Company Overview
Diesel Jet at a glance DieselJet was established in 2003. Since 2011 it is owned by METATRON, an industrial group operating in the automotive field as CNG and LPG systems manufacturer. METATRON and DieselJet now have their main locations in Castel Maggiore (Bologna). DieselJet is focused on the engineering design, development and industrialization of Common Rail Diesel Engine and Gasoline engines derived from the auto industry for aviation rotary and fix wings applications: New Generation Diesel Common Rail engines Gasoline injection engines Transmissions and electronic control systems (FADEC). Gear box and Engine installation kits 2
Growth Through Technology Leadership First Italian diesel engine for aviation certified since 1943 in Italy Strong Electronics and mechanical skills engineering Big experience in Diesel Control Propulsion systems Availability of metrological laboratories and test facilities including Dyno test cell, propeller test rig (under construction) Connections with major Research Centre and University 3
Advantages of aviation Diesel Engines as automotive spin-offs By making the most of the experience gained in large-scale product manufacturing, the result is a considerable reduction of the (hardly recoverable) costs and time that would have been necessary for designing, developing and producing a specific engine. Thanks to a statistically relevant population, the conspicuous and reliable data at hand allow to evaluate the product safety. The fast and continuous technological evolution of the automotive industry results in potentially interesting innovations in the aviation engines field. 4
Common Rail Diesel Engines, born to fly Advantages of Diesel Engines for Aviation use Significant fuel consumption reduction, estimated around 30% Opportunity to use the same fuels that propel jet aviation engines, such as kerosene Jet A-1 or JP 8, thus profiting from easier availability, higher safety and lower costs compared with gasoline Good suitability for turbocharging with consequent high specific power and capability to keep the performance constant with the altitude High torque even at low speed with positive results in terms of gearbox weight reduction Robustness, reliability and longer maintenance intervals Low lubricant consumption 5
Product Range Family and Field of Applications UAV General Aviation Light Sport Aircraft Diesel Common Rail engines Gasoline injection engines Gear box and Engine support Electronic control systems (FADEC) 6
Engines Range Power (KW) 300 TDA CR 3.0 24V 230 KW Future development 400 CV range 250 200 150 100 50 TDA CR 2.0 16V 160 KW TDA CR 1.9 8V 1.4 gasoline 121 KW injection Industrialization phase 1.0 2.0 3.0 300 CV range 200 CV range 100 CV range Engine Displacement (liter) 7
Key Features of TDA CR 2.0 16V 8
TDA CR 2.0 16V Encumbrance dimensions 9
Full Authority Digital Electronic Control FADEC (Full Authority Digital Electronic Control) is the digital control system managing the Common Rail Diesel engine and is connected to the cockpit instruments and control. It can also be controlled by a FCS (Flight Control System). FADEC is based on a «hot redundant» architecture concept adopting identical dual LANEs and redundant Power Supply Units plus BACK-Up Logic (BUL). This means that each section (named LANE) has its own microprocessor with dedicated hardware and software capable of independently controlling the engine; it includes a diagnostic feature monitoring the LANE s FADEC Architecture health and, if required, the correct operation\use of the engine. By means of a dedicated internal communication media and software, each LANE exchanges its own engine parameter with the other LANE in order to detect faults, isolate them and perform recovery action in real time. The BUL manages the LANE s operation by monitoring run time, health and correct availability of each FADEC section thanks to dedicated hardware signals. The scope is to keep only one LANE in charge of the engine control and maintain the engine running with optimum performance in safe conditions. 10
Gear Box COVER NOSE GEARS Propeller FLANGE ENGINE SUPPORTING FRAME FIXING POINTS 11
From the automotive industry, the excellence in aircraft engines Cessna onboard installation for flight testing 12
Down-to-earth technology, sky-high performance Flight test with DieselJet common rail diesel engine 13
Certifications On 6 December 2006, DieselJet obtained the first engine manufacturing approval for TDA CR 1.9 8V according to EASA Part 21 subpart F by ENAC (Italian Aviation Authority) On 9 July 2008, DieselJet was approved by EASA as Design Organization with c.a.n. EASA.21J.283 On 11 June 2010, DieselJet obtained the Type Certificate for its engine TDA CR 1.9 8V n. EASA.E.079; the new TDA CR 2.0 16 V is now under Certification 14
References 15
Facilities: Castel Maggiore (Bologna) Site 16
Facilities: Volvera (Turin) Site 17
METATRON, Diesel Jet Owner METATRON manufactures components and systems for using Natural Gas (CNG &LNG) as fuel for automotive purposes, passenger cars and trucks; with more than one million regulators/systems supplied, METATRON is leader in the O.E.M. market. Enjoying its motoring and propulsion control expertise, METATRON acquired DieselJet in 2011 with the aim of diversifying its business perimeter by using its «core skills». 18
METATRON facilities Metatron Headquarters are located in Castel Maggiore (Bologna, Italy) and cover an area of 5.500 sq; the engine Engineering and the Electronics operations are carried out on the premises of Volvera (Turin) plant. In the above locations METATRON shares a part of the plant area, technical staff and facilities with Diesel Jet. The presence of the Company in highly potential territories is enhanced by the Shanghai branch dealing with the entire Asia Pacific market. 19
METATRON Industries, Companies and Locations Castel Maggiore-Bologna ITALY Headquarters Management Finance&Control Sales Products Engineering R&D Operations 80% 100% 95% Metatron Control System SHANGHAI Shanghai-CHINA Metatron Asia Pacific Branch Marketing & Sales Service Taylor-made solutions AP logistic hub Engineering &Electronic Division Volvera Turin ITALY Engines Engineering Systems Engineering Electronics Development Testing & Labs Castel Maggiore-Bologna ITALY Management Operations Sales Products Engineering 20
METATRON, main Products Pressure regulators Components / accessories ECU The pressure regulators are the core product of the company. They are all based on piston technology and R10 / R110 homologated ISO 15500. Components fuel injector Rails sensors pipe & fittings HDS (stand-alone) Engine control system for Heavy Duty CNG only propulsors SDU (Smart Drive Unit) LPG P&H injector driver for passenger car 21
METATRON, main Applications Heavy duty (CNG Engine only) Light duty (Bi-fuel Engine) Commercial Vehicles Passenger cars Heavy Trucks Service Vehicles Buses Light Delivery Vans Medium Delivery Vans 22
METATRON, Engineering & Electronic Teams The robust process is achieved thanks to a team of 15 people, including engineers and expert technicians, that can rely on overall skills and facilities such as: Senior Project Manager with almost 25 year of experience in engine control systems Engine, Control and Electronics engineers team for integrated engine/engine control system development team Simulation environments for fast prototype of control strategies and SW Electronics HW design team SW development expert team on multiple layer SW development Engine test bed for real scale Engine Control System validation team Testing equipment for full HW and SW validation Engine parts design and validation Engine Control Module calibration engineers team Production process quality engineer The human resources and relevant skills are fully shared by Metatron and Diesel Jet. 23
Electronic Components: Process Development Engineering & Electronics Div. develops injection systems with the most modern and safe technologies. The development process includes: Customer Requirements Documentation feasibility analysis Engine Requirements Analysis and system outlook definition Integrated System Concept development (ECM Sensors Actuators Wiring Harness definition) System Specification Draft definition SW design on fast prototype development tools chains HW prototype development and manufacturing SW prototype development and preliminary debug and functional validation on SW on the loop environment Prototype HW and embedded code integration for real scale functional validation (embedded code from automatic generation tool chain) HW design freezing and full validation Concurrent Engine Control Module Calibration according to engine manufacturer CRD Embedded code full validation Final Design Release for production and System Specification Freezing 24
R&D, Technical Dpt and testing Labs Metatron Technical Dpt develops and continuously improves the core product and heart of the CNG fuel system: pressure regulators and all the other accessories such as hoses and fuel rails. A complete product development - from feasibility analysis through concept definition to engineering release - strictly complying with ISO-TS APQP process. The R&D, Technical and testing teams count on 18 people including engineers and expert technicians. The tasks, accomplished by means of 0D software, CAD and post processing software, include: Simulations Mechanical design of all components Requirements and specifications for suppliers Testing is carried out at Metatron fully equipped Laboratory for complete automotive validation: Mass spectrometer leak measurement device Climatic room + air temperature conditioning machine Thermal shock room; Vibration test bench Salt spray room Automatic flow rate test benches 25
Thank you for your attention 26