CHENNAI-11

The 3rd Edition of the conference on

“Automotive R & D trends 2015”

"Sustainable Mobility: Technologies, Systems, Best Practices”

Presentation Topic

Collaborative Innovation in Product DevelopmentCollaborative Innovation in Product Development by

Dr V BALASUBRAMANIANDr. V.BALASUBRAMANIANEXECUTIVE DIRECTOR (ENGINEERING & DEVELOPMENT)

M/S SIMPSON & COCHENNAI 15th Oct 2010

CHENNAI-11 Welcome To Amalgamations Group

The Amalgamations Group, like the banyan tree, has spread its beneficent shade way beyond its origins. And like a banyan tree, it has provided shelter to thousands, and has stayed deeply rooted to its values while reaching for the sky.

The Group is unique not only for its diversity, but for its deep-rooted values –such as product quality and customer satisfaction, a spirit of innovation, ethical p q y , p ,practices, respect for the individual and a concern for society.

The Group has the talents and tools the vision and resilience plus the wisdomThe Group has the talents and tools, the vision and resilience, plus the wisdom and insights to keep the flag of Excellence flying high in any sphere of activity.

The Amalgamations Group’s activities fall under four broad categories: i) Engineering, including auto-related manufacturing activities ii) Trading & Distribution iii) Plantationsiii) Plantations iv) Services

CHENNAI-11 AMALGAMATION GROUP

Founder : Mr. S . AnantharamakrishnanFounded in : 1938

Members consisting of : 17 in Manufacturing: 10 in Trading & Distribution: 06 in Service Sectors: 06 in Service Sectors: 03 in Plantations

The Group Turnover : Over US $ 1.2 Billion (INR 5000 Cr.)The Group Turnover : Over US $ 1.2 Billion (INR 5000 Cr.)

SIMPSON & CO is a Member of the Amalgamations Group

MANUFACTURING COMPANIESCHENNAI-11

Simpsons & Co Ltd(Diesel Engines)

India Pistons Ltd(Piston, Pin, Rings & Liners)

Tractor and Farm Bimetal Bearings Ltd

Addison Paints & Chemicals Ltd(Paints, Lacquers & Enamels)

Addison & Co Ltd

IP Pins & Liners Ltd(Piston Pin & Liners)

Tractor and Farm Equipment Ltd

(Tractors)

TAEF ACCESS Ltd

Bimetal Bearings Ltd.(Thin wall Bearings)

Addison & Co Ltd(Cutting Tools & M/c tool

Accessories)

Amalgamations Repco Ltd.(Cl t h A bli & D i

IP Rings Ltd(Steel Piston Rings)

(Farm Equip & Accessories)

AMCO Batteries Ltd(Lead-Acid Batteries)

Amalgamations Valeo Clutch Ltd.

(Clutch Assemblies & Driven Plates)

MAHLE IP Ltd(Piston)

India Pistons-Repco Ltd(Flywheel ring Gear)Shardlow India Ltd

(Crankshafts & Forgings)

(Clutch Assemblies)

Stanadyne Amalgamations Ltd.(Fuel Injection Equipments)( )

L.M. Van Moppes Diamond Tools India Ltd.

(Diamond Tools)

CHENNAI-11 MAJOR PRODUCTS MANUFACTURED

CHENNAI-11 SIMPSON & COSimpsons is perhaps one of the oldest business establishments in theSimpsons is perhaps one of the oldest business establishments in the country, with origins dating back to 1840. From 1840 to 1950 it pioneered the building of coaches and carriages, ornate railway coaches, motorcars, steam passenger buses and public service vehicles in India.

Simpsons became synonymous with diesel power when it ushered in engine technology into India in 1955 through a Sales & Distribution Agreement with Perkins of U KPerkins of U.K.

Simpsons was the first Indian company to indigenously manufacture diesel engines for surface transport vehicles. Today it is India's leading

f t f hi h f di l i t i t id i tmanufacturer of high performance diesel engines catering to a wide variety of applications ranging from 20 to 100 HP covering agriculture, industrial, vehicular, power generation and marine applications.

CHENNAI-11 INDIA PISTONS Ltd

India Pistons (IPL) was born in 1949 as the Group's first auto-ancillary manufacturing unit.ancillary manufacturing unit.

Today it has a world-class facility with most advanced equipment to manufacture Pistons, Rings, Gudgeon Pins, Circlips and Cylinder Liners for IC engines that meet global standards of performance.

CHENNAI-11 EXPECTATIONS of STAKE HOLDERS

CUSTOMER MANUFACTURER

FUEL & OIL CONSUMPTION

EMISSIONS

DEVELOPMENT TIME& COST

EMISSIONS

NOISE

MAINTENANCE COST

VIBRATION &

HARSHNESSRELIABILITY &

LIFE

The above are the KEY factors driving any New Product DevelopmentThe above are the KEY factors driving any New Product Development

CHENNAI-11 CURRENT ( PROBLEM) OPPORTUNITY

ISSUE:

To reduce the Lube oil consumption and Blow By in a 4 CylinderNaturally Aspirated Direct Injection Diesel Engine.y p j g

Customer requirement for improvement in Oil consumption werereviewed.

In this case specific requirement of reduction in oil consumptiont ti diti i i l fat operating condition was given special focus

CHENNAI-11 CURRENT ( PROBLEM) OPPORTUNITY

DESIGN CONCEPTDESIGN CONCEPT:

The piston is a conventional one with steel strut controllede pansion t pe Problem of higher part load condition oilexpansion type. Problem of higher part load condition oilconsumption can be attributable to strut type piston where theexpansion is controlled, which creates more clearance passagefor oil transport along Pin axisfor oil transport along Pin axis.

The solution identified is the eliminating strut design. Based onthe above “collaborative innovation” a comprehensive proposalthe above collaborative innovation a comprehensive proposalwas evolved with help of the vendor – IPL.

During this process, scope for improving the existing design byway of reduction of inertial masses (piston weight reduction),improvement in ring pack features to match recent trends werealso taken up. Internally, Simpson modified & improved the

h d f b h imethod of bore honing.

All the improvements were firmed up concurrently.

CHENNAI-11 ENGINE SPECIFICATION

S Series

CHENNAI-11 INNOVATIVE UP GRADATION

The focus parameters for improvement were short listed as:

• Non strutted ALFIN piston against steel strut piston currently used

• Piston inertial mass reduction of approx 10%

• Modified Piston ring pack with features inline with modern trend

• Enhancement of Piston design features for good Oil control & improved• Enhancement of Piston design features for good Oil control & improved drainage.

• Cylinder liner bore finish with Plateau honing featureCylinder liner bore finish with Plateau honing feature.

• Reduced distortion of cylinder bore achieved through torque plate honingg

CHENNAI-11 INNOVATIVE UP GRADATION

MODIFIEDCURRENT

PISTON DESIGN MODIFICATION

Steel strut

CHENNAI-11INNOVATIVE UP GRADATION

The prime requirements are reduction of Engine Oil consumption &Blow by gases with optimized Piston assembly and improved cylinderb fi i hbore finish .

A concept design proposal is evolved out of basic design guidelineA concept design proposal is evolved out of basic design guidelineestablished with due consideration covering benchmark database trendof similar engine application.

To satisfy the requirement for a Design review, analytical techniquesy q g , y qare necessary in the competitive environment, which leads us to take upSimulation & FEA analysis prior to validation.

CHENNAI-11 Oil Consumption Mechanisms

CHENNAI-11Oil Consumption Mechanisms

Simulation consists of Seven proprietary modules, calculation of these complex modules predicts Oil Consumption, Blow-by.

Three main mechanisms considered for Oil consumption.

a) Evaporation : Oil film present on the top portion of the liner gets a) apo at o O p ese t o t e top po t o o t e e getsexposed to high temperature as the piston moves down .

b) Throw off : Oil carried by top ring leading edge will be thrownb) Throw-off : Oil carried by top ring leading edge will be throwninto combustion chamber /exhaust during TDCreversal.

c) Entrainment : Oil carried by the blow back gases into the combustion chamber from the clearance spaces between piston-bore and ring-grooves.

CHENNAI-11 Design inputs considered

Piston, ring pack and liner configuration and geometry.

Material properties (Hardness & En) of rings, piston and liner.

Surface finish parameters of the components.

Lubrication oil properties.p p

Engine operating conditions.a. Engine speed.b. Cylinder gas temperature over a cycle.c. Cylinder gas pressure over a cycle (P-Theta).d. Crankcase gas temperature & pressure over a cycle.

Temperature distribution of the piston and liner by software simulation .

CHENNAI-11 ANALYTICAL APPROACH

PISTON ANALYSIS

Three-dimensional geometrical models of the piston assembly is designed basedThree dimensional geometrical models of the piston assembly is designed basedon the Inertial and friction factors, the design parameters of piston are reviewed toimprove the functional requirement by converting Steel Strut piston to Non-strut,Internal Core shape was optimized based on design guideline to match the

t i t t d Pi t i k l t d f th d i d i t

The Design has been fully analyzed by 3D finite element analysis and meets all the strength and temperature criteria. The focus is been directed toward the

current piston trend. Piston ring pack was selected for the designed piston.

Performance Implication before proceeding into the Engine.

CHENNAI-11 ANALYTICAL APPROACH

RINGPAK ANALYSIS

A professional software was used as a simulation tool for investigating the lube oil consumption and Blow by generating ring dynamics in the

& f fexisting engine & modified ring pack configuration

CHENNAI-11 SIMULATION RESULTS

Comparison of Oil Consumption and Blow by for Base and Proposed Configurations through Simulation

CHENNAI-11 EXPERIMENTAL TEST MATRIX ENGINE BORE PISTON RINGS TESTENGINE NO:

BORE Spec.

PISTON Spec.

RINGSSpec.

TEST CYCLE

04303 Current Current Current FLRS

04303 Current Current Current PL

04303 Current Current Current DC

04576 Modified Modified Modified FLRS

04576 Modified Modified Modified PL

04576 Modified Modified Modified DC04576 Modified Modified Modified DC

04686 Modified Modified Modified FLRS

04686 Modified Modified Modified PL

04686 Modified Modified Modified DC

FLRS : Full Load Rated Speed

PL: Part Loads

DC: Duty Cycle ( field Data)

CHENNAI-11 ENGINE UP GRADATION

RESULTS OF THE EXPERIMENT : (*) This data will be changed in presentationThe chart shows the comparative results from two engines with modification as compared to the current engine.as compared to the current engine.

ENGINE NO ENGINE STATUS TEST CYCLE

LOC (gms/hr)

BLOW BY (lpm)

04303 Std ( Before) FLRS 15.8 35

04303 Std ( Before) PT 11.2 30

04303 Std ( Before) LOC 11.6 30

04576 Modified (After) FLRS 14.6 25

04576 Modified (After) PT 9.4 23

04576 Modified (After) LOC 9.8 21

04686 Modified (After) FLRS 11.2 24

04686 Modified (After) PT 7.9 22

04686 Modified (After) LOC 7.8 20

CHENNAI-11 ENGINE ENDURANCE

ENDURANCE TEST 500 Hrs:

In order to validate the improvement obtained on the engine with theIn order to validate the improvement obtained on the engine with the modification , it was decided to carry out a 500 hrs Full Load rated speed endurance on the engine dynamometer in our R&D.

CHENNAI-11 RESULTS- ENGINE ENDURANCE (500 Hrs)ENDURANCE TEST

30

35

40

45

m)

ENDURANCE TEST

10

15

20

25

30

BLO

W B

Y (lp

m

BEFOREAFTER

0

5

0 100 200 300 400 500ENDURANCE HOURS (hrs)

ENDURANCE TEST

14161820

)

2468

1012

LOC

(kg/

hr)

FLRS BEFOREFLRS AFTER

02

0 100 200 300 400 500ENDURANCE HOURS (hrs)

CHENNAI-11 CONCLUSIONS

Engine with the modified piston, ring pack & improved bore condition resulted in ;

• Reduction in oil Lube oil consumption by ~10% in FLRS & by~15% in PL/DC

•Overall reduction in engine blow by~ 25%

•Performance was satisfactory after 500 Hrs Engine Endurance test.

CHENNAI 11CHENNAI-11

Innovative improvements in a product with a collaborative

approach has resulted in benefit to all the stake holders.

CHENNAI-11

Thank you ALL