Quality and Workability above all when it comes to engine components

Defining the lifeline for every engine through quality products

The cohesive force of the vital engine components is what defines the overall workability of any automobile unit. The working of an engine is solely dependent on the engine components they are made of. Finer the components, the better workability of the engine. To ensure that it is all smooth sailing, engine manufacturer companies follow a number of parameters just to ensure the components are those of highest quality in terms of workability and precision technology. As one of the renowned engine components manufacturers of India, Cooper Corporation has been able to integrate engineering excellence into their manufacturing systems.

Today, they are among the leading piston, crankshaft manufacturers and flywheel manufacturing company in the country, supplying products to some of the leading automobile companies, infrastructure companies, marine companies etc. in India and rest of the world. As one of the renowned flywheel manufacturers, they have been supplying their products to several of the OEM’s and automobile companies round the world and across India. Ditto, with the other components as well as the company has attracted the attention of a number of renowned manufacturing companies across all sectors.

Wide range of application and use for engine components

The use and application of a flywheel for any automotive engine is that of a point of power supply from motor to machine if through storing of rotational energy during the moment of inertia. When the engine faces loss of momentum or comes to a halt for whatever reason, the stored energy in the flywheel are used up by converting into heat energy in the brakes.  Cooper is among the renowned flywheel manufacturing companies in India supplying products worldwide for a wide range of automotive uses and applications. Being a vital engine component, the material used, engineering, technology adapted play a vital role. Some of the materials used by flywheel manufacturers like Cooper include-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. Since the flywheel vary flywheel vary in diameter, weight and the quality of substance used, flywheel manufacturing companies take into consideration the various elements such as design, process mechanism, marketing to enable flywheel reach the right target audience.

Engine components form 60 percent of the company’s revenues. While this is where the company initially grew from 50 years ago, the company has diversified into engines and generators over a period of time. Whether it is about being one of the top crankshaft manufacturers or that of other automotive components, they ensure that the designing, production processes etc.are integrated with technology. When it comes to cylinder liners, Cooper is among the largest cylinder liner manufacturers in the country, where the current monthly production is pegged at 2.6 million. They supply about 175,000 liners to Jaguar and engine manufacturers like Cummins.  

Quality control over engine components

AS one of the key exporters and flywheel manufacturers, Cooper exports flywheels, cylinder liner, crankshaft and other engine components to equipment and engine manufacturers across Africa, China, Europe and Sri Lanka and has of late expanded its horizon to the US markets as well. In the process of being among the renowned engineering company or a manufacturer of individual auto component like crankshaft manufacturers, stress test and strain analysis is conducted by applying the required force and pressure. This is just one of the many ways where individual components are tested for quality.

As one of the key manufacturers 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. 

Engine components-precision technology and dynamic designs

The Indian auto-components industry has been showing a steady growth in the recent years and amounts for 2.3 per cent of India’s GDP. With such robust growth forecast, opportunities have also multiplied resulting in Foreign Direct Investment (FDI) inflows into this segment especially in the past two decades. The vital engine components such as the pistons, crankshafts, flywheel, and cylinder liners etc., contribute to what is known as the organized business which largely supplies to Original Equipment Manufacturers.  Satara-based Cooper Corporation is India’s renowned auto components industry and original Aluminium parts manufacturers that supply their products to the automobile industry and OEM’s across the world including Jaguar, Kawasaki, GE, Maruti Suzuki, Cummins etc. Besides, the 70% of components used in the Cooper engines and generators are manufactured by the company itself. This being their USP, there’s better quality control in the production and manufacturing process. 

Engine components-precision technology and dynamic designs

Cooper Corporation is one of the key Aluminium parts manufacturers for engine components, largely catering to the agricultural, automotive sectors, infrastructure and marine segments within and across the globe. Over the years, the company has consistently been investing in the state-of-the-art-technology at its manufacturing plants in Satara with active assistance and industrial collaboration from consultants across the world. Today, they are among the largest flywheel manufacturing companies, crankshafts, cylinder heads/blocks and piston manufacturers. Pistons are the key engine parts that are made to fit into the cylinder liners with the help of piston rings. The material chosen in the manufacture of pistons have to be in accordance to the material chosen for the cylinder liners and that of the piston rings. Piston manufacturers have to provide a high quality, cost-effective and perfectly engineered finished product that can fit into that cylinder liners. As one of the piston manufacturers in India they manufacture pistons for large bore liners using materials such as cast iron tin plating or in aluminium in order to improve the wear resistance even at high temperatures.

The use of precision technology, efficient labour and manufacturing finesse is seen in all of the Cooper engine components especially critical automotive parts such as flywheels. As one of the preferred flywheel manufacturing companies to OEM’s and other automotive companies, Cooper ensures that various parameters such as the material used, designing of flywheels, overall weight, diameter etc., are as per the exact brief. Flywheels are in a way the reservoir of energy that calls for fine engineering and manufacturing expertise. Flywheel manufacturing companies have to therefore ensure that the right material is used so as to sustain high levels of stress and to prevent breaking apart of flywheels. High quality materials including cast iron, composite materials like carbon merged with cast iron, e-glass fibre composite are used in the making of flywheels.

Flywheels make for a better option than rechargeable batteries in terms of energy sustenance, design, compactness and also occupy lesser volume. They are also used to store electricity produced by solar panels and supply stored electricity to drive generators and illumination. Several considerations for effective use of flywheels include the planning and design of flywheels, effective use of flywheels and optimization of parametric factors for better energy storage in the flywheels. The cost-effectiveness and engine sustenance- in comparison to the rechargeable batteries make then a better option as compared to rechargeable batteries. As a pioneer among flywheel manufacturing companies in India, as well as a renowned engine component manufacturer Cooper Corporation is known for compact and dynamic design, yet excellent energy storage capacity owing to the use of composite materials and carbon fibres. They are known for their wear-free technology and long lasting flywheels that are designed for better capacity irrespective or charging cycles. With constant innovation and dedicated workforce, the company

Excellent quality control over the manufacturing of engine components

Engine components define the workability and efficiency in mechanism of automotive parts while also defining the overall health of the engines. Seamless working of the engine is dependent solely on the manner in which its key components such as flywheel, crankshaft, piston, cylinder liners and cylinder sleeves function. Talking about flywheels, they are used to store energy effectively and points of power supply from motor to machine. Flywheel manufacturing companies use flywheels of varied weight and size to enable storage of energy based on acceleration and torque. Crankshafts on the other hand is the main component of the internal combustion engine that converts linear motion to rotational motion. Crankshaft manufacturers use aluminium composites in the manufacturing process as it smoothens the engine revolutions as against the iron crankshafts that are a cheaper alternative. Needless to say, flywheels and crankshafts have been used for many years to ensure smooth rotation of engine.

In manual transmission flywheel is mounted on the engine shaft and is put to use when the driver engages the clutch to shift gears. The friction plate that is placed between the flywheel and pressure plate allows engine shaft to turn on the transmission. While they offer smooth flow of torque to the machine release energy without any change in speed, Flywheel manufacturing companies use aluminium as they are lighter in weight as compared to steel or iron, thereby allowing optimum functionality when engine is running. The use of cast iron, mild steel, other composite materials made by combining steel and glass fibre are also used widely in the manufacture of flywheels. Since flywheels are in a way the repositories of energy, the use of the right material, precision technology and manufacturing expertise are to be followed strictly.

When it comes to crankshaft manufacturers, use of high ductile iron and aluminium are widely used as crankshafts are the main rotating components in the engines. Crankshafts are vital automotive engine components which convert the linear motion to rotary motion through the force created when the pistons move up and down. Cast crankshafts and forged crankshafts are used in automotive industries and by other manufacturing industries. The making of crankshafts is a critical process which involves the use of refined high strength steel which can prove the tenacity of the engine during operation. The use of material, the quality of steel is relative and is based on the industry type and use and applicability. Secondly, the structure, architecture and design of the crankshafts is complex in nature and varies as per depending on the number of cylinders.

Crankshaft manufacturers have to ensure that they bear all these aspects in mind during the process of crankshaft manufacturing. As one of the major players in this industry, Cooper Corporation ensures that the crankshafts are conditioned to optimal quality and are hardened to main and pin diameter of 50~60 HRC. In order to maintain performance efficiency and cost-effectiveness, these engine components are subject to stresses as a test for tenacity. Cooper is among the reputed flywheel manufacturing companies in India, supplying end products to several Original Equipment manufacturers- OEM’s across the globe and several automotive companies.

Cooper uses high ductile iron and aluminium. The overall functioning of the modules of crankshafts such as crankpins, crank webs, supporting bearings etc. are micro-monitored to support large loads of manufacturing. Whether it is about flywheel or crankshafts, they are made to suit the requirements of both diesel/Gas-powered engines. With a manufacturing expertise spanning over five decades, the company understands that quality control measures, timely upgradation of technology, superior raw materials, consistency, legislative compliances are a key to maintain a long-term relationship and trust of the customers. With a strong manufacturing heritage consisting of committed workforce and contemporary technology Cooper has grown on to be one of the largest crankshaft manufacturers and flywheel manufacturing companies in India.

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