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11 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
22 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
SOGEFI Group Overview
SOGEFI S.p.A.
FLUID FILTRATION
SOGEFIENGINE SYSTEMS
Division
SOGEFI SUSPENSION COMPONENTS
Division
Milan Stock Exchange43,60%
CIR56.40 %
SOGEFIIAM
Division
SOGEFI PURCHASING
AIR & COOLING(MARK IV AIC acquisition)
33 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Management Organization
SOGEFI S.p.A
SOGEFI CORPORATEEmanuele BOSIO
ENGINE SYSTEMS DivisionKeith DREW
IAM DivisionAndrea TASCHINI
SUSPENSION COMPONENTS Division
INDUSTRIAL VEHICLES
Heinrich WINKELS
PASSENGER CARSC. PASSERA – P.
ROTA
AIR & COOLINGLuc SCHWAB
FLUID FILTRATIONPierre L’ALLORET
LP-DN Subsidiaries Subsidiaries Mark IV SM subsidiaries
44 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Suspension Components
Sogefi offers a complete range of elastic vehicle suspension elements and high performance precision springs
SUSPENSION ELEMENTS
SOGEFI Group Overview
55 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Filter Systems
The product range comprises engine, oil, petrol, diesel, air and cabin air filter elements and complete modules for the first equipment and the original and independent aftermarket
FILTER SYSTEMS
SOGEFI Group Overview
66 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Engine Systems
Sogefi Group can provide to car manufacturers sub-assemblies and complete modules with high added value in the areas of air intake and cooling
AIR INTAKE & COOLING SYSTEMS
SOGEFI Group Overview
77 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
SOGEFI Group Turnover (M€)
AIR INTAKE & COOLING
Nota: For information only. Consolidated figures to be published in 2011 results.
0
200
400
600
800
1000
1200
1400
2005 2006 2007 2008 2009 2010 2011
ENGINE SYSTEMS (+ IAM) SUSPENSIONS TOTAL
88 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
ENGINE SYSTEMS Division
99 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
SOGEFI Engine Systems OE Products
AIR
LUBRICATION
REMOTE ENGINE AIR INTAKE SYSTEMS
TOP COVER ENGINE AIR
INTAKE SYSTEMS
METALIC DIESEL FUEL FILTERS
PLASTIC GAZOLINE
FILTERS
PLASTIC DIESEL FUEL MODULES
ECO ENGINE LUBRICATION
MODULES
FUEL
CRANKCASE VENTILATION
REMOTEHIGH
EFFICIENCY BLOW BY
SEPARATORS
INTEGRATED ENGINE
COVERS
ENGINE COOLING
THERMOSTAT HOUSING WATER PUMPS
HIGH PRESSURE DUCTS
WATER PIPES
MANIFOLD
SPIN ON LUBRICATION
SYSTEMS
1010 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
SOGEFI Engine Systems Footprint
CanadaMontreal (Production)
USARochester (Sales & Tech center)Sterling Heights (Production)Dearborn (Sales & Project)Huntington (Production)
MexicoMonterey (Production)
IndiaNew Delhi (Tech Center & Production) Bangalore (Tech center & Production)
China Shanghai (Sales, Projects & Production)
RomaniaPitesti (Production)
JapanNagoya (Sales & Tech office)Tokyo (Sales & Project office)
BrazilSao Paulo (Sales, Tech Center & Production)Gravatai (Production)Mateus Leme (Production)
SloveniaLadja (Production)
United KingdomLlantrisant (Sales, Project & Production)Tredegar (Production)
ItalyTorino (Sales, Project & Production)
SpainBarcelona (Production)
FranceGuyancourt (FF Headquarter, Sales, Tech center & Project)Orbey (A&C Headquarter, Sales, Project, Tech center & Production )Vire/Argentan (Tech Center & Production)Saint Père (Production)Marcillac (Production)Fraize (Production)Châteauroux (Production)
ArgentinaBuenos Aires (Production)
1111 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
2010 World TOP 10 Customers
SOGEFI Engine Systems Customers
10. GEELY-VOLVO GROUP
8. TOYOTA GROUP
7. VW GROUP
6. BMW GROUP
3. GM GROUP
5. FORD GROUP
1. PSA GROUP
2. FIAT-CHRYSLER GROUP
4. RENAULT-NISSAN GROUP
9. DAIMLER GROUP
1212 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
AIC DivisionCustomer
1313 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Air intake and coolingTurnover Trend (M€)
1414 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Air intake and cooling
AIR INTAKE MANIFOLD COMPLEX ACTIVE MANIFOLD
FUNCTION RESPONSIBILITY &SYSTEM COORDINATOR
COOLING SYSTEMCOMPLEX ACTIVE components
FUNCTION RESPONSIBILITY &SYSTEM COORDINATOR
AIR INDUCTION & CHARGED SYSTEMFUNCTIONS INTEGRATION
PEEST (Hytrel) and HT materialsProcess 3D suction (blow molding) & Injection
Product portfolio
1515 SOGEFI AIR & COOLING SYSTEMSORBEY, March 2012, 19° SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Location: ORBEY A&C headquarter
95 people55 engineers
40 technicians
Organization by product line
More than 100 projects ongoing
EUROPEAN TECHNICAL CENTER
1616 SOGEFI AIR & COOLING SYSTEMSJune 2012SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Design facilities
CAD equipments in Orbey:
17 Catia V5 licences 5 NX 7.5 licences 1 Pro-E licence
22 CAD stations
CAD exchanges:
FT MasterFTP websiteSpecific access to customer data-centers
1717 SOGEFI AIR & COOLING SYSTEMSJune 2012SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
3D CAD model specific tools developped:
Check done on each part
Drawings checkingStack analysis
thickness analysis
functional analysis
demolding analysis
Design facilities
Welding line analysis
1818 SOGEFI AIR & COOLING SYSTEMSJune 2012SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
3D CAD Library:
In order to share our knowledge in the company, a 3D CAD library has been created to standardize our design
This library is accessible from each R&D tech-center
3D CAD Model
description
Design facilities
1919 SOGEFI AIR & COOLING SYSTEMS2012_02SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Mechanical:
ANSA
Abaqus CAE & solver
ETA reporting
Moldflow
CAE SOFTWARE
CFD:
GT Power
LMS Amesim
LMS Star CCM+
CF Turbo
Thermal internal soft
2020 SOGEFI AIR & COOLING SYSTEMSORBEY, April 2012SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Moldflow
Blow moulding simulation
Thickness prediction
Injection moulding simulation
Warping analysis, mold cooling optimization
Rheology calculation
2121 SOGEFI AIR & COOLING SYSTEMS2012_02SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Acceleration : Axis Y
-10
0
10
20
30
40
50
60
70
80
0 100 200 300 400 500 600
Frequency (Hz)
Ac
ce
lera
tio
n (
G)
Throttle Body
Throttle body (without bracket)
Mechanical calculation
Static calculation
Frequency response
2222 SOGEFI AIR & COOLING SYSTEMS2012_02SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
CFD calculation StationnaryFlow arround thermostat
Cooling part
Air intake part
ManifoldEGR Mixture and thermal
2323 SOGEFI AIR & COOLING SYSTEMS2012_02SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
CFD calculation UnstationnaryTempérature egr en entrée
270
275
280
285
290
295
0,0 100,0 200,0 300,0 400,0 500,0 600,0 700,0
angle vilebrequin (degré)
Tem
pér
atu
re e
gr
(°C
)
Taux d'egr par cylindre sur 1 cycle moteur
30,0%
31,0%
32,0%
33,0%
34,0%
35,0%
36,0%
37,0%
38,0%
39,0%
cylindre 1 cylindre 2 cylindre 3 cylindre 4
Ta
ux
eg
r (%
)
33,4% 37,8% 37,6% 32,9%
Taux global d'egr injecté : 35,4%
% egr = megr / ( megr + mair) par cylindre
Température sur le dôme durant 1 cycle moteur
0
20
40
60
80
100
120
140
160
180
200
0 100 200 300 400 500 600 700
angle vilebrequin (degré)
T (
°C)
Partie inf dôme
Partie sup dôme
178,3 °C
155,8
129,6
178,3 °C
155,8
129,6
2424 SOGEFI AIR & COOLING SYSTEMS2012_02SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Acoustic:
ANSA
Abaqus solver
LMS Virtual Lab
ADEME
GT Power
CAE SOFTWARE
2525 SOGEFI AIR & COOLING SYSTEMS2012_02SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Acoustic calculation
Modal analysis
0 100 200 300 400 500 600 700 800 900 1000-30
-20
-10
0
10
20
30
40
frequency (Hz)
magnitude (
20 log10(p
/Q))
Transfer function pressure (p) / volume velocity (Q)
Cavity analysis
EmissivitySimulation of radiated noiseEmissivitySimulation of radiated noise
2626 SOGEFI AIR & COOLING SYSTEMSORBEY, April 2012SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Our tools:
0 1000 2000 3000 4000 5000 6000 700060
70
80
90
100
110
120
DrehZahl [1/min]
Sch
allD
ruck
[dB
A]
Octave Tracking dBA: Ziel InnenGeräusch
GesamtPegel
Ziel: GesamtPegelZiel: Oct 125 Hz
Ziel: Oct 250 Hz
Ziel: Oct 500 Hz
bba_oct125bba_oct250
bba_oct500
/4 (380 Hz)
3.6L Helmholtz (100 Hz)
1.2L Helmholtz (380 Hz)
luft
3 Resonators:
Orifice noise Orifice noise prediction made by simulation toolsOrifice noise Orifice noise prediction made by simulation tools
GT-Power
linear a
coust
ics
non-linear a
coust
ics
Acoustic calculation
2727 SOGEFI AIR & COOLING SYSTEMS2012_02SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Chambre CR2 : Longueur 15mmOuverture 15mm
Silencieux SIL1 :Volume 66cm3Longueur 32mm11x6mm
0 500 1000 1500 2000 2500 3000 3500 4000 4500 50000
5
10
15
20
25
30
35
40
45
50
TL
(dB
)
estimation de l'atténuation
frequences (Hz)
TL-0720-v16
TL-0720-v18
Critère
Chambre CR1:Longueur mini 30mmLongueur maxi 45mmOuverture 18mm
After-turboAfterturbo acoustic treatment for noise reductionAfter-turboAfterturbo acoustic treatment for noise reduction
Acoustic calculation
2828 SOGEFI AIR & COOLING SYSTEMS2012_02SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
AIR & COOLING PRODUCTS
• 10X Hot Chambers
• 3X Hot/cold Chambers
• 1X Cold chamber
• 2X Climatic Chambers
• 1X Travel Vs Force measurement system
• 1X Torque vs Angle measurement system
• 1X Vibration System
• 3X Standard cyclic pressure systems
• 1X High performances cyclic pressure system
• 1X Burst test bench
• 1X Leakage test bench
• 1X Impact test bench
• 1X Collar tension band
Testing & Reliability
2929 SOGEFI AIR & COOLING SYSTEMS2012_02SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
AIR PRODUCTS
• 1X Decoupling test bench
• 1X Differential temperature cyclic pressure
• 1X Differential temperature ageing
• 1X Flow Bench
• 1X Water separation evaluation system
• 1X Back fire test bench
• 1X Heat exchanger test bench
• 1X Flap system endurance
Testing & Reliability
3030 SOGEFI AIR & COOLING SYSTEMS2012_02SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
COOLING PRODUCTS
• 1X Water pump test bench
• 1X Hydraulic characterization test bench
• 1X Glycol cyclic pressure test bench
• 1X Thermostat housing test bench
• 1X Thermostat opening test bench
Testing & Reliability
3131 SOGEFI AIR & COOLING SYSTEMS2012_02SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Diesel engines
EGR + Swirl
500,000/year
Air Intake
modules
800,000 / year
Turbo Petrol
Engines
L4(tumble) & V6
500,000 / year
Diesel engines
EGR
2,200,000 / yearPetrol
engines
L4 to V10
1,400,000 / year
… And more than 80 AIM in production since 1988
ENGINE SYSTEMS
2010
In 2010 more than 5 400 000 engines equipped with our Air Intake Manifolds
AIR INTAKE MANIFOLD Production
Air Intake & Cooling Portfolio
3232 SOGEFI AIR & COOLING SYSTEMS2012_02SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Cooling
modules
600,000/year
Water pump
800,000*/ year
Water/EGR
Module
320,000*/year
Water pipes
2,600,000*/ year
Thermostat
housing
2,700,000*/ year
3 Way-valve
SOP 2013
ENGINE SYSTEMS
2010
In 2010 more than 4 000 000 engines equipped with our Cooling Components
* incl. Cooling Modules production)
COOLING SYSTEM Production
Air Intake & Cooling Portfolio
3333 SOGEFI AIR & COOLING SYSTEMS2012_02SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
In 2010 more than 4 600 000 vehicles equipped with our Air Line Components
Dirty air duct
1,400,000/ year
Resonators
700,000/ year
Intercooler
Outlet ducts
2,000,000/ year
Turbo
outlet Ducts
2,100,000 / year
Turbo Inlet ducts
1,400,000 / year
Air cleaners*
4,300,000/ year
* incl.SOGEFI air Filtration Production and Tier2 OEM Sales (Filter Element)
AIR INDUCTION & CHARGED SYSTEM Production
ENGINE SYSTEMS
2010
Air Intake & Cooling Portfolio
3434 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
AIR INDUCTION & CHARGED SYSTEM SALES
3535 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Trend of our Sales
ForecastMARK IV + Sogefi Air Filtration
Air Induction Sales
Other AIC Sales
► A Growing Business in our Global AIC Sales
SOGEFI-MARK IV AICS SALES
3636 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Our Customers in Automotive OEM
► A Large and Diversified Customer Base in Automotive OEM which will represent around 85% of our projected AICS Sales on 2011
AIS TIER 2 (Filtration) AIS TIER1-Customer Panel
SOGEFI-MARK IV AICS SALES
3737 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
AICS Sales by Region
ForecastMARKIV + Sogefi Air Filtration
Europe
Nafta
► International growth foreseen on AIS thanks to Charged engines development all over the world and new Mercosur & Nafta presence
sales expansion
Mercosur
Asia
SOGEFI-MARK IV AICS SALES
3838 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval. CONFIDENTIEL 3821/04/20
23
10. GEELY-VOLVO GROUP
8. HONDA GROUP
7. DAIMLER GROUP
6. FORD GROUP
3. FIAT GROUP
5. VW GROUP
1. PSA GROUP
2. RENAULT-NISSAN GROUP
4. GM GROUP
9. MAHINDRA-MAHINDRA
2010 TOP10 Customers
PSA Share in our AICS Sales
Source : SOGEFI Air Filtration + AIC
SOGEFI-MARK IV AICS SALES
29% of AICS
Sales
3939 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
PSA GROUP
SOGEFI-MARK IV AICS SALES
Detail of our Presence per Function
reprendre
4040 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Richard
comment on concoit specifi ligne d’air et besoin caoutchouc
Montrer des produits/durit/procédés
Tendances du marché robustesse
4141 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Air intake ducts: High pressure side
CONFIDENTIEL4121/04/2023
MARK IV AIC standards for Air Intake
Hot side:Injection molding PPA
FMVQ calandred silicon hoses
Hot side:Injection molding PPA
FMVQ calandred silicon hoses
Cold SideBlow molding
Mono-layer TPC-ET
Cold SideBlow molding
Mono-layer TPC-ET
4242 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Product overview: Hot side ducts
Page n° 42
Quick connector or patch for collar
Decoupling rubber hose FMVQ/VMQ
Reinforced fixations + Steel Compression
limiters
Dispersion rubber hose
Acoustic damper with / without Quick
connector
Suitable material to resistHIGHEST TEMPERATURE (200-220°C)
Typical BOM for
Afterturbo outlet duct BOM
4343 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Product overview: Cold side ducts
Page n° 43
Typical BOM for
Intercooler outlet duct
Hytrel duct with sensor
3D suction blow molding
Quick connectors or Gasket+ collar
Brackets unreinforced
Sensors integration
Bellows for flexibilty
4444 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Process: injection molding
Page n° 44
Injection molding with rotative dies
Conventional injection molding with moving dies
2 parts + welding
1 part
Injection molding coupled with welding can give an cost effective alternative to blow molding. Additionnal funtions integration and material thickness control are key features with this technology
4545 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval. Page n° 45
Kautex
Conventionnal 2D blow molding enables low costs solutions with multiple parts in the same mold.
PSA 405 / Xantia1.9L et 2.1L TurboD
punching
PSA 1.6 Diesel Euro 4
3D Blow molding by manipulator enables long and complex shapes without parison trap
moviemovie
Process: blow molding
4646 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval. Page n° 46
For Turbo outlet ducts , 3D suction blow molding is dedicated to complex shapes and
PA66GF20 PA666GF20 PPSGF15
Renault Traffic 2.0 DCI Euro IV
Bend
Cross section increasef35mm f50mm
Process: blow molding
4747 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Turbo interface
Page n° 47
SOGEFI’s existing solutions for Turbo outlet connections
Flat flange with seal groove
Male end-fitting with O-ring
Short extruded hose with clamps
Female Quick connector
Machined flat face
Female Tube+ screws
Spigot
Male Connector
4848 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
EGR/Throttle inlet interface
Page n° 48
: SOGEFI’s existing solutions for Thottle body/Intercooler connections
Flat flange with seal groove
Female Quick connector
Machined flat face
Spigot
Male Connector
Collar + Seal
4949 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Simulation tools
Computationnal Fluid DynamicsComputationnal Fluid Dynamics
NVH - vibroacousticsNVH - vibroacoustics
Structural analysisStructural analysis
5050 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Design for pressure resistance
Page n° 50
Pressure resistance is the key point for durability of charged air ducts, more especially in the welding nuts.The simulation (FEA) illustrates and guides the designers to a safe definition.
Stress analysis in welding
FEA Calculation with ABAQUS CAEStress values evaluation with admissible stress in Wöhler curves (fatigue behavior) needed by raw material suppliers
5151 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Design for flexibility
Page n° 51
Hytrel ducts passed durability test with 2M cycles of motion
Lengths upper than 600mm and bends make TPC-ET ducts suitable for engine displacement absorbtion. Bellows can be added onto the ducts to increase the flexibility and to reduce reaction forces.
w/o bellow With bellows
FEA simulations helps designers to place the necessary bellows corresponding to the
displacement to absorb
5252 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval. Page n° 52
Reaction forces reduction
0
20
40
60
80
100
120
140
0 10 20 30 40 50
Displacement (mm)
Rea
ctio
n f
orc
e (N
)
Initial FZ[N]
Optim Bellows FZ[N]
Target [N]
Reaction forces to highBends flexibility
Reaction forces acceptableThanks to bellows in bends
+/- 24 mm
Flexibility of Hytrel ducts for assembly is ensured by additionnal bellows. Assembly forces are strongly influenced by the assembly sequence or fixation points positions
Design for flexibility
5353 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Laboratory tests: cycling pressure
Page n° 53
Thermal : External Temp 50°C to 300°C
Internal Temp : up to 250°C
Cyclic pressure : -800 mbar rel. to 6 bar rel, Freq : ~ 0.5Hz
Oil injection : 0 to 10 gr/h
Cycle exemple
Overall view
Air input
Air outputParts inside the thermal chamber
5454 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval. Page n° 54
Decoupling endurance :
Thermal Ageing -40°C / 200°C + %HR+ Cyclic pressure 0 to 6 bar rel.+ Displacement +/- 60 mm, sine or square+ Different inside air T° up to 250°C+ Oil injection 5 gr/h
Displacement
Cyclic pressure
parts with silicon rubber hoses
Laboratory tests: big motion
5555 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
New testing bench in SOGEFI’s lab for ageing in external/internal temperatures
Different Temp inside and outside the parts Inside parts Temp : 30 to 300°CThermal chamber : 30 to 250°C
Small Temp difference input and output the parts : < 10°CFlow rate : 300Kg/h
Overall view
Synoptic
Laboratory tests: differential T°C
5656 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Laboratory tests: Acoustics
Page n° 56
1 6 0 400 1 k 2. 5k 6.3k
Hz0
1 0
2 0
3 0
4 0
5 0
6 0
7 0
8 0
9 0
1 0 0
1 1 0
dB
3rd O c ta ve m c l4 [D u c t N °B 88 te s t2] 3rd O c ta ve m c l4 [D uc t N °B 84 (w ith ho s e )] 3rd O c ta ve m c l4 [R e fe re nc e te s t2] 3rd O c ta ve m c l4 [R e fe re nce w ith h o s e] 3rd O c ta ve m c l4 [B a c kg ro und n o is e]
Ch. 3 : Micro Up [dB A]
1 6 0 400 1 k 2. 5k 6.3k
Hz0
1 0
2 0
3 0
4 0
5 0
6 0
7 0
8 0
9 0
1 0 0
1 1 0
1 2 0
dB
3rd O c ta ve m c l2 [D u c t N °B 88 te s t2] 3rd O c ta ve m c l2 [D uc t N °B 84 (w ith ho s e )] 3rd O c ta ve m c l2 [R e fe re nc e te s t2] 3rd O c ta ve m c l2 [R e fe re nce w ith h o s e] 3rd O c ta ve m c l2 [B a c kg ro und n o is e]
Ch. 4 : Mic D ow n [dB A]
frequency
1/3
octa
ve S
PL
Radiated noise tests
comparatif atténuation acoustique APS K9K
0
5
10
15
20
25
30
35
40
45
50
1000 1500 2000 2500 3000 3500
frequences (Hz)
Tra
nsm
issi
on
Lo
ss (
dB
%1)
TL_maqpha2_modif3_0m3/h
TL_maqpha2_modif3_230m3/h
TL_maqpha2_modif3_460m3/h
Acoustic damping of resonators (with flow)
SOGEFI has a Semi-anechoic room for acoustic measurementDedicated test rigs for acoustic radiation and transmission on charged duct are used during development
5757 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Recent commercial applications
Page n° 57
• Products presentation & specifications
2 bar
200°C
250°C
150°C
Turbo to intercooler duct Renault Kangoo 1.5 Dci
1.7 bar
200°C
250°C
150°C
Turbo outlet duct PSA 1.6 Hdi
2 bar
200°C
250°C
150°C
Turbo to intercooler duct Renault Clio/Modus 1.5 Dci
5858 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Turbo outlet K9K Step3/4 X95
Injection/welded PPAGF30 ducts with turbo damper
Calandered silicon hose
Henn HC connectors
Specs:- Continuous pressure 2.0 bar - Continuous Air Temp. 200°C- Big motion Amlitude 40mm
Application Renault Megane III ph21.5 Dci engines
Plant Fraize (FR)
Prod. volume 1300 parts/day
SOP SEPT 2011
2.0 bar
200°C
250°C
150°C
5959 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Turbo outlet K9K gen5 CMO10
Injection/welded PPAGF30 ducts with turbo damper
Calandered silicon hose
Henn HC connectors
Specs:- Continuous pressure 2.0 bar - Continuous Air Temp. 200°C- Big motion +/- 17 mm
Application Small Ptf Renault/Dacia1.5 Dci engines
Plant Tistesti (ROM)
Prod. volume 1500 parts/day
SOP MARCH 2012
2.0 bar
200°C
250°C
150°C
6060 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Recent commercial applications
Page n° 60
Over pressure: 2.0 barDisplacement range: 20mm
Over pressure: 2.0 barDisplacement range 42mm
Intercooler outlet duct Renault Clio/Modus 1.5 Dci
Intercooler outlet duct Renault Clio/Modus 1.5 Dci
Intercooler outlet duct Renault Laguna 1.5 Dci
Intercooler outlet duct Renault Laguna 1.5 Dci
Throttle body inlet Daimler 250 CGI
Throttle body inlet Daimler 250 CGI
Over pressure:2.0 barNo displacement
6161 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
H4/H5 CMO2010 intercooler duct
Blow molded duct in TPC-ET with injection molded Flange in PBTGF30.P/T sensor and connection to Intercooler by Henn HC38 connector.
Specs:- Continuous pressure 1.8 bar - Temp 90°C (Peak 110°C)- Big motion +/- 21.3mm
Application Small Ptf Renault/Dacia0.9L & 1.2L GDI engines
Plant Tistesti (ROM)
Prod. volume 1700 parts/day
SOP JUNE 2012
6262 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Pressure-temperature trend for after turbo ducts
Page n° 62
100
120
140
160
180
200
220
240
0,5 1 1,5 2 2,5 3
Pression (bar rel.)
Tem
per
atu
res
(°C
)
Engine Downsizing Increased Temperature / Increased Pressure
New Material need
Specification comparison
Gasoline
Diesel €5
MA
TER
IALS
DESIGN
SOGEFI Technology Market coverage
SOGEFI Serial Production
6363 SOGEFI AIR & COOLING SYSTEMSORBEY, 21 avril 2023SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Hoses material
Material temperature classesContinuous Temp. (°C) 100 125 135 150 165 175 185 200 220
Peak temp (°C) 125 150 165 175 185 195 200 225 240Inner layer CM CM AEM AEM ACM ACM FVMQ FVMQ FKM
Fabric Polyester Polyester PolyesterPara-aramide
Para-aramide
Meta Aramide
Meta Aramide
Meta Aramide
Meta Aramide
Cover CM CM AEM AEM ACM ACM VMQ VMQ VMQ
Heat ageeing are performed on plates of vulcanisate rubber:
Continuous
Peak
Main hoses material used by SOGEFI for after-turbo ducts:
6464 SOGEFI AIR & COOLING SYSTEMSORBEY, 21 avril 2023SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
PROCESS MATIERE>ACM<>AEM<>CM<>CM<AR>CM<>CR-SF<>EAM-SF<>FPM/MVQ<>FPM/VMQ/AR/VMQ<>FPM/VMQ<>FPM<AR>VMQ< >MVQ-SF<>TPA-ES<
Extrusion
SCHEMA
Renfort textile
Renfort matière
Knitted reinforcement
Plain stitch
Lock stitch
Extrude hoses = Only one reinforcement with knitted textile aroud the duct.
Hoses process: extrusion
6565 SOGEFI AIR & COOLING SYSTEMSORBEY, 21 avril 2023SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.
Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
>FMVQ<>FPM VMQ< >FVMQ/VMQ< >VMQ<
Calandrage
Renfort textile
Renfort matière
Tricot (knitted) Tissus (woven)
Hoses process: calandered
6666 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval. Page n° 66
European hoses Suppliers
• Calandered silicon for convoluted or shaped
FMVQ/VMQ
AEM/VMQ
• Extruded
AEM
HTACM
FKM/VMQ
Thermal, static or motion decoupling at turbo outlet needs flexible hoses compatible with high temperature. Depending of OEM’s specification the rubber hoses can be convoluted, straight or shaped.
Hoses European suppliers
6767 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Innovative solution for reduced reaction load on brackets
Research program for pressured ducts
New assembly process with overmolding & overblowmolding
New materials for 220/240°C engine applications
Improved simulation accuracy for hoses reaction load
New connexions for 220/240°C engine application
Improved simulation accuracy for blowmolding thickness
distribution
2013 20142013 2014
New acoustic generation
6868 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
4% 19%
14%
18%1%
3%
23%
18%
Filter Inlet Air Duct FIlter Outlet Air Duct Turbo Outlet Ducts Cooler Outlet Ducts
Degas tanks Water Ducts Manifolds Water Outlet Housing
5%
47%29%
10%7%
2010 product share
4%19%
14%
18%
1%3%
23%
18%
2015 product share
Renault Group: macro-analysisProduct Portfolio
Turnover evolution
• Air filter & Manifold• Cooling
thermomanagement• Romania & India facilities• Satisfying performance
level0
10
20
30
40
2008 2009 2010 2011 2012 2013 2014 2015
Mill
ions
Worldwide AIC Sales for Renault Group (€)
6969 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Renault Group: turn over by production facilities
0
10 000 000
20 000 000
30 000 000
2008 2009 2010 2011 2012 2013 2014 2015
Renault Group turnover by SOGEFI production location - country (€)
Inde Roumanie France
Préciser qu’il ya de gros potentiels Asie, Inde et Amsud
7070 SOGEFI ENGINE SYSTEMS04/05/2012
SOGEFI is the legal owner or licensee of any intellectual property rights contained in this confidential document.Any use, in whatever form or for whatever purpose, in whole or in part, and regardless of the means used, is subject to SOGEFI's prior written approval.
Renault Group: thanks to a relevant Alliance
Répartiteur d’air moteur H4DaFabrication SOGEFI Titesti pour livraisons Pitesti, 220 000 p/anDMS : 2013
Répartiteur d’air moteur M9T - SwirlFabrication SOGEFI Orbey, France et ROKI Rayong ThailandeSites de livraison Cléon (Renault) et Rayong (Nissan)300 000 p/an (2/3 France)DMS : 2013
Ligne d’admission d’air, système complet P32Fabrication SOGEFI Tredegar, UK pour livraisons NMUK (Nissan)180 000 p/an réparties sur 6 moteursDMS : 2014
Version pilotée Version pilotée
Boitier entrée eau H4BtFabrication SOGEFI Titesti pour livraisons Pitersti180 000 p/an réparties sur 6 moteursDMS : 2012