The new engine is the result of a close collaboration between Cooper and Ricardo engineers, using the latest in design processes and computer aided engineering (CAE) technology to deliver a world-class design. The new product incorporates 1400 bar common rail direct injection technology for its diesel variant or multipoint gas injection for CNG and LPG applications, using centrally mounted injectors for optimum combustion.

Performance and emissions were optimized using Ricardo’s WAVE engine performance and gas dynamics simulation software. The cylinder head incorporates double camshafts with roller finger followers for low friction, actuating four valves in each cylinder for excellent engine breathing. Extensive use of finite element analysis was made using both the Ricardo FEARCE product as well as other industry standard software, to produce a durable, thermally and mechanically efficient cylinder head design.

The robust nature of the engine and its superior NVH signature are assisted by the use of a structural bed plate configuration, with the crankshaft and crankcase subjected to stress and fatigue analysis using the Ricardo ENGDYN coupled crankshaft and cylinder block analysis product.

Low cost of ownership was of paramount importance to the design team, and the new engine boasts excellent longevity and ease of service. This longevity is evidenced by a B10 life of 7,000 hours (the service life for a statistical expectation of 10% attrition) or 250,000 km in a vehicle application. With a highly competitive regular oil change interval of 500 hours, all service points are provided on one side of the engine and hydraulic lash adjusters help to avoid the need for periodic tappet adjustment. The new engine is also designed for straightforward long term maintenance, for example with the inclusion of wet cylinder liners for simple replacement.

A man either lives up to his father’s expectations or makes up for his father’s mistakes. I am doing the former with the strategic objective of leaping in the automotive value chain from a foundry and component manufacturer to an engine and vehicle manufacturer. For the engine project, the brief which was given to Ricardo was that the engines must meet the latest emission standards comparable to those currently applicable in advanced markets like Europe and USA; the objective was to achieve ‘power without pollution’. Ricardo took this assignment and the joint effort of this fruitful collaboration has resulted in the present 2 cylinder engine family launched today. Together with the 4 and 6 cylinder engine families under development, these products will meet the needs of users ranging from small passenger cars to large commercial vehicles, reducing overall emissions while improving the conservation of fuel.

—Farrokh Cooper, Cooper Corporation’s chairman and managing director

Cooper’s corporate goal is to develop one new engine every year.