Pt.
1: The First PowerSki SupertorqueXT™ Engine Parts Are Hot
Off The Die Cast Tooling & Ready For Mass Production
SAN CLEMENTE, CA. January 11, 2005.
PowerSki International Corporation
(PSI) received a new progress update from our engine supplier,
Daesung Fine Tec Co., Ltd. of Korea, announcing today that production of the
patented
SupertorqueXT™ marine engine for the PowerSki Jetboard™
Igniter 330 is
clearly under way. Their update included pictures showing that
not only has
the tooling process begun, but some of the tooling for the main
parts has
already been completed, and the first parts have been turned out.
Along with all the conventionally fabricated parts, the engine's
main components have, up until now, been made using a conventional
sand casting process. Sand casting is commonly used when low,
up-front costing is imperative. The moltenmetal
is poured into molds that are actually made of sand. These molds,
often referred to as tooling, are relatively inexpensive and that's
why it was the process of choice for initial, limited production
of the SupertorqueXT™ marine engine. This process can produce
quality parts, however, it just isn't cost effective for large
scale mass production.
The new manufacturing technique that Daesung Fine Tec Co., Ltd. uses is called
die casting. In a very costly process, die cast molds or dies,
are cut from large steel blocks. The production of these tools
are further complicated with requirements for cooling passages,
sprues, gates, runners, elaborate ejection systems, and so on.
"This is a major step for Powerski. A portion of these parts
have already been die cast and are now being inspected in Korea."
explained Leo Greene, VP of Engineering. He added, "Having
developed the entire engine with PTC's Pro/ENGINEER Wildfire software, the tooling is being completed at an astonishing rate!"
Bob Montgomery, CEO of PowerSki International Corp. said, "PowerSki
and Korea
are discussing a plan to expedite the delivery timeline to meet
our scheduled ramp up for mass production at the beginning, rather
than the end, of April, which I believe is everyones' choice.
Rather than ship the first two orders of engines by boat, which
would take 4 weeks including clearing Customs, we believe it's
better to air frieght in the engines due in March, as well as
a good portion of the engines scheduled for April. Powerski could
assemble and test the first 10 engines here in San Clemente. The
next batch of engines would be assembled in Korea. PowerSki could
fly in some of the assembled engines from Korea, to also expedite
the delivery schedule. After testing, Daesung Fine Tec Co., Ltd. of Korea is capable
of ramping up to one thousand units in May."
"This die cast process produces PowerSki's patented SupertorqueXT™
marine engines that are lighter (by 20%), higher quality, higher
volume, all with repeatability that is unsurpassed. Leo Greene,
VP of Engineering stated, "This is the process of choice
for the large scale mass production of complex metal parts."
He added, "These first parts produced with this method indicate
the seriousness by which Daesung Fine Tec Co., Ltd. takes this project. It's clear
that they firmly believe, along with all of us, that hundreds
of thousands of these unique and marvelous engines could be produced
and sold in the next few short years."
Belt Cover Mold - Click
here to view parts made from this mold
Coupler Mold - Click
here to view parts made from this mold
Crank Shaft Insert Mold
Finish Cover Mold
|
Update
on PowerSki 250000 Catalytic Converter™ EPA Testing
Paul Lancaster, the inventor of the PowerSki 250000
Catalytic Converter™ stated, "I've been testing the
new PowerSki 250000 Catalytic Converter™ on the PowerSki
SupertorqueXT™ for over 70 hours. The results have been
excellent. The oil residue is being burned off proving that the
design is highly efficient because it's regenerating within the
filter."
Paul added, that PowerSki in the next few days,
is shipping the engine fitted with the new PowerSki 250000 Catalytic
Converter™ from Advanced Emission Technologies/PowerSki
Emission Development in Loudon, Tennessee to the Automotive Testing
& Development Services (ATDS) in Ontario, Ca. Once it arrives,
they will immediately start setup dyno and emissions data retrieval
for EPA testing. The test process takes 2 weeks. Paul will be
on site in California for the final week of testing for final
calculations and to prepare the proper presentation documents
for the EPA. He will also being making our case to CARB (California
Air Resource Board) while he’s there.
Converter Package Testing Method and Procedure
Paul said, "The converter package and catalyst
performance are tested to Federal Test Procedure (FTP) as governed
by 40CFR85 - Code of Federal Regulations (Cal/EPA). The procedure
will be an EPA sanctioned two-stage test (15% idle, 85% run).
Bench testing in a programmed thermal cycling
oven for one week, ages the metallic substrate to a simulated
100 hours of use per Federal Test Procedure.
A water break dynamometer is used in this testing.
Computer controlled dyno testing simulates actual use, including
idling and acceleration to full run. During dyno testing a gas
chromatograph continuously monitors and records the CO, CO2, HC,
02 and NOx emissions. The results are compiled into a Sweep Test.
The dyno test runs for approximately two weeks. Test results are
then compared to the percentage curves required by EPA for compliance
and verification.
A flow-bench is used to measure the gas flow through
the package as tested in order to insure that we meet or exceed
the flow rates of competitive units.
Dimensional stability testing (DST) determines
if there have been dimensional changes in the packaging (resulting
from aging and testing) that could adversely affect the reliability
of the unit.
Salt Spray Test. Determines the resistance of
the outer shell to corrosion. The corrosion resistance of Grade
304 Stainless Steel is well known, and is used as the benchmark
for marine and units requiring high durability. Shaker
Test. A customer may elect to perform a shaker test under simulated,
or actual, road test conditions." |
