The global internal combustion engine (ICE) market is projected to reach 370 million units by 2030, with a compound annual growth rate (CAGR) of 9.3% during the forecast period from 2022 to 2030. Technological advancements to reduce pollution, improve fuel efficiency, and enhance performance will drive demand significantly during this period. Additionally, the lack of electric vehicle charging infrastructure worldwide, coupled with the increasing output of shale gas and growing demand for ICE in defense, mining and construction vehicles, is further driving the market growth.
Continuously driven by severe legislative requirements for greater combustion efficiency to minimize environmental consequences and exhaust emissions, Powertrain OEMs and Tier Suppliers keep improving the design of their components/systems and their manufacturing equipment and processes.
In the ICE sector, the main challenge is to meet the new technical specifications without increasing manufacturing costs. Because of the scale effect, every production cost increase may immediately impact the overall profitability of the program. The production value chain is critical, especially in highly competitive environments like the automotive industry.
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Challenge
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Solution
A major Tier Supplier in Europe producing critical parts for high-pressure injection systems wanted to reduce the operating costs of its four precision machining systems, onsite process and quality engineers agreed to run a comparative field trial of the Pall Supralon® retrofit filter product fitted in an existing filter vessel of its current filter supplier, operated for one year to have enough evidence to draw firm conclusions.
The key performance indicators to track included the number of parts produced during the typical service life between filter element changeouts, the consistency of fluid quality, and the achievement of the technical specifications for the component.
Filter Operating Conditions
- Fluid: Low viscosity neat cutting oil
- Flowrate: 985 Lpm
- Pressure: 8 bar
- Temperature: 38 to 42 °C
Pall installed Supralon retrofit elements into the filter vessels without needing adaptation and took frequent measurements of the machine tool fluid cleanliness level circulating into the machining center. Until their changeout, the fluid cleanliness was very clean and consistently steady, typically ISO codes <-/9/6 per ISO4406, measured using Pall's PCM500 mesh blockage fluid monitoring technology to not impact the readings due to the presence of free air in the neat cutting oil.
The average annual production output corresponding to the longer life between filter changeouts experienced with the Pall Supralon retrofit filter elements was 56% higher than that of the other supplier under the same operating conditions.
Cleanliness Code Ratings
| Media Grade Code | Rating (μm ßx(c)>2000 based on ISO 16889 | CST* ISO Code Rating based on SAE ARP 4205 |
|---|---|---|
| Z | 3 | 06/04/<1 |
| P | 5 | 12/08/<1 |
| N | 7 | 14/09/04 |
| S | 12 | 18/16/08 |
| T | 25 | 19/17/12 |
*CST: Cyclic Stabilization Test to determine filter rating under stress conditions, based on SAE ARP4205.
Note these ISO codes are laboratory measurements under standard conditions. Cleanliness measured in actual operation will depend on operating conditions and sampling method.
Conclusion
Based on these comparative field trial results, the Tier supplier upgraded its four precision machining systems with Pall Supralon retrofit elements. Beyond relying on excellent filtration performance (efficiency and service life), the tier supplier reduced its operating costs per machine by 22%.
Compared to the original supplier, Pall Supralon retrofit elements exhibited a more predictable filter changeout date. Over 600 mbard, the remaining service life of the original supplier filter was inconsistent from one filter set to another. It was very challenging for its maintenance and procurement teams regarding resource availability and inventory management.
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