Expertise

Holypower Engineering have experience in the design of modern internal combustion engines for a wide variety of market and customer needs, from motorcycles, 3 wheelers, to passenger cars, heavy duty (on road and off-road),agricultural, tractor, marine, industrial, power generation and several others as per customer demands. Some typical examples of various projects handled by our combined expert team during working experience are:
1. Contribution for powertrain in successful best in class award winning Intermediate Commercial Vehicles ,Heavy Commercial Vehicles with BS III, BS IV,Euro V CNG range of buses and trucks for local and export markets.
2. Achieving BS IV emissions with Inline Fuel Injection Pump and Exhaust Gas Recirculation (EGR) instead of Common Rail Direct Injection Pump and Selective Catalytic Reactor(SCR).
3. A range of single and multi-cylinder gasoline, diesel, alternate fuel, hybrid research and production engines with high Brake Mean Effective Pressure (BMEP) and heavy thermal loading capability.
4. Clean sheet design and technology demonstration of 150 cc 4 stroke hybrid gasoline electric powertrain for 3 wheeler application, completed within 15 months.
5. Design modification, testing and production release of 2 liter CRDI Euro IV engine from collaborator from Automotive to electrical power generating sets.
6. Complete new concept to field testing of clean sheet design and technology demonstration of 150 cc 4 stroke liquid cooled gasoline engine for hybrid electric 3 wheeler.
7. Design modification, performance and emission optimization, testing and production release of 2.4 liter indirect injection (IDI) from collaborator to direct injection (DI) engine for Aomotive, tractor application
8. Innovative technologies on Cylinder Deactivation, Variable Valve Timing, Waste Heat Recovery, Engine Start-Stop Technology, Thermal Efficiency Improvement, Friction Reduction, Accessory power optimization, turbo compounding.

2. Introduction of Automatic Manual Transmission (AMT), drivability and fuel consumption optimization with, Antilock Braking System (ABS), organic diaphragm clutch, axle, tire, components and models variety reduction.
3. 5 Forward and 1 Reverse gear Box and 4X4 Transfer case with centre differential, ECU, wet clutch for on the fly automatic switching over from 2 Wheel Drive to 4 Wheel Drive, All Wheel Drive, High and Low gears on running Sports Utility Vehicle for Export market.
4. Introduction of Automatic Manual Transmission (AMT), adaptation to existing 6 speed gear box, with pneumatic controller in place of hydraulic controller, drivability, grad ability, uphill and downhill performance and fuel consumption optimization.
5. New first of its kind design of modern Synchromesh 5 Forward 1 Reverse gear transaxle (gear box with integrated differential) with unique gear shift mechanism for 4-wheeler Light Commercial Vehicle.
6. Sequential shift sliding mesh and synchromesh wet and dry clutch transaxles, gear boxes,4/5/6/9/12/16 speed, front and rear mounted , wet and dry clutch for 4 and 3 wheeler vehicle,2 Forward 1 Reverse gear marine gear box, Manual, Automated Manual, Automatic, auto clutch, dual clutch, Hybrid , electric, continuously variable, differential, drive shafts, axles, wheels, brakes.

Applying our expert skills in powertrain design, analysis and modeling (thermodynamic, combustion, fluid flow and mechanical) in combination with our track record practical experience in selection and the design of powertrain systems, we are able to construct mathematical models of the total system. This provides a comprehensive understanding of the complex loadings, mechanical, thermal, gas exchange process, noise, vibrations, and harshness emanating from the combination of reciprocating and rotating machinery. Performance, mechanical and thermal analysis, pollutant formation of the total system enables the best engineering of products with an optimum balance of basic technologies at target cost.
Activities consists of supplier identification and finalization, parts procurement, inspection, prototype assembly, Mechanical Development, thermal development, cooling, lubrication, intake and exhaust systems, combustion system, fuel injection system, emission control systems, after treatments, CATCON, DPF, SCR, EGR, Performance plots, failure analysis and resolution,durability,B10 life, testing for worldwide driving cycles and emission standards, release for production, field complaints resolution, conformity of production (COP) etc.

Customized Solution Package: Our processes for model based development of powertrain mechanicals, thermal, simulation techniques, hydraulics, pneumatics, electronics, control, and software can be customized to the unique business and product requirements.
1. Bench marking, Selection of optimum engine / transmission/driveline for the program through benchmark
studies, Market Research, intelligent idea generation, dimensions, features, material, weight, zero base costing, manufacturing process, assembly, Teardown analysis, disassembly, torques, settings, check points, wear limit, power to weight ratio.
2. Voice of customers, target quality table, performance plots, programme management, stage gate process, concept, layout, assembly, integration
3. Analysis, CAE, CFD, softwares, mechanical calculations, DFA, DFM, DFMEA, PDM, PLM, bottleneck engineering
4. Design release, 3D models and 2D manufacturing drawings with GD&T, stack up tolerances material, heat treatment, PPAP, assembly procedure, end of line testing, rejection control
Component function, feature, special characteristics analysis and recommendations.
5. Prototype builds, component sourcing, costing, weight, acceptance criteria.
6. Testing, calibration, optimization, certification, on rig and on road testing, validation, durability, failure analysis and control.
7. Introduction, resolving manufacturing issues, sign off, mass production and field support
Service, maintenance, warranty and Training.
8. Product catalogue, spare parts list, developed views, bill of materials
Rejection Elimination.

Hybridisation, fuel cell and electrification of powertrains to meet ever stringent current and future global emission regulations. Powertrain Technology, with a in depth knowledge of engine, accessories, systems design and drive cycle simulation experience, is able to offer the range of services including:
1. Concept, design, analysis, development, testing of downsized, down speeded engines.
2. Design modifications, prototype build, testing, certification and implementation of emission reduction strategies, with specialist technologies for consistent on road real world driving performance.
3. Integration of engines with various combinations of hybrid powertrains.
4. Selection, sourcing, costing of electric motors, controllers, sensors and battery storage
5. Fuel Cell, hydrogen and other alternate power plant selection and application.
6. Drive cycle simulation, on road real world performance, optimization, certification of powertrains

Holypower Engineering offers services in advanced electrical, electronics, hydraulics, mechanotrics, and software systems for a variety of industries, including automotive, oil and gas, screw compressors, energy generation, alternate power plants etc. Support covers from small-scale analysis and evaluation, mini projects, demonstration assignments through to large-scale turn key projects requiring design, prototyping, testing, optimization, problem solving, validation, introduction to customer etc.
We can design, develop, test, find right source for a wide range of instruments, sensors, detecting and indicating devices, actuators, batteries, electrical ,mechatronic, electronics machines, speed governors, systems etc.
From input information, data, preliminary testing, we analyze and find appropriate solutions for special problems, complaints, difficult applications, generally starting from basics and by modifying and developing new technologies to overcome performance barriers.
We have various softwares, modern techniques, automated methods to speed up the design and analysis process, helping clients to meet their tight deadlines quickly.
As we are independent technology consultants, our strict confidential services enables total flexibility with concept, ideas, design, patents, legacy data conversion and joint ownership with customers as the case may be.

Holypower Engineering in association with experts has a wealth of experience in the specification, design, procurement, calibration, commissioning, installation, problem solving and trouble free operation of a variety of test rigs, special purpose machines, equipments, instruments for proof of concept, product development, calibration, optimization, emission certification, homologation, durability, reliability and sign-off. Some examples of our support work are:
Gear box, transaxle test rig for performance, quality, lubrication, efficiency, durability, simulation of on road driving conditions, end of line testing.
Rear axle and 4X4 transfer case test rig for performance, differential function, quality, lubrication, efficiency, durability, simulation of on road driving conditions, end of line testing.
Emission test bed equipment, chassis dynamometer, dynamic test bed

• Business Analysis
• Market Research (MR)
• Statistical Analysis
• Strategy Development
• Business Case Recommendations
• Emerging Markets
• Technology Roadmap
• Effective Entry Strategy
• Brand Building
• Return on Investment

We have authorized Agency and representation of highly advanced competitive global analysis softwares and services in Computer Aided Engineering (CAE), Computational Fluid Dynamics (CFD).These softwares, relevant modules are available for sale, licenses at competitive optimum prices to have value for money and advanced technology.

For hybrid powertrain, further integration and simulation considering the complexity of drive trains, the design and analysis and best matching to produce a technically competitive product within project budget and market price as per customer demands. We have a range of skills and experience including:

1. Vehicle, engine, transmission and driveline dynamic drive cycle simulation, Gear Ratio Optimization, Progression, Gear Shift Quality Assessment(GSQA), synchronization, performance matching, clutch dynamics, lubrication, Selection of tools, cutters, machines, jigs, fixtures, gauges, checkpoints.

2. Benchmarking, specification, design, analysis and integration of drive train and driveline components with vehicle packages, gear boxes for marine, electric, hybrid, industrial applications

3. Turnkey Test Facility creation for complete drive train, clutch, gear box, propeller shaft,4X4 transfer case, power take off, single and twin speed rear axle, axle driveline testing. Calculation, selection, budgeting, commissioning, performance analysis, interpretation, validation, durability, efficiency, end of line testing etc.

The use of conventional and alternate energy is a continuous demand for current and future, with increased focus on inventing highly efficient and cost competitive environment friendly solutions. The experienced members at DE have expertise in advanced engines and alternative energy applications. Our skills in thermodynamics, combustion, computational analysis, electronics, hydraulics, wind, solar, alternate fuels like CNG, LPG, LNG, Hydrogen, alcohol, coal, vegetable oils, compressed air and multiphysics analysis provides a range of engineering services in various sectors.

Euro VI/Euro 6 emission standards compliance with dramatic reduction in Nox and fuel consumption.

Patented global proven technologies approved and adapted by leading manufacturers to meet Euro VI/Euro 6 emission norms with substantial reduction in Nox, CO2 and fuel consumption in real driving environment (RDE) without need of any defeat devices. This technology also have extended application to electric power generating sets, stationary, industrial, marine and other Engine Applications. Retrofitting advanced vehicle technologies to existing vehicles

Engine Cylinder Deactivation

Variable Valve Timing

Turbo compounding

Waste Heat Recovery

Engine Start-Stop Technology

Thermal Efficiency Improvement

Powertrain Efficiency Improvement

Optimum interaction between a vehicles’ powertrain and the ancillaries required to provide an effective HVAC system which have a major impact on vehicle efficiency due to parasitic drive losses, environment and thermal effects. Addition to these technologies such as start/stop, heating/cooling, variable coolant pumps and switchable oil circuits needs to be managed to ensure the comfort of the occupants without affecting vehicle performance. We have a range of experience with these technologies, including:
1. HVAC system matching within vehicle modeling environments
2. Data, analysis and knowledge of current and future HVAC systems
3. Efficient selection, design, specification, calculation of ancillary components required for HVAC
4. Adaptation with power train cooling, gas exchange and lubrication systems.