Plastic housing modules. Light, multifunctional, economical.

Transcription

1 Plastic housing modules. Light, multifunctional, economical.

2 ElringKlinger present in automoti Canada Leamington USA Livonia Branchburg Mexico Toluca Brazil Piracicaba Germany Dettingen/Erms Langenzenn Spain Reus Italy Mazzo di Rho South Africa Johannesburg People s Republic Cylinder head gaskets Specialty gaskets Housing modules Topographic housing Shielding systems Transmission components applications 4 Modules Innovation all-in-one 6 Cam cover modules 7 Cover modules 8 Housing modules for transmission 9 New applications 11 Cam cover gaskets 2 13 Development expertise 15 Materials expertise

3 ve markets throughout the world. Runkel Bietigheim-Bissingen Heidenheim/Brenz Idstein Rottenburg/Neckar Great Britain Redcar Gateshead of China Changchun South Korea Changwon Japan Tokyo India Ranjangaon Bipolar plates for fuel cells Original Elring spare parts PTFE components Engine measuring and testing services Experience mobility Drive the future: The ElringKlinger group of companies. ElringKlinger innovative development partner and series supplier to the international automotive industry and other industries. We think ahead and take on responsibility. For more sustainability and environmental compatibility. Today and tomorrow. Our trendsetting technologies and sophisticated product solutions contribute to further reduce fuel consumption and emissions, and enable the use of alternative fuels and the development of new drive technologies. With comprehensive engineering and production expertise, we allow more freedom of design for engines, transmissions, exhaust systems, and auxiliary aggregates. Together with our customers, we successfully promote new technologies. To this end, we have around 3,400 employees working at 21 locations throughout the world. 3

4 4 Modules. Innovation all-in-one.

5 Engine development is geared toward reduced fuel consumption while increasing performance. Lightweight constructions are therefore indispensable. However, modern engines are also measured against driving comfort, a distinct reduction of noise emissions, and environmental compatibility. Engine components are therefore required to meet stringent demands with regard to: Integration of multiple functions into one module Weight reduction/lightweight construction Reduced development times and costs Recyclability Modern appearance for an impressive engine design High degree of operating efficiency The solution from ElringKlinger: ready-to-install modules intended for the engine compartment, comprising a plastic housing, sealing system, fastening systems, and additional functions. The integration of quality from engineering through production and complete assembly of all components, to the automated function and quality control and the just-in-sequence delivery, to the production line of the customer. 5

6 Multifunctional cam cover modules. Impressively lightweight. The comprehensive know-how and systems expertise of ElringKlinger in sealing technology, and in elastomer processing in particular, forms the basis for innovative solutions for modules made of thermoplastic materials (polyamide) and thermosetting materials. Many functions can be integrated very efficiently and economically thanks to the special processing properties of plastic. It is thus possible, for example, to completely dispense with subsequent machining such as deburring, thread cutting or surface finishing during production. Another essential advantage of plastic modules involves weight reduction. Polyamide cam cover module with mounted cover module. Cam cover Elastomer gasket Oil separator Bolts/sleeves Filler cap Pressure control valve Complete assembly Automated 100% function and quality control Just-in-sequence delivery Polyamide cam cover module comprising integrated oil separator and pressure control valve. Cam cover module made of thermosetting materials and comprising integrated metal oil separation. From single components to the finished plastic cam cover module. 6

7 Multifunctionality. For example, plastic cam cover modules Integration of the oil separation (blow-by gas) Integration of the pressure control valve of the crankcase ventilation Pre-assembled gasket Pre-assembled isolating elements Pre-assembled oil filler cap Decorative plastic surface design with inscription Polyamide cam cover module for commercial vehicles. The advantages Production reliability by performing functional tests of the complete module Simplified logistics enabled by a smaller number of parts Economy of time during engine assembly Cover modules. More than just beauty. Modern engines exhibit impressive performance, optimum consumption and emission values, together with good acoustic behavior (focusing on noise reduction). Furthermore, functionality is combined with aesthetics by means of an attractive, modern engine compartment design. Plastic engine compartment covers from ElringKlinger therefore take on other tasks while sporting an attractive appearance: The isolated mounting and special soundproofing foam provide these so-called cover modules with a Cover module. noise-reducing effect. The heat channels integrated in the foam enable a targeted transfer of heat and thus prevent heat build-up. Another advantage: The special fastening elements ensure that the cover modules are easily fitted on the engines without any tools. Cover for ignition module. 7

8 Housing modules for transmission. Integrated functionality. More functionality and operating efficiency In the field of transmission too, ready-to-install plastic cover modules with complete sealing technology and fastening systems including additional functions are increasingly replacing the single components used so far. The modules can be precisely adapted to the respective requirements in terms of media, temperature, forces, stiffness, etc. Integrated quality and systems expertise from a single source ElringKlinger. Plastic oil pan module for transmission. The advantages Integration of multiple functions Weight reduction/lightweight construction Shorter development times State-of-the-art engineering and production technologies Complete assembly of all components in integrated production cells 100% function control and quality control Just-in-sequence deliveries High degree of operating efficiency Gearbox cover with radial sealing for electronic plug. Plastic housing modules: less weight, more advantages. A variety of additional functions can be implemented very efficiently and economically owing to the special processing properties of plastic. Best example: The integration of oil filter systems enables the delivery of a ready-to-install module, which is already checked for leak tightness and which minimizes the required installation space in addition to cutting costs. Gasket Suction filter module Transmission oil pan with integrated filter. Captive installation of magnets without additional parts Magnet Oil pan module with captive installation of integrated magnets and integrated filter. Optimum spinning of the magnets in the secondary flow Oil pan 8

9 Oil pan Elastomer gasket Bolts/sleeves Oil filter Oil baffle Magnets Oil drain plug Complete assembly Automated 100% function and quality control Just-in-sequence delivery Example of application: Plastic compared with aluminum ElringKlinger has developed a plastic oil pan module, which offers decisive advantages compared with the aluminum oil pan used so far in series production: The sealing behavior of the elastomer sealing system integrated in the plastic module is clearly superior to that of the composite gasket that used to be mounted separately until now. It is thus possible, among others, to reduce the number of fastening points from 22 to 11. The sealing course of the new plastic oil pan was designed so as to still reliably seal all the 22 fastening points used until now, and ensure that the module can be retrofitted in transmissions that have already been delivered. The aluminum oil pan (left) was replaced with a plastic oil pan module with integrated gasket (right). This enabled a reduction in the number of fastening points by half. The weight was reduced by more than 40 percent compared with the aluminum component, and costs were also cut considerably. Innovative solutions. Tailor-made, multifunctional for new applications. Plastic engine oil pans. Lighter, cheaper, quieter. ElringKlinger relies on the use of plastic as the cover material in the field of oil pan modules as well. The particularly high strength values required for this purpose can be achieved by means of new, efficient materials made of reinforced plastics. Furthermore, it is also possible to integrate numerous additional functions. 9

10 The advantages in comparison with engine oil pans made of metal are obvious: Engine oil pans made of plastic are lighter, cheaper, and also quieter due to the reduced intrinsic structure-borne noise and their damping of engine noise. Integrated functions Oil suction pipe with screen filter Dipstick Drain plug Bracket for oil filter Pressure oil pipe to the oil filter Oil sensor Pre-assembled gasket with fastening elements Quick connector for oil filling Screw-connection points for cable ducts, etc. Stone impact protection Plastic engine oil pan; interior and exterior views. Clutch pistons for automatic and double-clutch transmissions. Shift gears faster in confined spaces. We also use our core competences in metal forming, and elastomer technology in a targeted fashion in the new field of application of dynamic sealing. For the growth segment of automatic transmissions and doubleclutch transmissions, automatic robot systems are used to manufacture high-precision clutch pistons based on elastomers especially designed for this purpose, and high-strenght steel types. Materials expertise, precision forming technology, and state-of-the-art elastomer technology result in clutch pistons having reduced friction force to guarantee shortest possible time to shift gears. This results in a reduction of power losses in transmissions a significant contribution to reduce fuel consumption of passenger car engines. Chain case cover made of plastic. A new generation of plastic applications on the engine. The acoustic behavior optimized by means of the finite element analysis and the achieved weight reduction are among the main advantages of the innovative plastic chain case covers by ElringKlinger. Furthermore, there are different technical possibilities to integrate additional functions, such as fastening elements, cyclone oil separation, as well as mounting of various pump units and toothed belt tensioners. With this new product, which can replace the aluminum covers used commonly until now, ElringKlinger has opened another field for plastic applications under the hood. 10

11 Cam cover gaskets. A quiet solution. Noise-isolated The elastic isolation of resonant bodies such as cam covers, intake manifolds, and oil pans can effectively reduce engine noise. In doing so, the conflicting requirements and characteristics of the components must be combined in the isolating system: the increased damping effect of an isolating element and the increased sealing force of the elastomer gasket. The quiet solution from ElringKlinger: noise-isolated sealing systems. Precisely designed right down to the last detail. Sleeve (load-carrying element) Rubber grommet Housing component/ resonant body Gasket retention feature Elastomer gasket Elastomer gasket Bolt Elastomer gasket and isolating system. Isolating element Gasket F/N F/N Working point Compression/mm Force-deformation curves of the isolating system. The combination of finite element calculations, laboratory simulations, and material development enables customized noise-isolated sealing systems. 11

12 Cam cover gasket with elastomer-sheathed steel beam for cam covers made of aluminum, magnesium, and steel. Requirements Isolation of structureborne noise isolation Secure fastening Seal Pre-assembled system Assembly Service Solutions Elastic installation of the component between the elastomer gasket and the isolating element Component combination of bolt and sleeve Optimum elastomer materials in terms of price and performance, and a gasket design with optimum functionality The isolating system is fixed in a loss-proof fashion to the component The bolt is mounted adjustably in the sleeve. The module is simply mounted on the engine as a single, complete unit. A centering tip on the bolt facilitates automatic assembly The isolating system can be replaced easily and cost-effectively Universal applications in cam covers made of plastic, aluminum, and steel Sealing system and isolating system from a single source and adapted to one another optimally Materials adapted precisely to the specific application ensure maximum reliability Non-noise-isolated Elastomer gasket with three-dimensional shaping and isolating system. Economical sealing solution for cam covers made of plastics, aluminum, magnesium, and steel Variety of systems enabling optimum adaptation to the installation space in each case Integration of additional component functions Cam cover gasket with integrated cable duct. 12

13 Expertise. From development to readiness for start of production. As a competent, innovative development partner and experienced series supplier, ElringKlinger is a one-stop provider of reliable solutions: Readyto-install modules with complete sealing technology and fastening systems as well as accessories specifically adapted to suit customer requirements. Plastic cover Material Design Stiffness Gasket Material Design Pressure control valve Membrane Spring Plate Fastening system Design Material Oil separation Design Function 3D CAD drawing. Plastic modules Function Acoustics Costs All from a single source ElringKlinger Design and assembly monitoring (3D CAD) FEM calculation Seal Isolation Cover Prototype parts Mold flow calculation Tools Rig tests Durability Function Pressure control valve Oil separation Engine tests Vehicle testing Customer Construction/Design Construction/design in the 3D CAD system of the customer s choice Analyses of installation space performed at the earliest possible stage of development Integration of the different module functions Cold test in the climate chamber. 13

14 Finite elements analysis Computer simulation of structural stiffness of plastic components and sealing systems during the design process Flow calculations Acoustics simulation for early reduction of noise emissions Reduction of development times and costs by means of simultaneous engineering of housing module, filter/oil separation system, and sealing system Testing/Simulation Prototype testing on ElringKlinger test benches to ensure effective Simulation of acoustic behavior. sealing for the service life of the component Laboratory simulation of module functions that are integrated in the Dynamic thermal shock testing. plastic components Engine tests to validate various functions that are integrated in ElringKlinger components Special test benches for determining the oil separation performance in ElringKlinger plastic modules Prototype test. 14

15 Materials Expertise. Plastics and elastomers of the finest quality. Identification of thermodynamic characteristics Elastomers must provide a reliable sealing performance for a wide range of engine operating conditions. This holds true at an operating temperature of -40 C just as at an operating temperature of 150 C, regardless of the dynamic movements of the sealing gap. Material tests Identification of the dynamic characteristics of elastomers. Sealing force [N] Test duration [hours] 200 C 175 C 150 C 135 C In order to guarantee that the sealing performance of ElringKlinger materials will last throughout the service life of the components, test procedures have been established so as to predict the sealing behavior of our components depending on their lifetime, temperature, and the dynamics of the sealing system. These results are also processed further in our FEM analyses. Elastomer materials As elastomer materials, ElringKlinger exclusively uses in-house developments, which are optimized to special customer requirements. Specialization in high-performance materials emphasizes the systems expertise in sealing systems in the field of engine and transmission. 15

16 Overview of elastomer materials Elastomer selection based on oil and temperature resistance. Abbreviation FPM MVQ MFQ ACM AEM EPDM ECO HNBR (ISO 1629) Chemical term Fluoro- Silicone Fluoro- Poly- Ethylene Ethylene Epichlor- Hydrated carbon rubber carbon acrylate poly- propylene hydrin nitril rubber silicone rubber acrylate diene rubber rubber rubber rubber rubber Range of applications Fuel o Coolant + o o o Oil + o Thermal application -40 to -70 to -70 to -40 to -40 to -50 to -40 to -30 to ranges +230 C +200 C +180 C +160 C +160 C +150 C +120 C +150 C Product examples CHG, CHG, CHG, Oil pan, Oil pan, Water Special Special intake special special cam cover cam cover pump appli- appliarea appli- appli- cations cations cations cations in the field of fuel + well suitable / 0 suitable / - unsuitable / CHG = cylinder head gasket Temperature resistance EPDM MVQ LSR Improved resistance to fuels/oils Improved cold flexibility FMVQ FKM ACM/AEM HNBR Temperature resistance Temperature resistance NR CSM AU NBR CR SBR Oil resistance 16

17 Plastics (thermoplastic materials/thermosetting materials) As one of the largest processors of polyamide and thermosetting materials, ElringKlinger has leading materials expertise in the field of plastics. Suitable test methods form the basis for a component-compatible selection of materials and a precise prediction of the component behavior during actual engine operation. ElringKlinger s comprehensive know-how surrounding materials further facilitates the optimum, application-specific selection of materials and a design approach individually adapted to different materials. Polyamide cam cover module. E-module [MPa] Temperature [ C] Material 1 Material 2 Material 3 Material 4 Cam cover module made of thermosetting materials. 17

18 The information contained in this brochure is the result of technological analyses. They may be subject to changes depending on the design of the system. We reserve the right to make technical changes and improvements. The information is not binding and does not represent warranted characteristics. Any claims for compensation based on this information shall not be recognized. We accept no liability for printing errors Lorenz & Company ElringKlinger AG Max-Eyth-Strasse Dettingen/Erms Germany Tel. +49 (0)71 23/724-0 Fax +49 (0)71 23/ info@elringklinger.de