Post on 11-Aug-2014
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Adam Gryglak, Lead Diesel EngineerEd Waszczenko, Engine Durability Engineer
Scott DeRaad, NVH Engineer
F-Series: Best selling truck in U.S. for 32 years; in Canada for 43 years
33 million sold in 60 yearsLargest customer base: 9 million strongMore trucks on road with 250,000 miles
LEADERSHIP
• 60% of commercial segment drives Super Duty
• They build America’s infrastructure• Wyoming energy company tows 21,000 lbs to natural gas wells • Florida utility company tows “swamp buggies” and goes off-road• Texas construction firm hauls away thousands of pounds concrete • Chassis cab upfitted as fire trucks, dump
trucks tow trucks, aerial trucks
SUPER DUTY CUSTOMER
Designed and built by Ford New compacted graphite iron block
v. cast iron Aluminum cylinder heads v. cast iron Innovative inboard exhaust and
outboard intake architecture Industry-first single-sequential
turbo housed in the “V” of the engine block
30,000 psi high-pressure fuel system
Compatible with B20 Biodiesel Tested to 250,000 miles 111 powertrain patents
DIESEL TECHNOLOGY
Compacted graphite iron blockcontributes to 160-pound lighter total engine
TWICE THE STRENGTH, MINUS THE WEIGHT
Smarter Design. Greater Efficiency. Better Performance.
INBOARD EXHAUST
Outboard Exhaust Inboard Exhaustvs.
One impeller, two wheels
More responsiveSeamless transition
SINGLE SEQUENTIAL TURBO
Two turbos. One package.
Common-rail SystemRigorous testing. Proven durability.
30,000 PSI HIGH PRESSURE FUEL SYSTEM
Reduced weightSix head boltsDual water jackets
ALUMINUM CYLINDER HEADS
Twin pilot combustionRobust turbo mount Tuned acoustic coversComposite oil panInboard exhaust – less radiated noise
NOISE VIBRATION HARSHNESSKeeping it Quiet
Cab-on service capability External fuel injectors, lines, glow plugsSpin-on oil filterRepair time reduced by:
Turbo – 4.5 hours EGR cooler – 5.2 hours High pressure fuel pump – 4.7 hours
DEF refill timed to oil change interval
Less Down Time + Greater Productivity Better Bottom Line
EASY TO WORK ON
TESTED FORD TOUGH• Extensive CAD, CAE testing prior to hardware tooling• Data driven analysis incorporating: - Previous warranty data - Customer data to develop real-world test programs: driving styles, road types, vehicle usage• 250,000-mile durability lab tests• Thousands of hours in over-boosted, over-pressurized, overloaded conditions• 30-day running at maximum speed, boost• Started engine below zero 2,600 times• Thermal shocking: alternating hot, frigid fluids • Simulated 10 year use in arctic conditions• Field testing on torturous roads, courses
BUILT FORD TOUGH • Built at Chihuahua Engine Plant• Clean room manufacturing environment • CAD/CAE manufacturing lay-out to maximize plant efficiency • Extensive assembly personnel training • Flexible manufacturing capability• Data-driven Quality Operating Systems• In-plant dynamometer test stations • Prototype builds exceeded quality metrics
DIESEL TAILPIPE EMISSION STANDARDS
SELECTIVE CATALYTIC REDUCTION
THE WHOLE PACKAGE