Precision Engineering / Quality Defined / Case Studies

CASE STUDIES

NIZPRO MARINE

In 2008 Yamaha released their brand new Offshore and Super High Output series of outboard engines and dubbed them the "Game Changer". The US market instantly embraced the new Yamaha 6 Cylinder 4.2L Marine Outboard engines with many applications even running two outboards to maximise their performance potential. This triggered a new development program at Nizpro Marine with the goal to produce the most powerful 6 cylinder marine outboard on the planet, with less weight, drag through water and no additional service costs.

Nizpro Marine Director Simon Gishus approached Harrop Engineering and shared his idea to create a positive displacement Supercharger to suit the Yamaha V6. Simon recognised Harrop as the perfect partner for the project, given our rich history in designing and manufacturing TVS Supercharger systems for OEMs globally like Toyota, Lotus and Ford and our emphasis on quality control at our Melbourne based ISO9001 Certified manufacturing facility.

After many months spent analysing the complex packaging requirements and rotating group suitability for the application, a TVS1900 Supercharger Kit was cast and prototype parts manufactured to begin comprehensive testing. The heart of the Supercharger is an Eaton R1900 rotating group which is packaged within the Supercharger manifold featuring twin water to air charge intercooler cores. The Supercharger is driven by an 8PK drive belt and auto tensioner and only adds 55lbs to existing F and VMAX series engines. A key design requirement was for the Supercharger to fit under the factory cowl, a challenging task due to the limited packaging space left by the OEM but achieved with the use of a 105mm spacer. The Supercharger Kit was launched at SEMA 2017 on the Harrop and Eaton booths, winning a Global Media Award in the New Product Showcase for Best New Performance Product.

The results speak for themselves, with an impressive increase of peak 95HP and 91 ft lbs of torque with an impressive performance increase seen through the entire rev range. On the water that translates to over 100mph, tested by Nizpro Marine in a Force F19X Social Hull.

Harrop is proud to be the production partner for Nizpro Marine, for more information on the Yamaha 450s Supercharger visit www.nizpromarine.com.

CONTINUUM

Continuum are a world leader in Hi-Fi record player turntable systems being awarded sterophile 2006 product of the year - with high praise from leading audio magazines such as Hi-Fi news, Home Entertainment, Stereophile identifying the Caliburn model as the new reference benchmark for vinyl replay. It is based on this level of achievement and excellence that the Melbourne Australia based company selected Harrop Engineering to produce complex parts to very tight tolerances that its competitors are incapable of achieving.

With Continuum's passion and resolve to continue their standing as the leader in their field Harrop worked hard to assist in achieving their goals in relation to key components. As a leader in complete engineering services Harrop is able to provide a "state of the art" facility with up to 8 axis CNC machining capability to service Continuum's intricate and precise requirements for turntables, frames & tone arms.

During initial machining trials Continuum were extremely impressed with Harrop's open approach to previous issues they had encountered and appreciated the solutions and processes that were offered and subsequently implemented. The ability to completely machine many items in only one setup, or a maximum of two setups for the most complex parts was seen as efficient in reducing costs, increasing accuracy and eliminating part damage due to multiple handling. Harrop is proud to be a supply partner to Continuum and for more information on their outstanding audio products refer: www.continuumaudiolabs.com

GM HOLDEN "EFIJY"

When GM Holden made the decision to produce the wildest concept car ever, Holden designer Richard Ferlazzo, the brainchild of the "EFIJY" approached Harrop Engineering to gauge interest in the project. With confidentiality agreements in place we discussed at length our enthusiasm to be involved in producing many of the components required. This was a perfect opportunity to showcase our capabilities to a world wide audience.

More than 20 suppliers and designers offered their time, parts and expertise to build the car over 12 months. In 2005 Holden estimated the build cost to be over $1.5M; today many consider EFIJY to be priceless. The car is based on the stretched and widened underpinnings of a C5 Corvette and features a Harrop polished LS supercharger assembly together with the finned billet rocker covers for the 6 Litre LS2 based HSV engine. With 480Kw of power and 775Nm of torque it is almost 11 times more powerful than the 45Kw (60hp) engine in the 1953 FJ Holden.

Harrop also produced the 22" diameter rear, and 20" front, 2 piece, billet outer and spun inner rims, together with intricate 5 axis machined billet hub caps. With such high levels of powertrain performance our Ultimate Brake Kit featuring 15" (381mm) dia. front discs with 6 piston calipers and 14" (355mm) dia. rear discs with 4 piston callipers were the obvious choice to achieve necessary braking performance.

EFIJY was voted best US Concept Car of the Year for 2007. GM Holden Director of Design Tony Stolfo, said the award bestowed upon the EFIJY highlighted the talent and capability of all involved in its creation and the end result was a testament to their dedication and creativity.

"KERB-CAM" RACE VISION

Motorsport fans around Australia and New Zealand enjoy some truly exciting TV coverage from the V8 Supercars television team. Add to this a commentary team using cut-away mechanical parts and 3D technical computer models to help explain various aspects as the race unfolds, it all makes for both exhilarating and informative motor racing coverage.

You may not realise that clever design and precision manufacturing by Harrop Engineering is instrumental in delivering this ethanol-fuelled presentation into your lounge room. In addition to engineering parts for race cars performing at their limit, Harrop also created one of the slowest components at the event and one that literally brings TV viewers to the tarmac. "Kerb-Cam" is a unique (now familiar) road-level-view TV camera that dramatically conveys the high speeds achieved by premium category racing. The design team at Harrop was approached to develop a special housing capable of meeting the unusual requirements of the "Kerb-Cam" installations.

The solution was modelled and then virtually tested to ensure that the final CNC machined billet housing would be capable of withstanding extremes of weather and temperature plus the tyre force inflicted when struck by a V8 Supercar travelling at 280 km/hr.

Ironically, the machined aluminium wheel nuts that help a V8 Supercar deliver it's punishment to "Kerb-Cam" could have come from the very same CNC machine since Harrop makes wheel nuts for various V8 Supercar race teams.

In fact, Harrop has designed so many parts for race cars over the years that they are able to display a multitude of 3D CAD models to show just how the various components all work together. These proprietary data 3D models are presented to the TV audience during a race telecast to enhance the commentator's technical explanation of the corresponding live action. This technology is believed to be a world first in motor racing commentary, enabling immediate detailed references to events unfolding during a race without the use of a physical vehicle.

The impressive technology is an integral part of Harrop Engineering's operations and is used every day by the engineering team for every aspect of the design and development function. Fortunately, as motorsport fans, a member of our engineering team is invited to attend major race meetings, such as Bathurst, to support the V8 Supercar telecast team. Bringing one of Harrop's full CAD workstations with them to the track, they work alongside the series expert commentator Neil Crompton to present in intimate detail every major component of the V8 Supercar, from the front splitter to the rear wing.

Being a live broadcast it is impossible to anticipate how the races will unfold and what problems may arise, so pit-lane communications and broadcast audio is constantly monitored to identify potential topics for live discussion and reference to Harrop's CAD models. The full collection of CAD models is constantly open and ready to view at a moment's notice

Harrop has also developed special display components such as a cut-away engine, rear differential assembly and front upright assembly as additional training and presentation tools utilised by expert commentator Mark Larkham in the popular tech garage. Keep an eye out for future developments in telecast innovation when you are next watching the Great Race.