Untitled

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HIGH-PRESSURE COMPRESSED AIR FOR BRAKING POWER

As Newton’s first law of motion stated, an object stays at rest or motion until and unless an external force is applied to it; thus, this idea gave rise to the Braking system in the automobile industry.

Automobile Market in India

India is the 4th largest producer of automobiles in the world, with an average annual production of more than 4 million motor vehicles. As per the reports, the Indian passenger car market is expected to reach USD 160 billion by 2027 while registering a CAGR of over 8.1% between 2022-27. India could be a leader in shared mobility by 2030. As a result, many manufacturers are investing in new manufacturing plants and increasing capacities in existing plants to cater to the increasing demand.

Overview

Brakes are one of the most critical parts of the active safety systems in automobiles. Better the brakes, the safer the vehicle. Based on the power source, brakes are classified as follows.

Mechanical braking system

Hydraulic braking system

Air or pneumatic braking system

Vacuum braking system

Magnetic braking system

Electric braking system

Out of the above, hydraulic brakes, especially disc brakes, are used predominantly in modern-day automobiles because of higher reliability, increased braking force, etc. Most cars manufactured today use the disc brake system; some manufacturers still use drums; however, their effectiveness diminishes in comparison to the disc brake.

Disc Brake Systems are most widely used in almost all modern-day vehicles, so the need for a good quality disc brake at optimum cost is extremely high. This, in turn, creates a market for more research to be done to optimize the product by keeping the safety intact, thereby creating a huge potential in the field of testing.

Disc Brake Operation

The disc braking system involves many different components, but at its most basic function, the system consists of a disc/rotor, a brake caliper, and brake pads. When the brake pedal is applied, brake fluid creates pressure, squeezing the brake pad against the rotor and creating friction. This friction slows the rotation of the wheels and the vehicle itself.

Brake calipers are a clamp-like component that fits over the disc. Their primary function is to push the brake pads into the disc, and they do this via pistons and hydraulic brake fluid. Inside the calipers are pistons, which have brake pads attached to them. When we put our foot on the brake, pressurized fluid is sent to the pistons, and they push against the pads, which come into contact with the disc surface.

Testing of Brake Calipers

No product reaches the user before it gets tested. Different products undergo different testing processes. Even though various braking system components are tested separately, the calipers should be tested after assembly for leakage and fault-free operation.

Though the hydraulic brake uses brake fluid for the operation, pneumatic testing with high-pressure air will be used in the testing process of the brake assemblies. Using high-pressure air relatively decreases the testing time and increases the life of components compared to hydraulic testing. It also prevents hydraulic oil spillage, thus maintaining a clean and safe work Environment.

Once the brake caliper components are assembled, high-pressure air will be filled and held inside the component. The Pressure range would be approximately 250 barg. In case of any leakages, there would be a drop in air pressure, and thus the leakages in the component will be identified.

The products passing the test parameters will be approved, and the components get rejected if there are any leakages.

Testing of Brake Hoses

Since the actual operation of these brakes is with hydraulic oil, the oil needs to be also fed at pressure to the callipers during operation. This is achieved by a hose connecting the fluid sump to the callipers.

Since the brake operation is at high pressure, the hose carrying also has to be rated at high pressure; thereby, they are also subject to high-pressure pneumatic testing to maintain overall safety.

Solutions at ELGI SAUER

‘Reliable Systems Provide Reliable Solutions’.

ELGI SAUER Compressors have proven expertise in designing and supplying high-pressure air and gas compressors that deliver consistent performance with utmost reliability.

Direct driven – high efficiency and low losses

Capable of working from 0) C to 55 C

Excellent reliability, even during intermittent operation

100 % compressor check at final pressure

State-of-the-art compressor control

Long operating life 24/7

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STORAGE OF RENEWABLE ENERGY [CNG] AT HIGH PRESSURES

In 2022, India became the fourth largest country in the world by valuation of the automotive industry. With this massive influx of automobiles, India is leaning towards Compressed Natural Gas (CNG) as a significant renewable energy variant. CNG as a fuel helps curtail emissions from traditional fuels such as diesel and petrol. India’s projected sales of CNG vehicles will increase from 863.22 thousand units in 2021 to 1,463.46 thousand units by 2029.

Government Initiatives to Promote CNG Vehicles:

Individual states are investing heavily to build a CNG infrastructure.

Keeping the price of CNG lower than traditional fuels prompt customers to see it as a cost-saving option.

SATAT Scheme for producing automobile-grade CNG from biogas generated from waste.

The segment was dominated by passenger vehicles; sales of CNG accounted for 12.1 percent of sales at 177,410 units as against 120,070 units in 2021; carmakers are betting on CNG in a big way as it gives owners a more affordable driving option. The top CNG car manufacturers are Maruti Suzuki, Tata Motors, Hyundai, Bajaj & Mahindra.

Infrastructure:

One of the critical elements to support this boost in sales will be technology in the form of safer storage for this flammable gas at higher pressures. CNG is stored at 250 barg pressures in the cascades at filling stations and transferred into smaller cylinders, cars, buses, etc.

CNG Cylinder Types and Manufacturers:

CNG tanks can be categorized into Type 1, Type 2, Type 3, and Type 4. The type is determined primarily based on design, production method, and liner material. Generally, in India, Type 1 Cylinder comprises all steel, which is relatively economical and heavier. The varying capacity of 30 L, 60 L, and 90 L cylinders are used in 3-wheelers, cars, trucks, and buses.

Use of Compressor:

A high-pressure compressor is used in a very critical stage of the manufacturing process. The air leakage test is one of the final, conclusive tests wherein the cylinder's integrity is checked before it is given a clean chit for dispatch. Compressed air at 400 barg pressures and 200 m3/hr flows are generally required for the process.

COMPRESSORS SOLUTIONS FROM ELGI SAUER RANGE FOR CNG CYLINDER TESTING APPLICATION:

Suction pressure: max. 16 bar g Final pressure: max. 500 bar g Volume Flow Rate: max. 500 m3/ h Rated Power: max. 75 kW for Air

ORKAN series compressors are based on a flexible modular system and cover a wide output range.

High-pressure air compressors up to 500 barg

Real gas boosters with inlet pressures of up to 16 barg

Hermetically gas-tight designs with magnetic coupling

Standard products for air, nitrogen , helium , CNG , and hydrogen .

Ex-proof versions acc. to ISO 80079-34:2018 and the European ATEX directive 2014 / 34 / EU

Magnetic coupling drives for Gas Boosters.

Orkan gas boosters feature Sauer's first magnetic coupling drive for hermetically gas-tight compressors. It guarantees absolute gas tightness, is extremely low maintenance, and operates with maximum reliability.

CubeCooler

The new CubeCooler enables re-cooling temperatures more than 30% lower than conventional cooler configurations. Coolers have been arranged radially around the combined fan and flywheel for a high cooling capacity like this

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Manufacturers of High Pressure Gas Compressors - Elgi Sauer

Our High pressure gas compressors are used to increase the pressure of gases such as Nitrogen, Hydrogen, etc . Our Booster Compressors are available in 200 & 300 bar range

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Compressors support increased production capacity of your fertilizer plant

Population expansion, excessive resource utilisation and reclamation of land for settlement have primarily resulted in the loss of nutrient content in ground soil. Owing to this change in composition, it has become impossible to cultivate land for crop without the use of fertilizers*.

*The most well-known is urea, a white crystalline substance, made up of 46% nitrogen.

What is urea?

Also known as carbamide, carbonyldiamine or amino methanamide, Urea is an organic compound with two amides joined by a carbonyl functional group.

In smaller amounts, urea is present in the blood, liver, lymph nodes and serous fluids, and in the waste of fish and many other lower species.

Urea was first produced industrially by the hydration of calcium cyanimide. When combined with carbon dioxide, it resulted in the formation of ammonium carbamate which could then be dehydrated to urea.

Agriculture

Fertilizer: 90% of the urea produced is used as fertilizer. It is added to the soil to provide nitrogen to plants. Low-biuret (less than 0.03%) urea is used as a foliar fertilizer. It dissolves in water and is applied to the leaves of plants that yield fruit, especially citrus.

High nutrient content: Urea’s rich nutrients are essential for metabolism in plants. It helps in the absorption of light during photosynthesis.

Multiple applications: Urea is added to the soil after harvest to help retain its nutrient content. In the soil, it hydrolyses back to ammonia and carbon dioxide. The ammonia is oxidized by the bacteria in soil to nitrate, which can be easily absorbed by plants.

Chemical Industry

Urea finds application as a raw material in the manufacturing of many important chemicals including:

Various plastics, especially the urea-formaldehyde resins

Adhesives, such as urea-formaldehyde or the urea-melamine-formaldehyde used in marine plywood

Urea nitrate, which is used as an explosive

Automobile Systems

Urea is used in SCR (selective catalytic reduction) and SNCR (selective noncatalytic reduction) to reduce the nitrogen pollutants in exhaust gases from combustion, eg: in power plants and diesel engines.

Commercial Uses

A component of animal feed, providing a relatively cheap source of nitrogen to promote growth

An ingredient in many tooth whitening products

An ingredient in dish soap

An ingredient in some hair conditioners, facial cleansers, bath oils, skin softeners, and lotions

A reactant in some ready-to-use cold compresses for first-aid use, due to the endothermic reaction it creates when mixed with water

As a solubility-enhancing and moisture-retaining additive to dye baths for textile dyeing or printing laboratory uses

DE-ICE

Urea is a safe, non-corrosive fertilizer alternative for de-icing. The chemical is easy to use on runways and walkways as well as on landing gears and other vital parts located on the under-carriage of aircraft that must always be protected from corrosion.

However with compressed air at 160-180 Bar pressure this stainless-steel layer, which generally contains up to 24% chrome, forms a very resistant brownish Cr03 layer which keeps the oxidation and corrosion in equilibrium and protects the inner layer of the reactor from getting corroded.

Passivation air compressors – ELGi Sauer

ELGi Sauer

The role of compressed air for passivation in urea manufacturing is rather crucial, since the process is continuous and compressor duty cycles are 24/7 at full load.

ELGi Sauer has a range of air compressor models like HURRICANE Series, apt for this process having flow capacities ranging from 22 to 100 m3/hr and pressures from 100 to 400 bar. These compressors are made from special materials to protect them against corrosive atmospheres. These compressors are direct driven, compact, rated for the continuous duty application with low life cycle cost and ease of serviceability.

The ELGi Sauer Compressors Ltd. is a conglomerate between ELGi –India and Sauer Compressors, Germany and comes with expertise& leadership to provide complete engineering solutions with indigenized contents for high pressure air and gas solution and prompt product support. ELGi Sauer Compressors Ltd. has been providing state-of-the-art products and customized solutions for Defence,Shipping, Industrial and Petro markets in India and neighbouring countries. The successful collaboration between the two leading companies has led to numerous achievements over the years.

Read more about ELGi Sauer’s capabilities.

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Elgi Sauer Compressors: High-Pressure Air & Gas Compressors

ELGi Sauer is a Global Leader in the manufacturing of high-pressure air compressors for Navy, Commercial Shipping, General Industry, Petro Industry & Defence.

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Oil Free Gas Compressors | Oxygen Booster Compressors | Sauer

Sauer Haug Oil-Free Gas & Oxygen Booster Compressors are absolutely dry running, hermetically gas-tight, used in applications within medicine, chemistry & gas supply.

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Oil Free Gas Compressors | Oxygen Booster Compressors | Sauer

Sauer Haug Oil-Free Gas & Oxygen Booster Compressors are absolutely dry running, hermetically gas-tight, used in applications within medicine, chemistry & gas supply.

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High Pressure Helium Compressor | ELGi Sauer Compressor

ELGi Sauer manufactures high pressure helium gas compressors that are ideal for helium recovery systems and cylinder filling. Explore our Compressors products.

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HIGH-PRESSURE COMPRESSED AIR FOR BRAKING POWER

As Newton’s first law of motion stated, an object stays at rest or motion until and unless an external force is applied to it; thus, this idea gave rise to the Braking system in the automobile industry.

Automobile Market in India

India is the 4th largest producer of automobiles in the world, with an average annual production of more than 4 million motor vehicles. As per the reports, the Indian passenger car market is expected to reach USD 160 billion by 2027 while registering a CAGR of over 8.1% between 2022-27. India could be a leader in shared mobility by 2030. As a result, many manufacturers are investing in new manufacturing plants and increasing capacities in existing plants to cater to the increasing demand.

Overview

Brakes are one of the most critical parts of the active safety systems in automobiles. Better the brakes, the safer the vehicle. Based on the power source, brakes are classified as follows.

Mechanical braking system

Hydraulic braking system

Air or pneumatic braking system

Vacuum braking system

Magnetic braking system

Electric braking system

Out of the above, hydraulic brakes, especially disc brakes, are used predominantly in modern-day automobiles because of higher reliability, increased braking force, etc. Most cars manufactured today use the disc brake system; some manufacturers still use drums; however, their effectiveness diminishes in comparison to the disc brake.

Disc Brake Systems are most widely used in almost all modern-day vehicles, so the need for a good quality disc brake at optimum cost is extremely high. This, in turn, creates a market for more research to be done to optimize the product by keeping the safety intact, thereby creating a huge potential in the field of testing.

Disc Brake Operation

The disc braking system involves many different components, but at its most basic function, the system consists of a disc/rotor, a brake caliper, and brake pads. When the brake pedal is applied, brake fluid creates pressure, squeezing the brake pad against the rotor and creating friction. This friction slows the rotation of the wheels and the vehicle itself.

Brake calipers are a clamp-like component that fits over the disc. Their primary function is to push the brake pads into the disc, and they do this via pistons and hydraulic brake fluid. Inside the calipers are pistons, which have brake pads attached to them. When we put our foot on the brake, pressurized fluid is sent to the pistons, and they push against the pads, which come into contact with the disc surface.

Testing of Brake Calipers

No product reaches the user before it gets tested. Different products undergo different testing processes. Even though various braking system components are tested separately, the calipers should be tested after assembly for leakage and fault-free operation.

Though the hydraulic brake uses brake fluid for the operation, pneumatic testing with high-pressure air will be used in the testing process of the brake assemblies. Using high-pressure air relatively decreases the testing time and increases the life of components compared to hydraulic testing. It also prevents hydraulic oil spillage, thus maintaining a clean and safe work Environment.

Once the brake caliper components are assembled, high-pressure air will be filled and held inside the component. The Pressure range would be approximately 250 barg. In case of any leakages, there would be a drop in air pressure, and thus the leakages in the component will be identified.

The products passing the test parameters will be approved, and the components get rejected if there are any leakages.

Testing of Brake Hoses

Since the actual operation of these brakes is with hydraulic oil, the oil needs to be also fed at pressure to the callipers during operation. This is achieved by a hose connecting the fluid sump to the callipers.

Since the brake operation is at high pressure, the hose carrying also has to be rated at high pressure; thereby, they are also subject to high-pressure pneumatic testing to maintain overall safety.

Solutions at ELGI SAUER

‘Reliable Systems Provide Reliable Solutions’.

ELGI SAUER Compressors have proven expertise in designing and supplying high-pressure air and gas compressors that deliver consistent performance with utmost reliability.

Direct driven – high efficiency and low losses

Capable of working from 0) C to 55 C

Excellent reliability, even during intermittent operation

100 % compressor check at final pressure

State-of-the-art compressor control

Long operating life 24/7

For brake assembly and hose testing, ELGI SAUER offers different series of products that operate at a wide range. However, as the volume of air consumed in this process is typically low, compressors with low flow rates are generally used.

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Helium Compressors

With over 50 years of expertise in the manufacturing of gas tight helium compressors Sauer has designed and developed helium gas compressors for various research applications. Anchored by reliable technology and safe solutions, many leading research institutes and universities rely on Sauer compressors for all kinds of helium applications. Most of the gas companies worldwide trust Sauer compressors and benefit from their unique technologically advanced solutions. The incorporation of reliable technology in each and every product makes Sauer the leading supplier of helium compressors in the market.

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The future of hydro power generation

Globally, India stands 5th in the installed hydroelectric power capacity.

According to the report, ‘All India installed capacity (in MW) of power stations’ published on 31st March 2020, India’s installed utility-scale hydroelectric capacity was 46,000 MW. This accounted for 12.3% of its total utility power generation capacity.

In the future, it is estimated that India’s hydroelectric potential shall reach up to 148,701 MW. Furthermore, it is said that an additional 6,780 MW from smaller hydro schemes which have capacities of less than 25 MW can be deemed as exploitable.

Apart from this, a total of 56 sites for pumped storage schemes with an aggregate installed capacity of 94,000 MW have also been identified.

Pump Storage Plants

At times of low electrical demand, excess generation capacity is used to pump water into the upper reservoir.

When the demand rises, the water is released into the lower reservoir through a turbine which generates electricity. This reversible turbine/generator assembly plays the dual role of a pump and turbine generator.

Once the evaporation losses from the exposed water surface and conversion losses are taken into consideration, close to 70-80% of recovery can occur. This technique is currently the most cost-effective means of storing large amounts of electrical energy.

Apart from generating hydroelectricity, pumped storage units find their application in pumping stations to supply river water for upland irrigation, industrial use and, generating drinking water.

Use of Compressed Air in Pump Storage Plants

In pump storage plants, the turbine and generator are operated in the reverse direction of the pump water from the lower reservoir to the upper reservoir during lean periods of power consumption.

This is achieved by the Draft Tube Water Depression System.

ELGi Sauer Compressors

ELGi Sauer is a joint venture between ELGi Equipments India and JP Sauer & Sohn Germany. This conglomerate caters to the needs of high-pressure applications in India and the subcontinent regions.

3 Stage Air Cooled

Pressures 50-80 Barg Flow - 90 to 300 m3/hr

Explore now

5 Stage Water Cooled

Pressures 40-100 Barg Flow - 600-700 m3/hr

Explore now

3 Stage Water Cooled

Pressures 50-100 Barg Flow - 170-190 m3/hr

Explore now

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HIGH-PRESSURE COMPRESSED AIR FOR BRAKING POWER

Automobile Market in India

India is the 4th largest producer of automobiles in the world, with an average annual production of more than 4 million motor vehicles. As per the reports, the Indian passenger car market is expected to reach USD 160 billion by 2027 while registering a CAGR of over 8.1% between 2022-27. India could be a leader in shared mobility by 2030. As a result, many manufacturers are investing in new manufacturing plants and increasing capacities in existing plants to cater to the increasing demand.

Overview

Brakes are one of the most critical parts of the active safety systems in automobiles. Better the brakes, the safer the vehicle. Based on the power source, brakes are classified as follows.

Mechanical braking system

Hydraulic braking system

Air or pneumatic braking system

Vacuum braking system

Magnetic braking system

Electric braking system

Out of the above, hydraulic brakes, especially disc brakes, are used predominantly in modern-day automobiles because of higher reliability, increased braking force, etc. Most cars manufactured today use the disc brake system; some manufacturers still use drums; however, their effectiveness diminishes in comparison to the disc brake.

Disc Brake Systems are most widely used in almost all modern-day vehicles, so the need for a good quality disc brake at optimum cost is extremely high. This, in turn, creates a market for more research to be done to optimize the product by keeping the safety intact, thereby creating a huge potential in the field of testing.

Disc Brake Operation

The disc braking system involves many different components, but at its most basic function, the system consists of a disc/rotor, a brake caliper, and brake pads. When the brake pedal is applied, brake fluid creates pressure, squeezing the brake pad against the rotor and creating friction. This friction slows the rotation of the wheels and the vehicle itself.

Brake calipers are a clamp-like component that fits over the disc. Their primary function is to push the brake pads into the disc, and they do this via pistons and hydraulic brake fluid. Inside the calipers are pistons, which have brake pads attached to them. When we put our foot on the brake, pressurized fluid is sent to the pistons, and they push against the pads, which come into contact with the disc surface.

Testing of Brake Calipers

No product reaches the user before it gets tested. Different products undergo different testing processes. Even though various braking system components are tested separately, the calipers should be tested after assembly for leakage and fault-free operation.

Though the hydraulic brake uses brake fluid for the operation, pneumatic testing with high-pressure air will be used in the testing process of the brake assemblies. Using high-pressure air relatively decreases the testing time and increases the life of components compared to hydraulic testing. It also prevents hydraulic oil spillage, thus maintaining a clean and safe work Environment.

Once the brake caliper components are assembled, high-pressure air will be filled and held inside the component. The Pressure range would be approximately 250 barg. In case of any leakages, there would be a drop in air pressure, and thus the leakages in the component will be identified.

The products passing the test parameters will be approved, and the components get rejected if there are any leakages.

Testing of Brake Hoses

Since the actual operation of these brakes is with hydraulic oil, the oil needs to be also fed at pressure to the callipers during operation. This is achieved by a hose connecting the fluid sump to the callipers.

Since the brake operation is at high pressure, the hose carrying also has to be rated at high pressure; thereby, they are also subject to high-pressure pneumatic testing to maintain overall safety.

Solutions at ELGI SAUER

‘Reliable Systems Provide Reliable Solutions’.

ELGI SAUER Compressors have proven expertise in designing and supplying high-pressure air and gas compressors that deliver consistent performance with utmost reliability.

Direct driven – high efficiency and low losses

Capable of working from 0) C to 55 C

Excellent reliability, even during intermittent operation

100 % compressor check at final pressure

State-of-the-art compressor control

Long operating life 24/7

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Manufacturers of High Pressure Gas Compressors - high pressure booster compressors - Elgi Sauer

Our High pressure gas compressors are used to increase the pressure of gases such as Nitrogen, Hydrogen, etc . Our Booster Compressors are a

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High Pressure Hydrogen Compressors | ELGi Sauer, India

We offer a wide range of high-quality and reliable hydrogen compressors for all Industrial hydrogen applications such as industrial gases, medical gases, etc.

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Power play: Efficient ways to cool down

Indian air conditioner manufacturers meet rising urban demand with ELGi Sauer Air Compressors

Executive summary 

Rapid urbanisation has resulted in increased demand for energy-efficient residential and commercial air conditioners across India. One of the leading manufacturers in India, meets this demand by deploying high-quality ELGi Sauer air compressors across its production and testing facilities.

Industry Overview

In the 21st century, people live, work, and play in highly customised interior spaces. Unique in design and application, they reflect the new-age consumer and their evolved needs. The most important parameters are the interior temperature and advanced HVAC (Heating, Ventilation, and Air Conditioner) systems that provide comfort and reprieve from increasing heat and external weather conditions.

In India, where the average summer temperature ranges between 32-40° Celsius, air conditioners are fast becoming a vital commodity for homes, offices, and industrial units. This is especially true in urban regions in the northern part of the country, where the HVAC industry share is the highest.[1]

Additionally, the emergence of inverter technology in appliances and IoT-enabled temperature control systems is predicted to strengthen the demand for air conditioners even further.

Furthermore, while residential air conditioners in the country are available in the window and split formats, light air conditioners, variable refrigerant flow (VRF) systems, and chillers are the most common product types in the commercial segment. However, there is demand for air conditioners in segments that utilise inverter technology resulting in reduced energy consumption, operating costs, and carbon impact. Besides, increased awareness and growing environmental concerns are changing the HVAC industry. In addition, energy regulations and policies that promote energy efficiency are also evolving.

About the company

One of the most popular and energy-efficient air conditioner brands in India, the company understands the importance of individualised space and comfort in the 21st century, and its HVAC products reflect this philosophy. Having its manufacturing facility in Kadi, Gujarat, the company manufactures a wide range of products, including but not limited to the following:

Residential air conditioners: New technological breakthroughs enable the manufacturers to provide energy-efficient and reliable window and split air conditioners

Commercial air conditioners: A wide range of large-scale HVAC systems for industrial and residential project needs, including chillers, cassette air conditioners, ductable air conditioners, telecom air conditioners, and VRF systems

The customer challenges

The manufacturer aims to deliver high-quality, efficient air conditioners, that are reliable and environment friendly. Innovative engineering and manufacturing support the company's vision of safety, comfort, and sustainability.

One critical utility that the company relies on for manufacturing and testing is the uninterrupted supply of high-pressure compressed air, which is necessary for testing the condenser coils of air conditioners.

The solution

To meet its demand for high-pressure, high-flow, and high-quality compressed air, the company installed ELGi Sauer air compressors at its manufacturing facility. It installed the Passat Series 3-stage air-cooled direct-driven compressors that demonstrate exceptional endurance, even under the most stringent operating conditions of up to 55°C ambient temperature. The ELGi Sauer air compressor models provide an even distribution of pressure ratio per cylinder, resulting in lower cylinder compression temperatures. This increases the life of internal components, providing a long-lasting and high-quality supply of compressed air.

Business Benefits

Since the manufacturing company installed ELGi Sauer air compressors, there has been an increase in energy efficiency and production output. With ELGi's direct-drive technology, reduced power consumption per cubic metre has led to a 40% reduction in energy consumption, boosting the factory’s profitability. The machines are practically maintenance-free. ELGi Sauer also provides standard maintenance routines at regular intervals to ensure efficiency, despite high uptimes during peak seasons.          

“ELGi Sauer’s air compressors have boosted the firms air conditioner testing capacity. With the delivery of high-pressure compressed air coupled with high energy efficiency and zero breakdowns, ELGi Sauer compressors power Hitachi’s production plans consistently.” - Mitesh Trivedi, Assistant Manager, Plant Engineering.

Speaking about successful installations of high pressure compressors across the nation, Satish Kini, CEO, Elgi Sauer Compressors Limited said, “Over the past decade, ELGi Sauer has significantly expanded its business portfolio in the industry and offshore markets, continuing its strong foothold in the defense business. ELGi Sauer has become the most preferred choice across major industry segments in India, such as steel, auto, power, general industry, and oil & gas.”

“Looking ahead at the growing business prospects in the key focus markets, ELGi Sauer has started to build a greenfield manufacturing facility expected to be operational by the end of 2022. The new plant would support the organic growth and cater to the engineering and product testing requirements of its joint venture partner Sauer, Germany, and its subsidiaries. This expansion will contribute significantly to double the business turnover in the next five years to over INR 800 million. Today, ELGi Sauer covers most of the SAARC countries and explores more business prospects in upcoming years.”

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HIGH-PRESSURE COMPRESSED AIR FOR BRAKING POWER

Automobile Market in India

India is the 4th largest producer of automobiles in the world, with an average annual production of more than 4 million motor vehicles. As per the reports, the Indian passenger car market is expected to reach USD 160 billion by 2027 while registering a CAGR of over 8.1% between 2022-27. India could be a leader in shared mobility by 2030. As a result, many manufacturers are investing in new manufacturing plants and increasing capacities in existing plants to cater to the increasing demand.

Overview

Brakes are one of the most critical parts of the active safety systems in automobiles. Better the brakes, the safer the vehicle. Based on the power source, brakes are classified as follows.

Mechanical braking system

Hydraulic braking system

Air or pneumatic braking system

Vacuum braking system

Magnetic braking system

Electric braking system

Out of the above, hydraulic brakes, especially disc brakes, are used predominantly in modern-day automobiles because of higher reliability, increased braking force, etc. Most cars manufactured today use the disc brake system; some manufacturers still use drums; however, their effectiveness diminishes in comparison to the disc brake.

Disc Brake Systems are most widely used in almost all modern-day vehicles, so the need for a good quality disc brake at optimum cost is extremely high. This, in turn, creates a market for more research to be done to optimize the product by keeping the safety intact, thereby creating a huge potential in the field of testing.

Disc Brake Operation

The disc braking system involves many different components, but at its most basic function, the system consists of a disc/rotor, a brake caliper, and brake pads. When the brake pedal is applied, brake fluid creates pressure, squeezing the brake pad against the rotor and creating friction. This friction slows the rotation of the wheels and the vehicle itself.

Brake calipers are a clamp-like component that fits over the disc. Their primary function is to push the brake pads into the disc, and they do this via pistons and hydraulic brake fluid. Inside the calipers are pistons, which have brake pads attached to them. When we put our foot on the brake, pressurized fluid is sent to the pistons, and they push against the pads, which come into contact with the disc surface.

Testing of Brake Calipers

No product reaches the user before it gets tested. Different products undergo different testing processes. Even though various braking system components are tested separately, the calipers should be tested after assembly for leakage and fault-free operation.

Though the hydraulic brake uses brake fluid for the operation, pneumatic testing with high-pressure air will be used in the testing process of the brake assemblies. Using high-pressure air relatively decreases the testing time and increases the life of components compared to hydraulic testing. It also prevents hydraulic oil spillage, thus maintaining a clean and safe work Environment.

Once the brake caliper components are assembled, high-pressure air will be filled and held inside the component. The Pressure range would be approximately 250 barg. In case of any leakages, there would be a drop in air pressure, and thus the leakages in the component will be identified.

The products passing the test parameters will be approved, and the components get rejected if there are any leakages.

Testing of Brake Hoses

Since the actual operation of these brakes is with hydraulic oil, the oil needs to be also fed at pressure to the callipers during operation. This is achieved by a hose connecting the fluid sump to the callipers.

Since the brake operation is at high pressure, the hose carrying also has to be rated at high pressure; thereby, they are also subject to high-pressure pneumatic testing to maintain overall safety.

Solutions at ELGI SAUER

‘Reliable Systems Provide Reliable Solutions’.

ELGI SAUER Compressors have proven expertise in designing and supplying high-pressure air and gas compressors that deliver consistent performance with utmost reliability.

Direct driven – high efficiency and low losses

Capable of working from 0) C to 55 C

Excellent reliability, even during intermittent operation

100 % compressor check at final pressure

State-of-the-art compressor control

Long operating life 24/7

For brake assembly and hose testing, ELGI SAUER offers different series of products that operate at a wide range. However, as the volume of air consumed in this process is typically low, compressors with low flow rates are generally used.

for visit : https://www.elgisauer.com/blogs/high-pressure-compressed-air-for-braking-power/

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STORAGE OF RENEWABLE ENERGY [CNG] AT HIGH PRESSURES

In 2022, India became the fourth largest country in the world by valuation of the automotive industry. With this massive influx of automobiles, India is leaning towards Compressed Natural Gas (CNG) as a significant renewable energy variant. CNG as a fuel helps curtail emissions from traditional fuels such as diesel and petrol. India’s projected sales of CNG vehicles will increase from 863.22 thousand units in 2021 to 1,463.46 thousand units by 2029.

Government Initiatives to Promote CNG Vehicles:

Individual states are investing heavily to build a CNG infrastructure.

Keeping the price of CNG lower than traditional fuels prompt customers to see it as a cost-saving option.

SATAT Scheme for producing automobile-grade CNG from biogas generated from waste.

The segment was dominated by passenger vehicles; sales of CNG accounted for 12.1 percent of sales at 177,410 units as against 120,070 units in 2021; carmakers are betting on CNG in a big way as it gives owners a more affordable driving option. The top CNG car manufacturers are Maruti Suzuki, Tata Motors, Hyundai, Bajaj & Mahindra.

Infrastructure:

One of the critical elements to support this boost in sales will be technology in the form of safer storage for this flammable gas at higher pressures. CNG is stored at 250 barg pressures in the cascades at filling stations and transferred into smaller cylinders, cars, buses, etc.

CNG Cylinder Types and Manufacturers:

CNG tanks can be categorized into Type 1, Type 2, Type 3, and Type 4. The type is determined primarily based on design, production method, and liner material. Generally, in India, Type 1 Cylinder comprises all steel, which is relatively economical and heavier. The varying capacity of 30 L, 60 L, and 90 L cylinders are used in 3-wheelers, cars, trucks, and buses.

Use of Compressor:

A high-pressure compressor is used in a very critical stage of the manufacturing process. The air leakage test is one of the final, conclusive tests wherein the cylinder's integrity is checked before it is given a clean chit for dispatch. Compressed air at 400 barg pressures and 200 m3/hr flows are generally required for the process.

COMPRESSORS SOLUTIONS FROM ELGI SAUER RANGE FOR CNG CYLINDER TESTING APPLICATION:

Suction pressure: max. 16 bar g Final pressure: max. 500 bar g Volume Flow Rate: max. 500 m3/ h Rated Power: max. 75 kW for Air

ORKAN series compressors are based on a flexible modular system and cover a wide output range.

High-pressure air compressors up to 500 barg

Real gas boosters with inlet pressures of up to 16 barg

Hermetically gas-tight designs with magnetic coupling

Standard products for air, nitrogen, helium, CNG, and hydrogen

Ex-proof versions acc. to ISO 80079-34:2018 and the European ATEX directive 2014 / 34 / EU

Magnetic coupling drives for Gas Boosters.

Orkan gas boosters feature Sauer's first magnetic coupling drive for hermetically gas-tight compressors. It guarantees absolute gas tightness, is extremely low maintenance, and operates with maximum reliability.

CubeCooler

The new CubeCooler enables re-cooling temperatures more than 30% lower than conventional cooler configurations. Coolers have been arranged radially around the combined fan and flywheel for a high cooling capacity like this.

for visit : https://www.elgisauer.com/blogs/storage-of-renewable-energy-cng-at-high-pressures/