Power Cylinder System Design

Developing, manufacturing and purchasing the heart of the engine as one coherent unit from a single source offers a variety of advantages. Federal-Mogul believes working closely with its customers at the highest level of the engine development process provides substantial benefits:

• Optimized system for mass and performance
• Reduced supply complexity
• Higher productivity of OE engineering resources
• Fewer requirements to specify
• Reduced system cost and development lead time
• Increased value added for both partners

Concept Engineering

Federal-Mogul has created an innovative design process that meets the increasing requirements for Power Cylinder Systems while reducing lead time for development. One of the ways we’ve reduced lead time is by changing the linear nature of the process to an approach by which several tasks can be managed simultaneously by transient teams.

We offer complete design services, from the customer’s initial engine proposal through design and analysis to delivery of the prototype product.

Our Concept Engineering process consists of three phases, based on a number of critical parameters:

1. Function and performance
2. Cost
3. System delivery to project key dates

Based on these parameters, we develop an optimized solution involving the piston, rings, conrod and liner.

Prototype Analysis

The purpose of Power Cylinder Analysis is to verify at an early stage that the proposed system meets the customer’s technical requirements. Predictive analysis reduces the number of required tests, thus reducing both time and cost.

We typically analyze three key areas in prototype analysis to guarantee soundness of design:

• Confirm structural features using thermo-mechanical finite element analysis and life prediction.
• Validate performance requirements using various analysis techniques involving engine thermodynamics, kinetics and tribology.
• Analyze manufacturing features (for example, the ability of the casting process to provide good-quality, cost-effective castings).

Validation

Validation ensures that the system dynamics work together as a whole: the tribological interface of the piston rings and cylinder liner; the gas dynamical system of the piston ring and the piston; and the power transmission system of the piston, piston pin and connecting rod.

The products are thoroughly tested by Federal-Mogul and our customers to investigate all aspects of performance, including the following areas:

• Oil consumption
• Fuel consumption
• Emissions
• Blowby
• Friction
• Durability
• Wear (system)
• Noise
• Reliability

Testing of new Power Cylinder System assemblies can be broadly divided into two categories. Standard verification of component performance and durability includes the measurement of fuel consumption, emissions, blowby, wear and durability. Advanced measurement techniques allow a quantification of NVH, an evaluation of the system’s friction and its influence on oil consumption and emissions.