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MarineDiesel Services Profile: Engineering

 

 

We at MarineDiesel often refer to ourself as an engineering company, rather than as a manufacturer. The reason we do so is that a substantial portion of our annual revenues come from engineering services, rather than engine sales.

As a diesel engine maker, we are required to invest in a substantial level of infrastructure that is highly specialized. This infrastructure is used to customize engines and design engines for specific purposes, which makes MarineDiesel ideally suited to offer complete engineering services to our customers, whether they use our engines or not. Indeed, we consider several of our competitors also to be customers, since we have completed many such projects for them. This is a primary selling point for MarineDiesel: We can usually accomplish things both quicker and cheaper than our much larger competition cannot.

These services include, but are not limited to:

  • Torsional vibration analysis
  • Flow simulation
  • Engine Testing
  • Emissions Testing
  • Compliance Testing (eg. NATO or Intrinsically Safe)

As long as our facilities allow it, in terms of size (We do not have the facilities to test two stroke, 2 mW engines, for example), we can offer customers complete turnkey engineering solutions. Our facilities are state-of-the-art, designed by GM. We have the latest test cells, software, and equipment.

MD ENGINEERING hosts three engine dynos in its test facility, with each test cell having its own unique measurement range and options. This provides us a great span in terms of engine size and application to better meet our client’s requirements and specifications. All cells are equipped with high frequency, multi-channel data logging.

MD Engineering has been involved in complete engine control systems in a multitude of areas, some areas where we have deep knowledge and long experience:

• Control safety systems
• Torque management and control
• Air system diagnostics (MAF, EGR, Swirl)
• EOBD and OBDII controls and diagnostics
• Engine thermal management control and diagnostics
• After treatment systems control and diagnostics
• Stop/start control
• Boost system control for a wide variety of hardware setups:
• Single wastgate turbo and by-pass turbo
• Two-stage turbocharging
• Supercharger
• Twin turbo
• VNT turbo

Our engineers and product analysis experts can take a wide client brief for comparative benchmark and cross product comparison. This includes all aspects of the process from virtual analysis, desktop studies, static and dynamic repeatable test scenarios to full product teardown, measurement reporting and recommendations.

MarineDiesel, through the normal course of business, maintains partnerships with numerous naval architects, engineering firms, automobile manufacturers, other engine manufacturers, and designers. In fact, we are often the ones providing the project management services on complex projects.

To illustrate, we recently were involved in a project where we provided the engines for a new boat, along with the design, and handled the entire contracting process with the shipyard.

MD Engineering is a division of MD Group that comprises of three divisions with fields ranging from engineering to powertrain supply and marine propulsion engines.

For your next engineering project, please contact us today with the project details for a complete proposal.

 

 

 

 

 

 

 

 

Our VGT Series for Industrial Use

 

 

As we’ve written in the past, MarineDiesel manufactures engines for both marine use and industrial use. we are licensees of General Motors’ entire line of available engine blocks, and can modify those blocks to meet many different applications.

Our VGT Series is a standardized, marine version of the GM 6.6 L V-8 block. We manufacture these engines as the premier part of our product line.

However, we can also manufacture this engine for industrial use, through our MDPT subsidiary, providing a wide range of power, torque, control, and cooling options. We have manufactured this engine in the past for the following types of projects:

1. Tanks

2. Amphibious vehicles

3. Airboats

4. Generators

5. Pumps

6. Winches

7. Railroad

Take a look at the specifications below, and contact us today with any projects where this engine could provide a solution.

Specifications:

Engine Model: VGT

Displacement: 6.6 litre

Cylinders: 8

Bore X stroke: 103 X 99 mm

Power: 100-280Kw depending on rpm and application

Compression ratio: 16,0

Turbocharger type: VGT

Fuel type: Diesel

Min working temp: -30C

Fuel system: Bosch common rail 1800bar

Weight: approx 360kg (dep on accessories)

Size (LXWXH): 812 X 680 X 780 mm

Scope of Supply:

  • Starter motor and alternator
  • Exhaust manifold and turbocharger
  • Intake manifold and basic air filtration system
  • Integrated oil cooler
  • Integrated oil filter
  • Integrated fuel filter
  • Belt system and tensioner
  • Flywheel
  • Engine wiring harness and ECU (J1939)
  • BTU data for sizing radiator and intercooler
  • Diagnostics software

Options:

  • SAE #3 bell housing and matching coupler
  • Cooling package including radiator, intercooler, electric fan, hoses etc
  • Engine monitoring displays of different sizes
  • Multiple engine mounting options
  • Multiple calibration options for continuous and variable speed applications and different duty cycles.
  • Multiple air intake option
  • Multiple exhaust system options
  • Private label diagnostics software (with your company logo)
  • Diagnostics and mechanical training
  • Hardware CAN cable for diagnostics software
  • Emissions certifications
  • NATO Milspec certification
  • After treatment components

 

 

Best of 2014 – Industrial Engine Week, Airboats

 

 

We wish all MarineDiesel customers a happy holiday season. Our factory will close from December 22 through January 5. For the balance of the year, we will be re-running our most popular articles from 2014, based on the number of visitors. We will start new daily articles in the New Year. We hope that you continue to find them interesting.

Today is the final day of our industrial engine week, and we focus on a niche market that has been up-and-coming for MDPT over the last couple of years: Airboats. Hmmm…

Industrial?

Correct. Airboats are a special case that is handled by MDPT rather than the larger MarineDiesel group because airboats are a hybrid of sorts. They are boats, but they use engines that are engineered for use on land. This makes them unique in the marine world.

Traditionally, airboats were simple vehicles: A shallow, flat bottomed boat with a (usually) used aircraft engine mounted astern that featured a direct coupling to an aircraft propeller straight off the flywheel. Ratios were inexact, with propeller pitch largely used to control performance levels.

Modern airboats bear little more than a casual resemblance to these old vessels. Modern airboats can now be equipped with climate controlled cabins, gun positions for military use, and are always equipped with modern, compact and high powered engines. Propellers are designed with lightweight composites, and there are complex gear or belt drive systems that can include variable gear ratios. Indeed, some airboats are now equipped with contra-rotating dual props that provide huge amounts of torque and extremely high speeds.

Airboats are often commonly seen in the Everglades, or on TV shows like “Swamp People”, and so on. They handle conditions in swamps quite well, being shallow draft and not having any propeller to run aground or get snagged. However, there are many other applications for airboats, and this niche market is booming: Military use for patrol, rescue, use on ice. All of these uses are now common.

For more information:

Leppek, Adam P., “Optimization of an Airboat Design” (2012). Honors Theses. Paper 2180. offers a good and interesting overview of modern airboat design and why airboats are well suited for their application.

MDPT is at the forefront of powering some of these cutting-edge designs. Our marine heritage serves us well in providing specialized engines for airboats. As we mentioned earlier, airboats are a hybrid of sorts. They use engines designed for use on land, but they are exposed to the harsh marine environment. We have the ability to combine these two fields of expertise into a single, customized and application-specific product, with appropriate injectors, connectors, and cooling systems. We also work very closely with the drive manufacturers, propeller manufacturers, and designers to offer complete airboat propulsion packages.

We have completed airboat projects in Russia, Finland, the USA, Australia, and Thailand, and this market segment is becoming a specialty of MDPT. Contact us today on your next project, but please see below for some previous MDPT installations.

PantherDuramaxFinland AA 022012022??????????????????STAATSOLIE

Engine Comparisons: MDPT 6.6L Land Vehicles

 

 

Recent comparison of the MDPT 6.6L engine modified for off-road land vehicle use in extreme climates:

Specifications:

Engine Model: MDPT VGT

Displacement: 6.6 litre

Cylinders: 8

Bore X stroke: 103 X 99 mm

Power: 100-280Kw depending on rpm and application

Compression ratio: 16,0

Turbocharger type: VGT

Fuel type: Diesel

Min working temp: -30C

Fuel system: Bosch common rail 1800bar

Weight: approx 360kg (dep on accessories)

Size (LXWXH): 812 X 680 X 780 mm

Scope of Supply:

  • Starter motor and alternator
  • Exhaust manifold and turbocharger
  • Intake manifold and basic air filtration system
  • Integrated oil cooler
  • Integrated oil filter
  • Integrated fuel filter
  • Belt system and tensioner
  • Flywheel
  • Engine wiring harness and ECU (J1939)
  • BTU data for sizing radiator and intercooler
  • Diagnostics software

Options:

  • SAE #3 bell housing and matching coupler
  • Cooling package including radiator, intercooler, electric fan, hoses etc
  • Engine monitoring displays of different sizes
  • Multiple engine mounting options
  • Multiple calibration options for continuous and variable speed applications and different

duty cycles.

  • Multiple air intake option
  • Multiple exhaust system options
  • Private label diagnostics software (with your company logo)
  • Diagnostics and mechanical training
  • Hardware CAN cable for diagnostics software
  • Emissions certifications
  • NATO Milspec certification
  • After treatment components

 

BENEFITS OF MDPT ENGINES:

1. Extended Life Cycle: MDPT engines have a much longer life cycle than competing engines. There are several reasons as to why. First, the GM block has been produced in the millions of units, and is currently used by military organizations around the world. The reliability is unmatched. The MTBO of MDPT engines can range from 2,500 hours to over 5,000 hours depending on rating, climate, use, and engine MAP. At an average cost of a rebuild exceeding 60% of the cost of replacement, this long life cycle translates into thousands of Euros per year in savings. Additionally, the power and torque curves of competing engines show “spikes” that increase strain and wear of not only engines, but other vehicle components, and thus significantly shorten the life cycle and service intervals necessary to keep the engines running. Competing engines typically start with larger engines that are de-rated in order to provide a longer life cycle. The MDPT engines are designed specifically for compact, light, long life applications. The VGT Series is NATO compliant and certificates can be issued.

2. Customizable: Truck engines are designed to provide a huge amount of torque at the outset, and gradually decrease as momentum is maintained on a highway. This situation rarely occurs with off-road vehicles. The NIRA ECU in MDPT engines is completely customizable. Cummins and other manufacturers tend to use Bosch ECUs for engine controls that cannot be changed without significant extra expenditures (If it can be done at all. The Bosch ECU itself is limited in functionality.) What does this all mean? For instance, MDPT can “shift” the power and torque curves based on customer requirements. For example, with amphibious vehicles, MDPT engines can be programmed to allow more torque and power while operating amphibious, all at a touch of a switch by the operator. This functionality is known as an engine MAP, and MDPT can allow multiple MAPs that can easily be altered based on customer requirements. Other examples:

  • Use of the vehicle in urban settings
  • Use under extreme environmental conditions
  • Optimized for speed on-road
  • Optimized for use off-road
  • Extra torque for rapid acceleration

3. Reduced Vibration and Noise: MDPT engines are a V-8 configuration that, due to the laws of physics, produce far lower levels of torsional vibration than inline 6-cylinder engines.  As to noise, MDPT engines are among the quietest in the market. MDPT has extensive experience with noise reduction and control. Engine noise can be minimized before shipment in our test bays and labs, and further reduced by engineering design and aftermarket silencing systems that we can package with the engine.

4. Light Weight: The MDPT VGT Series of engines weigh a mere 360 kg, compared to the Cummins ISB at 485 kg or the QSB5.9 at over 500 kg. The MDPT engines were designed for high power to weight ratio. Competing engines are de-rated from higher horsepower, and are thus much heavier.

5. Torque: Competing engines have torque curves that sharply spike on the low end of the RPM range and then sharply decrease. MDPT engines feature torque curves that evenly distribute the torque produced at a high level along the entire curve.

6. Engineering: MDPT provides a complete turnkey package. Factory supervision and consultation will be provided from initial engineering, to drawings, to installation, commissioning, mechanical training, and operations training.

7. Rating for Climate: MDPT engines come rated for the local climate. Customers in tropical climates will not see the power loss that is commonly seen with competing engines.

8. Emissions: MDPT engines are in compliance with Tier IV off-road requirements in the EU or USA.

9. Fuel Efficiency: The VGT turbochargers on MDPT engines provide high power while minimizing fuel consumption, to a far greater extent than older, mechanical engines.

10. Compact Size: MDPT engines are designed to fit in compact engine compartments. We are one of the smallest engines in terms of size on the market.

11. Extended Warranty: An extended warranty is available.

engine comp

MD:                                       812 X 680 X 780

Cummins:                       844 X 950 X 857

Scania:                               1406 X 861 X 1113

CAT:                                     1089 X 986 X 970

Iveco:                                  1017 X 805 X 790

 

Curves:

MDPT:

vgt torque

Cummins:

cummins torque

Scania:

scania torque

scania power

CAT:

cat torque

 

Iveco:

Iveco torque

Tight spaces and tighter places

 

 

MarineDiesel engines are the lightest, and most compact, of any engine on the market in our class. That is indisputable fact.

Why does this matter?

Quite simply, MarineDiesel engines can fit into tight places that simply do not have the space for our larger competitors. On boats, especially RHIBs or small high speed craft, this is a very important product feature. RHIBs, in particular often have tiny engine compartments located immediately under the deck, with little excess room. The vessel pictured above is a recreational vessel with three engines. Engines made by our competitors would not only never fit in the limited space, but their extra weight would shift the LCG of the vessel considerably.

With catamarans or trimarans, a different problem emerges. The beam on each hull. Port or starbord, engine compartments are narrow, with little extra room.

This can be an issue in industrial applications, too. Our MDPT subsidiary is currently involved in a re-powering project involving armored vehicles. These vehicles are designed with precisely zero excess space, and the smaller, lighter MDPT engines make a big difference in vehicle performance and ease of operation.

In fact, the biggest problem we face in these cramped quarters is providing adequate cooling for the engines, whether on land or at sea. Engines produce a lot of heat, and that heat must be dissipated. Through years of experience, MarineDiesel has learned practices and techniques that provide adequate cooling, such as louver design, blowers, and engine placement.

To illustrate, see the ventilation diagram below:

A - Air should exit the engine bay and the upper section B – Air should enter the engine bay at the lower section

A – Air should exit the engine bay and the upper section
B – Air should enter the engine bay at the lower section

 

 

 

 

Engine Management System Development

 

 

MD Engineering is a division of MD Group that comprises of three divisions with fields ranging from engineering to powertrain supply and marine propulsion engines. Applications – MD Engineering together with MD Powertrain work in a vast field with a wide array of specialized applications such as automotive and truck industries, engine manufacturers, industrial applications and a field of specialty custom applications. Together MD Group can take responsibility not only for engineering activities but if required also product supply and field support as required by the customer.

Engine Testing:

MD ENGINEERING hosts three engine dynos in its test facility, with each test cell having its own unique measurement range and options. This provides us a great span in terms of engine size and application to better meet our client’s requirements and specifications. All cells are equipped with high frequency, multi-channel data logging.

TEST CELL A – Measurement range:

• 0-700 kW (1000 – 6000 rpm)

• 0-3,000 Nm (1000 – 6000 rpm)

TEST CELL B – Measurement range:

• 0-700 kW (1000 – 6000 rpm)

• 0-3,000 Nm (2500 – 6000 rpm)

TEST CELL C – Measurement range:

• 0-2,100 kW (1000 – 4000 rpm)

• 0-15,000 Nm (700 – 4000 rpm)

MD Engineering has been involved in complete engine control systems in a multitude of areas, some areas where we have deep knowledge and long experience:

Apart from pure engine control development, MD Engineering is a comprehensive service provider, delivering solutions from single components, multi-part mechanism based drive train systems through fully-engineered powertrains. We offer a breadth of expertise and high-class facilities to an ever growing customer base to support the development of powertrain technologies. Our industry-leading engineers and technicians ensure that test and product development programs produce the accurate, repeatable and representative results you demand. Drawing on extensive OEM engineering experience, our engineering team is able to design, release, prototype and production release almost any powertrain component into a range of diverse applications. One of our test cells is equipped and capable of performing steady-state emissions testing on most engine applications to further meet the stringent emissions requirements. With our emissions equipment we can measure raw exhausts and diesel particulates.

TEST CELL A and C

Equipped for Emissions testing.

Emission bench for raw exhaust measurements AVL CEBII

Exhaust component: Measurement range:

NOx 0-1500 ppm

HC 0-48000 ppm

CO low 50 – 2500 ppm

CO high 0-5%

CO2 1-20%

CO2 EGR 1-20%

Diesel Particulate measurement equipment Pegasor M-sensor (for calibration)

Measuring principle: Measurement range:

ION current 1ugm3 – 250 ugm3

Diesel Particulate measurement equipment MICRO-PPS dilution tunnel

(certifications)

Emissions testing

• Control safety systems

• Torque management and control

• Air system diagnostics (MAF, EGR, Swirl)

• EOBD and OBDII controls and diagnostics

• Engine thermal management control and diagnostics

• After treatment systems control and diagnostics

• Stop/start control

• Boost system control for a wide variety of hardware setups:

Single wastegate turbo and by-pass turbo

Two-stage turbocharging

Supercharger

Twin turbo

VNT turbo

Access to our extensive test facilities on-site enables full test and validation and ensures OEM standards of robustness and durability.

Our engineers and product analysis experts can take a wide client brief for comparative benchmark and cross product comparison. This includes all aspects of the process from virtual analysis, desktop studies, static and dynamic repeatable test scenarios to full product teardown, measurement reporting and recommendations.

MD Engineering has vast experience in other powertrain areas such as:

• Engine test and development

• Engine calibration

• Engine benchmarking

• Engine validation and durability

• Gaseous fuel engine calibration

• Gaseous fuel engine development and validation

• Up to 15,000 Nm torque

• Exhaust emissions and fuel consumption development

• Advanced propulsion, charging and fueling

• Program management

• Engine and components analysis – Fatigue, vibration,

life cycle and durability.

Software

• Torque or speed based fuel controller

• Ability to run Wastegate, VGT or twin turbo

• Integrated EGR controller

• J1939 communication with DM services

• GMLAN and NMEA2000

• Software ready for engine ranging from 2 cylinder

up to 8 cylinder

• After treatment compatible up to Euro VI level

• Ability to change and make new software functions within

the NIRA i7r platform

Engine Calibration MD Engineering

• Base engine calibration

• Transient calibration

• Emission calibration

Three steady state test cells for engine calibration and emissions test.

 

Celebrate Industrial Engine Week! Airboats

 

 

Today is the final day of our industrial engine week, and we focus on a niche market that has been up-and-coming for MDPT over the last couple of years: Airboats. Hmmm…

Industrial?

Correct. Airboats are a special case that is handled by MDPT rather than the larger MarineDiesel group because airboats are a hybrid of sorts. They are boats, but they use engines that are engineered for use on land. This makes them unique in the marine world.

Traditionally, airboats were simple vehicles: A shallow, flat bottomed boat with a (usually) used aircraft engine mounted astern that featured a direct coupling to an aircraft propeller straight off the flywheel. Ratios were inexact, with propeller pitch largely used to control performance levels.

Modern airboats bear little more than a casual resemblance to these old vessels. Modern airboats can now be equipped with climate controlled cabins, gun positions for military use, and are always equipped with modern, compact and high powered engines. Propellers are designed with lightweight composites, and there are complex gear or belt drive systems that can include variable gear ratios. Indeed, some airboats are now equipped with contra-rotating dual props that provide huge amounts of torque and extremely high speeds.

Airboats are often commonly seen in the Everglades, or on TV shows like “Swamp People”, and so on. They handle conditions in swamps quite well, being shallow draft and not having any propeller to run aground or get snagged. However, there are many other applications for airboats, and this niche market is booming: Military use for patrol, rescue, use on ice. All of these uses are now common.

For more information:

Leppek, Adam P., “Optimization of an Airboat Design” (2012). Honors Theses. Paper 2180. offers a good and interesting overview of modern airboat design and why airboats are well suited for their application.

MDPT is at the forefront of powering some of these cutting-edge designs. Our marine heritage serves us well in providing specialized engines for airboats. As we mentioned earlier, airboats are a hybrid of sorts. They use engines designed for use on land, but they are exposed to the harsh marine environment. We have the ability to combine these two fields of expertise into a single, customized and application-specific product, with appropriate injectors, connectors, and cooling systems. We also work very closely with the drive manufacturers, propeller manufacturers, and designers to offer complete airboat propulsion packages.

We have completed airboat projects in Russia, Finland, the USA, Australia, and Thailand, and this market segment is becoming a specialty of MDPT. Contact us today on your next project, but please see below for some previous MDPT installations.

AUIMG_3442??????????????????Finland AA 022012022STAATSOLIE7_3PantherDuramax

Celebrate Industrial Engine Week! Re-power Projects

 

 

It is day four of industrial engine week, and this makes an ideal time to discuss re-powering projects.

MDPT’s re-power projects take many forms, but are usually associated with military vehicles. Indeed, the 6.5L GM block we use on our 170 hp – 300 hp range is one of the same blocks that were originally used to power the AM General Humvee, so the legacy is there when you start discussing the need to re-power these types of vehicles.

In the past, we have provided not only engines, but service, testing, development, and technical assistance (technology transfer) to numerous organizations when the time arrives to change power methods or equipment.

An example could be a project where we provided engines for light tanks. The engine compartment was small and highly compact, in addition to tanks generally operating in extremely harsh conditions. The engine chosen must be able to operate in wide temperature extremes, dirty conditions, and, most importantly, reliably. The engine must be easy to install, remove, and service, with easy accessibility to major components. Since we can move the location of oil filters, for example, to remote or different locations, this engineering capability makes for a major selling point on MDPT engines.

Politics, for example, can also have an impact. We have one customer whose vehicles were all manufactured in a country now in a state of war. The manufacturer was able to provide service when the political situation was stable, but now that it isn’t, our customer is having severe service and spare parts issues, necessitating a change of engines, since these issues are now impacting their own operations.

This is where companies like MDPT come into the mix. We were asked not only to re-power the vehicles, but also to effectively restructure the service network and the spares supply chain: A massive project, indeed.

For all your re-powering projects, consider MDPT as a “one stop source” for difficult or complex power solutions.