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Ford : Ford Powertrain GLOBAL POWERTRAIN STRATEGY BUILDS ON FORD'S BETTER IDEAS
* Ford Motor Company's global powertrain strategy has produced three industry-leading internal-combustion gasoline engine families - V-8/V-10, V-6 and I-4. * Ford is bringing leading-edge technologies to mainstream engines, such as the all-new 5.4-liter, 3-valve Triton™ V-8 and all-new 6.0-liter Power Stroke® Diesel, to achieve new levels of power, refinement and efficiency. * New technologies, such as electronically controlled continuously variable transmissions (CVTs), drive-by-wire and hybrid-electric power will appear in high-volume, mainstream Ford Motor Company products where they can make the most impact on fuel economy and emissions. * Ford is introducing its partial-zero emissions (PZEV) Ford Focus in California beginning in January 2003, made possible by an all-new global I-4 engine. * An all-new V-6 family of engines is to power Ford vehicles by mid-decade. * Ford also is introducing a new lineup of innovative transmissions during this decade, such as the new TorqShift® 5-speed automatic. By 2008 more than 50 percent of its automatic transmissions in North America will be all new. Ford Motor Company's approach to powertrain development assures that as ever-cleaner and more fuel-efficient engines go into the products of today and tomorrow, customers don't have to pay a price in reduced performance. In fact, thanks to modern engine design and sophisticated electronic controls, the opposite is true - Ford's newest engines, such as the 5.4-liter, 3-valve Triton V-8 and the 6.0-liter Power Stroke Diesel, offer more power and performance, and are quieter and more durable than ever before, all while producing fewer emissions and offering improved efficiency. Successes like these prove that the internal-combustion engine - in the right hands - can adapt to meet customer and societal demands far into the future. As Automotive News pointed out in its March 4, 2002, issue: "The automotive powertrain will see more innovation during the next 10 years than it has in the last 100." "It's fitting that as we mark 100 years as an automotive company, we continue to build on the powertrain leadership that Henry Ford established," said Dave Szczupak, vice president, Powertrain Operations, Ford Motor Company. "From that first removable cylinder head of 1908 to the all-new 3-valve cylinder head on the 5.4-liter Triton V-8, Ford has continued to write the history of performance." Technology leads the way Ford's investment in technology has paid off in both products and processes. For example, the modular V-8 engine family that began life in the early 1990s as the 4.6-liter, single-overhead-cam (SOHC) engine on the Lincoln Town Car has since given birth to a host of variations, including high-performance four-valve engines displacing 4.6 and 5.4 liters; the 4.6-liter and 5.4-liter Triton V-8 truck engines; 6.8-liter Triton V-10; as well as the supercharged SVT F-150 Lightning and SVT Mustang Cobra engines. Ford's "MOD" V-8/V-10 engine family has proven to be adaptable to the latest engine control technologies - including many that weren't even on the drawing boards when the original modular engines debuted. Sophisticated computer-aided engineering tools have enabled engineers to tune out unwanted sound and vibration in the engine block, while computer-aided manufacturing tools allow them to pre-run assembly lines, to ensure the most efficient manufacturing processes. At Ford's Livonia, Mich., transmission facilities - the worldwide "center of excellence" for Ford Motor Company automatic transmission development and testing - engineers use one of the world's most powerful X-ray machines to examine engines and transmissions to ensure quality. This seamless integration of technology into daily work processes is reflected in the extensive use of electronic controls in Ford Motor Company's new engines and transmissions. These systems continuously monitor and analyze total vehicle performance and driver inputs, and adjust the engine and transmission to deliver the desired response. New 5.4-liter, 3-Valve Triton V-8 Ford Motor Company's newest innovation is the 5.4-liter Triton V-8 engine, which uses three valves per cylinder - two intake and one exhaust - along with variable-cam timing and other technologies to deliver a new level of performance and refinement. This engine will debut in the all-new 2004 Ford F-150. "The new 5.4-liter Triton V-8 will be the newest member of our '300 Club,' with more than 300 horsepower and class-leading torque across the entire rev range," said Pete Dowding, manager of Ford's modular engine programs. "We were the first to introduce sophisticated overhead-cam engines in pickup trucks. Now we are launching second-generation technologies for improved performance, efficiency, emissions and quiet, smooth operation." 6.0-liter Power Stroke Diesel 6_Liter_Diesel.jpg New 6.0-liter Power Stroke Diesel Ford's new 6.0-liter Power Stroke Diesel engine will replace the well-regarded 7.3-liter Power Stroke in the F-Series Super Duty lineup, offering even more power with better response and quieter operation. This engine will be matched to a new 5-speed automatic transmission. This combination, designed by engine and transmission engineers working as a team, will deliver exceptional durability and towing performance and improved fuel economy. One of the benefits of this holistic approach to powertrain design is a driver-activated "tow-haul" mode, in which the electronic powertrain controller is able to sense when engine braking is needed in a steep descent, and automatically downshift the transmission once or twice, depending on circumstances, to help the driver maintain a comfortable feeling of control. Global I-4 Engine New_I4_Engine.jpg New Global I-4 Engine At the opposite end of the size spectrum from the Power Stroke Diesel is Ford's new I-4 engine family, which will power the new partial-zero emissions (PZEV) Ford Focus, to be introduced in California this January. This modern four-cylinder engine family has the potential for more than 100 variations in a wide range of vehicles around the world, whether optimized for fuel economy, sport performance or torque, as in the Ford Ranger pickup. Ford eventually expects to build more than 1.5 million I-4 engines annually. The new global I-4 also is leading the way in modern and cost-efficient manufacturing, under Ford's global manufacturing strategy. This engine, to be built in four engine plants on three continents, will benefit from the efficiencies and quality improvements offered by flexible manufacturing techniques. Common-rail diesels In Europe, Ford has partnered with PSA Peugeot Citroën to develop a line of industry-leading, common-rail diesel engines, which offer dramatic fuel-economy benefits, without any of the negatives often associated with diesel engines. Common-rail technology uses electronic control of the diesel engine's fuel injection system to eliminate harshness, noise and excessive exhaust smoke and odor. Ford Motor Company believes that North American consumers will embrace this promising technology, with infrastructure improvements and availability of low-sulfur diesel fuel starting in 2006. Ford intends to lead the way in small-diesel technology in the North American market, as it does in Europe, and is studying offering a diesel-powered Ford Focus within the next five years. Continuously variable transmission (CVT). CVT_Cutaway_1.jpg Powertrain innovations continue In 2004, Ford will begin building a new version of its Duratec V-6 engine for the new Ford Freestyle and Ford Five Hundred sedan. Both vehicles will feature continuously variable transmissions (CVTs), for smooth, step-free operation and improved fuel economy. For 2003, the new Lincoln LS gets updates that make its dual-overhead-cam (DOHC) 3.0-liter V-6 engine among the most powerful naturally aspirated engines of its size on the market. Continuously variable intake valve timing allows engineers to optimize performance, making it one of the top 3.0-liter V-6 engines in the world in both torque and horsepower. The electronic engine controller automatically chooses from four possible intake manifold configurations, for best performance. Electronic throttle control provides a host of benefits, including improved responsiveness. In addition, to augment its V-6 lineup of engines, Ford will bring an all-new V-6 engine to market in mid-decade to power a variety of future Ford Motor Company vehicles. New transmissions coming More than 50 percent of Ford Motor Company's transmission lineup will be all new by 2008, due to new 6-speed front-wheel drive and rear-wheel drive transmissions and the new CVT, in addition to the new 5-speed TorqShift transmission introduced in the 2003 F-Series Super Duty. These new 6-speeds will use a compact, lightweight architecture, and will feature wider ratio spans than the transmissions they replace. This offers both better launch performance in lower gears and better fuel economy at highway speeds. "Typical automatic transmissions offer a relatively low ratio span - in the range of 3.5 to 4.0," said Phil Yuhasz, chief engineer, Automatic Transmission Operations. "Our new 6-speed transmissions and our new continuously variable transmissions will both offer a ratio span of 6.0. We expect our new Ecotronic CVT to offer fuel economy improvements of around 8 to 10 percent." All of Ford's carryover transmissions also will be heavily revised - a process that is already paying dividends. Customer satisfaction with Ford automatic transmissions is at its highest level in recent years. In addition, Ford Motor Company and General Motors Corp. recently announced a memorandum of understanding, in which they will work together to develop a new front-wheel drive 6-speed automatic transmission that will offer fuel economy improvements over current front-wheel drive products. Ford also is partnering with transmission specialists ZF on CVT design and production. The new Ford Ecotronic family of second-generation CVTs will be built at ZF Industries Batavia (Ohio) Transmission Plant near Cincinnati. Production is to start next year at the Batavia plant for European vehicles and in 2004 for North American products. Ford Escape Hybrid 2003_Escape_Hybrid_Rear.jpg Advanced Propulsion Ford Motor Company was the first manufacturer to announce a hybrid-electric sport utility, the Ford Escape Hybrid, which will debut in late 2003. Ford also is applying hybrid technology to fuel cell vehicles, with its new Focus Fuel Cell Vehicle. The Focus FCV is expected to achieve a 160-200 mile (250-320 kms) operating range - a significant improvement on previous fuel cell vehicles with no sacrifices in performance. Ford remains the leader in the alternative fuel vehicle (AFV) market, producing more AFVs than all other manufacturers combined. Ford offers products that operate on natural gas, propane, ethanol or combinations of alternative fuels and gasoline. Flexible manufacturing Flexible manufacturing offers multiple benefits to a carmaker - dramatically lower production costs and greater ability to respond to changing marketplace needs and consumer tastes. New 3V head line at Ford's Windsor Engine Plant. 3V_Engine_Heads.jpg Ford Motor Company has already begun introducing flexible manufacturing techniques at its engine plants worldwide. The cylinder-head line at Windsor (Ontario) Engine Plant, which will produce the 5.4-liter, 3-valve Triton V-8, features all-new fully flexible manufacturing. After a $350-million overhaul, the Cleveland Engine Plant No. 1 will use flexible manufacturing to build a new generation of V-6 engines. "Our standardized global manufacturing strategy allows us to quickly adopt best practices from around the world," said Kevin Bennett, director of Powertrain Manufacturing Engineering for Ford. "We're able to get a plant up and running more quickly and at less cost than ever before. And we're able to deliver better quality products to our customers." Heart of the vehicle Ford Motor Company's powertrain development and manufacturing involve hard work and innovative thinking by thousands of professionals, from the computer work stations to the assembly line. Because this activity takes place behind the scenes, it is easily overlooked. That is, until the moment you step on the accelerator. Then there's no hiding, and no excuses. From small vehicles like the Ford Focus and Escape Hybrid to supercars like the Aston Martin Vanquish with its 460-horsepower V-12 engine and the new 500-horsepower Ford GT, Ford Motor Company's mission is to deliver great powertrains. "For more than 100 years the internal-combustion engine has not really had a true competitor," said Dave Szczupak, vice president of Ford Powertrain Operations. "It has been the chosen method of powering vehicles. "Now with hybrids, ICEs fueled with hydrogen and fuel-cell vehicles on their way, traditional powertrains are being pushed now more than ever before to be near zero in emissions and to maximize fuel economy. At the same time the customer expects no compromises with performance. Through our work here at the Ford Motor Company, we feel the IC engine is up to the challenge, and the best is yet to come." "The powertrain is the heart of every car," Szczupak adds. "The things we are doing today will assure that we continue to deliver great powertrains and great vehicles to our customers well into the future." 11/05/2002
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