kb autotech overview - kotra profile/09_kb autotech... · quality control germany plant brazil...

Confidential © Copyright 2013 KB AutoTech All Rights Reserved.

KB AutoTech Overview


• History

• Oversea Branches

• Company Facts

• Organization

• Management

• Main Customers

• Sales by Year

• Products Group

• Sales by Products

• New Car Development Status

• Certification

• Production Capability

Contents of Company overview


1962

1969

1980

1980

Established under the name of Hyundai International Inc.

Started to mass-produce automotive radiator

Company name changed to Mando Machinery Corporation

Mass-produce A/C for Passenger vehicle, Bus, and Train

2009 KB AutoTech Co, Ltd. launched

2004 Modine Korea, LLC launched

2012 KB AutoTech India (Pune) established

2011 KB AutoTech China (Shanghai) established

History


Overseas Branches

USA (Detroit)

INDIA (Pune)

Europe (Frankfurt)

China (Shanghai)

Korea (Asan)

Japan (Tokyo)

PlantHeadquarter Branch Office


Head Office & Plant

Total 595 employees

Total 55,392 m2

Manufactures:

- Air Conditioning systems

- HVAC systems

- Cooling module

- Heat exchangers

R&D Center (Lab & CWT)

80 Researchers

Area: 9,170 m2

A

B

C

Company Facts – Korea Headquarter

Plant & Office R&D Lab CWTA B C


China Office & Plant

Investment

- Shareholder: (KBAT100%)

- Capital: 2.10M USD

Plant

- 3,489㎡

ground 2,728㎡

office 761㎡

Products:

- A/C systems,

- HVACs,

- Compressor,

- Cooling Modules,

- Heat Exchangers

(HTR, Evaporator, Condenser)

Location:

- Shanghai

Major Customer

- Hyundai Heavy Industry

- SANY

- XUGONG

- JAC

WINIA Warehouse

WINIA Plant

Company Facts – China plant


Company Facts – India plant

India Office & Plant

Investment

- Invested : U$5mil.

- Planned (by 2014) :U$5mil.

Plant

Total 5 acre

(F1: 1 acre . F2: 4 acres )

Product

- A/C systems,

- HVACs,

- Cooling Module

- Compressor

- Bus Air Conditioner

Location :

Chakan, Pune, India

Major Customer

- TATA

- Ashok Leyland

- EICHER

- M&M


Executive director

CEO

Auditor

Sales R&D

System Design1

System Design2

Electronic

Design

Advance

Development

Sales 1

Sales 2

Sales 3

Administration

Finance

General Affairs

Purchasing

Oversea Entity

China Plant

India PlantManufacturing

Production

Development

Production

Control

Material

Management

Quality control

Germany Plant

Brazil Plant

Quality Assurance

Quality Control

USA Office

Japan Office

Plant

Salaried 193

Worker 402

Total 595

Testing

PM

Organization

EU Office


Major Customers


200

Unit : 1 Million USD

192 183

226

2008 2009 2010 2011 2012 2013

260

400

231

370

Sales Revenue


Products Group – Passenger car

INTERCOOLEROil Cooler

Seat Cooler with

BLDC Motor

Controller

HVAC

Cooling Module

Ventilation Booster

Battery Cooling Blower

APTC

Heat Exchangers

(Heater & Evaporator Cores)

ATF Warmer

Condenser

(WEOC) (TMOC)

CAC.pptx

CAC.pptx

Seat%20Cooler.pptx

Seat%20Cooler.pptx

HVAC.pptx

HVAC.pptx

OILC.pptx

OILC.pptx

APTC.pptx

APTC.pptx

Battery%20Cooling%20Blower.pptx

Battery%20Cooling%20Blower.pptx

HEAT%20Exchangers.pptx

HEAT%20Exchangers.pptx

CRFM.pptx

CRFM.pptx


Sales by Product (2012)

Bus / Train / Mil

Air conditioner

17%

Other

22%

Cooling Module

9%

Intercooler

7%

Car Air

conditioner

45%


LRQA: Lloyd’s Register Quality Assurance

KOSHA: Korea Occupational Safety & Health Agency

Organization RenewalCertification

LRQA 2010ISO 9001

LRQA 2010TS 16949

Description

Quality

Certified

1994

KOSHA 2000KOSHASafety 2000

LRQA 2010ISO 14001Environment 2001

2001

Certification


R & D Introduction


Agenda

R&D Overview• Organization

• Product Development System (PLM)

• CAD/CAE

• Benchmarking System

• Test Facilities

Product Development

• Air Conditioning Parts

• Engine Cooling Parts

• Electronic Parts


Organization

R&D Center

Automotive

A/C system Design

Automotive

Electric systemAdvance

development

System Design-2System Design-1 Electric Design Advance Development

Testing & Proto

Test & Prototyping

Cooling Module

Design

System Design-3

Bus / Train / Military

A/C system Design


Enterprise PLM (Product Lifecycle Management) System

Distributed drawings management system

Groupware System

Web SystemECO’s

Management

Distributed

drawings

management

CAD System

System

Interface

BOM

Management

Parts

Management

Document

& DrawingsProject

Management

[ New Product Development process]

ProductionProduct PlanningDesignR&D Planning

Internet

Supplier

PLM Function

(PDM)

Sales Engineering ProductionQC,PurchaseDevelopment

APQP Process

(PMS)

ERP System

Web System

KBAT Product Development System: PMS(APQP) + PDM

Distributed drawings management system

Product Development System (PLM)


Product Development Process (APQP)

Advanced Production Quality Planning


CAE (Computer Aided Engineering)

CFD (Computational Fluid Dynamics)

• Fluid flow Analysis

• Pressure distribution Analysis

• Thermal Analysis

FEA (Finite Element Analysis)

• Structural Analysis

• Vibration Analysis

• Heat Transfer Analysis

1-D Performance Simulation

• H/X Performance simulation

• Cooling Module Performance Sim.

• A/C system Performance Sim.

0 1000 2000 3000 4000 5000 6000 700020

24

28

32

36

40

44

48

52

56

60

64

Tem

pera

ture

(C

)

Time (s)

A1 Exp.

A1 Sim.


Tech. Trends

Customer

Requirements

Quality Issues

Setting

Analysis GoalsAnalysis

Generating

Reports

(Database)

Performance

Durability

Cost

Structure

Trends

Characteristics

Secure Samples Application

Benchmarking intranet

Benchmarking System

Process & Applications

Benchmarking items: A/C system, HVAC,

Cooling module, Electrics and HEXs

Benchmarking intranet


NEFFF470 160CH

Automatic Test SequenceData Acquisition &

Control

3.00 m2

4.65 m2

Small

Large

Nozzle Size

Single Axial Fan, 470 kWFan & Motor

300 ~ 1400 W/m2Solar Simulation

DC 160 kW, 2WD, MovableChassis

Dynamometer

5 km/h ~ 160 km/hWind Speed

10% ~ 95% RHHumidity

-40℃ ~ +60℃Temperature

14.7m (L) x 7m (W) x 5m (H)Test Chamber Size

• Application: Evaluating HVAC and

Engine Cooling Systems

• Facility completion: April 2001

• Floor space: 2,458 m2

• Facility description

• Simulation test

• Cool down test

• Oil circulation rate test

• City traffic test

• Warm test

• Defrosting test

• Demisting test

• Engine cooling test

Test Facilities – Climate Wind Tunnel

Climate wind tunnel


Anechoic Room AC Calorimeter (I) (II) Vibration TesterFan Performance Tester

H/E CalorimeterI/C & O/C CalorimeterPerformance &

durability facilities

• CAC pressure cycle tester

• Corrosion tester

• WEOC impulse tester

• HVAC system test rig

• Motor torque tester

• BAC comp calorimeter

• TAC calorimeter

• WEOC calorimeter

• E/RAD calorimeter

• Erosion tester

• CAC performance tester

• WEOC thermal cycle tester

• HVAC calorimeter

• APTC calorimeter

• SCHM calorimeter

• BAC calorimeter

Test Facilities – Performance Test Facilities (22 Units)


SWAAT CAC Thermal CycleBurstThermal Shock

Pressure Cycle Electronic Durability

• Salt spray

• Dust

• Cleaning

• Flammability

• Water spray

• ON/OFF durability

• Hot & Cold chamber

• Magnetic vibration

• Power relay durability

• Bubble leak

• Desiccators

• Pencil hardness tester

• DuPont impact tester

• Burning quality

Test Facilities – Durability Test Facilities (20 Units)


• Hybrid recorder

• Programmable LCR meter

• Discharge simulator

• Electronic load

• Insulation tester

• Function generator

• Power Supplier

• Data Acquisition(MX-100)

Electrostatic Discharge SimulatorVoltage : 0.20 ~ 30.0KV

Surge SimulatorVoltage : 0~40V

Automotive Transient Surge SimulatorJASO D001-94 : Class A-1 ~ Class E

Impulse Noise SimulatorVoltage : 0.2KV ~ 4KV

APTC Heater CalorimeterTEMP control : -40 ~ 80℃

FAN Performance TesterAir Flow : 1 ~ 200 CMH

SCHM CalorimeterTEMP control : -10 ~ 40℃

Test Facilities – Electric Test Facilities (15 Units)


Air Conditioning Parts


HVAC Module

※ Center type• Multiple use for LHD & RHD

• Enlarged Passengers’ side Space

• Light Weight & Compact Size

※ Semi-Center type• Optimized for Passenger Car

• Compact Size & Light Weight

※ Lateral 1 piece type• Compact size (x,y direction)

• Optimized for Van & Small Vehicles

HVAC Module Development Status

Space, High Performance, Zone Control

Su

b M

od

ule

, V

olu

me &

Weig

ht,

Co

st

Ad

van

tag

e

Lateral 3-pieces

Lateral 2-pieces

(Heater off set)

Semi-Central

(Blower off set)

Central

mounted type

Lateral 1-piece


Evaporator Cores

Features

• Parallel refrigerant flow design (multiple path)

• Flexible design for height & width by vehicle type

• Excellent hydrophilic function (superior to Inorganic Resin)

• Long life alloys for high corrosion resistance and

strengthened with Zn coating

New 35mm Evaporator

- 15% Weight Down

- 5% Performance Up

Parallel Flow Structure (38mm)

※ Annual Production Capability

- 1,350,000 Units / Year 4 Tanks

Extrusion Tube

IN OUT

58mm depth core 38mm depth core

New Development (35mm)


Heater Cores

Features

• High performance & Low press. Drop

• Flexible fitting design by vehicle type

• Design flexibility (Width/Height)

• Long life durability

• Excellent corrosion resistance

• Folded Dimple tube

• High efficiency louvered Fin

- 10% Weight Down

- 15% Performance Up

New 27mm Heater core

27mm depth

(U-Turn Flow)

27mm depth

(One Pass Flow)


- 1,125,000 Units / Year

One Pass Flow Type

Tube Fin

U-Turn Flow Type

27mm

6.2

27mm

Flow Structure (27mm) New Development (27mm)


Condenser

Features

• Thin core size (22mm, 16mm, 12mm available)

- Optional mounting Receiver Drier

- Fin Pitch : 1.2 ~1.8 mm (Louvered or Non-Louver)

• PF (Parallel Flow) design with multiple path

- Long Life & anti corrosion Extrusion tubes

without Zn coating

• Low cost & High performance design

- New extrusion header / fittings and brackets

Depth 22mm Depth 18mm

Depth 16mm Depth 12 / 14mm

Baffle

Cap-Header

Brackets

Side plate

Fitting-IN

Fitting-OUT

Header

Fins & Tubes

R/Drier

Integrated R/drier Type Separated R/drier Type


- 1,290,000 Units / Year

Condenser Structure (12mm)


Engine Cooing Parts


Cooling Module

Features• Short assembling processes and time, excellent quality product and module unit.

• Consists of Radiator, Charge Air Cooler, Oil Cooler, Condenser with Fan and Shroud.

- Optional by vehicle type

0

10

20

30

40

50

60

70

0 1000 2000 3000 4000

0

10

20

30

40

50

60

70

0 1000 2000 3000 4000

High Efficiency & Lower Noise

Fan & Motor

(1)

(2)

(3)

(4) (6)

(5)

(1) Radiator

(2) Fan & Motor Ass'y

(3) Condenser

(4) Oil Cooler

(5) Shroud

(6) Charge Air Cooler (Inter Cooler)


Charge Air Cooler (Inter Cooler)

Features• Welded long-life tube core (50, 62, 70 and 90 mm depth)

• Extruded long-life tube core (30, 49, 64 and 83 mm depth)- KB AutoTech standard / Field experienced since 2004

• Flange-up header technology to lower the internal pressure

loss and increase durability ☞ covered Euro-6 regulation

• Self-breaking side members to allow thermal expansion

• Designed for optimized material, weight & cost by vehicle type

※ Plain & Louvered Air Fin

- Pitch : 1.5 ~ 3.6 mm ※Patented Flange-up header

※ Internal turbulator

- Pitch : 1.3 ~ 3.2 mm ※ Plain & Slit insert Fins

AL Die-casting Tank Type

PL Tank Type

Full Face Type Variable Core Depth (mm)

4050

62 7090

105 129

Tank


Oil Coolers for T/M, E/G, P/S

Product Engine & Trans Mission Oil cooler Engine Oil Cooler Fin Cooler

Shape

(in Module)

Type Drawn cup type PF type Layered Core type Fin & Tube type

Oil Engine oil / Trans mission oil Engine oil Power Steering oil

Cooling Air Cooled Air Cooled Water Cooled Air Cooled

Remark production under development production production


Electronic Parts


※ APTC: Air Positive Temperature Coefficient

APTC heater

Features• Type : 3step Manual type / PWM / LIN Control type

• Electrical Power : 1.0kw ~ 2.2kw / 5.0kw

• Low inrush current / No inrush current (PWM type)

• Low air pressure drop

• Interface : CAN-bus, LIN-bus on PWM type

• Optimized thermal efficiency

- Applied Louver type fin

- Applied thermal conduction bonding

- Thin heat rod & fin

Heating tube

PTC-Element

Contact path

Heat Rod Insulation

Fin

APTC Heater Application

~ 1kW 1~1.2kW 1.2~2.5kW ~ 5kW

Shape

core size (mm)

245 X 114X 12 245.5 x 114.2 x 12 215.2 x 102.9 x 16 267 x 310 x 20

Press. Drop50 Pa

@ 300 Kg/h

50 Pa

@ 300 Kg/h

70 Pa

@ 300 Kg/h

90 Pa

@ 300 Kg/h

Voltage DC 12V,24V DC 12V,24V DC 12V, 24V,72VDC 180V

(DC 370V)

In-rush Current

Max 80 A Slow Start Slow Start Slow Start

Network N/C CAN or LIN CAN or LIN CAN or LIN

Connecting type

ConnectorPower : Connector

Network :Connector

Power : Bolt or Radsok

Network : Connector


BLDC (Brush Less DC) Motor

Features• Semi-permanent (No limit) life as brush less and no mechanical wear

• Low mechanical noise

• High efficiency

• Adjustable motor speed (Linear RPM control) and soft start

• Simplified motor control circuit

• Recovery system and Self diagnosis for over-load and trouble

Ventilation Motor Battery Cooling

Hybrid / E-car

Seat Cooling

HVAC Blower MotorCond. Fan Motor

BLDC Motor Application


Electric Fan & Shroud

Features• Optimized Fan and Shroud (Φ 280 ~ 520 mm Fan available)

• All Blades designed by the In-house Software

• High Air Volume and Low Noise Level

• Long Life Motor (Brushless Motor available)

• Pull Type / Push Type

Shape

(in Module)

Fan Size Out dia. 280 mm Out dia. 365 mm Out dia. 468 mm Out dia. 520 mm

Vehicle Type Passenger Car Passenger Car SUV Mini Van

Electric Fans application


Seat Cooling & Heating Module (SCHM)

Features• KBAT designed all units

• Peltier effect used

- Cool & Warm effect through TED

• BLDC motor: Low noise, High performance

- Dual wind out type (only one blower) use

• Control logic designed by KBAT.

- Applied registered KBAT patents

- Avoided competitor’s patents

• APTC Heater

- Improved head rest pad heating function

※ SCHM : Seat Cooling and Heating Module

SCHM

Shape

Size 229 X 127 X 30

Air-Flow 32 CMH

Noise 36.2dB @ 7.5V

Control

TED

APTC Heater

BLDC motor, Sensor

※Thermal Electric Device


Seat Cooling & Heating Module (SVHM) ※ SVHM : Seat Ventilation and Heating Module

Features• BLDC motor : Low noise, High performance

- Dual wind out type (only one blower) use

• Control logic designed by KBAT.

- KBAT patents applied

- Avoided competitor’s patents

• APTC heater used

- Seat heating instead of heat wire type

- Safety, High performance, Long life

SVHM

Shape

Size 128 X 108 X 27.5

Air-Flow 30.0 CMH

Noise 35dB @ 7.5V

BLDC Motor, Sensor

Control

APTC Heater


Ventilation Booster (Rear Blower)※ Ventilation Booster : Ventilation Blower for rear passenger comfort in center console

Features• High air flow efficiency & Optimized design BLDC motor

and Low current consumption Blower Fan.

• Cost reduction

- Reduce the cost though low operating current.

• Applied SCHM blower technology design.

SCHM Blower Blower Fan


BCS Blower

BLDC Motor

※ BCS : Battery Cooling SystemFeatures• BLDC motor: Low noise, High performance

- Double fan & single motor type

- Double inlet & one way out type

• slow start and linear fan speed controlled and

Self diagnosis for over-load and trouble

Battery Pack

Hybrid Bus


HVAC Controllers

Lever type Rotary type Push Button type

MTC ATC

MTC: Manual Temperature Control

ATC: Automatic Temperature Control


Products and Services for the Future

Thank you !

kb autotech overview - kotra profile/09_kb autotech... · quality control germany plant brazil...

Documents