T echnology H ighlights and R&D Ac tiv ities at FEV
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The New FEV India Technical Center in Pune
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As a result of the strong demand for engine and powertrain development and testing, FEV has established a
Technical Center in Pune, India. Pune is in western India
and is considered a strategic location because existing
Indian clients like TATA, Mahindra + Mahindra, BAJAJ,
SUMMARY
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The New FEV India Technical Center in Pune
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NVH Challenges for Two- and
Three-cylinder Engines
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Further Development of FEV’s Fully Variable
VCR System
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GT 2: Two-stage Charging as a Downsizing
Concept for Large SI Engines
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FEVALYS – New FEV Solution for Efficient
Test Data Evaluation
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Short News
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www.fev.com
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Greaves, Kirloskar as well as multinational OEMs (e.g.
GM, VW, JCB and MNEPL) have already established
their headquarters there.
This Technical Center primarily provides the following
key services:
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Comprehensive endurance test programs
Engine design and CAE solutions
Sales and service for its customers
Skilled manpower for FEV advanced test systems
commissioning and operation
The Technical Center covers an area of approximately
20,000 m2 and offers direct access to Pune City and
the International airport in Mumbai.
© FEV 2009, based on UN map No. 3665 + 4112 Rev 2
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I s sue 42, September 20 09
FEV SPECTRUM
Preface
Dear Spectrum Reader,
Preparing a vehicle to be launched in a
foreign country can represent a major
challenge, even when the production
vehicle has been successfully launched in
its home market. To ensure a successful
launch, the final phase of the development
process must be repeated. In addition,
suppliers have to be selected, managed
and qualified to consistently guarantee
a high-level of quality. The influences of
operating conditions and fuels have to be
checked, which sometimes requires the
design to be adapted as well.
Market-tailored derivates are gaining increasing
importance. Based on previously validated
platforms, the specific requirements of the target
market – in most cases also the production location
– must be taken into account to be successful.
India and China are examples of markets which
justify an approach that includes additional
development effort.
FEV’s new technical center in India is ready to
support you in meeting the local challenges
of this emerging market. Pune is the central location for many Indian and international automotive
manufacturers and is also the site of our technical
center, with all the required design, calculation,
testing and calibration resources at its disposal.
Our local team of employees is equipped with
detailed knowledge of the Indian suppliers, on-site
conditions and combined with the experience of
our employees in our headquarters in Aachen and
the worldwide FEV technical centers. We would
be glad to assist you in meeting these local
challenges.
Phase I of the Technical Center’s construction has
been built and will be expanded to match the future
requirements of the Indian OEMs. From an economic
standpoint, efficient process sequencing and high
plant availability are key factors for success in the
construction of such a test facility. The FEV India
Technical Center is equipped with our advanced testing technology that will support the endurance and
development testing requirements of future engine
generations.
This center has attached special importance to efficient work flow as well as to the definition and organization of effective processes in the workshops
and in test rig operations. All of the features of the
building, the media supply services and the test
rig technology were optimized for high test bench
availability, including the necessary redundancies.
Highly-standardized test rigs are featured that can be
operated dynamically; however, the facility will also
feature a design that is largely modular to accommodate conditioning units. FEV’s usual high engine and
powertrain testing standards will be maintained.
The test facility is configured into several interconnected wings, with a usable floor space of approximately
9,000 m2. The structure is an excellent example of state
of the art test facilities, which feature containerized test
benches. The well organized structure and efficient
planning will ensure continuous operation of the plant,
24 hours a day / 365 days a year, with clearly defined
responsibilities and work processes.
Test operations started in July 2009, with two test
benches. Additional test benches are currently undergoing the commissioning process and will soon
be operational for clients. These test programs in the
FEV India Technical Center are conducted on fullyautomated test rigs, based on the latest state of the
art technology.
Yours faithfully,
Dr. Ernst Scheid, Executive Vice President
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Fig. 1: P
rof. Franz Pischinger, Prof. Stefan Pischinger and
representatives of the Indian and European automotive industry after “Lighting Lamp”, an Indian
ceremony marking the beginning of new projects
FEV SPECTRUM
The center was inaugurated by Prof. Dr. Franz
Pischinger – Chairman FEV Group Worldwide and
other top FEV officials on July 2nd.
The FEV India Technical Center provides tremendous
support to automotive OEMs, fuel research labs, R&D
centers and component suppliers in India. This was
evident by their presence in large numbers during FEV
India’s Technical Center Inauguration held on July
2nd and during the “1st FEV India Day of Powertrain”
held on July 3, 2009.
Fig. 2: “Coconut Breaking”, a traditional Indian inauguration
ceremony for good luck, celebrated by Prof. Stefan
Pischinger and Sushil Berry (Managing Director FEV India)
Fig. 3: Phase I of the new facility buildings in Pune, India
FACTS AND HIGHLIGHTS OF THE NEW TECHNICAL CENTER
The Phase I of FEV India Technical Center includes:
T hree steady state engine test rigs are setup for performance Tests including emissions measurement for engines
up to 400 kW
■ One transient dyno test rig for performance evaluation including emissions measurement for engines up to 250 kW
■ Two durability test rigs of up to 130 kW
■ Two Commissioning test rigs
■ Assembly / workshop / operating shops, laboratories
and offices
■ Design center
■ Local construction of FEV Test Systems
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Continuous operation 24 hours a day / 365 days a year
utomatic safety monitoring of defined shut-off limits
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Large number of measuring channels
Potential for data pick-up from the Engine Control Unit
(ECU)
■ Possibility for loading auxiliary units
■ Possibility for analyzing the raw exhaust gas concentrations during the test cycle
■ Availability of independent cooling systems (hot/cold) for
fast thermal cycles
■ Analysis of all operating liquids (< 24 hour response time)
■ Use of conventional fuels or special fuels
■ Extensive ratings for all tested engine parts, including
photographic documentation
■ Comprehensive reporting on progress and failures,
if applicable
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