Ford Focus 1 l EcoBoost Presentation
-
Upload
sven-wiesner -
Category
Automotive
-
view
13.397 -
download
8
Transcript of Ford Focus 1 l EcoBoost Presentation
2
Why are we here?
The Ford Focus The 1.0-litre EcoBoost Engine
An amazing new engine in a great, technologically advanced
family car
Fuel efficiency without compromise on power
Driving is believing – and fun!
3
The Route
1. START
2. LUNCH
3. LAUSANNE
La Maison
de Bonthoux
Hotel Le Mas
de Pierre
Hotel Alpha-
Palmiers
4
New 1.0 litre Ecoboost Powertrain
Andrew D.J. Fraser
Manager, Gasoline PT Development
March 4th 2012
5
Introduction
• Ecoboost is a new generation of Ford petrol engines, which deliver
outstanding fuel economy, together with great fun to drive and refinement in
line with the Ford brand DNA.
• Ecoboost offers customers a genuine alternative between conventional
naturally aspirated petrol engines, and very efficient, but increasingly
complex and expensive Diesels.
• The new 1.0l engine is the fourth in the Ecoboost series, which started with
the 3.5 V6, launched in North America in 2009, continued with the 2.0 and
1.6 in 2010, and extends further with the 1.0 launch in 2012.
6
Ecoboost Engine Families
1.0 I31.0 I3
1.6 I4
2.0 I4
3.5 V63.5 V63.5 V6
0
100
200
300
400
500
600
0 50 100 150 200 250 300
Power [kW]
To
rqu
e [
Nm
]
7
Ecoboost Family Philosophy
• All Ecoboost engines feature significant downsizing vs. naturally aspirated derivatives, as a means to enhance fuel economy. Downsizing offers numerous advantages:
• Lower mass: better performance, reduced real world consumption, improved dynamics, smaller tyres, less energy consumed by PAS.
• Less cylinders: lower cost, keeps technology accessible for consumer
• Reduced friction: fewer cylinders, bearings, less lubrication
• Significantly better warmup for both good fuel economy and rapid cabin heating.
• Key engineering challenge is to maintain, or enhance, performance and refinement, while delivering the fuel economy advantages of downsizing, as customers have shown that they are reluctant to compromise.
8
European Diesel share vs. performance.
• Diesel sales growth driven by performance gains, not FE advantage.
0
10
20
30
40
50
60
88 89 90 91 92 93 94 95 96 97 98 99 00 01 02 03 04
Year
Die
sel
Sh
are
[%
]
80
130
180
230
280
330
380
Peak T
orq
ue [
Nm
]
Diesel share (%)
Peak Torque [Nm]
9
Customer Performance Expectations
• Traditional petrol engine customers enjoy smooth, free-revving nature and
peak power figure high in RPM range.
• Diesel customers like high peak torque from low RPM, and relaxed cruising.
• Ecoboost engines offer both of these attributes, and careful matching to the
vehicle by means of gearing, means that Ecoboost engines appeal to wide
variety of customers, driving style and environments.
10
Engine Torque Comparison
Engine Torque Output
0
50
100
150
200
250
300
1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
Engine Speed [rpm]
En
gin
e T
orq
ue
[N
m]
1.6 T/C Diesel
1.6 Petrol
1.0L Ecoboost
11
1.0L Ecoboost Performance 6th Gear
Torque at Wheels - Top Gear Flexibility
0
100
200
300
400
500
600
700
20.0 40.0 60.0 80.0 100.0 120.0 140.0 160.0 180.0 200.0 220.0 240.0 260.0 280.0
Vehicle Speed [kph]
Wh
ee
l T
orq
ue
[N
m]
1.6 T/C Diesel
1.6 Petrol
1.0L Ecoboost
1.0L Ecoboost has
more torque at wheels
than 1.6 Diesel up to
80 KPH
12
Ecoboost Technology
• Ecoboost engines feature three key enabling technologies:
• Turbocharging – allows much greater torque & power from smaller engine
• Direct injection – improves combustion efficiency
• Variable camshaft timing – increases bottom end torque, mid range
efficiency and peak power capability.
13 Ecoboost: Three Key Elements Working as a System
Turbocharging
- 50% engine size reduction for same power
- Proven, reliable, cost effective technology
- Matched for low speed response
Direct Injection
- Charge cooling for improved efficiency
- Higher knock limit/more torque at low RPM
- Enables scavenging action
Twin VCT - Scavenging for low RPM response
- Improved efficiency and stability at part load
- Higher peak output
14
Ecoboost Technology - Turbocharging
• Ecoboost focus is on responsiveness and low speed torque rather than very
high peak power figures.
• Torque at 1500 RPM, and time for torque to increase to maximum output are
key metrics.
• Achieved by utilising very small, low inertia turbochargers, capable of
running at very high speeds, up to 248,000 RPM on 1.0L
• Low inertia turbos greatly reduce “lag” in response when throttle is opened
from low RPM, a traditional problem with turbocharged engines
15
Ecoboost Technology – Direct Injection
• Fuel is injected directly into combustion chamber via high pressure solenoid
injectors, with 6 holes giving precise fuel targeting and mixing.
• High injection pressures (up to 150 Bar) give excellent atomisation and
mixing.
• Multiple injections per stroke are used at some operating points to optimise
fuel economy, emissions and stability
• Evaporation of fuel in cylinder cools mixture before combustion, reducing
tendency to “knock”.
• Allows higher Compression Ratio than normal for turbo engines, improving
part-load fuel efficiency.
• Eliminates transfer of fuel mixture from inlet to exhaust during valve overlap,
improving fuel consumption and reducing exhaust emissions.
16
Ecoboost Technology – Variable Cam Timing
• Variable cam timing on both intake and exhaust allows great flexibility to
optimise engine efficiency under all conditions, e.g.
• Moderate overlap at full load to improve breathing and output with
reduced boost level
• Low overlap at idle for stability
• Late exhaust valve opening at part load for fuel efficiency
• Greatest benefit is for low speed torque and responsiveness, where valve
overlap can be increased to allow scavenging effect.
17
• At low speed & high load,
during the valve overlap period,
it is possible for the intake
manifold pressure to exceed the
instantaneous exhaust back
pressure due to turbo-charging.
• Under these circumstances,
“scavenged” air will flow directly
from the intake into the exhaust.
• Scavenging flushes residual
gases from cylinder, increasing
mass of following charge, and
cooling gas to reduce tendency
to knock. It also increases
turbo mass flow, helping spool-
up turbo.
• Intake Manifold Pressure > Exhaust Back
Pressure (due to boost)
Scavenging Effect
18
Ecoboost – Low RPM Torque Benefit
Scavenging Torque Enhancement 1.0l Ecoboost
80
90
100
110
120
130
140
150
160
170
180
800 1000 1200 1400 1600 1800 2000
rpm
To
rqu
e/ N
m
Zero scavenging, stoichiometric
exhaust AFR
Steady state scavenging,
stoichiometric combustion AFR
Transient 'turbo spool-up'
scavenging, stoichiometric
combustion AFR
30Nm benefit at 1250RPM
40Nm benefit at 1400RPM
19
1.0L 3-Cyl Ecoboost Technology Highlights
• Extremely compact block design, enabled by use of cast iron ilo
aluminium, small bore, long stroke geometry (71.9mm x 82.0mm),
and 6mm siamesed bore design. Total block length 286.2mm.
• Aluminium cylinder head with integrated exhaust manifold (IEM). 4V
layout with central injector & compact spark plug. 10.0:1 CR
• Rapid warmup due to small iron block, IEM, and split cooling system
with horizontally split head and controlled block/head circuits.
• ECU controlled variable displacement oil pump and low loss
lubrication system
• New Continental turbocharger with vacuum actuated wastegate,
allowing opening when off boost to reduce backpressure.
• Ultra-low friction design, with offset crank, coated pistons & tappets,
low tension rings, low friction crank seals.
• Cam drive via unique belt-in-oil design, giving full life belt, with
advantages of quietness & lightness vs. chain.
20
LHS engine Mount Velocity
0
8
16
24
32
40
48
56
64
Vertical Lateral
Baseline
Optimised
RHS engine Mount Velocity
0
4
8
12
16
20
24
28
32
Vertical Lateral
Baseline
Optimised
Force
Resultant engine
motion about
centre of gravity
In-line 3 cylinder engines
naturally develop a 1st order
(engine speed) couple resulting
in a combined pitch and yaw
motion
Vehicles are often sensitive to
this 1st order forcing and this is
manifested as a booming noise
and vibration in the vehicle
Balance shafts are conventional
technology to counteract out-of-
balance forces in a I3 engine.
However, they increase engine
weight and degrade friction thus
fuel economy and CO2
performance
Instead of
employing energy-
draining balance
shafts, Ford
strategy on the 1.0
engine is to
intentionally
“unbalance” the
flywheel and crank
pulley in
conjunction with
P/T mount
optimisation to
offset the primary
engine shaking
forces into a less
sensitive direction.
1st order balance
shaft
1.0L Ecoboost Balancing Strategy
• Patents applied for: DE102009047545.1, DE102011078356.3
21 1.0L Ecoboost Noise and Vibration Refinement
Modified
driveline to
achieve
optimum
balance between
vibration
transfer path
and
ride/handling
attribute
Engine mount system refined to decouple
shaking forces and provide best balance
between idle and pullaway vibration
performance
DMF (125PS) and clutch damper
tuning, flywheel inertia
optimisation (100PS) to minimise
torsional excitation – better
vibration characteristics and
rattle avoidance
120PS (DMF)
100PS (SMF)
22
Ford 1.0L 120PS EcoBoost Full Load Radiated Noise Performance
60
65
70
75
80
85
90
95
100
105
1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000
Engine Speed (rpm)
So
un
d P
ressu
re L
evel
New Ford 1.0 I3 engine has been targeted to
achieve exceptional quietness for this power
density and out perform naturally aspirated
engines in the class above
Fuel injector
isolators and
fuel pump soft-
landing
strategy to
control high
frequency
noise content
Engine
structure
optimised for
best radiated
noise, stiffness
and weight
Integrated engine
mount bracket and
front cover for best
stiffness and weight
Belt-in-oil primary drive
system provides low
noise content and
controls any whine
character
Engine acoustic foam
cover to reduce top end
noise
1.0L Ecoboost Noise & Vibration Refinement
23
1.0L Ecoboost
• Outstanding performance, flexibility & responsiveness for 1.0 l engine
• Benchmark fuel economy
• Class leading refinement
24
What You Need
• TO BE SAFE
• This is not a race, but hopefully an experience we will all enjoy...and all arrive in
one piece
• TO NOT SPEED
• Any speeding tickets will need to be paid for by the driver of the vehicle
• TO ASK QUESTIONS
• We have badges for the toll roads and maps etc but if we forget anything feel free
to ask
• TO ENJOY YOURSELF
Good scenery, good food, good driving and good company
If you need it the hashtag for the drive is #fordpowerdrive
25
In Geneva
• Ford Kuga –Rugged SUV provides more load space and
new technologies including hands-free tailgate lift
• Ford B-MAX– Ford’s ingenious new car with best in class
technologies, powertrains and all new ‘easy-access’ door
system
• Fiesta ST – Global production reveal of Ford’s small
car performance vehicle
• PLUS: Focus BEV, and the Transit Tourneo