Working in close cooperation with the automotive supplier Bruss and DuPont, Daimler has achieved a genuine breakthrough by developing a modular design for its new 4-cylinder diesel engines (model OM651), which consists of a die-cast aluminium upper shell and a multifunctional lower shell, made of DuPont™ Zytel® 70G35 HSLR.
The oil pan for the new 4-cylinder diesel engines from Daimler is a new design, whereby, for the first time in a serial-production car, an engineering polymer plays a significant role: the 6-litre-capacity oil pan (below), made of DuPont™ Zytel® 70G35 HSLR, is screwed onto a die-cast aluminium frame. An oil deflector (top), which is also used to stiffen the module, is welded onto the pan.
The implemented design assures the part’s stiffness, and, at the same time, achieves a significant weight reduction of 1.1 kg versus an entirely aluminium design. Moreover, production efficiency is increased due to the high flow of the heat-stabilised, glass-fibre reinforced nylon, enabling long flow distances, short injection times and the reliable moulding of thin-walled sections. The material’s high compatibility with vibration welding further benefits productivity. The new oil pan design will be first used in the Mercedes-Benz C Class.
The rear section of the oil pan, which forms the sump for approximately 6 litres of oil, is very rigid due to its shape. The front section is of a flatter design due to chassis and steering gear space requirements. As a consequence, this section’s resistance to bending and stiffness is relatively low, requiring additional design measures to minimise warpage and deformation, and to eliminate the potential for leakages at the joint with the aluminium upper shell.
The solution was to create a sandwich design with a second injection-moulded part: A separately-produced oil deflector, welded onto the flat section of the pan, helps calm the oil, churned by the crankshaft and balance shaft, and directs it back into the oil pan. Between them, the pan and the deflector, as well as further refinements to the overall design, help ensure stability under all operating conditions. In the oil sump section, warm-embedded brass inserts accommodate the oil discharge screw and oil level switch. The high ribs in the sump act as baffles, helping to calm the oil and direct it towards the sump.
Before producing the first tool, Bruss requested technical support from DuPont in addition to their own, comprehensive simulation software. Finite element analysis (FEA) was used to refine the positioning of ribbing at the edge of the pan (outside of the area covered by the oil deflector) to significantly improve the overall stiffness of the critical, flat section, yet with minimal effect on the overall height of the design. Flow studies, also based on FEA modelling, were used by DuPont to gauge the impact of wall thickness, the number of gates, and their positioning, on weld line formation and warpage behaviour, and to optimise the respective processing parameters. Indeed, due to the high melt flow of Zytel® 70G35 HSLR, one single, central gate was enough to completely fill the mould cavity, while permitting short moulding cycles. In comparison to multi-point gating (which would potentially be necessary for other nylon grades), tool costs are reduced and process control is simplified, while the number of weld lines and the risk of air entrapments are also minimised.
Finally, at the DuPont European Technical Centre in Geneva, the structure’s properties were further analysed by simulating the combined engine and transmission being dropped forcefully by a fork-lift truck. Real-life testing at Bruss, using prototype components, confirmed the success of the adopted design: Even after 1000 hours of aging in hot oil at 150 °C, the pan is able to withstand these severe test conditions without incurring critical damage.
Overall, the use of thermoplastic polymers for oil pans creates a significant opportunity for further functional integration. Already, in its current form, the oil deflector has been integrated – used to encourage a calmer flow of oil back to the sump. Additional functions, envisaged for integration in future oil pan models, could include the oil pick-up pipe, oil level switch, oil filter, other oil return components or oil pumps.
The DuPont Engineering Polymers business manufactures and sells Crastin® PBT and Rynite® PET thermoplastic polyester resins, Delrin® acetal resins, Hytrel® thermoplastic polyester elastomers, DuPont™ ETPV engineering thermoplastic vulcanizates, Minlon® mineral-reinforced nylon resins, Thermx® PCT polycyclohexylene dimethylterephthalates, Tynex® nylon filaments, Vespel® parts and shapes, Zenite® liquid crystal polymers and Zytel® nylon resins and Zytel® HTN high-performance polyamides. These products serve global markets in the aerospace, appliance, automotive, consumer, electrical, electronic, healthcare, industrial, sporting goods and many other diversified industries.
DuPont is a science-based products and services company. Founded in 1802, DuPont puts science to work by creating sustainable solutions essential to a better, safer, healthier life for people everywhere. Operating in more than 70 countries, DuPont offers a wide range of innovative products and services for markets including agriculture and food; building and construction; communications; and transportation.
The DuPont Oval, DuPont™, The miracles of science™, and Zytel ® are registered trademarks or trademarks of E.I. du Pont de Nemours and Company or its affiliates.
Horst Ulrich Reimer | Du Pont
When your car knows how you feel
20.12.2017 | FZI Forschungszentrum Informatik am Karlsruher Institut für Technologie
Did you know how many parts of your car require infrared heat?
23.10.2017 | Heraeus Noblelight GmbH
Satellites in near-Earth orbit are at risk due to the steady increase in space debris. But their mission in the areas of telecommunications, navigation or weather forecasts is essential for society. Fraunhofer FHR therefore develops radar-based systems which allow the detection, tracking and cataloging of even the smallest particles of debris. Satellite operators who have access to our data are in a better position to plan evasive maneuvers and prevent destructive collisions. From April, 25-29 2018, Fraunhofer FHR and its partners will exhibit the complementary radar systems TIRA and GESTRA as well as the latest radar techniques for space observation across three stands at the ILA Berlin.
The "traffic situation" in space is very tense: the Earth is currently being orbited not only by countless satellites but also by a large volume of space...
An international team of researchers has discovered a new anti-cancer protein. The protein, called LHPP, prevents the uncontrolled proliferation of cancer cells in the liver. The researchers led by Prof. Michael N. Hall from the Biozentrum, University of Basel, report in “Nature” that LHPP can also serve as a biomarker for the diagnosis and prognosis of liver cancer.
The incidence of liver cancer, also known as hepatocellular carcinoma, is steadily increasing. In the last twenty years, the number of cases has almost doubled...
In just a few weeks from now, the Chinese space station Tiangong-1 will re-enter the Earth's atmosphere where it will to a large extent burn up. It is possible that some debris will reach the Earth's surface. Tiangong-1 is orbiting the Earth uncontrolled at a speed of approx. 29,000 km/h.Currently the prognosis relating to the time of impact currently lies within a window of several days. The scientists at Fraunhofer FHR have already been monitoring Tiangong-1 for a number of weeks with their TIRA system, one of the most powerful space observation radars in the world, with a view to supporting the German Space Situational Awareness Center and the ESA with their re-entry forecasts.
Following the loss of radio contact with Tiangong-1 in 2016 and due to the low orbital height, it is now inevitable that the Chinese space station will...
Fraunhofer Institute for Organic Electronics, Electron Beam and Plasma Technology FEP, provider of research and development services for OLED lighting solutions, announces the founding of the “OLED Licht Forum” and presents latest OLED design and lighting solutions during light+building, from March 18th – 23rd, 2018 in Frankfurt a.M./Germany, at booth no. F91 in Hall 4.0.
They are united in their passion for OLED (organic light emitting diodes) lighting with all of its unique facets and application possibilities. Thus experts in...
A new scenario seeking to explain how Mars' putative oceans came and went over the last 4 billion years implies that the oceans formed several hundred million...
23.03.2018 | Event News
19.03.2018 | Event News
16.03.2018 | Event News
23.03.2018 | Materials Sciences
23.03.2018 | Agricultural and Forestry Science
23.03.2018 | Physics and Astronomy