An oil sump moulded from DuPont™ Zytel® nylon resin, is helping the Swedish commercial vehicle manufacturer Scania meet new challenges with regard to noise, emissions and weight. The lightweight yet equally robust oil sump – the lower shell of the oil pan module - is amongst the host of innovative technical solutions incorporated by Scania in its new Euro 6 engines.
An oil sump moulded from DuPont™ Zytel® nylon resin is amongst the host of innovative technical solutions incorporated by Scania in its new Euro 6 engines. It has enabled a reduction in the weight of the component by over 50 percent, or 6 kg, versus its aluminium predecessor to improve fuel economy and reduce emissions.
The ground-breaking application was produced in Sweden by the Plastal Group AB, a leading supplier of engineered plastics to the automotive industry, with the material, design and processing support of DuPont representatives in the country and across Europe and the input of prototype specialists Idé-Pro of Skive, Denmark.Amongst the range of technological highlights contained within the new 440 and 480 hp (324 and 353 kW) 13-litre Euro 6-compliant engines, unveiled by Scania in spring 2011, is the premiere of an oil sump moulded from a heat-stabilized, glass-fibre reinforced grade of Zytel® 66 nylon. The adoption of the DuPont material for this application - a first for the truck market and only the second development for commercial production vehicles worldwide following the launch of the award-winning Daimler oil pan module in 2008 - has enabled a reduction in the weight of the component by over 50 percent, or 6 kg, versus its aluminium predecessor to improve fuel economy and reduce emissions. Perhaps just as significantly, with regard to the environmental impact of the noise emitted by trucks, Scania found switching from metal to plastic in the oil sump dampens engine noise to help meet Euro 6 noise emission standards.
Having settled on the initial design and material, Scania contacted Idé-Pro to undertake the first steps in the parts' development. Idé-Pro not only produces tools and moulds parts, but also offers the development tools and expertise needed during the prototype stage. In such a way the design of the mould could be optimized to minimize warpage.Beyond material selection, DuPont also assisted Scania in refining the sump's design and the production process, particularly with regard to achieving a consistently tight seal between the sump and the engine. This required very precise tolerance control of a large component, measuring 847mm (length) x 467mm (width) x 203mm (height), achieved by comprehensive mould flow analyses, prototype testing and ongoing optimisation of processing parameters. “Ribbing on the underside of the sump also plays a key role in remaining within the permitted tolerances for the part, as well as performing a secondary function as a defensive shield against stone impacts,” said Murray Smith development specialist at DuPont Performance Polymers in Sweden.
DuPont Performance Polymers is committed to working with customers throughout the world to develop new products, components and systems that help reduce dependence on fossil fuels and protect people and the environment. With more than 40 manufacturing, development and research centers throughout the world, DuPont Performance Polymers uses the industry’s broadest portfolio of plastics, elastomers, renewably sourced polymers, filaments and high-performance parts and shapes to deliver cost-effective solutions to customers in aerospace, automotive, consumer, electrical, electronic, industrial, sporting goods and other diversified industries.
Rémi Daneyrole | DuPont
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
Breakthrough provides a new concept of the design of molecular motors, sensors and electricity generators at nanoscale
Researchers from the Institute of Organic Chemistry and Biochemistry of the CAS (IOCB Prague), Institute of Physics of the CAS (IP CAS) and Palacký University...
For photographers and scientists, lenses are lifesavers. They reflect and refract light, making possible the imaging systems that drive discovery through the microscope and preserve history through cameras.
But today's glass-based lenses are bulky and resist miniaturization. Next-generation technologies, such as ultrathin cameras or tiny microscopes, require...
Scientists from the University of Zurich have succeeded for the first time in tracking individual stem cells and their neuronal progeny over months within the intact adult brain. This study sheds light on how new neurons are produced throughout life.
The generation of new nerve cells was once thought to taper off at the end of embryonic development. However, recent research has shown that the adult brain...
Theoretical physicists propose to use negative interference to control heat flow in quantum devices. Study published in Physical Review Letters
Quantum computer parts are sensitive and need to be cooled to very low temperatures. Their tiny size makes them particularly susceptible to a temperature...
Let’s say the armrest is broken in your vintage car. As things stand, you would need a lot of luck and persistence to find the right spare part. But in the world of Industrie 4.0 and production with batch sizes of one, you can simply scan the armrest and print it out. This is made possible by the first ever 3D scanner capable of working autonomously and in real time. The autonomous scanning system will be on display at the Hannover Messe Preview on February 6 and at the Hannover Messe proper from April 23 to 27, 2018 (Hall 6, Booth A30).
Part of the charm of vintage cars is that they stopped making them long ago, so it is special when you do see one out on the roads. If something breaks or...
15.02.2018 | Event News
13.02.2018 | Event News
12.02.2018 | Event News
16.02.2018 | Information Technology
16.02.2018 | Health and Medicine
16.02.2018 | Physics and Astronomy