Product Development Process

Transcription

1 ENGINE ENGINEERING SYSTEM INTEGRATION COMMERCIAL VEHICLE ENGINEERING ENGINE ENGINEERING DRIVETRAIN ENGINEERING SIMULATION & TESTING SERVICES PRODUCTION TECHNICAL APPLICATION SOFTWARE & SUPPORT

2 Product Development Process ECS development activities in the field of engine engineering starts from the concept up to complete engines as well as the integration of the complete drivetrain in the vehicle. The broad range of knowledge guarantees a perfect combination of technology and application development which is focussed upon the success of the final product. The ECS Know How combines newest technology with the experience of serial production. This combination ensures the best solution under consideration of a well established development process to place the right product on the corresponding market. Concept and Pre-development System Performance & Function System Cost Efficiency & Emission Requirements Weight & Packaging Design Simulation Testing Thermodynamic Acoustics and Vibration Homologation Benchmarking Great History Great Future

3 Design & Simulation Design In the engine design, state of the art CAEtools will be used in coordination with the customer. The range of CAD systems covers CATIA, Pro/Engineer, Unigraphics, etc. We also include engineering processes such as FMEA, risk management and reverse engineering. State of the art interfaces ensure uodate and excahnge of CAD data and BoM with the customer. Our engineering services cover the whole range starting with the component development (e.g. mass balancer systems) up to the complete engine. We support the complete development process beginning with the concept up to serial production. Simulation Beginning with the concept phase we start in the very early stage with modern simulation methods to ensure system and component optimization. The utilized software ranges from gas exchange simulation, oil system investigation to simulation methods like MBS, FEM and CFD. We carry out stiffnes and fatigue calculation with FEMFAT, as well as CFD analysis of the water jacket and the complete cooling system. Special cranktrain dynamic models and brackets for accessories as well as acoustic simulation of the complete engine/ transmission assembly for comfort and acoustic optimisation will be done. The Virtual Engine We can offer the competence to carry out a complete engine development with the same mindset of considering modularity and the customer expectations specific engine business: High durability standards, long-life cycles, costeffective and feasible design under consideration of local manufacturing requirements and customer s needs.

4 Testing In today's engine and vehicle development process comprehensive testing and measurement methods are the base for efficient processes and exact prediction. For dynamic and steady state testing we use fully automatic engine test benches with modern measurement. ECS operates a proving ground capable to validate the engine functions. Our services include the testing of components, up to fully dressed engines according to an agreed DVP&R during an overall engine development program, as well as engineering support. Functional Testing Function tests will be done for the following main topics: Cooling system Lubrication system Valve train and valve adjustment Cranktrain and bearings Belt drive system and auxiliaries Cold start and warm-up Endurance testing Based on the long lasting experience in the field of engine and component testing on state of the art test benches and facilities, ECS has a multi-faceted base of testing standards. Depending on customer's requests we can offer this support as an engineering service or include it in a complete engine development program. ECS offers not only the durability testing but also the overall package of engine disassembling, engine audits, wear investigation and derived from the results, can provide recommendations and countermeasures. Benchmark In line with benchmark investigations and years of experience in the field of engine engineering ECS can offer the overall Know- How according to customer requirements. Based on customer requirements we can offer single tasks or a complete vehicle benchmark which can include the following scope of work: Vehicle driveability Vehicle thermal management Vehicle emission verification and ODB/CARB analysis Cooling and lubrication system Fuel and oil consumption Heat balance of the engine Combustion analysis / fuel injection strategy Emission analysis EGR and emission aftertreatment strategy In- and outlet system investigation Friction analysis according to tear down method Thermodynamic Development The market and customer requirements regarding fuel consumption, in combination with increased performance as well as severe emission regulations require an ongoing development. To fulfil this target it is essential to have an overall comprehension of the combustion process. The optimisation will be done under consideratio of thermodynamic, air and fuel path, cooling system as well as the mechanical properties of engine components particularly with regard to serial production.

5 Engine Integration Under consideration of future CO2 emission legislation the optimisation of the complete drivetrain regarding the overall efficiency is the main target. ECS scope of work covers the complete engine integration under considerations of emission regulations, OBD and driveability, acoustics and NVH as well as component and system development. Packaging and DMU The complexity of engine systems and the continous performance-upgrade increase the demand on the exploitation of the engine compartment. Under exertion of state of the art sorftware tools as CATIA DMU Navigator, Unigraphics - IMAN the layout of optimized packaging concepts and assembly simulations can be carried out. Cooling Systems ECS offers optimized solutions for integration of existing or new developed cooling and A/C systems under consideration of specific customer requirements. In close collaboration with system and component suppliers all cooling and climatic relevant parts as well as function and control devices will be adjusted. In the concept phase the layout of the cooling system is supported under exertation of state of the art software tools (CFD, KULI ) and the optimization and validation will be approved by thermal verification Suspension The high quality requirements of modern vehicles, that no distracting, audible noise or noticeable vibrations coming from the drivetrain are transmitted to the passenger department. The development and optimization of the drivetrain mounting under consideration of chassis structure requirements is very important and has to be paid attention to during the engine integration. The approval of the simulation results will be done on the one hand with modern component test rigs regarding fatigue and on the other hand during vehicle validation. Engine Calibration ECS offers the complete range for engine calibration, to fulfill the homologation targets as well as a brand-specific differentiation in regard to driveability and "fun to drive". The calibration will be done on modern engine test benches as well as in the vehicle whereby an optimized interaction of all base functions of the engine with the vehicle will be assured. To ensure reaching the targets regarding emission legislation, diagnosis, fuel economy and durability, a customized combination of technology, methods and tools will be used. Exhaust Gas Aftertreatment Exhaust gas aftertreatment systems for gasoline and diesel engines will be developed and optimized according to customer specific requirements to meet emission and fuel consumption targets. The engineering service covers layout and design of oxydation catalyst, diesel particulate filter and NOx aftertreatment systems. The development will be done on state of the art dynamic test benches and later on verified and fine tuned in the vehicle ona chassis dyno and upon customer request in a long time vehicle field test.

6 Electronics Years of experience in the field of electronic engine control systems, provide to our customer a full range of development services Hard and software development Optimization and calibration of different control units for engine/transmission/drivetrain managent Intelligent sensors, actuators with control function System development for mechatronic components and systems as well as production preperation and quality inspection Support for homologation and integration into customer platforms CAN Interface and vehicle LAN management Diagnosis as well as service interface and security concepts On-Board Diagnostic System The OBD application has a big influence on customer satisfaction and for the success of the vehicle. Premise is a robust calibration, which should consider all possible influence parameters such as tolerances, fuel quality, aging and environmental conditions. Our Services comprehend the examination of existing OBD/CARB functions, simulation of failures of all emission related components and systems, error code memory including continous documentation according to EOBD, OBD II as well as customer requirements. Marine Application ECS has years of experience in the development and production of marine engines. The marine application of existing engines as well as the complete development of marine engines up to serial production is a main focus of our engine development and includes the concept development, power upgrade, combustion and exhaust optimizaiton to achieve customer requirements.

7 High Pressure Fuel Injection Development Ongoing increase of injection pressure, variable nozzles orifice and injection rate control are the basis for modern diesel engines. Years of experience in the development of high pressure fuel injection systems guarantee premium engineering from concept up zo serial production. From unit injector up to CR system, piezo or solenoid controlled all systems are covered, whereas this core competence is applied in further special hydraulic applications. Modern design and simulation methods, quality management and special measurement competence offer to our customers an ocerall development service for future injection technologies. Today, our hydraulic and actuator competence is used in new business fields, e.g. electronic controlled transmissions. Vehicle Testing Functional testing Cold and hot weather condition test Vehicle thermal testing Emission calibration NVH Investigation Data aquisition Vehicle endurance testing

8 Reference Section Selection of Engineering & Development Projects Engineering Center Steyr Your competence partner for engine engineering worldwide... ISO TS ISO 9001 ISO OHSAS Automotive Quality Management System Quality Management System Environmental Management System Health- & Safety Management System

9 ContaCt Ronald Penzinger Product Manager Engine Engineering Engineering Center Steyr Ges.m.b.H. & Co KG Steyrer Strasse St. Valentin, Austria Phone: Mobile: Fax: Dr. Valentin Kordesch Manager Engine Engineering Asia Engineering Center Steyr Ges.m.b.H. & Co KG Steyrer Strasse St. Valentin, Austria Phone: Mobile: Fax: Noriyuki Muramatsu Sales Manager Japan Engine & Commercial Vehicle Engineering Engineering Center Steyr Magna Internatiuonal Inc. Yaesu k Building 5F Yaesu, Chuo-ku, Tokyo, , Japan Phone: +81(0) Mobile: +81(0) Fax: +81(0) noriyuki.muramatsu@magnapowertrain.com ECS_engine-engineering_2009/05 Aisheng Tang Sales Manager China Magna Powertrain China 6F, Tower A, Eton Place, 69 Dongfeng Road Pudong New Area, Shanghai, PRC, Phone: Mobile: Fax: aisheng.tang@magnapowertrain.com