Engine components for better workability of the engines

The overall health and workability of the engines are dependent on the quality of the engine
components used in the making of engines. They must be of the highest quality without there
being any room for short-cuts either in terms of material used, manufacturing process or even
in the design. These factors not only ensure stability and tenacity but also can ensure longevity
and workability of the engine. Cooper Corp is among the renowned engine and engine component
manufacturing company in India and has a distribution network across the country and world
over. The engine components are used for engines developed for the Original Equipment
Manufacturers (OEMs) and can be used for engines used in a wide range of applications
including the agricultural, gensets, automotive applications.

With 700 engine components going into the making of an engine, Cooper Corporation has
emerged as one of the key cylinder sleeve manufacturer, heads and blocks, piston,
flywheel and crankshaft manufacturers in India. These wide range of components which
form an integral part of engines cover 75% of the products available in the market and manufacture
d in-house at the Cooper foundry.

Doing what it takes for high quality control

Owing to a specific for components that contribute towards the clean energy and in the
making of high-performance engines, engine component manufacturers have had to brace
up their manufacturing systems to deliver high quality components. Even in terms of competition
, engine component manufacturers have faced stiff competition from the likes of those components
manufactured in the USA and Europe. Demand for components that are in line with those manufactured in USA and Europe, have ensured consistency, standardization and precision of the end products. Flywheel, Cylinder sleeve manufacturer like Cooper Corporation have to take into account all the factors in their endeavour to develop innovative engine components. With time tested technology and product innovation, Cooper has been able to deliver components which provide reliable solutions for both diesel- and gas-powered engines. With the coming of the new age Tier 4 engines, adjustment of fuel and air mixture during combustion is now possible and has also led to computer monitoring of real time conditions of engines. The R&D team at Cooper takes into account all the above factors as well make efforts to curtail the emission of harmful pollutants during the stage of designing and monitor them intently during the production stage as well.

A trusted name in Engine component manufacturing

Cooper generators carry 70% of the engine components manufactured by Cooper and has
been received well by a broad user base nationally and internationally. This proves the
efficiency of their components. As one of the key crankshaft manufacturers in the country,
they have achieved a rare distinction of supplying 100% of the export demand of crankshafts
for Cummins as well as distributing for some of the renowned automotive companies of the
world such as Jaguar, ford, USA, Maruti Suzuki, Bajaj Auto in India and Kawasaki in Japan.
In recognition of the manufacturing excellence, Cooper Corporation has been granted with
the Jaguar Land Rover Quality (JLR-Q) award for Quality excellence.

Cylinder liners are the vital engine components that are fit into the cylinder blocks with piston moving within the liners to enable combustion and deliver the required force for the engine to function. The liners are the foundation of any engine and are believed to outlive the life of the engine- therefore performing a vital role in the operation of cylinder blocks, heads, timing case and flywheel. Cylinder liner manufacturers have to ensure that quality control measures are in place for safety and optimum functioning. They are designed to withstand varied temperature levels and pressure on the engine to sustain a longer service life and have wear-resistant properties for other cylinder parts. Today, Cooper Corporation is a renowned name among cylinder liner manufacturers distributing them to the original Equipment manufacturers and manufacturers in India and countries across the South East Asia, Africa, the USA, Sri Lanka and Europe.

Quality Engine components for seamless functioning of engines

If the engine is considered to be the heart of any automotive part, the efficiency and health of the engine depend on the functioning of the various engine components such as cylinder sleeve, cylinders, crankshafts and flywheel. The engine components are known to outlive the engine; for which reason, planning, designing, development and manufacture all play a very important role in defining engine components. Cooper Corporation is a name that everybody is familiar with. As a manufacturing company of over five decades, the company has been re-defining India’s manufacturing story by developing a manufacturing portfolio consisting of generators, engines, engine components consisting of varied capacity and ranges. Product Design and development, manufacture and distribution of engine and engine components for markets within and outside India is their area of core competence.

Cooper Corporation is a market outperformer as a Cylinder Sleeve manufacturer supplying about 175,000 liners to Jaguar and to engine manufacturers like Cummins. Since the Cylinder sleeves form the basis of engines, the company designs and manufactures sleeves depending on the engine specifications; be it, by changing alloys, metallurgy, a thickness of material and accuracy of machining. Since the cylinder sleeves are used for a wide range of applications such as in compressors, generators, agricultural applications and other types of equipments, they are made available in a broad range of bore diameter, length and thickness. So as a Cylinder sleeve manufacturer, Cooper ensures that the sleeves are tailor-made keeping in mind the purpose, application and use and as per the exact specifications that are given by its customers.

Quality control over engine components

Today, the company exports cylinder sleeves and other engine components such as crankshafts or flywheels to equipment manufacturers and engine manufacturers across Africa, China, Europe and Sri Lanka and has of late expanded its horizon to the US markets as well. From agricultural pumps to high-capacity engines with capacity up to 1MW, all of them are manufactured at their own foundry in Satara. Since most of the engine components used for their engines or for the use of OEMs are manufactured indigenously by Cooper Corporation, quality control, standardization of products are possible at every stage. For example: In order to achieve optimal levels of resistance even for high-performance engines, crankshaft manufacturers ensure that the designing, production process etc., is given a lot of consideration. The material used is made of high-quality ductile iron to suit the various industrial applications. The functioning and structure of various modules of the crankshafts such as the crankpins, crank arms or webs, supporting bearings etc., are micro-monitored to support the large load cycles that the crankshafts operate on. To ensure standardization as per international levels, Crankshaft manufacturers conduct stress test and strain analysis in accordance with the load applied on the crankshafts.

The flywheels being the vital components of any automotive engine function as points of power supply from motor to machine by storing rotational energy during the moment of inertia. So when the engine faces loss of momentum, the stored energy is used up by converting into heat energy in the brakes. While the material used for the manufacture of a flywheel depends on the application and industry of use, cast iron, mild steel, composite material like carbon fibre and cast iron followed by a composite material made by marging steel and E-glass fibre are used in the manufacture of flywheels. Since the flywheels vary in diameter, weight and the quality of substance used, the design, manufacturing process and marketing of flywheels to the right target audience plays an important role.

As one of the key manufacturer of engine components, Cooper Corporation has established itself as a global player in the field of manufacturing be it generators, engines or engine components. Today, if the generator sales have a critical user base, the engine component segment attributes to a major chunk of company’s revenues. The company’s rapid expansion and capacity enhancement is the testimony to high skilled labour, qualified personnel, technological advancement and above all commitment to quality and in par with international standards.

India’s Largest Crankshaft Manufacturers and Supplier - Cooper Corp

A crankshaft is a key automotive engine component that converts the linear motion of the piston into rotary motion. In other words, the force created by the pistons moving up and down is converted to a force that enables the wheels in circular motion to move forward. As one of the essential part of any engine, a crankshaft is used in the production of an automotive engine that can either be forged or cast. Crankshaft manufacturers have to, therefore, ensure that the manufacturing material used for the making of these crankshafts is of very high-quality ductile iron as they are the main rotating component of an engine. As one of the established players in the field of manufacturing of engine components, Cooper Corp is among the renowned crankshaft suppliers and crankshaft manufacturers in India as well as globally. The company is known for its manufacturing excellence coupled with great talent and dedicated workforce for over five decades now. With this in the background, let us now look into the on what it takes for the making of high-quality crankshafts.

About crankshafts in a nutshell:

Forged crankshafts have long been used for engines and are stronger than cast crankshafts which are now used extensively by automotive industries and other manufacturing units. Crankshafts are manufactured by forging and making of spheroid-shaped cast iron through the critical production process. The process includes a wide range of refined high strength steel that defines tolerance and tenacity of the engine in total. Cooper corp ensures that the steel specifications vary depending on industry use, size and applicability. The designing process takes into consideration that the crankshafts achieve extreme levels of strength and impact resistance to take care of the high-performance engines. Speaking about engines and engine components in entirety, the structure, and architecture of the crankshaft is a very complex geometry of sorts. It consists of the crank pins which connects the rods, the shaft parts that revolve in the bearings, crank arms or webs that connect crankpins to the shaft components. The crankshaft ‘main’ makes circular rotations with the help of the supporting bearings causing the offset rod journals to rotate and the big ends of the rods contain bearings which ride on the rod journals. Crankshaft manufacturers have to consider the structure and for the large number of load cycles that the crankshaft operates on; the design, production, and manufacturing processes are equally crucial. Being the hub of manufacturing, crankshaft manufacturers in India have to ensure that each step of the manufacturing process is standardized and as per international standards.

Manufacturing of crankshafts-from design to supply:

Crankshaft manufacturers in India ensure that the designing of crankshaft takes into account the engine requirements that can vary between single and multiple cylinders. At Cooper corp, all the crankshafts are conditioned to the optimal quality where all the internal stress is removed and the structure is stabilized to specified hardness. The crankshafts are induction hardened to main and pin diameter at 50~60 HRC and is equipped with the casting and support facilities for manufacturing S.G. Iron crankshafts.  The cost-effectiveness, engine performance, and the strain analysis are well taken into consideration during the initial processes itself. In order to address the engine failure issues due to fatigue, crankshaft manufacturers have to make sure that accurate levels of stresses are applied and strain analysis is conducted on the basis of the nature of the load applied on the crankshaft. As one among the key players as crankshaft manufacturers in India, Cooper corp ensures that due care and caution is taken in the entire manufacturing process right from the ‘shaping on the lathe’ till the final inspection process. In its attempt to do so, each of the crankshafts manufactured by Cooper Corp is subjected to stresses that are potentially equivalent of several tonnes of force to test for its tenacity.

Cooper Corp has been a dominant player in the industry both as one of the key crankshaft manufacturers in India and as a crankshaft supplier nationally and worldwide. The products have wide industrial application including the manufacture of engines, generators, vehicular components, and automotive industry. The company has a wide network of the distribution chain and caters to individual industry requirements and industry specifications. Being one of the major crankshaft suppliers in India and globally, Cooper Corp produces ready-to-install crankshafts for high-performance automotive engines.  The company has a supply chain across India and internationally with the broad network of client base having automotive, marine and industrial applications.