Engg Presentation

842019 Engg Presentation

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Overview of Engineering

Division Activities



1 Development of engine and transmissioncomponents for localization

a Absorption of Diesel Engine technology from FPTand GMPTE within SPIL

b Design optimization for localization c Product data and engineering standard

administration

d Development of components and componentsuppliers

e Project management for Diesel EngineDevelopment



2 Engine testing for localization of engine

a Type of tests performed during validation

b Evaluation of components

c Manufacturing support with regard to technical

issues

3 Vehicle testing for localization of engine

4 Market problems related to YN-4 D engine



1a Absorption of Diesel Engine Technology

Displacement 1248 cm3

Layout valves 4 cylinder in line ndash 4 valvescylinder

Maximum power [BHP] (ECE 85) 75 4000 rpm

Maximum power [kW] (ECE 85) 55 4000 rpm

Maximum Torque [Nm] (ECE 85) 190 2000 rpm

Fuel Diesel Bore amp Stroke 696 mm amp 82 mm

Compression ratio 176

Mass (DIN 70020 A) 137 kg

Dimensions (Lenght x Width x Height) [mm]

(dressed engine - only for reference)4325 x 485 x 6515

Emissions (ECE Regulation 9869) Euro 4 capable

Block Cast iron

Cylinder head Aluminum

Fuel injection system Common Rail 1400 bar Multijet reg

Valvetrain DOHC ndash ldquomini-lashrdquo adjuster ndash roller finger







1b Design Optimization for Localization(ex)

Current design

New design1 Modified due to non-availability of data2 Keeping in mind new cylinder block in the

future

New Cylinder Block



1c Product Data Administration

bull E-BOM

bull SMC Drawings

bullFPT Drawings

bull FIAT Engineering Standards

bull Engineering Change Requests

bull Engineering Change Notices

bull CRFs



1d Development of Components andComponent Suppliers

Engine Testing (at MUL)-India

Beta parts development

Beta parts approval(PI)- Filling of GP-11docs

Beta Engine Build (at FPT protoshop)- Italy

Feedback on parts aftertesting

Engine Testing (at FPT)-Italy

Beta Vehicle Testing (at MUL)

Beta Vehicle Build (at MUL)- India

Kick off meeting (Engg+PI)

KSM (Key stake holders Meeting) (Engg+WWP+PI)

RFQ send to Probable suppliers (WWP activity)

Technical Reviews (Engg+WWP+PI)

Supplier nomination (WWP)



1d Development of Components andComponent Suppliers (contd)

Gamma Engine Build (at SPIL)

Feedback on parts after testing

Vehicle Build (at MUL)Engine Testing (at FPT)Engine Testing (at MUL)

Vehicle Testing (at MUL)

Gamma parts development

Gamma parts approval(PI)

SOP of Engine (at SPIL)

SOP of VEHICLE (at MSAIL)

PP Engine Build

PP Engine Testing (at FPT)PP Engine Testing (at MUL)

PPAP of parts

PPAP Approval (PI)

Pilot Engine Build

Pilot Engine Testing (at FPT)Pilot Engine Testing (at MUL)



1e Program Management of Localization

Program



1e Definition of development stages

ALPHA STAGE Concept stage ndash to confirm that the design is workable

BETA STAGE Product validation stage- to confirm that the product specifications areachievable ( Process can be as per suppliers choice)

GAMMA STAGE Process validation stage- confirms the process to be used for manufacturing

a particular product (Finalised process sequence and machines to beused)

PPAP STAGE

Production Part Approval Process ndash Ensures that all equipments gaugesand process quality control requirements are in place

RUNRATE STAGE It ensures that mass prodn volumes can be achieved (qty and Quality) at a

rate in line with customerrsquos requirement



2a Type of tests performed during

validation

bull Synthesis Test

bull Reliability Growth Test

bull Valve Wear Testbull Piston Scuffing Test

bull Engine Mapping

bull Thermal Shock Test



Dynamometer Setup

Dynamometer

Dyno controller

No of dynos = 4



2b Evaluation of components

1 Measurement of the components before the Synthesis TestDurability running

2 Measurement of the components after the Synthesis TestDurability running

3 Visual Inspection of the Components before and after testing

4 Evaluation of the wear defects against the permissible wear

5 Evaluation of parts for degradation in performance after durability testing

6 Evaluation of SoR parts carried out along with supplier support



2c Manufacturing Support With Regard to

Technical Issues

1 Engineering Analysis of the parts for Quality Related Problemsduring Mass Production

2 Conducting Trials for Finding the Root Cause of the problems

3 Implementation of the Countermeasures at SPIL or supplier end



3 Evaluation of Vehicle (using MUL

facility)

Dyno controllers

Vehicle under test

Chassis dyno rollers

Equipment forsampling exhaustgasses for analyzer



3b Technical support for diesel engine and

vehicle integration by SMC

1 Durability Testing

2 MAF Sensor Modification

3 EGR Valve Testing

4 Depopulated ECU Incorporation



Manual Transmissions 5-Speed (FWD)

Current TM YN4-D

YY4 YN2 amp YV1(Export)

Under Dev TM YC5 YL6 YV4-D YV4-P



Counter Shaft Sub Assy

Input shaft sub Assy

Differential sub Assy

Gear Shifter

Major Parts In Transmission



Shifter Shafts (Low High5th amp Rev)

Clutch -Slave Cyl Assy



A YN4-D Transmission with Higher Toque Carrying Capacity up-to 250Nm

Salient Features of Transmissions



B CSC (Concentric Sleeve

Cylinder) is used in YN4-D ampYY4 for improved ClutchPedal Feeling



YN4-D amp YY4 is Equipped withHydraulic Clutch Actuation

system in place of conventionalCable type system



YN4 ndash Clutch Actuation System

Conected to Pedal

Connecting Pipe

Release Bearing

Pipe

SleeveT-Joint



C Double Cone Synchronizer in 1st amp

2nd gear introduced in place of

conventional Single Cone or DoubleCone only in 2nd Gear For smootheffortless down shifting at higher RPM



D Improved NVH

characteristics of Gear Boxwith assistance of

a) Differential systemsupported on pre-loadedTaper Roller Bearings inplace of conventional BallBearings



Major Responsibilities for TM Design

1 Co-ordination with MSIL engineering (ENT)2 Design amp PDM related activities for export

models (uncommon parts)3 Development activities for 2nd sourcing4 In house line problem solving5 ECNECR follow up amp implementation for

MSIL models



Future Responsibilities for TM Design

1 Localization of Gears amp other TM parts2 Design amp Development of new

generation TM systems

3 More involvement in partsdevelopment of MSIL models

4 Second source development for TMcomponents to meet annual

requirements



Thank you for you

attention



1 Development of engine and transmissioncomponents for localization

a Absorption of Diesel Engine technology from FPTand GMPTE within SPIL

b Design optimization for localization c Product data and engineering standard

administration

d Development of components and componentsuppliers

e Project management for Diesel EngineDevelopment







issues

















Block Cast iron











Current design


future

New Cylinder Block




bull E-BOM

bull SMC Drawings

bullFPT Drawings




bull CRFs




























PP Engine Build


PPAP of parts

PPAP Approval (PI)

Pilot Engine Build





Program








PPAP STAGE







validation

bull Synthesis Test



bull Engine Mapping




Dynamometer Setup

Dynamometer

Dyno controller

No of dynos = 4













Technical Issues







facility)

Dyno controllers

Vehicle under test









3 EGR Valve Testing





Current TM YN4-D








Gear Shifter





















Conected to Pedal

Connecting Pipe

Release Bearing

Pipe

SleeveT-Joint








D Improved NVH








MSIL models








requirements



Thank you for you

attention







issues

















Block Cast iron











Current design


future

New Cylinder Block




bull E-BOM

bull SMC Drawings

bullFPT Drawings




bull CRFs




























PP Engine Build


PPAP of parts

PPAP Approval (PI)

Pilot Engine Build





Program








PPAP STAGE







validation

bull Synthesis Test



bull Engine Mapping




Dynamometer Setup

Dynamometer

Dyno controller

No of dynos = 4













Technical Issues







facility)

Dyno controllers

Vehicle under test









3 EGR Valve Testing





Current TM YN4-D








Gear Shifter





















Conected to Pedal

Connecting Pipe

Release Bearing

Pipe

SleeveT-Joint








D Improved NVH








MSIL models








requirements



Thank you for you

attention















Block Cast iron











Current design


future

New Cylinder Block




bull E-BOM

bull SMC Drawings

bullFPT Drawings




bull CRFs




























PP Engine Build


PPAP of parts

PPAP Approval (PI)

Pilot Engine Build





Program








PPAP STAGE







validation

bull Synthesis Test



bull Engine Mapping




Dynamometer Setup

Dynamometer

Dyno controller

No of dynos = 4













Technical Issues







facility)

Dyno controllers

Vehicle under test









3 EGR Valve Testing





Current TM YN4-D








Gear Shifter





















Conected to Pedal

Connecting Pipe

Release Bearing

Pipe

SleeveT-Joint








D Improved NVH








MSIL models








requirements



Thank you for you

attention








Current design


future

New Cylinder Block




bull E-BOM

bull SMC Drawings

bullFPT Drawings




bull CRFs




























PP Engine Build


PPAP of parts

PPAP Approval (PI)

Pilot Engine Build





Program








PPAP STAGE







validation

bull Synthesis Test



bull Engine Mapping




Dynamometer Setup

Dynamometer

Dyno controller

No of dynos = 4













Technical Issues







facility)

Dyno controllers

Vehicle under test









3 EGR Valve Testing





Current TM YN4-D








Gear Shifter





















Conected to Pedal

Connecting Pipe

Release Bearing

Pipe

SleeveT-Joint








D Improved NVH








MSIL models








requirements



Thank you for you

attention




bull E-BOM

bull SMC Drawings

bullFPT Drawings




bull CRFs




























PP Engine Build


PPAP of parts

PPAP Approval (PI)

Pilot Engine Build





Program








PPAP STAGE







validation

bull Synthesis Test



bull Engine Mapping




Dynamometer Setup

Dynamometer

Dyno controller

No of dynos = 4













Technical Issues







facility)

Dyno controllers

Vehicle under test









3 EGR Valve Testing





Current TM YN4-D








Gear Shifter





















Conected to Pedal

Connecting Pipe

Release Bearing

Pipe

SleeveT-Joint








D Improved NVH








MSIL models








requirements



Thank you for you

attention




























PP Engine Build


PPAP of parts

PPAP Approval (PI)

Pilot Engine Build





Program








PPAP STAGE







validation

bull Synthesis Test



bull Engine Mapping




Dynamometer Setup

Dynamometer

Dyno controller

No of dynos = 4













Technical Issues







facility)

Dyno controllers

Vehicle under test









3 EGR Valve Testing





Current TM YN4-D








Gear Shifter





















Conected to Pedal

Connecting Pipe

Release Bearing

Pipe

SleeveT-Joint








D Improved NVH








MSIL models








requirements



Thank you for you

attention




Program








PPAP STAGE







validation

bull Synthesis Test



bull Engine Mapping




Dynamometer Setup

Dynamometer

Dyno controller

No of dynos = 4













Technical Issues







facility)

Dyno controllers

Vehicle under test









3 EGR Valve Testing





Current TM YN4-D








Gear Shifter





















Conected to Pedal

Connecting Pipe

Release Bearing

Pipe

SleeveT-Joint








D Improved NVH








MSIL models








requirements



Thank you for you

attention








PPAP STAGE







validation

bull Synthesis Test



bull Engine Mapping




Dynamometer Setup

Dynamometer

Dyno controller

No of dynos = 4













Technical Issues







facility)

Dyno controllers

Vehicle under test









3 EGR Valve Testing





Current TM YN4-D








Gear Shifter





















Conected to Pedal

Connecting Pipe

Release Bearing

Pipe

SleeveT-Joint








D Improved NVH








MSIL models








requirements



Thank you for you

attention




validation

bull Synthesis Test



bull Engine Mapping




Dynamometer Setup

Dynamometer

Dyno controller

No of dynos = 4













Technical Issues







facility)

Dyno controllers

Vehicle under test









3 EGR Valve Testing





Current TM YN4-D








Gear Shifter





















Conected to Pedal

Connecting Pipe

Release Bearing

Pipe

SleeveT-Joint








D Improved NVH








MSIL models








requirements



Thank you for you

attention



Dynamometer Setup

Dynamometer

Dyno controller

No of dynos = 4













Technical Issues







facility)

Dyno controllers

Vehicle under test









3 EGR Valve Testing





Current TM YN4-D








Gear Shifter





















Conected to Pedal

Connecting Pipe

Release Bearing

Pipe

SleeveT-Joint








D Improved NVH








MSIL models








requirements



Thank you for you

attention













Technical Issues







facility)

Dyno controllers

Vehicle under test









3 EGR Valve Testing





Current TM YN4-D








Gear Shifter





















Conected to Pedal

Connecting Pipe

Release Bearing

Pipe

SleeveT-Joint








D Improved NVH








MSIL models








requirements



Thank you for you

attention




facility)

Dyno controllers

Vehicle under test









3 EGR Valve Testing





Current TM YN4-D








Gear Shifter





















Conected to Pedal

Connecting Pipe

Release Bearing

Pipe

SleeveT-Joint








D Improved NVH








MSIL models








requirements



Thank you for you

attention







3 EGR Valve Testing





Current TM YN4-D








Gear Shifter





















Conected to Pedal

Connecting Pipe

Release Bearing

Pipe

SleeveT-Joint








D Improved NVH








MSIL models








requirements



Thank you for you

attention




Current TM YN4-D








Gear Shifter





















Conected to Pedal

Connecting Pipe

Release Bearing

Pipe

SleeveT-Joint








D Improved NVH








MSIL models








requirements



Thank you for you

attention






Gear Shifter





















Conected to Pedal

Connecting Pipe

Release Bearing

Pipe

SleeveT-Joint








D Improved NVH








MSIL models








requirements



Thank you for you

attention




















Conected to Pedal

Connecting Pipe

Release Bearing

Pipe

SleeveT-Joint








D Improved NVH








MSIL models








requirements



Thank you for you

attention








D Improved NVH








MSIL models








requirements



Thank you for you

attention






MSIL models








requirements



Thank you for you

attention








requirements



Thank you for you

attention



Thank you for you

attention

Engg Presentation

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