Abstract No.:
3685

 Scheduled at:
Wednesday, May 21, 2014, Hall H1 & H2 2:20 PM
Automotive Industry 1


 Title:
State-of-the-art control and measurement techniques for high performance arc sprayed cylinder bore coating in automotive engine production

 Authors:
Wolfram Wagener* / BMW Group, Germany
Alois Bauer / BMW Group, Germany
Patrick Woisetschlaeger/ Institute of Metal Forming and Casting (utg), Technical University of Munich (TUM), Germany

 Abstract:
For the continious implementation of a holistic, innovative approach, the BMW Efficient Dynamics® program was developed with the aim to continuously implement the latest ideas and technologies into BMW vehicles to simultaneously offer increased performance with lower fuel consumption and reduced CO2 emissions. Along with trend of downsizing, this philosophy is being implemented consistently by introducing new generations of engines. By, for example weight reduction, improved thermal management and tribological optimizing of the crankcase, the overall efficiency of the engine is increased further. The use of thermally coated cylinder bores allowed the achievement of requirements.
For the first time in serial high volume production arc wire spray technology was used for high performance thermal coating of cylinder bores. The BMW 4-cylinder gasoline engine with Twin Turbo Power technology was introduced to the market in 2012 and imaged the first crankcase improved by this technology in high scale serial production. The development and adaptation of arc spray coating processes towards efficient automotive production lines lead to extraordinary efforts in data mining, process visualizing and monitoring.
This article describes a tide, high efficient process chain for implementation of precise measurement technology and process diagnostics systems covering crankcase casting, inspection systems, machining and spray technology to fast and optimal quality loops. New, innovative systems are presented to supervise quality influenced data, to ensure a capable and reproducible mass production. These include e.g. optical methods of analysis, condition monitoring systems and camera systems for online process monitoring.


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