Presentation on Cooper Corporation and its products Corp Presentation - 2014 (1).pdf ·...

Presentation on Cooper Corporation and its products

© Ricardo plc 2010RD.08_101403.02

and its products

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AGENDA :

• Introducing Cooper Corporation – The History and Milestones

• Manufacturing Facilities – An Overview

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• Manufacturing Facilities – An Overview

• Cooper’s Product offerings – Engines and Gensets



Sir D B Cooper established Cooper Engineering , Satara in 1922

Business Philosophy : Cooper Corporation believes in a forward-looking approach to business. As an effective insulation from the vagaries of economic cycles, the company has consistently ploughed back its profits into operations.

Contract for Design of most modern Euro IV compliant CRDI Engine family with Ricardo

Expansion of engine and automotive business

Manufacture of Cylinder heads

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2010s1920s 1940s 1960s 1990s 2000s

Built India’s first Diesel Engine in association with Imperial Keighlyand Duncan Stratton

Manufacture of CB, CC, CD type of horizontal diesel engines

CR26 Ricardo Comet III diesel engine introduced followed by CR19, CR14, CR40 & CR50

Cylinder heads

Engine & Gensets Business started, Engines also for own automotive application from 1.2 to 6.8 L capacity

Manufacture of Wind Power CastingsManufacture of

Cylinder Liners

Manufacture of Crankshafts &Foundry established

2012s



Cooper : Nine Locations in Satara

M-60-1 (Engine Plant)

M-60 (E O U) N-17 (ZS EngineersMachine Shop)

L-3 (Corp. Office & Foundry)

K-11-1,2,3 (Machine Shop)

ADDL. MIDC AREA

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Mumbai – Bangalore Highway : NH-4

K-10 (Foundry Project)

J-1 (Veh. Project)

E-11- Beverage Proj.)

Cooper Metals Pvt. Ltd. (Crankshaft Div.)



Cooper Vintage Engines : Manufactured in 1940 & 50s

© Ricardo plc 2010RD.08_101403.02 5PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor


Cooper Corporation – Some Key Highlights

� Developed India’s first Diesel engine in 1922.

� ISO 9001 and TS 16949 Certified.

� 9 Manufacturing Plants.

� Over 2000 employees.

� Set up a Mega Project for Engine and Genset manufacture – US $60M investment.

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� Set up a Mega Project for Engine and Genset manufacture – US $60M investment.

� Launched 2 cylinder CRDI engine.

� Launched the 3, 4 & 6 cylinder Engines.

� Engines in Diesel and Gas (LPG and CNG).

� Single Cylinder and 2 Cylinder Non-Common Rail engines to be launched by Jan-2014.

� Euro IV and CPCB Stage II compliant.

� Exporting Engine Components to all major engine manufacturers across the globe – Crankshafts, Cylinder Liners, Heads, Flywheels, etc.



• Cooper has an unique labour relationship, whereby a registered cooperative society formed and run by workers, provide labour to run the factories.

• This is a unique scheme initiated by our HRD Director Mr J B Patil.

• We employed 2018 people of which:

Capabilities

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– Workmen 1641– Engineers 194– Quality 80– Admin staff 43– Others 60

• Land 2,672,655 sq ft.• Built-up area 482,610 sq ft.



ENGINEERING CAPABILITIES

• Development and validation of 2, 3, 4 & 6 cylinder engines completed in a period of 4 years from concept design to production.

• Full fledged In-house Design Engineering and Product Engineering for refining the designs and also for validation of components & engines.

• Engineering is supported by design engineers and application engineers.

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• Engineering is supported by design engineers and application engineers.

• Gensets designed and validated with acoustic enclosures.

• We currently use AutoCAD 2004, Unigraphics, 3D CAD and CAM.

• We have procured CAE software for FEA analysis.



Cooper’s manufacturing philosophy is based on

“Do-It-Yourself” principle and

is supported by an expert engineering team

• Cooper’s 9 plants are located at Satara, in the state of Maharashtra, India

• Engineering and manufacturing are located at the same site and jointly design the parts

• Most tooling is made, maintained and calibrated in-house and only critical inspection gauges are

manufactured and calibrated by other manufacturers

• Engineering supports manufacturing by

– Designing all the dies, fixtures, tooling

– Preparing the control plans, work instructions required for each part

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– Preparing the control plans, work instructions required for each part

• Over $31M (Rs.158 Cr)have been invested in manufacturing facilities over the past 5 years

• Plan to invest >$20M (Rs.102 Cr) in expanding manufacturing facilities over the next 3 years

State-of-the-art Foundry Shop State-of-the-art Machine shop Engine plant with automated line



Cooper is an ISO 9001:2000 certified company

for manufacture of engines and Gensets

• The quality system is in line with the ISO

9001:2000

• The quality system runs as per the quality

manual and quality system procedures

• All new part developments are routed through

the APQP process

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• In manufacturing, quality is assured by way of:

– Process monitoring and operating

instructions

– Control plans and checklists

– Set-up approval

– Process capability evaluation



STATE OF THE ART OF FOUNDRY SHOPWITH 12 CAROUSEL MACHINES &14 MELTING FURNACES



State of the Art Robotic Machine Shop



Cooper Engine Plant



Cooper Engines

2 Cylinder 3, 4 and 6 Cylinder

Cooper Engine Families

`

1 Cylinder 2 Cylinder

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2 CylinderBore : 87,

Stroke : 100 mm

3, 4 and 6 CylinderBore :107, Stroke :126 mm

2Cyl. 1.2 Litre

3 Cyl.3.4 Litre

4 Cyl. 4.5 Litre

6 Cyl. 6.8 Litre

1 Cyl.0.9 Litre

1 CylinderBore:95 & 107,Stroke:116 mm

2 Cyl.1.56 Litre1.89 Litre

2 CylinderBore/Stroke : 95/110 mm = 1.56L

Bore/Stroke: 102/116 mm = 1.89L



Cooper Products – Engines and GensetsEngine product range

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Genset product range



Parameter Unit FC1A5 FC1A7.5 FC2A10 FC2A15 Rated Output (Prime Continuous Rating) @1500 rpm

kW (hp) 5.97 (8) 7.5 (10) 12 (16) 15 (20)

Rated Output (Prime Continuous Rating) @1800 rpm

kW (hp) 7.15 (9.6) 8.94 (12) 14.32 (19.2) 17.90 (24)

Number of Cylinder No's 1 1 2 2

Cooper - Single Cylinder and 2 Cylinder (Non-Common Rail ) engines to be launched by Mid 2014.

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Number of Cylinder No's 1 1 2 2 Cooling Method AC/WC AC AC AC AC Cylinder Bore mm 95 107 95 102 Cylinder Stroke mm 116 116 110 116 Aspiration NA/T/TA NA NA NA NA Governing - A2 Class A2 Class A2 Class A2 Class BMEP Kg/mm2 6.4 6.5 6.4 6.5 SFC @ 75% Load * gms/kW-hr 215 210 215 210 SFC @ 100% Load * gms/kW-hr 225 225 225 225 Max. Lub. Oil Consumption

Liters/hr 0.5% of SFC

max 0.5% of SFC

max 0.5% of SFC

max 0.5% of SFC

max Lub. Oil Change Period Hrs 500 500 500 500 Lubrication Oil Sump Capacity *

Liters 4 4 5.5 5.5



- High Fuel Efficiency

-Airflow and combustion control

-Common Rail High Pressure Diesel Fuel Injection & Rotary Fuel systems

-HLA Arrangement.

- Low noise and vibration

-Bedplate architecture

-Cast Iron structure

- High Durability

EXCLUSIVE ENGINE DESIGN FEATURES:

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- High Durability

-Compacted Graphite Iron Cylinder head

-Bainitic Material Wet Cylinder liners

- Lower Operating Cost

-Higher Service Interval (500 Hours).

-Lesser consumable spare requirement.

- Meet current and forthcoming emissions standards with minimum after treatment

-Euro Stage IV

-EPA/CARB Tier 4 Final



Cooper 2 Cylinder Engine

For Automotive & Genset ApplicationIn Diesel, LPG and CNG versions

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Cooper’s engines have been developed in technical collaboration with Ricardo UK and are compliant with the latest emission norms



COOPER 2 CYL ENGINESTECHNICAL SPECIFICATIONS




For Automotive And Genset Applications In Diesel version

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TECHNICAL SPECIFICATIONS OF COOPER 3 CYL ENGINES

Parameters 3 Cylinder Engine Specifications

Fuel Diesel Diesel Diesel Diesel

Version TC TCIC TC TCIC

Bore mm 107 107 107 107

Stroke mm 126 126 126 126

Displacement cm3 3400 3400 3400 3400

Compression Ratio 17.5:1 17.5:1 17.5:1 17.5:1

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Compression Ratio 17.5:1 17.5:1 17.5:1 17.5:1Direction Of Rotation(From Flywheel Side) Anticlockwise Anticlockwise Anticlockwise Anticlockwise

Cooling Water cooled Water cooled Water cooled Water cooled

Dry Weight kg 520 540 520 540

RPM 1500 1500 2200 2200

Max. Power Ps(Automotive) _ _ 91 118

Max. Torque(Nm) _ _ 356 @ 1300 rpm 455 @ 1300rpm

Prime Power Ps(Genset) 68 102 _ _

Application Genset Genset Automotive Automotive




For Automotive And Genset Applications In Diesel and CNG version

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Fuel Diesel CNG Diesel CNG

Version TCIC TCIC TCIC TCIC

Bore mm 107 107 107 107

Stroke mm 126 126 126 126

Displacement cm3 4500 4500 4500 4500

Compression Ratio 17.5:1 12:1 17.5:1 12:1

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Compression Ratio 17.5:1 12:1 17.5:1 12:1Direction Of Rotation(From Flywheel Side)

Anticlockwise Anticlockwise Anticlockwise Anticlockwise


Dry Weight kg 558 546 558 546

RPM 1500 1500 2400 2200


Max. Torque(Nm) _ _ 540 @ 1800rpm 535 @ 1800rpm







Fuel Diesel CNG Diesel CNG

Version TCIC TCIC TCIC TCIC

Bore mm 107 107 107 107

Stroke mm 126 126 126 126

Displacement cm3 6800 6800 6800 6800

Compression Ratio 17.5:1 12:1 17.5:1 12:1

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Compression Ratio 17.5:1 12:1 17.5:1 12:1Direction Of Rotation(From Flywheel Side)

Anticlockwise Anticlockwise Anticlockwise Anticlockwise


Dry Weight kg 698 687 698 687

RPM 1500 1500 2200 2200


Max Torque(Nm) _ _ 960 @ 1800rpm 800 @ 1800rpm





Cooper 6 Cylinder Fuel Consumption Comparison Chart



� Up to 30% lower fuel consumption

� 42% saving in maintenance cost

� 10 times quieter

Cooper’s Gensets powered with Cooper’s own engines and offer various advantages as compared to competition; main advantages are lower life cycle cost and future emission compliant.

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� 10 times quieter

� 30% small in size

� 40% lighter in weight

� Emission complying with US & European norms

� CPCB approved silent & super silent options



Cooper Diesel Generator Set Technical Specifications 10 to 40 KVA

Genset Model CD10 CD15 CD20 CD25 CD30 CD40

Power Rating (KVA) 10 15 20 25 30 40

Power Rating (KW) 8 12 16 20 24 32

No. of Phases. 1/3 1/3 1/3 1/3 1/3 1/3

Canopy Size

Length (mm) 1950 1950 1950 1950 1950 1950

Width (mm) 950 950 950 950 950 950

TECHNICAL SPECIFICATIONS OF GENSETS powered by COOPER 2 CYL ENGINE GENSET

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Width (mm) 950 950 950 950 950 950

Height (mm) 1300 1300 1300 1300 1300 1300

Engine Specifications

Engine Model 2A1D1C-10 2A2D1C-15 2A2D1C-19-20 2A2D1A-25 2A2D1A-30 2A2D1A-35-40

Rated Power (kW) 10.3 16.1 18.8 26.2 31.4 34.5

Engine RPM 1500 1500 1500 3000 3000 3000

Aspiration NA TC TC TC TC TC

Cooling System Liquid Cooled with Radiator

Governing Synchronous (Electronically Controlled Fuel Injection System-ECU)

Genset Models also available in 1800 & 3600RPM



Cooper Diesel Generator Set Technical Specifications 62.5 to 180 KVA

Genset Model CD62.5 CD75 CD82.5 CD100 CD125 CD140 CD160 CD180

Power Rating (KVA) 62.5 75 82.5 100 125 140 160 180

Power Rating (KW) 50 60 66 80 100 112 128 144

No. of Phases. 3 3 3 3 3 3 3 3

Technical details of Cooper Higher Range Gensetspowered by Cooper 3, 4 & 6 Cylinder Engines

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Power Factor 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8

Canopy Size

Length (mm) 3000 3000 3000 3400 3400 4000 4000 4600

Width (mm) 1200 1200 1200 1400 1400 1400 1400 1400

Height (mm) 1500 1500 1500 1700 1700 1700 1700 1700

Genset Models also available in 1800RPM



Cooper : Sales and Service network

to support customers

Delhi, Ghaziabad Noida, Gurgaon

ChandigarhLudhiana

Lucknow

VaranasiAhmedabad

Jaipur

Jammu

PatnaUdaipur Jodhpur

GauhatiAllahabad

Dehradun

JKanpur

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Varanasi

Kolkatta

Bhubaneswar

Hyderabad

Chennai

Kochi

Bangalore

Goa

Mumbai

Pune

Nagpur

BhopalIndore

Rajkot

Ahmedabad

Vapi

Baroda

Vijaywada

Coimbatore

Kolhapur

73 Established sales and service contact point

37 To be established by March 2014

Sangli

Satara

Ranchi

Vizag

Trivandrum

Mangalore

Aurangabad

PondicherryMadurai

Hubli

Raipur

Jabalpur



Cooper Corporation network :

across the globe

Grove City PA

Milwaukee WI Dillingen Germany

Helsinki

UK

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Grove City PA

Statesboro GALaredo TX

Dubai

Zambia

Nigeria

Kenya

Chiuhuahua



Thank You

Registered OfficeCooper Corporation Pvt. Ltd.

COOPER CORPORATION PVT. LTD.

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Cooper Corporation Pvt. Ltd.L-3, Addl. MIDC, Kodoli, Satara – 415 004.Maharashtra, IndiaPhone No. 02162 240413, 240272 Fax No. 02162 240271.Website – www.coopercorp.inwww.coopergenset.com

Office No.7, Madhuban, Lane 5, Koregaon Park, Pune- 411 001Maharashtra, IndiaTelefax: +91 20 26150624

Marketing Office



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