Ford's EcoBoost Technology : A Central Element of a

Sustainable CO2 and Fuel Economy Strategy with

Affordable Products

M. Wirth

Ford Motor Company

ACEA Automotive Summit

Brussels, Nov. 9-10, 2010
Contents

• Introduction

• EcoBoost Technology Package

• EcoBoost Engine Lineup

• Fuel Economy Based on EcoBoost Technology

• Future Ecoboost Technology Extensions

• Summary
Contents

• Introduction

• EcoBoost Technology Package

• EcoBoost Engine Lineup

• Fuel Economy Based on EcoBoost Technology

• Future Ecoboost Technology Extensions

• Summary
Global CO2 Emissions by Source

Natural
96% man-made 4%

Public 2%

Domestic
16% Business
20%
Domestic air
Energy Int'l air
Agriculture, Transport
40% 5% 7%
forestry 22%
1%
Water
Cars 10%
45%
Freight
trucks

23%

Cars: 12% of man-made CO2 Rail 2%

Buses 6%
2-3 wheelers 2%
* (DEFRA data 2004)
CO2 Emissions Reduction*

2006
- 30%
CO2
*New Ford Models C02
Emissions Reduction 2020
(Europe & USA)
Technology Migration and EcoBoost Deployment
2007 2012
Near Term
Begin migration to
advanced technology
Near Term
• Significant number of vehicles
with EcoBoost technology
• Dual clutch and 6-speed
transmissions replace 4- and
5-speeds
• Increased hybrid applications
• Increased unibody applications
• Introduction of smaller cars and
CUVs
• Electric power steering 80% - 90%
• Battery management systems 75%
• Aero improvement up to 5%
2020
Mid Term
Full implementation of
known technology
Mid Term
• Weight reduction of 250 - 750 lbs
• Engine displacement reduction
aligned with weight save
• EcoBoost available in nearly all
vehicles
• Increased use of hybrids as a
percentage of gas engines
• Additional Aero improvements
up to 5%
• EPAS approaching 100% on
light-duty vehicles
• Low volume introduction of plug-
in hybrids
2030
Long Term
Volume roll-out of hybrid electric
technologies and alternative
energy sources
Long Term
• Percentage of internal
combustion dependant on
renewable fuels
• Volume introduction of hybrids
and plug-in hybrids
• Introduction of BEV and fuel
cell vehicles
• Clean electricity / hydrogen
Introduction of EcoBoost Technology
2007 2012 2020 2030
Contents

• Introduction

• EcoBoost Technology Package

• EcoBoost Engine Lineup

• Fuel Economy Based on EcoBoost Technology

• Future Ecoboost Technology Extensions

• Summary
EcoBoost Technology Package

NA 4V
DOHC
PFI
Variable
Cam
Timing

CO2

Technology Deployment
EcoBoost Technology Package

NA 4V
DOHC
PFI
Variable
Cam DI
Timing Homogeneous
(incl. CR)
CO2

Technology Deployment
EcoBoost Technology Package

NA 4V
DOHC
Variable
PFI
Valve
Variable Lift
Cam DI
Timing Homogeneous
(incl. CR)
CO2 Stratified Lean

Downsizing

Architecture Base EcoBoost =

& Downsizing / Boosting + GDI + TI-VCT
Boosting (TC)

Technology Deployment
Contents

• Introduction

• EcoBoost Technology Package

• EcoBoost Engine Lineup

• Fuel Economy Based on EcoBoost Technology

• Future Ecoboost Technology Extensions

• Summary
EcoBoost Engine Lineup

600
3.5 V6
500

400
Torque [Nm]

2.0 I4
300
1.6 I4
200
1.0 I3
100

0
0 50 100 150 200 250 300
Power [kW]
3.5L V6

• I-VCT and TI-VCT Versions

• 272 and 276 kW
• 475 Nm @ 1500 rpm and 542 Nm @
2000 rpm (19.5 bar BMEP)
• B/S = 1,07
• 10:1 Compression Ratio (95 RON)
• Side Mounted MH Injectors
• 150 bar fuel pressure
• Twin TC with dual wall manifolds
• 950 °C Turbine Inlet Temp.
• 0-20s feedgas emissions
supporting PZEV emissionability
2.0L I4

• TI-VCT
• 149 and 176 kW
• 300 Nm @ 1750 rpm and 340 Nm @
1750 rpm (21.4 bar BMEP)
• B/S = 1,05
• 9.5:1 Compression Ratio (95 RON)
• Side Mounted MH Injectors
• 150 bar fuel pressure
• Sheet Metal dual wall exhaust
manifold and integrated TC housing
• 970 °C Turbine Inlet Temp.
• 0-20s feedgas emissions
supporting PZEV emissionability
1.6L I4

• TI-VCT
• 110 and 132 kW
• 240 Nm @ 1500 rpm (18.9 bar
BMEP) , 260 Nm Overboost
• B/S = 0,97
• 10:1 Compression Ratio (95 RON)
• Central mounted MH Injectors
• 150 bar fuel pressure
• Steel cast exhaust manifold and TC
housing
• 1050 °C Turbine Inlet Temp.
• 0-20s feedgas emissions
supporting PZEV emissionability
1.0L I3
EcoBoost Lineup : Torque Characteristics

600

500
Engine Torque [Nm]

400

300

200

1.6 SCTI 150 hp 1.6 SCTI 180 hp

100 2.0 SCTI 203 hp 2.0 SCTI 240 hp
3.5 GTDI I-VCT 3.5 GTDI TI-VCT
0
0 1000 2000 3000 4000 5000 6000 7000
Engine Speed [rpm]
Contents

• Introduction

• EcoBoost Technology Package

• EcoBoost Engine Lineup

• Fuel Economy Based on EcoBoost Technology

• Future Ecoboost Technology Extensions

• Summary
Part Load Fuel Economy vs. Benchmark

500
n = 2000 rpm ; BMEP = 2 bar
480
1.6l GDI Twin Scroll
460 1.8l GDI TC
1.4l GDI Compr. + TC 1.8l GDI TC
440
PFI TC
BSFC [g/kWh]

420 2.0l GDI TC

400 PFI NA
380 1.4l GDI TC DI TC
360

340 FORD 1,6l SCTI FORD 2,0l SCTI

320 EcoBoost EcoBoost
Source : AVL
300
600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000
EngineDisplacement [cm3]
Engine Torque and A/F Ratio Strategy

300
134 kW
98 RON
250

λ < 0,9
Torque [Nm]

180 kph
200

160 kph 0.9 < λ < 1.0

150
130 kph
120 kph
100
100 kph

80 kph Overfuelling area is

50 kph
reduced to a minimum
50 30 kph for robust real world
fuel economy

1000 2000 3000 4000 5000 6000

Engine Speed [rpm]
EcoBoost Real World Drive Fuel Consumption
Dynamic and moderate driving of new C-MAX 1.6
EcoBoost vehicle performed in the french sea alps
100%
minimal impact
95% of overfuelling

90% Sigificant impact

of driving style
85%
Overfuelling
80% Driveability
Optimization
75%
Overfuelling
Component
70% Protection

65% Cumulated Fuel

NEDC
Consumption
60%

5%

0%
dynamic drive moderate drive
Next Step for RWFE : Integrated Exhaust Manifold
Classic cylinder head I4 Turbo Cylinder head with integrated exhaust
for separate exhaust manifold manifold (ports and plenum)

Intake
Side

Exhaust
Side

Manifold
Single
Duct to
Turbine Turbine

Enabler for stoichiometric operation in entire engine map

CO2 Fleet Impact Study Assumptions (EU Market)

Take Rate Downsizing Downsizing + Downspeeding

Gasoline 2000 kg < ITW Ratio Gasoline CO2 Improvement
1750 kg < ITW < 2000 kg
100% 60% 18%
1500 kg < ITW < 1750 kg
90% 16%
1300 kg < ITW < 1500 kg 50%
80% 1100 kg < ITW < 1300 kg 14%
70% 925 kg < ITW < 1100 kg 40% 12%
60% ITW < 925 kg
10%
50% 30%
8%
40%
20% 6%
30%

20% 4%
10%
10% 2%

0% 0% 0%
Impact of Gasoline Downsizing on Fleet CO2
EU Market 2007

14000 7,0%

2000 kg < ITW

12000 6,0%
1750 kg < ITW < 2000 kg

Most important segments !

Annual Sales Volume *1000

CO2 Reduction Contribution

10000 1500 kg < ITW < 1750 kg 5,0%
1300 kg < ITW < 1500 kg
8000 1100 kg < ITW < 1300 kg 4,0%

925 kg < ITW < 1100 kg

6000 3,0%
ITW < 925 kg

4000 Total EU Fleet 2,0%

2000 1,0%

0 0,0%

CO2 Emission per vehicle

Contents

• Introduction

• EcoBoost Technology Package

• EcoBoost Engine Lineup

• Vehicle Fleet Fuel Economy Based on EcoBoost Technology

• Future Ecoboost Technology Extensions

• Summary
Thermodynamics : Approaching the Ideal Real Engine

500
PFI NA
PFI TC, 35% downsizing
450
DI-TC hom., 35% downsizing = EcoBoost 2010
DI-TC strat., 35% downsizing
DI-TC hom. Miller cycle, 25% downsizing
400
DI-TC hom. WOT cooled EGR, 35% downsizing
BSFC [g/kWh]

350

300

250

„Ideal Real Gas Engine“ :

200 • Min. thottling losses
0,0 50,0 100,0 150,0 200,0 • No knock limitation
250,0
• No overfuelling
Torque [Nm] • Friction scales with torque
 CO2 NEDC [g/km]

80
90
100
110
120
130
140
150
160
170
180
Ba
se
PF
IN
AT
I-V
CT
+F
Ma ricti
na on
ge
me + Th
n t erm
Pa
ck al
ag
+D e
Ih
om
og
en
eo
us
h ig
hC
+D R
ow
ns
Ar izin
CO2 Strategy NEDC

ch g 3
it e
ctu 5% w
re i
St th
ep

+D
ow
ns
pe
ed
in g

+C
VV
L

+S +C
t ra AI
t if i
ed
Pa
rt
Lo
ad
„Ideal Real Gas Engine“

+S
R e to p /
g e St
n B art
rak &
in g
Equivalent Test Weight = 1450 kg
Contents

• Introduction

• EcoBoost Technology Package

• EcoBoost Engine Lineup

• Vehicle Fleet Fuel Economy Based on EcoBoost Technology

• Future Ecoboost Technology Extensions

• Summary
Summary
• CO2 reduction is a challenge for human society and vehicle
based CO2 emissions need to be addressed together with all
other sources

• Ford’s EcoBoost technology package based on gasoline

engine downsizing is an effective way to reduce vehicle based
CO2 emissions

• EcoBoost will be combined with advanced combustion

systems and vehicle systems to maximize CO2 reduction

• Ecoboost is embedded in a large scope sustainable

technology deployment plan including electrification and all
reasonable upgrades of the internal combustion engine for all
future fuels