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Jaguar details the technology behind the I-Pace

Jaguar I-Pace

Ahead of it public debut at the Geneva International Motor Show next month, McLaren has released further information on the Senna. Fitted with a 4.0-liter twin-turbocharged V8 – McLaren’s most powerful IC engine ever produced for a road car – the limited release hypercar will develop 800ps and 800Nm.

Toyota details its new Dynamic Force engine

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The Japanese OEM has revealed its all-new powertrain system which is set to be installed in 80% of Toyota vehicles by 2023. Based on the Toyota New Global Architecture, the technology will feature a new continuously variable transmission (CVT), a 6-speed manual transmission and a 2.0-liter hybridized engine unit.

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As OEMs continue to announce plans to end production of diesel engines, Mercedes-Benz has unveiled its new diesel PHEV C-Class at the Geneva Motor Show. Will this powertrain development give TDI a new lease of life? 


Prodrive expands composites facility

Technology consultancy and precision-manufacturing specialist Prodrive has doubled the size of its composites facility, moving from motorsport-sized manufacturing batches to runs of several thousand. The expansion is driven by the company’s recent contract wins with three highly demanding manufacturers of premium sports cars. When added to established defense, marine and aerospace customers, Prodrive’s composites business now has an order book worth more than US$ 62 million.

Meeting the challenge of rapidly growing volumes required a combination of capital investment, recruitment and process improvement. “It would have been easy to simply expand the factory, but that would not have addressed the fundamental challenge,” explained Prodrive’s composites manager Ian Handscombe. “Clearly we did need more space, but the key to making this a sustainable business geared-up for the growing industry-wide use of composites is to take this opportunity to work on improving our processes and finding new ways of helping our skilled people to work more efficiently.”

The biggest investment has been in two additional high-spec autoclaves, together worth around US$1.2 million. The larger unit accepts parts up to 2m diameter by 4.3m long; the other 1.5m by 2.3m long. As well as allowing substantial panels to be manufactured in one piece, they open up new possibilities that could further improve high-volume production efficiency: with 350oC and 200psi now available, the use of thermoplastic composites becomes possible, with much faster cycle times and easier recycling.

Around US$750,000 has been invested in a new, five-axis milling machine, complete with vacuum clamping and dust extraction. It now takes only 20 minutes to trim a large post-mould component that previously took four hours by hand. “Supplementing the manual processes with appropriate automation has increased throughput, allowed us to ensure consistently high first-time quality, and we have reduced waste by around a third,” adds Handscombe.

A second machine for the NC-cutting of raw sheet material (pre-preg) is also being introduced, with CAD software to create optimized nesting of pre-cuts direct from component CAD data. The NC machine also allows automated cutting of thicker material (up to 2mm) to reduce the number of layers required. “This is one of the enablers for the manufacture of body-in-white (vehicle body) components,” explains Handscombe. “It’s more efficient and gives us a surface that is ready for painting.”

A dedicated lacquering unit with a sand-blasting facility to prepare parts has been commissioned and a second clean room has been added, with the prospect of a third in the near future. An enlarged manual trimming and fitting workshop handles those jobs unsuitable for automation. All together, floor area has more than doubled to 32,000 sq ft.

5 October 2011


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