In November 1997 Lotus Cars embarked on a European funded project to develop an µltra-low emission 2-stroke 4-cylinder passenger car engine. The engine design is based on a mono-block
concept, incorporating both cylinder head and block, thus eliminating the cylinder head gasket used at the seal face on conventional engines. The Lotus project, due for completion in three and a half years, marks their first venture into piston design. The UK manufactured pistons will be taller than usual, being longer than the stroke of the engine. In developing the new engine Lotus will be using a range of Taylor Hobson precision inspection equipment which, although suitable for some shop floor applications, will be dedicated to prototype development work for this project. Taylor Hobson has worked closely with automotive manufacturers for over 50 years, developing quality control
solutions for the inspection lab and shop floor alike.

Camshaft measurement
Inspection of surface texture, waviness and form on a self-contained system which is user-configurable for specialised measurement.

The FTSS 120 is used by Lotus to speed up the inspection operation with a versatile and user-friendly work station inspecting camshafts, cylinder bores, liner wear evaluation and valve stems.

When manufacturing camshafts, surface finish control is necessary to ensure the utmost quality and component performance. The surface on the lobes and journals must be smooth to reduce friction but remain capable of retaining an oil film for lubrication. The straightness of the cam lobe and its axial angle relative to the journal is also important to ensure correct contact with the follower, turning the follower slightly each time the engine rotates.

Engine Block Measurement
Flexible, robust, reliable measurement of large components with precise roundness and straightness.

A Talyrond is used on cylinder bore and crank form evaluation, balance shaft bore and housings and crankshaft journal roundness.

Excessive cylinder bore out-of-roundness could affect the sealing functionality and durability of the piston ring pack of an engine. Symptoms of excessive cylinder bore out-of-roundness are increased blow-by, oil consumption and hydro-carbons emission. It is therefore essential to manufacture cylinder bores that are as round as possible. Out-of-roundness can arise from several factors, typically; errors in machining, incorrect clamping of the cylinder head to the engine or cylinder wear.

Outputs from the Talyrond show inspection data in simple easy-to-read graphical format that can be readily understood. The highly accurate results give in-depth knowledge of the design and manufacture of the engine components.

Surtronic 3+
Portable surface finish measurement, fast simple operation, accurate and versatile.

Lotus claim the Surtronic 3+ is an invaluable instrument in daily use because it provides reliable performance and excellent easy-to-use software and visual output.