Diesel Forum Presentation

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Web presentation given during the media forum hosted at the Beech Daly Technical Center on September 08, 2009 to discuss design, capability and fuel economy of the new 6.7L Ford SuperDuty engine.

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Diesel Forum Presentation

  1. 1. Adam Gryglak, Lead Diesel Engineer<br />Ed Waszczenko, Engine Durability Engineer<br />Scott DeRaad, NVH Engineer <br />
  2. 2. LEADERSHIP<br />F-Series: Best selling truck in U.S. for 32 years; in Canada for 43 years<br />33 million sold in 60 years<br />Largest customer base: 9 million strong<br />More trucks on road with 250,000 miles<br />
  3. 3. SUPER DUTY CUSTOMER<br /><ul><li>60% of commercial segment drives Super Duty
  4. 4. They build America’s infrastructure
  5. 5. Wyoming energy company tows 21,000 lbs to </li></ul> natural gas wells <br /><ul><li> Florida utility company tows “swamp</li></ul> buggies” and goes off-road<br /><ul><li> Texas construction firm hauls away thousands</li></ul> of pounds concrete <br /><ul><li> Chassis cab upfitted as fire trucks, dump trucks</li></ul> tow trucks, aerial trucks<br />
  6. 6. DIESEL TECHNOLOGY<br />Designed and built by Ford<br />New compacted graphite iron block v. cast iron <br />Aluminum cylinder heads v. <br /> cast iron<br />Innovative inboard exhaust and outboard intake architecture<br />Industry-first single-sequential turbo housed in the “V” of the engine block<br />30,000 psi high-pressure fuel system<br />Compatible with B20 Biodiesel<br />Tested to 250,000 miles <br />111 powertrain patents <br />
  7. 7. TWICE THE STRENGTH, <br />MINUS THE WEIGHT<br />Compacted graphite iron block<br />contributes to 160-pound lighter total engine<br />
  8. 8. INBOARD EXHAUST<br />Outboard Exhaust<br />vs.<br />Inboard Exhaust<br />Smarter Design. Greater Efficiency. <br />Better Performance.<br />
  9. 9. SINGLE SEQUENTIAL TURBO<br />One impeller, two wheels<br />More responsive<br />Seamless transition<br />Two turbos. One package. <br />
  10. 10. 30,000 PSI HIGH PRESSURE <br />FUEL SYSTEM<br />Common-rail System<br />Rigorous testing. Proven durability.<br />
  11. 11. ALUMINUM CYLINDER HEADS<br />Reduced weight<br />Six head bolts<br />Dual water jackets<br />
  12. 12. NOISE VIBRATION HARSHNESS<br />Keeping it Quiet<br />Twin pilot combustion<br />Robust turbo mount <br />Tuned acoustic covers<br />Composite oil pan<br />Inboard exhaust –<br /> less radiated noise<br />
  13. 13. EASY TO WORK ON<br />Cab-on service capability <br />External fuel injectors, lines, glow plugs<br />Spin-on oil filter<br />Repair time reduced by:<br />Turbo – 4.5 hours<br />EGR cooler – 5.2 hours <br />High pressure fuel pump – 4.7 hours <br />DEF refill timed to oil <br /> change interval <br />Less Down Time <br />+ Greater Productivity<br /> Better Bottom Line <br />
  14. 14. TESTED FORD TOUGH<br /><ul><li>Extensive CAD, CAE testing prior to </li></ul> hardware tooling<br /><ul><li> Data driven analysis incorporating: </li></ul> - Previous warranty data <br /> - Customer data to develop real-world<br /> test programs: driving styles, road <br /> types, vehicle usage<br /><ul><li> 250,000-mile durability lab tests
  15. 15. Thousands of hours in over-boosted, </li></ul> over-pressurized, overloaded conditions<br /><ul><li> 30-day running at maximum speed, boost
  16. 16. Started engine below zero 2,600 times
  17. 17. Thermal shocking: alternating hot, </li></ul> frigid fluids <br /><ul><li> Simulated 10 year use in arctic conditions
  18. 18. Field testing on torturous roads, courses </li></li></ul><li>BUILT FORD TOUGH<br /><ul><li>Built at Chihuahua Engine Plant
  19. 19. Clean room manufacturing environment
  20. 20. CAD/CAE manufacturing lay-out to </li></ul> maximize plant efficiency <br /><ul><li> Extensive assembly personnel training
  21. 21. Flexible manufacturing capability
  22. 22. Data-driven Quality Operating Systems
  23. 23. In-plant dynamometer test stations
  24. 24. Prototype builds exceeded quality </li></ul> metrics<br />
  25. 25. DIESEL TAILPIPE EMISSION STANDARDS<br />
  26. 26. SELECTIVE CATALYTIC REDUCTION<br />
  27. 27. THE WHOLE PACKAGE<br />

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