Customer Turns to Airchannel for Expertise

11 Apr 2008

Cosworth is already a valued customer of Airchannel, so when the engineering Company secured a contract to supply forged pistons to aero-engine manufacturer Lycoming, it turned to the compressed air specialists to provide the most energy efficient air package for their new piston line. 

Airchannel has historically supplied the Northants facility with 2 fixed speed Compair Cyclon 330 rotary compressors. However, because the new line required additional periodic capacity of up to 500 cfm, something the older compressors were not capable of, a new solution had to be found. 

As well as considering the requirements of ISO14001, Airchannel was looking to achieve energy savings to help counter the effects on Cosworth of escalating utility costs. The solution has been a CompAir L45SR variable speed compressor, which has been linked to the two Cyclon compressors and a massive 2800 litre air receiver which is used to store compressed air. 

The engineering contract has required Cosworth to invest in a new state-of-the-art manufacturing cell, which has enabled Cosworth to produce forged pistons at competitive rates for a much broader range of niche applications.  

The machining process is fully automated, once blank pistons have been loaded. Forgings are bead blasted, loaded into the machining line and manufactured to a 9 gram weight tolerance. 

CompAir's LSR series of speed regulated compressors incorporates a variable speed switched reluctance drive system which matches power consumption to air demand.

The LSR series compressors are able to accurately maintain a set pressure while responding instantly to changes in air demand. 

Maintaining air system pressure at an exact pre-set level eliminates the need to operate within pressure bands, further enhancing energy performance by reducing electrical and mechanical loads. 

As part of the contract Airchannel has also installed a Domnick Hunter air dryer and new Transair pipework system for the new production cell to ensure a smooth flow of uninterrupted clean air. 

Maintenance Manager Ian Goodridge comments “The new production line represents a massive investment for Cosworth and the supply of economical, clean compressed air is a critical aspect of our work”

“When we needed a solution to the extra capacity, we turned without hesitation to Airchannel, for advice and trusting in their expertise, we went with their suggested package.”

Already paying its way the new variable speed compressor is expected to pay for itself in energy savings over the course of the next two years.