url : ㈜하트만 e-mail : …… . introduction-1 heartman co., ltd have established as a company...
TRANSCRIPT
URL : ㈜하트만http://www.heartman.co.kr
E-mail : [email protected]
URL : http://www.heartman.co.krE-mail : [email protected]
[email protected] [email protected]@heartman.co.kr
2
Inspection facilitiesⅤ
Develop & ReserchⅥ
Korean government development projectⅦ
IntroductionⅠ
Main productsⅡ
Production processⅢ
Production facilitiesⅣ
Development of fuel injection parts localizationⅧ
The othersⅨ
Table of Contents
Ⅰ. Introduction-1
HEARTMAN Co., Ltd have established as a company manufacturing the fuel injection
parts for marine diesel engine from June 1965, our company has accumulated
the precision processing technology and implemented advanced production
facilities for about 40 years over. Based on such technology and facilities, we
have provided essential parts nozzle, plunger ass'y, fuel valve & pump ass'y for
medium speed (4-stroke) marine diesel engine
We have selected as a certified cooperation company by Hyundai Heavy Industries
and succeeded in development of fuel injection valve, pump, exhaust & intake,
and Fuel cam for 4-stroke medium speed diesel engine and have supplied them
to Hyundai Heavy Industries.
Through such activities, we have been recognized as a leading company providing
high-quality products.
Greeting
Ⅰ. Introduction-2
Summery
● Name Heartman Co.,Ltd.
● Established November, 24. 1999
● Head Office/Plant 1530-6, Songjeong-dong,
Gangseo-gu, Busan, Korea
● Area Ground 3,301㎡, Building 2,076㎡
● Manpower 60 Persons (dated on 30th of
December, 2011)
● Business Parts Fuel Injection Pump & Valve Assy
Plunger Assembly
Nozzle Tip / Spindle Guide
● Marketing Area Domestic of KOREA, Germany, UK,
China, Taiwan, Greece, etc…
Busan●
LOCATION
［Busan Noksan National Industrial Complex］
Heartman
Ⅰ. Introduction-3
History
● Jun. 1965 Establishment of Shinsung Diesel KiKi Co.
● Oct. 1992 Authorization as a cooperation company of
Hyundai Heavy Industries Co., Ltd.
● Nov. 1999 Establishment of Heartman Co.,Ltd.
● Oct. 2001 Acquired as an Quality System ISO 9001 certification
● Mar. 2006 Acquired as an Environment System ISO 14001 certification
● Dec. 2008 Certified as an Inno-Biz Company by Korea SMBA
● Dec. 2008 Approved Corporate R & D Center by KOITA
● Jun. 2009 Confirmed enterprise specializing in parts materials
● Sep. 2009 Moved to Songjeong-Dong, Gangseo-Gu, Busan
● Dec. 2009 Awarded for 1million USD worth tower of export
● Jun. 2009Awarded as Export promising small and mediumenterprise by SMBA
Ⅰ. Introduction-4
Organization Chart
April 21. 2014Chairman
President
R&D Center(9 persons)
Production Dept.(44 persons)
Sales Management(7 persons)
Design / Development
Quality Assurance
Production 1 Team
Assembly
Test
Sales TeamProduction 2
Team
GrindingProcessing
Drilling
ManagementTeam
Domestic Sales
Overseas Sales
General Affairs
Accounting
Heat Treatment
(4 persons) (5 persons)
Ⅰ. Introduction-5
Sales valume
Sales volume per year
Domestic(70%)
Export(30%)
Sales structure per item
Rate of export/domestic
PLUNGER(35%)
NOZZLE(55%)
Others(10%)
3 3.2
3.9
4.5
5.5
6.2
77.5
2006 2007 2008 2009 2010 2011 2012 2013
Ⅰ. Introduction-6
Capacity & Investment
Production Capacity Investment present condition
● Annual production capacity ● 2011 year investment particulars
▶ 1 shift (10.5 hour daytime)
- Fuel Injection Pump : 2,400 Set
- Fuel Injection Valve : 3,600 Set
▶ Currently operation rate : 60%
▶ Surplus capacity : 40%
☞ Lack of capacity⇒2 shift change
▶ Person : $150,000
▶ Equipment : $1,600,000
▶ Education : $12,000
● 2012 year investment plan
▶ Person : $200,000
▶ Equipment : $1,200,000
▶ Education : $15,000
Ⅱ. Main products
Plunger & Barrel Ass’y Fuel Injection Pump Ass’y
Fuel Injection Valve Ass’y Spindle Guide
Ⅲ. Production process
MaterialMachining/
DrillingHeat-
treatment
Grinding/
HoningInspection Test
Ⅳ. Production facilities-1
MCT
CNC
LATHE
MILLING
Macining/Drilling Line INJ·
HOLE
GUN
DRILL
OIL
TANK
IV. Production facilities-2
CaRburizing
Subzero
Nitriding
Heat-treatment LineVacuum
Vickers
Rockwelmonitoring system
IV. Production facilities-3
IN·
DIA·
GR
HONNING
AFM/DEBURR
Grinding/Honing Line OUT·
DIA´
G
SURFA.GR
HONING
3Dcoordinate
Shape mea
Roughness
inspection Round
test
Micro scope
Prof i le
Pro j .
Ⅴ. Inspection facilities-1
Measurement room-1
Measurement room-2
Pump
Test
V/V
Test
Flow
Test
testNozzl e
Test
Nozz l e
Test
Cleaning
V. Inspection facilities-2
Automatic System
Manual System
VI. Research & Development
3D Modeling of Pump & Valve Plunger/barrel
2D redrawing
R&D centerScaning of plunger helix for redrawing
Measuring of needle valve angle/demention for redrawing
VII. Korean government development project
Terms of develop Development Project Item Government Branch
1999.04 ~2000.6MAN B&W L28/32H (4-stroke middle speed engine)
FUEL INJECTION VALVE ASS’Y
SMBA
(Small and Medium Business
Administration)
2001.04 ~2002.6MAN B&W L28/32H (4-stroke middle speed engine)
FUEL INJECTION PUMP ASS’YSMBA
2005.06 ~2006.8 Improvement of MAN B&W L28/32H
FUEL INJECTION VALVE/PUMP durability
MKE
(The Ministry of Knowledge
Economy)
2011.04 ~2012.6Adaptation DLC coating for
longlasting PLUNGER of
MAN B&W L16/24 Fuel Injection Pump
KIAT
(Korea Institute for
Advancement of Technology)
DateEngine type
Development item Q’ty
2003. 04 HHI H21/32 Fuel Injection High Pressure Block Ass’y 200 SET
2003. 10 H25/33 Fuel injection High Pressure Block Ass’y
2006. 03 H21/32 Fuel injection nozzle tip for low-NOX regulation86 SET
2006. 10 H32/40 Fuel injection nozzle tip for test 30 SET
2007. 02 H32/40 Fuel injection nozzle tip for low-NOX regulation 84 SET
2008. 07 H21/32 Fuel injection nozzle tip for test 96 SET
2011. 11 H17/28H32/40
Fuel injection valve for Test 30 SET
2012. 02 H32/40Fuel injection nozzle tip for test(double needle valve)
100 SET
VIII. Development of fuel injection parts localization
Ⅸ. The others
1. Nozzle Spray Hole Fluid Grinding & Flow Test
Before Grinding After Grinding Result
Picture
(B&W L32/40)Edge “R”
Creation
Flow Volume
(Spec:12,920~
13,720ml/min)
9,500~10,300
ml/min
13,290~13,350
ml/min
Flow Increasing
30~40%
Grinding Time 250 sec/ea
Effect of Fluid
Grinding
The deviation of flow is a little［Spec: 13,320ml/min±3%(12,920~13,720)
Actual control: 13,290~13,350］
Ⅸ. The others
Fluid Grinding & Flow Test Equipment
Fluid Grinding M/C Flow Test M/C
Ⅸ. The others
2. PLUNGER - Special coating
Spec. TiN/Coating WCC/Coating
Pic.
Application
ItemDK20, HIMSEN 21/32 MAN B&W 32/40
Hardness
(HV)2,000~2500(before coating:850~950)
Coefficient of
friction0.3~0.4(before coating:0.6~0.7)
Efficiency of
Coating◈ resist of abrasion/corrosion/impact/exfoliation
Ⅸ. The others
An original Heartman injection nozzle produces a fuel spray pattern that reduces
emissions, lowers fuel consumption, and also protects the piston from fuel impingement
on the crown and liner surface. The optimized heat release reduces the temperature of
components in the combustion chamber, thus providing longer life for
valves, liners, piston rings and valve seats.
By means of intensive tests the design and manufacturing procedures / techniques were
adjusted in a way to meet the best compromise of engine performance data (fuel
consumption, smoke behavior) and the thermal load of parts in the combustion
chamber (valve, piston and liner temperature). By doing this the use of genuine
Heartman nozzle elements provide:
•A more constant pressure and consistent atomization of the fuel over longer time
•A smaller droplet size and optimized fuel spray penetration angle is produced
•A complete combustion process is maintained, with less smoke and lower emissions
The different nozzle parameters like the nominal nozzle hole diameter and length,
nozzle hole inlet radii, longitudinal hole shape and others have a huge impact on the
spray pattern which in turn influence engine performance data and the thermal stress
level in the combustion chamber.
Effect of the running process to the spray distribution and droplet size
Non-original nozzle element without treatment
Spray angle=15.3°Droplet size=14.4µm
HEARTMAN nozzle element with treatment
Spray angle=12.2°Droplet size=12.7µm
Where’s the Difference?
Ⅸ. The others
Effect of the running process to the spray distribution in the combustion chamber
Non-original nozzle element without after treatment
HEARTMAN nozzle element without after treatment
Engine measurements with nozzles whose parameters were modified due to a changed after treatment process revealed the following:
•A deviation in droplet size of 12% and 3° wider injection angle of the fuel, measured with non-original injector nozzles, will result in significant differences in heat release and thermal stress.
•Increased operating temperature of critical engine components means shorter life for injectors as well as potential damage to other components.
Especially the Heartman after treatment process ensures an optimized nozzle geometry and therefore reliable and targeted engine performance data.From our experience, using original and genuine Heartman nozzle elements can lower cylinder liner temperatures up to 45°C, lower piston crown surface temperature by 30°C, and reduce exhaust valve temperatures by over 35°C.
What’s the Risk?
Heartman nozzles are fluid machined with a proprietary Caterpillar after treatment of the fuel delivery ports, where operating stress is reduced due to the smooth, rounded edges.
Inspection and testing of fuel injector nozzles from a ‘grey market’ manufacturer revealed a lower level of quality, materials and manufacturing resulting in major deviations from the Heartman specifications and original dimensions. There will be higher stresses in the area of the nozzle holes, which at the high operating temperatures can cause complete breakage of the nozzle tip, resulting in consequential damage to the cylinder head and exhaust valves.
Where’s the Difference?
Ⅹ. Reference
ROBERT BOSCH
Ⅹ. Reference
HYUNDAI HEAVY INDUSTRIAL
ZGPT DIESEL WOODWARD
Ⅹ. Reference
NICO CORPORATION
Ⅹ. Reference
EVERGREEN SHIPPING
Ⅹ. Reference
SSANG YONG
Thank you.