11/05/2010

www.plasticker.de

Hengst: Winner of SPI Grand Innovation Award

The Society of Plastics Engineers has awarded Hengst Automotive with the "2010 Grand Innovation Award” in the Powertrain category (under hood applications) for a multi function integrated module developed for the Audi - V6 Petrol Engine Series. The annual automotive award from the Society of Plastics Engineers is considered the most prestigious award for plastic products in the automobile industry. The award was presented to Hengst during the 13th Society of Plastics Engineers banquet in Dusseldorf, Germany on October 25th 2010.

Hengst appreciates this award very much. "Many of our Fluid Management Systems serve as innovative solutions and make us a competent development partner and system supplier for many international vehicle and engine manufacturers. The compact modular design focuses on increasing the efficiency of the application while decreasing the cost of individual functions. The basis for that to happen requires a top competency in material use, production process as well as precision and consistent good quality in our processes.” stated Dieter Baumann, board member of Hengst, OEM.

Hengst developed the multi-functional integrated plastic module in close collaboration with Audi. The module is mounted in the V-space between the cylinder heads and consolidates 5 functions in a space saving manner: crankcase cover, coolant channels, space optimized crank case pressure valve, crank case system with air intake and venting system and oil mist separator with multi cyclone and pressure valve. In order to withstand glycol as well as temperature extremes up to 160°C of the engine oil the plastic materials needed to be modified accordingly.

The crank case cover with integrated coolant channels is manufactured using the latest 3D injection molding technology. It has large cross sections, smooth inner walls and fast production cycles. The components of the ventilation system are pressure sealed connected to that basic plate. The blow by gas flows from both cylinder heads to the powerful multi cyclone with pressure bypass valve separating the finest oil mist from the air. It is then redirected back into the air intake passing the freeze free pressure control valve. Other parts such as connecting tubes, hose connectors, gasket seals, and mounting components are no longer needed. Hengst' module for the Audi V6 creates cost savings of 40% and reduces the weight to 50% which also increases the space availability for other functions. By providing anti freeze guard for the crank case ventilation system the level of separation of fine oil mist from the blow by reached 85% which helps to protect the engine from fouling and loss of power.

The production part is injection molded at the company's facility in Nordwalde, Germany. The high level of complexity and quality assurance of the production process was an important criterion for the jury of specialists. Multiple processes are being utilized in production such as injection molding with water (WIT) and gas (GIT) technology to result in a minimum differential pressure loss for the coolant system. Further, functional tailored assembly and joining techniques are utilized, as welding via laser, ultrasound and infrared. The challenge is to create a virtually scrap free Y-duct with two unsymmetrical and complex ducting paths combined with a sealed surface including integrated sealing groove to the engine block and other connecting components. The high standards in terms for even surfaces and tight tolerances are fulfilled via smooth tooling tempering and embossing.

This is the second time when Hengst was awarded with an award. In the beginning of 2010 another one of Hengst's multi functional modules has won the first price at the International Aluminum Die Cast Competition.