NW Diesel en Einzels 150dpi-2

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Engin

e

Compone

nts

Engine Components

www.novaswiss.com

Common rail piping systems

Fuel injection pipes

Air starting components


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Common rail piping systems

Co

mmon

rail

pipingsystems

2

hapa7 Fotolia.com

Kenneth Sponsler Fotolia.com

Nabil B IYAHMADINE Fotolia.com

The leading manufacturers of diesel engines

have selected NOVA SWISS fuel injection

pipes, common rail piping systems, and air

starting components as their prime choice for

many years.

No matter whether the engines are used to

power ships, locomotives, large commercial

vehicles or gen-sets, with common rail piping

systems from NOVA SWISS, modern

engines become cleaner and quieter and, on

top of that, help to protect the environment.


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www.novaswiss.com

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High-performance diesel engines becoming cleaner, safer and quieter

Not only the drastic increase in the emission

requirements, but also economic aspects

direct the focus to the more efficient common

rail technology, also in large engines. In close

collaboration with customers and system

partners, NOVA SWISS developed a com-

pact 2500 bar common-rail concept for diesel

engines in the performance range of 300 to

30 000 kW. It offers high flexibility because

high-pressure rails, accumulators as well as

connections or injection pipes can be adapted

to individual engine requirements.

Common rail systems offer a reduction in

NOx, CO and HC, and enable all users of

CR engines to comply with the more restric-

tive regulations. Improved engine performance

and savings in fuel consumption are additional

benefits.

The great advantage of common rail techno-

logy is the faster and more precise combustion

of the fuel (diesel or HFO). The electronic

control system adjusts the number of time

of injections, injection pressure, time and

volume, regardless of engine speed and load.

This reduces emissions, noise as well as fuel

consumption.

NOVA SWISS engine components for 2 or

4-stroke engines


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Fuel injection pipes

4

Higher safety through special treatment

The NOVA NHP-110

process is designed to avoid

longitudinal cracks, which

is the most frequent cause

of broken fuel injection

pipes. The process involves

plastic deformation of the

pipe bore, which converts

the tensile stresses at the

inside surface into compres-

sive stresses. The benefit is

a drastic increase in safety,

reliability, and tubing life up

to 80% compared to con-

ventional, untreated pipes.

Customized solutions for loads

up to 2500 bar

NOVA SWISS offers the perfect solution

for todays sophisticated diesel engine, because

all of the components developed and pro-

duced meet exactly the specified requirement

profiles of the engine.

with post-treatmentaccording toNOVA NHP-110

without post-treatment

number of pressure cycles

fatigue

streng

th

Fuel

injectionpi

pes


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www.novaswiss.com

Virtually any pipe geometry

is possible

NOVA SWISS fuel injection pipes are

individually designed based on defined

performance parameters. Each product is

carefully coordinated at an early develop-

ment stage guaranteeing full compatibility

with the injection system as a whole. Virtuallyany pipe geometry is possible. Exact shape

is a prerequisite for stress-free assembly and

uninterrupted operation.

Strict criteria for quality

NOVA SWISS high pressure fuel injection

pipes meet rigorous quality requirements

concerning material, tolerances, and surface

roughness of the bore. Selecting the optimized

HP tube material is based on the operating

conditions of the engine and the maximum

pulse pressures. Quality is also a question of

fine-tuning.

Clean as a whistle

Meticulous cleanliness of all injection compo-

nents is an absolute must for todays powerful

engine. In order to meet this requirement,

we have developed a highly efficient cleaning

concept with an environmental medium.

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Accumulators

Dynamic system pressure max.

2500 bar

Volume can be set individually

Fully sheathed

Leakage pressure to 200 bar max.

Several leak escapes are possible

Various high-pressure connections for

pipes and sensors

Minimum contact surface

Compact, modular structured high-pressure

accumulators, designed for flexible use on

every modern common rail engine up to

2500 bar to compensate for pressure oscilla-

tions. Additional applications areas are hydrau-

lic systems and static pressure generators.

The modular design ensures easy adaption for

different volumes. The adaption to different en-

gine configurations and the integration of high-

pressure distributors or even NOVA SWISS

leakage detection are possible without difficulty.

The design can be both single-wall and also

sheathed with and without leak-off connectors.

Accumulators and high-pressure rails

The flexible NOVA SWISS

power package

Accumulator

s,

high-pressurerails,airsta

rtingcomponents


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www.novaswiss.comAir starting components

Diesel and gas engines start safely and reliably every time with

NOVA SWISS air starting componentsNOVA SWISS air starting valves up to

40 bar and starting valve sets are universally

deployable and are suitable for all diesel and

gas engines with direct and indirect starting air

supply. They can be easily adapted to fit most

types of engines. Starting valves are placed

close to the combustion chamber, and are

therefore designed in special heat and cor-

rosion-resistant valve steel. The large working

surface of the differential control piston

ensures rapid opening and closing. Thus, four-

stroke engines with 6 and more cylinders and

2-stroke engines with 4 and more cylinders

can be started from any position.

The two components are perfectly matched.

Air distributors are fitted to the engine and

directly driven from the camshaft. NOVA

SWISS air distributors can be fitted

with a universal joint that compensates for

small axial displacements and are incidentally

manufactured out of two moving parts and

are maintenance-free in both rotational

directions.

Optimum combination: NOVA SWISS air starting distributors and starting valves.


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Innovations, products , safety

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Our products are virtually tested before

manufacture. The ear lier the wall thicknesses,

tensile forces, kinematics and crack resistance

can be tested in a product concept with its

intended functionality, the better. That ensures

shorter development time and lower costs.

We use cutting-edge CAD and FEM tools to

test the design structure of sensitive compo-

nents and products. This is how we recognise

any potential problem in early phases, which

allows us to act directly and swiftly.

The NOVA SWISS product test

In order to maintain the highest quality stand-

ards, we conduct special calculations as well

as high pressure pulse tests. For instance, dy-

namic endurance tests for components under

presure loads such as fuel injection pipes,

accumulators or common rail piping systems

can be performed with the NOVA SWISS

test bench for peak pressures up to 4000 bar.

As a result, findings can be incorporated within

early project stages, reducing the need for time

consuming and expensive pre-production tests.

NOVA SWISS Vibro Tight screw connections

Normal screw connections loosen with strong

vibrations, as it is typical during the operation

of diesel engines leaks are the result. With

NOVA SWISS Vibro Tight screw con-

nections, a special spring effect prevents the

screw connection from loosening and thereby

reduces the risk of leaks or even worse, trans-

verse pipe cracks.

Inn

ovations,p

roducts,safety


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www.novaswiss.com

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The NOVA SWISS leakage detection with

automatic leakage point display was devel-

oped to locate the leakage point in complex

sheathed common rail systems for MDO

operations.

Due to the simple and compact design, inte-

gration into the connection components

of the fuel injection pipe or the high-pressure

distributor is possible. Using NOVA SWISS

leakage detection reduces troubleshooting and

offers support to resolve leakage problems.

Thus, the engine down time can be significantly

reduced.

NOVA SWISS leakage detection

NOVA SWISS sheathing

A defective fuel injection pipe can cause fuel

spills or engine room fires, resulting in life-

threatening situations. This is not the case if the

HP pipe is equipped with the special NOVASWISS sheathing system: should a pres-

sure pipe burst, the sheathing pipe prevents

uncontrolled spraying of fuel onto hot engine

manifolds. Any fuel leak is therefore contained

within the sheathing pipe and drained to a

retaining tank. The NOVA SWISS profiled

sheathing pipe sheaths simply and cost-effec-

tively. It was developed for the highest flows

with an improved pressure resistance andthereby saves costs for materials and produc-

tion. The flow cross section is significantly

increased compared to any standard solution

through the profile formed into the sheathing

part. Dimensioning allows the use of compara-

bly higher leakage pressures over 500 bar. The

even contact to the pressure pipe distributedover the circumference allows complex radius

geometries and the flexible selection of fas-

tening points on the engine.

Highest possible safety

NOVA SWISS sheathing systems meet the regulations

of the classification societies.


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Research, development and production

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We establish the basis for new NOVA SWISS

products by constantly increasing our know-

how. These tasks include the assessment of

appropriate materials and manufacturing

processes in addition to complex calculations.

Therefore, we conduct a results-oriented

material analysis in our lab with state-of-the-

art equipment. For your safety, we constantly

ensure that all NOVA SWISS products

meet the latest requirements of the markets

and their legal regulations. We take our tasks

seriously:

New innovations, research and

development

Analyses and tests of materials and

coatings

Optimisations, quality assurance

Upsetting with different feeds

Micro-hardness measurements on the surface of a

carbonitrided steel

Trans-crystal fatigue crack in austenitesteel

Image analysis to determine porosity in a

heat insulation layer

R

esearch,

developmentand

product

ion


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www.novaswiss.com

Production

All components are manufactured at our

own plants and at the facilities of specialised

suppliers on modern, well-maintained

machines and systems perfectly suited for the

processes. This guarantees flawless produc-

tion and on-time delivery of our high-quality

products.

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Cutting-edge cold forming

machines for a wide variety of

work with short through-put

times and uniform quality

Modern production facility with Kanban/JIT concept


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The company

www.novaswiss.com

Nova Werke AG is a Swiss technology com-

pany with headquarters in Effretikon, near

Zurich, and branches in France and Germany.

It develops and produces innovative and top

quality products and services for high-per-

formance applications in the following markets

and areas:

Engine Components

High Pressure Technology

Surface Technology

Valve Service

Innovative high-tech components and

processes meet the strictest demands on

quality and reliability.

The management system

Quality is for all products, production

processes and services of central im-

portance. Nova Werke AG is cer tified

according to ISO 9001:2000 and regularly

recertified. The continuous improvement

process is a major component of these

requirements. It is systematically practiced

in all areas.

The division Engine Components conforms

to the standard of ISO/TS 16949:2002 and

thereby meets the highest demands on

technical specification, system and process

quality and management processes accord-

ing to the automotive industry.

Nova Werke AG

Vogelsangstrasse 24

CH-8307 Effretikon / Switzerland

Phone +41 52 354 16 16

Fax +41 52 354 16 90

www.novaswiss.com

[email protected]

A company of

www.mkholdingsa.com

Valve Service

Surface Technology

High Pressure Technology

Engine Components

Jan Will Fotolia.com

NOVA SWISS is the trademark of

Nova Werke AG, and is acknowledged

worldwide.

Engin

e

Compone

nts

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NW Diesel en Einzels 150dpi-2