Tag: Research and Development

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More Turbos from Mazda

CorkSport likes to be in the know on what Mazda is up to so I spend a good deal of time keeping in touch with my contacts at Mazda headquarters and searching the internet for clues on what Mazda is developing. I recently ran across a fascinating bit of information looking up patent applications with the US patent and trademark office that gives us a very interesting clue as to what Mazda may have in store for us in the future.

Mazda had a patent approved on January 12, 2010 for a forced induction engine with two sources of boost. The patent refers to an electric driven compressor (electric supercharger) which disengages when the engine reaches a pre-determined mid-range RPM point at which point the engine switches over to an exhaust driven compressor (a turbo charger).

This could be really handy for a small displacement engine when you want to get a large amount of power. The electric supercharger gives the engine the necessary boost to get the mid-range where the engine can then develop enough exhaust flow to spin the turbocharger.

This is the same theory used for a twin turbo charged engine but with instant boost from the electric supercharger. It can give a small displacement engine a decent torque improvement and the turbocharger will add the benefit of top-end power.

The whole idea gets even better with a variable vane turbine that would adjust to the engine speed. The faster the engine speed the more exhaust volume, allowing you to get the most out of the turbocharger efficiency.

This whole patent has the fingerprints of 2015 Mazdaspeed 3 written all over it if you ask me. You would still be getting the smaller, eco-friendly, SkyActiv engine but when you put your foot on it there is a big turbocharger lurking to give you gobs of torque just like the current Mazdaspeed 3.

I will give a word of warning though, not all things which have patents ever see the light of day, but the fact that Mazda spent the time and effort to patent this idea with the US patent office, gives me hope we will see a version of this patent in the next 3-4 years.

-Derrick

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Hello 2012!

As we usher in the dawn of a new year, CorkSport looks forward to what’s to come in 2012 and covers some highlights Mazda enthusiasts and CorkSport customers can expect to see in the coming months!

A New Website for CorkSport.com

In the relentless quest to provide our customers with the best online shopping experience possible, CorkSport will be launching a brand new website. Our newly designed website, scheduled to launch late this month, will feature improved navigation making it easier for our customers to find the parts they are looking for, a mobile optimized shopping experience for Android and iPhone users, easier to access content, photos and video clips along with a fresh new look. So be ready CorkSport fans because your shopping experience is about to get even better!

Suspension Packages
CorkSport is gearing up to offer a new line of staged suspension packages that will simplify handling upgrades for many of our customers. Our staged suspension packages will accomodate many levels of suspension upgrade needs starting from street performance through racing. We will be rolling out the the new suspension packages beginning with the Mazda 3 and Mazdaspeed 3 with our top package including a new coilover kit for Mazdaspeed 3 with amazing features for the price

SkyActiv Technology

We have blogged about this several times throughout the last year and now we are happy to say that Mazda has officially started rolling out its new line of SkyActiv technology for the Mazda 3 and will continue this trend into 2012 with the launch of the new CX5 platform to combine their legendary drivability with fuel efficiency.

B-Spec Race Series
For 2012 a number of sanctioning bodies have created a new segment of race cars called B-Spec that target the sub-compact market. The aim of this series is to provide more access to racing with the intention of the sanctioning bodies to maintain a single “spec” for the cars. Mazdaspeed Motorsports will be using the Mazda2 as their respective platform for this growing segment of the automotive industry.

CorkSport will also be continuing to compete in the SCCA ST-F class and we will be providing regular updates on our successes as the season evolves.

This represents just a small segment of what is in store for CorkSport and Mazda this year. We will continue to grow our product line and continue our unparalleled support for the Mazda community.

We are looking forward to a successful and exciting 2012!

Gwynne-

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When Products in Development Don’t Make the Grade

Things don’t always go as planned. We begin a project thinking our customers will be able to get good results out of a new performance product only to find, when we start testing, those results don’t show up.

An example of this is the CorkSport Cold Pipe. After investing months in the development process, we are choosing to abandon the product and put our development efforts elsewhere. Focus on products that will provide our customers with the type of performance benefits that inevitably did not show up during the testing of this product.

How it all began:

After seeing the great success of our Top Mount Intercooler and the amazing benefits it offered, we wanted to find a way to give customers who chose to stick to a TMIC even more performance. Looking over the TMIC system we noticed that when the air exits the intercooler it immediately hits a wall. It exits the intercooler towards the front of the car, but just after exiting it is forced to the driver side.

Once we identified this potential air flow restriction, we decided that it would be worth it to try and expand the stock cold-pipe to provide a better path for the air to flow, as well as a larger volume to accommodate the increased flow seen with a CorkSport TMIC.

The development process:

We scanned the stock pipe into a solid model so we could improve flow and still provide a great OEM fit.

Once we had a CAD model, we noticed the access to one of the four TMIC mounting holes became covered so we added an access hole to be able to tighten down this bolt as well as provide a NPT fitting to be used with water/methanol injection.

We proceeded with some virtual testing and discovered that the flow was more even and fluid as it moved through the redesigned pipe when compared to the stock pipe. Once we felt good about the revised drawing, we took the CAD model and did a 3D print to check fitment and conduct real world flow testing.

The part fit great and looked great. We were very happy with how the project was turning out, so the next step was to do some flow tests to determine the exact gains that the redesigned part offered.

The outcome:

We were disappointed with the results. The redesigned cold-pipe by itself offered a 15% increase in flow over the stock cold-pipe. When combined with a CorkSport TMIC however, both pipes flowed the same. Since the intercooler’s max flow (still significantly higher than the stock TMIC) was less than either of the cold pipes by themselves, the redesigned cold-pipe and CorkSport TMIC only flowed 0.7 CFM more than the stock cold-pipe and CorkSport TMIC, a negligible amount.

Knowing this, we now had a big problem. Why would anyone want to upgrade this part for a negligible performance improvement? Sure the option to do methanol injection would be great for some but we didn’t think most people would be interested, even at our target of $125.

We hit the forums, Mazdaspeed Forums to be exact, and asked what they thought of the product and if they would still be interested in the product with the minimal gains seen. The general consensus was that although it was a great idea and seemed to have a lot of development and engineering behind it, they didn’t feel like it would be worth the cost or that we would see enough sales to warrant producing the part.

With this feedback, we decided to abandon the project and cut our losses on the development time and money we put into the product. Unfortunately this happens occasionally. We work on a project only to end up killing it before we reach production. It’s just the way development goes sometimes, but each and every time we can take it as a learning experience to further our knowledge about what projects may or may not be worth pursuing in the future.

We want you to feel confident that our products do what we say they will do and though it’s not an easy decision to scrap a product after investing thousands of dollars on development, when the alternative is to release a product that has no performance benefit when our customers are expecting one, the choice is simple, abondon ship.

Andrew-