Yamaha DiASiL Cylinder

"DiASil": A name created as an abbreviation of Die-casting Aluminum-Silicon
Yamaha Motor Co., Ltd. (YMC) has succeeded in the development of an all-aluminum die-cast cylinder with 60% better cooling performance and 30% cheaper production cost than a conventional cylinder (*1). Called the Yamaha "DiASil Cylinder" (*2), this is the world's first all-aluminum die-cast cylinder and it achieves cooling performance equivalent to that of a nickel-plated cylinder, which is currently recognized as the best in the industry, but at a significantly lower production cost than a nickel-plated cylinder.

The material used is a 20% silicon content aluminum alloy, the manufacturing technology is the recently developed Yamaha CF Aluminum Die-cast Technology (*4), which enables the production of an all-aluminum die-cast cylinder. It is Yamaha's exclusive CF Aluminum Die-cast Technology that enables the mass production of a die-cast cylinder made completely of 20% silicon content aluminum alloy, something that could not be done with conventional die casting methods.

Merits of the Yamaha "DiASil Cylinder"
(in comparison to cast steel liner type aluminum cylinders)
(1) 60% better cooling performance is possible
(2) 30% lower manufacturing cost is possible
(3) Excellent recyclability
(4) Enables 30% lighter design
(5) Easily transferred to overseas manufacturing bases

Yamaha CF Aluminum Die-cast Technology = Yamaha Controlled Filling Die Casting. This is a die-casting technology that utilizes precise control of the casting conditions (degree of vacuum in the die, die temperature, injection speed of the molten aluminum) to reduce the amount of gas bubbles in the finished cast piece to just 20% of conventional methods in order to produce higher quality cast parts. Introduced in Feb. 2002.

In general, motorcycle engines run at high rpm (10,000 ~ 20,000 rpm) and the resulting high running temperature makes cooling performance very important. That is why lightweight aluminum, with its excellent heat transfer rate, is used for motorcycle cylinders. These cylinders made of inherently soft aluminum have a cylindrical cast steel liner inserted along the inner wall of the cylinder to reduce friction resulting from the piston's movement. Thus they are called "cast steel liner aluminum cylinders."

This construction, in which a cylindrical steel sleeve is inserted along the inner wall of the cylinder, produces a cylinder which is very reliable from the standpoint of reduced friction and reduced possibility of engine seizure. That is why Yamaha uses this kind of cylinder on approximately 70% of all the motorcycles it manufactures. In the case of models for the markets of Asia and Central and South America, this figure reaches about 90%.
However, there are also problems with the cast steel liner type aluminum cylinder, such as the complexity of the manufacturing process involved in inserting the steel sleeve, the poor recyclability of these cylinders and the limitations in heat transfer rate due to the presence of the cast steel liner (the heat transfer rate of steel is 1/3 that of aluminum). Other problems with cast steel liner type cylinders are environment-friendliness and manufacturing efficiency.

On the other hand, there is an alternative type of cylinder used on high-performance motorcycles that replaces the cast steel liner with a layer of metal plating on the cylinder wall. This kind of "plated cylinder" has superior cooling performance (about 60% better than a cast steel liner type) but also has the problem of higher production cost.

In specific terms, (1) the degree of vacuum in the die, (2) the temperature of the die and (3) the speed with which the molten aluminum is injected into the die are all precisely controlled in order to produce cast metal that has a highly abrasion resistant crystallization character with an even distribution of hard silicon particles. This makes it possible to mass-produce high quality all-aluminum die-cast cylinders without cast cavities.

- Comparison with Conventional Casting Method -

Basic structure for conventional die casting:
Due to conditions under which conventional die-casting occurs, including the degree of the vacuum in the die, the temperature of the die and the speed with which the molten alloy is injected into the die, there is a tendency for gas bubbles to form that limit the ability to cast parts with a good contact surface.

Structure for CF Die-cast Technology used for the Yamaha "DiASil Cylinder:
Due to the facts that (1) the die is enclosed in a box that enables a high degree of vacuum in even complex die shapes with many slides (six time greater vacuum than conventional die casting), (2) more stable molten aluminum temperature because the temperature of the die is controlled and (3) improved injection speed for the molten aluminum (five times faster than conventional die casting), it is possible to mass-produce aluminum cylinders with more complex shapes and good contact-surface quality.

K B series engine

Developing a fuel efficient, high performance, low emission, light weight engine, with lower Noise, Vibration and Harshness

The new KB series engine is a result of enormous R&D efforts and hours of design, validation and testing.
The engine realises the true spirit of the global design trend of optimizing engine performance through innovative design techniques.

Some of the salient features of the All new KB engine are:

All Aluminum Low weight engine for Best in class fuel efficiency
Innovative rocker-less DOHC Cam shaft, Plastic Intake Manifold & Offset crank shaft with low tension rings to reduce losses & improve fuel efficiency
Smart Distributor Less Ignition (SDLI) system with dedicated plug top coils, High pressure semi-return fuel system and Advanced injectors for superior atomization provide uniform and optimized combustion for better performance
Optimised Cylinder block, Light Piston and Nut-less Con Rod for light weight configuration
Improved engine stiffness and use of advanced technology like silent timing chain to improve NVH (Noise, Vibration & Harshness) characteristics
These and many more innovative technologies used in the new light-weight KB series engines helped to achieve best in class fuel efficiency, emission & performance with reduced Noise, Vibration and Harshness for customer delight.The KB series engine will be mounted on the forthcoming model, A Star, from Maruti Suzuki.The KB-series engine, while fully complying with the prevalent BS III norms, is ready to meet the future emission norms in the country. The Engine meets the Euro V norms for the export model of A Star.

Chevrolet Volt

Its to be launched in 2011 which is not basicaly a hybrid model.It is being called as plug in series hybrid vehicle.Unlike current commercially available hybrids, the actual propulsion of the Volt is accomplished by the electric motor, as the ICE is not mechanically connected to the wheels. With fully charged batteries, this electric power will initially be sourced exclusively from its on-board Lithium Ion batteries for up to 40 miles (64 km),After 40 miles (64 km), the range of the Volt will need to be extended through the use of a small 4-cyl ICE which drives a 53 kW generator. The electrical power from the generator is then sent to either the electric motor or the batteries, depending on the state of charge (SOC) of the battery pack and the power demanded at the wheels. The distribution is controlled by the electronic control unit (ECU) of the vehicle.

It introduced the E-Flex drive system, which is an attempt to standardize many components of possible future electrically-propelled vehicles, and to allow multiple interchangeable electricity-generating systems. The initial design as envisioned in the Volt combines an electric motor and 16 kWh (58 MJ) lithium-ion battery plug-in system[33] with a small engine (1.4 liter) powered by gasoline linked to a 53 kW (71 hp) generator. The vehicle is propelled by an electric motor with a peak output of 120 kW (160 hp).
Since the electrical drivetrain is not affected by the method used to charge the batteries, several options could be available for acting as an electrical power source. The primary configuration specified in the Volt promotional literature uses a turbocharged 1.0-liter engine with three cylinders, a flex-fuel engine capable of running gasoline or E85 (85% ethanol, 15% gasoline).
E-Flex Powertrain


Another engine-driven power option would be a pure ethanol (E100) engine, a diesel engine capable of running biodiesel fuel, or even a hydrogen fuel cell, once that technology becomes practical.

Indian Automotive mission 2006-2016

India's 10-year Automotive Mission Plan (AMP) 2006-2016 is out. Envisaging auto sector investments of $40 billion, the plan aims at enabling the country as a global automobile player in the next decade.

Accordingly, it would chart out a road map for the government and auto industry to achieve a turnover for the sector to increase to $145 billion by 2016, up from the current $35 billion, accounting for 10 per cent of GDP, said reports.

With India's auto sector exports seeking a raise of at least $35 billion if the nation is to be a substantial player in the global market, the auto sector needs around $40 billion investment. This would ensure employment to about 25 million people by 2016, it has been forecast.read more on www.dhi.nic.in/draft_automotive_mission_plan.pdf

Bosch new Smart Electronic start stop system

Bosch has developed an electronic system that will help in reducing fuel consumption by switching off the combustion engine when the vehicle is stationary, particularly during traffic jams or at traffic signals.This and other systems supplied by Bosch will also help reduce CO2 (carbon dioxide) emissions further. The technology is stated to have been used in production at BMW.

M&M is the first indian automobile industry to use it in its models.The device switches the engine off when the vehicle is stationary, and starts it again automatically as soon as the driver wishes to move off again.The Bosch system reduces fuel consumption and CO2 emissions by as much as eight per cent.

For the Bosch start-stop approach, developers have designed a specially adapted starter, the Smart Starter Motor. There is no need for any further adjustments to the drive train or the engine.

All new Kappa engine....

Hyundai launched a new 'i10', powered by a 1.2 litre Kappa engine, priced between Rs 3.99 lakh-Rs 5.43 lakh. The company has invested $421 million in research and development of the Kappa engine.The engine, developed in 48 months, would be launched in five variants of ‘i10’ such as Magna, SportZ, Asta, Asta Option, and Automatic, which will have sunroof, 2-din audio system and other special features.Kappa is the eleventh in its series of gasoline engines to be independently developed with Hyundai technology. The new fuel–saving power unit the Kia Kappa engine uses new technologies that cut weight and friction to boost fuel economy.Its some of salient features are -

• The new Kia Kappa engine manages a 5.0L/100km (47 mpg) fuel economy in a combined cycle and emits 119g/km of CO2 which is the lowest figure in its class. The Kia Kappa engine develops 80 PS at 5,200 rpm and 11.4 kgm of torque at 4,000 rpm in the 1.2 version. The Kia Kappa engine will power the i10, i20 A– and B–segment cars and has the lowest dry weight 82.4 kg. The new engine will be built at the Chennai plant in India.
• Hyundai´s i10 minicar with a 1.25 liter Kappa engine will deliver a fuel economy rating of 5.0L/100km (47 mpg) in the European combined test
• The engine block is made from high pressure die–cast aluminum which results in considerable weight savings.
• Weighing a mere 82.4kg is the lightest in its class among leading European and Japanese–made engines .
• Kappa´s main block features a ladder frame construction for superior structural stiffness while its cylinders are fitted with cast–iron liners for improved abrasion durability. Additional weight was shaved off by integrating the engine support bracket with the timing chain cover.
• The most significant engineering innovation is Kappa´s offset crankshaft. Unlike a conventional engine where the centreline of the cylinder bore is in perfect vertical alignment with the rotating axis of the crankshaft, the Kappa´s centreline is offset by a small distance. By creating this offset distance, engineers have succeeded in minimizing the side force created by the pistons. The net effect is an improvement in fuel consumption and a reduction in noise, vibration and harshness.
• The innovative piston concept to reduce piston mass. The shape of the piston skirt was optimized to reduce its size while the compression height of the piston was also reduced, resulting in precious weight savings.
• The optimized piston skirt is also treated with Molybdenum Disulfide (MoS2), a special anti–friction coating.
• A highly sophisticated process of Physical Vapor Deposition (PVD) is used to apply an ultra–thin layer of chromium nitride (CrN) to the piston´s oil ring. CrN ensures high wear resistance and a low friction coefficient. CrN–coated piston rings using PVD is an innovative technology borrowed from the Tau V8 engine that Hyundai introduced earlier this year. Friction between the oil ring and cylinder wall has been further minimized by reducing the oil ring tension. The smaller mass and special surface treatment of the piston skirt and oil rings yielded additional savings in fuel consumption.
• Kappa is the first Hyundai engine to be fitted with an accessory drive belt which does not require a mechanical auto–tensioning adjustment device, reducing the hardware and further lowering weight and cost. Because it is designed to maintain an ideal tension setting, the belt runs quieter and with proper preventative maintenance and care, the belt will last 100,000 miles.
• Kappa uses a new, longer reach spark plug which enabled engineers to enlarge the size of the water jacket to promote more efficient engine cooling around the critically important spark plug and exhaust port area. Cooler operation also prevents engine knocking.
• The long reach spark plug (M12 thread) also enabled engineers to enlarge the valve diameter for increased airflow and combustion efficiency.
• Kappa´s valvetrain features a number of innovations: roller swing arm lowers friction in the valvetrain thereby helping improve fuel efficiency. Hydraulic lash adjusters ensure clearances between the valve stem and roller swing arm are always perfect: zero, eliminating valve tapping noise.
• A new valve spring features an innovative beehive shape and smaller retainer. Its reduced weight and spring load help lower friction and improve fuel economy.
• Kappa´s valvetrain is driven by a silent–type steel timing chain that replaces roller–type timing chain: The optimized design greatly reduces impact forces and noise when the gear tooth and chain engage. Moreover, the chain requires absolutely no maintenance.
• A lightweight, heat–resistant engineering plastic was specified for the intake manifold. This reduces cost and weight and yields an overall performance improvement.
• The fuel delivery pipe assembly is a returnless type (to eliminate evaporative fuel emissions) and is made of SUS (steel use stainless) with an innovative inner structure for the reduction of pulsation noise.
• Kappa is controlled by two 16–bit 32Mhz microprocessors for digitally precise control of the ignition timing, idle speed, knocking and emissions.

This is what mekes it interesting..............

Electric indica...

Tata Motors’ electric version of Indica"Indica EV", set to enter the domestic market in next two years .The electric Indica prototype unveiled by the company’s Managing Director, Mr Ravi Kant, earlier during the week is set to make its debut in Norway in 2009. It would later be introduced in other European countries with Government support and infrastructure for such vehicles.The price range hoped to be somewhat near to reva range.

The left-hand drive 'Indica ev' was developed at the Tata Motors research facility in the UK, in collaboration with the top electric vehicle research and development firm in Norway, believed to be Miljoebil Grenland, partly owned by regional utility company Skagerak Energi and the $25-billion energy and integrated aluminium company, Norsk Hydro, with whom the Tatas were reported to have been mulling a new facility to develop light-body chasis in India a few years back.The car can run for 175 km to 200 km when fully charged with a "two-pack" battery,which takes 8 hours to recharge, though mileage could vary according to the type of battery used mostly lithium batteries and almost zero emission.

Tata Yazaki Autocomp Limited, a division of Tata Auto Comp Systems Ltd (TACO) has been working on electric and hybrid technologies for past many years. Tata Yazaki is already supplier of hybrid fuel technology to global majors like Ford. Tata is currently testing the Indica hybrid. The"mild hybrid" indica would have the facility to turn off the engine when it is not needed such as when the car is stopped at signals, and turned on again expected to launch in 2008. Besides the Indica Hybrid, Tata Motors is also working with a US-based company on electrification of its most popular light commercial vehicle, ‘Ace’, and hybrid buses for city transport. And expects to roll out fuel cell technology based buses by 2010....

Electric-drive version of the Nano called E-Nano,to be built in cooperation with the Norwegian electric car specialist firm Miljoebil Grenland.Also on the look out for alternate compressed-air OneCAT technology for the Indian market.

Mahindra & Mahindra is also working on a four-seater electric car that will be bigger than the Reva and plans to bring it on Indian roads by 2010. Currently, M&M has an electric three-wheeler called Bijlee, and is working on an electric version on its three-wheeler Alfa.

Do u think will it be same hit as indica other models..nd is it a good challenger to Reva...please comment....