wall technology,
creates tailored solutions from concept design and simulation, to
light weight and special materials are extremely important factors
acoustics and performance optimisation, to prototype production, to
which are increasingly being integrated into series production vehicles.
functionality and endurance tests, to special series production and
finally up to spare parts supply.
The business unit also specialises in the production of coolant, oil, fuel
and ventilation lines, EGR cooling systems as well as other vehicle components made of pipes and sheet metal. Using and processing special materials such as Inconel, aluminium and titanium is a part of our daily work at
Prototechnik. It allows us to meet the increasing demands in the various
high performance segments as well as the necessity for more and more
weight reductions. This knowledge is reflected in a number of successful
development, prototyping, special series and motorsport production projects over more than 25 years of the company’s history.
LIGHT WEIGHT:
In comparison to conventional stainless steel, titanium facilitates
weight reduction of more than 40 percent. Every ounce of weight
saved serves to reduce CO2 emissions and makes the vehicles
more environmentally friendly. In particular, the company’s special
expertise in the use of new materials makes it possible to develop
innovative exhaust technology products for series production passenger cars as well as commercial vehicles.
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A GOOD SETUP
“A l l c o m p e t e n c e s f r o m o n e s i n g l e s o u r c e .” T h i s p h i l o s o p h y h a s b e e n a f f i r m e d a n d d e v e l o p e d o n t h e b a s i s o f
n u m e r o u s p r o j e c t s . W e a r e a l w a y s w i l l i n g t o t a c k l e n e w, e x c i t i n g a n d d i f f i c u l t t a s k s – c o m p l e x s p e c i a l s e r i e s ,
manual operations combined with partially automated production processes. From the concept to series production and beyond. Access to Eberspächer R&D expertise and resources ensures that projects are completed
quickly and effectively and to an extremely high quality standard.
Quality and project management
Automotive standards (ISO 9001:2008, DFM, D/P-FMEA, risk management etc.)
ISO TS 16949 in the planning phase.
Concept and product
Prototype manu-
development
facturing
3D/2D CAD in
CATIA, PRO-E and
UG
CAE – CFD, FEA
Acoustics
Thermodynamics
Durability –
mechanical, dynamic and thermomechanical
One piece handmade
Samples for
functional and
durability testing soft tools
Preseries –
evaluation of series
production processes
Functionality and
endurance tests
Flow rig
Acoustics &
thermodynamics
Endurance testing –
component test
benches, engine
and chassis dynamometer
Purchasing and production preparation
Technical purchasing
Series production
purchasing supported by the Group
Series production
process planning
Quality planning
One project manager – one point of contact for the entire project, from concept to the spare parts
Special series
production
Partially automated
production
processes combined with manual
operations
Batch production
combined with
“one-piece flow”
Spare parts supply
10-15 years in
compliance
with the standards
and longer
CENTER OF COMPETENCE |
PRODUCT PORTFOLIO
We could be known as specialists for specific requirements. We develop and produce intake and exhaust
s y s t e m s f o r o p t i m a l e x h a u s t g a s f l o w, m a x i m u m p o w e r a n d t o r q u e , e x h a u s t g a s a f t e r t r e a t m e n t a n d s o u n d
e n g i n e e r i n g . W i t h a g r e a t d e a l o f a m b i t i o n a n d f l e x i b i l i t y, P r o t o t e c h n i k d e l i v e r s n i c h e - m a r k e t p r o d u c t s i n
a wide variety of market areas.
OUR PRODUCTS:
OUR MARKETS:
Intake manifolds and systems
Cars, road registered high-performance cars
Exhaust systems
Motorbikes
Exhaust manifolds
Commercial vehicles
- Turbular/high-performance manifolds
Agricultural and construction machinery
- Half-shell manifolds
Special applications (e.g. ship and boat engines, airplane engines,
- Air-gap insulated manifolds
stationary engines, defence...)
Catalytic converter and DPF systems, ceramic and metal
Hybrid and fuel cell vehicles
Muffler systems, optionally with valve technology
Motorsports
and rolled or pressed
Complete systems featuring “dual mode” and “air-to-air”
Exhaust gas heat exchangers
Other pipe systems (charge-air, coolant, oil and
fuel lines) in steel and aluminium design
Vehicle and chassis components
Vehicle prototype shop
Design and in-house manufacture of jigs and fixtures
We are seeking new challenges. Tell us your problem and let us solve it.
We are proud to say that our products can be found on land, on the
water and in the air – anywhere that combustion engines are at work.
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REFERENCES
O u r p r o d u c t s a re u s e d t h r o u g h o u t t h e e n t i re wo r l d . F o r ex a m p l e, a t m a n y i n t e r n a t i o n a l m o t o r s p o r t e v e n t s .
MOTORSPORT RANGE :
PORSCHE CARRERA GT:
Production of motorsport components for a wide variety of racing series
“Air-to-air” system development and series production of the intake mo-
and teams:
dule and the entire exhaust system for 2 years
AUDI Sport, DTM and LMP; BMW Motorsport, WTCC etc.; Mercedes
HWA, DTM, F3; Opel DTM; Porsche Carrera Cup, LMP etc. Motorsport
PORSCHE 911 GT3:
products: High-performance intake and exhaust manifolds, light-weight
Exhaust system development up to start of production within 18 months
catalytic converters and silencers, low and high pressure fuel lines, air
“Dual mode” (exhaust valve control) for 74 dB(A) with very low exhaust
lines, oil lines and welded chassis components
backpressure and with light-weight titanium design
SPECIAL SERIES PRODUCTION PROJECTS:
MERCEDES -BENZ MCLAREN SLR:
System development and prototype production for a variety of manu-
A very challenging system development of an exceptional exhaust system
facturers, e.g. Ford Focus RS, KTM X-Bow, Mercedes-Benz McLaren
packaged in the front end vehicle with “sidepipes”. Series production for
SLR, Mercedes-Benz SLK 55 AMG, Opel Zafira CNG, Porsche Carrera GT
5 years
Porsche 997 GT3 1st and 2nd generation, Volkswagen Touareg & Phaeton V10, VW Individual. Extra low volume series exhaust system pro-
MERCEDES-BENZ SLK 55 AMG:
duction for the Zeppelin airship
Exhaust system development, testing and series production of several
thousand systems per year. Benchmark in the sound (engineering) sector
PROTOTYPES:
AUDI AG, Quattro GmbH; BMW AG, BMW Motorrad; Daimler cars and
commercial vehicles; Deutz AG; KTM Motorrad; Mowag; MTU; Porsche;
Volkswagen; various system suppliers
CENTER OF COMPETENCE | 7
HISTORY
1985
Prototechnik GmbH founded
1989
IFT Ingenieurgesellschaft für
Fahrzeugtechnik mbH founded
1995
IFT Prüftechnik GmbH founded
2001 onwards
Affiliates move to joint offices in the new
administration building in the Gügling industrial
estate near Schwäbisch Gmünd
Special series production of Mercedes-Benz McLaren
SLR, Porsche Carrera GT, Mercedes-Benz SLK 55 AMG,
Ford Focus RS, Ducati 999 etc.
2003 onwards
Affiliated companies are acquired by Ricardo plc.,
Ricardo Deutschland branch
Special series production of Porsche 911 GT3/ RS/ Cup,
Dieselmax land speed world record
2010
BU Prototechnik becomes part of the
Eberspächer family
Güglingstraße 68-70
73529 Schwäbisch Gmünd
Germany
Phone: +49 71 71 87 48-100
Fax:
+49 7171 87 48-400
info@prototechnik.de
www.prototechnik.de
Version 11/2011 . VHM
Printed in Germany. Subject to change without notice.
Prototechnik GmbH & Co. KG