Ford launches production of 1.0-liter EcoBoost engine; could reach 1.3M units per year worldwide in future
|Cutaway of the 1.0L EcoBoost. Click to enlarge.|
Ford President and CEO Alan Mulally launched volume production of Ford’s smallest gasoline engine—the 1.0-liter, turbocharged, direct injection EcoBoost engine (earlier post)—at Ford’s Cologne (Germany) Engine Plant. The 1.0L EcoBoost will debut in Europe in early 2012 and ultimately be available worldwide.
Ford announced that when the three-cylinder EcoBoost engine debuts in the European Ford Focus, it will produce 125 PS (124 hp, 92 kW) with fuel consumption of 5.0 L/100 km (47 mpg US), and CO2 emissions performance of 114 g/km. A 100 PS (99 hp, 74 kW) version of the same engine will deliver best-in-class gasoline CO2 emissions of 109 g/km.
The engine also will feature in the Ford C-MAX, and in the new Ford B-MAX, which enters production in 2012. Further global applications for both the 125PS and 100PS variants will be announced by Ford later.
Mulally was joined by Hannelore Kraft, prime minister of Nordrhein Westfalen, Germany, and Elfi Scho-Antwerpes, mayor of Cologne, for the event. Ford said it invested €134 million (US$182 million) to develop a special high-tech line at the Cologne Engine Plant to build the engine. The plant’s 870 employees will build up to 350,000 units a year of the new engine.
European production capacity could increase to up to 700,000 units per year as production of the new small EcoBoost engine at Cologne is joined by Ford’s new engine plant in Craiova, Romania, in manufacturing the new 1.0-litre EcoBoost engine in early 2012. In the years ahead, Ford anticipates production to expand outside of Europe to deliver availability for customers around the world and global production of up to 1.3 million 1.0-liter EcoBoost engines per year.
This new EcoBoost engine delivers performance to rival a traditional 1.6-liter engine and with significantly improved fuel efficiency and lower CO2 emissions. The 1.0-liter EcoBoost cylinder block can fit onto a sheet of A4 paper (11.7 x 8.3 inches) but delivers up to 125 PS and 170 N·m (125 lb-ft) peak torque (with 200 N·m (148 lb-ft) overboost), giving it the highest power density of any Ford production engine to date.
The 1.0-liter EcoBoost engine was developed by Ford experts across Europe, including engineers at Ford’s European Research and Advanced Engineering Centre in Aachen, Germany, and the Dunton Technical Centre, UK.
The advanced EcoBoost production facility at Ford’s Cologne Engine Plant was designed by Ford’s Manufacturing Engineering team, Dunton, UK, using Ford’s Virtual Manufacturing laboratory, to offer maximum flexibility and efficiency. Nearly 100 new machining units and a 580-meter purpose-built assembly line have been installed.
Fifty-five automated and 14 semi-automated processes are used, alongside 90 work stations for skilled employees. The technology is capable of machining to an accuracy of 10 microns, 10 to 20% the width of a human hair.
Ford has introduced new manufacturing techniques that reduce the volume of coolant required when machining aluminium engine parts to just four or five milliliters per component from a previous requirement of up to two liters, a reduction of more than 99% that contributes to a reduced environmental footprint from manufacturing.
New “cold testing” technology allows completed engines to be tested without being started—reducing fuel usage and CO2 emissions from the process by 66%—while 100% of the remaining energy required to run the plant comes from renewable sources. Total electricity demands have been reduced by 66% compared with production of Ford’s 4.0-liter V6 engine, which ended at Cologne Engine Plant.