1

WELCOME

FORD POWER DRIVE :

NICE TO GENEVA

#fordpowerdrive

2

Why are we here?

The Ford Focus The 1.0-litre EcoBoost Engine

An amazing new engine in a great, technologically advanced

family car

Fuel efficiency without compromise on power

Driving is believing – and fun!

3

The Route

1. START

2. LUNCH

3. LAUSANNE

La Maison

de Bonthoux

Hotel Le Mas

de Pierre

Hotel Alpha-

Palmiers

4

New 1.0 litre Ecoboost Powertrain

Andrew D.J. Fraser

Manager, Gasoline PT Development

March 4th 2012

5

Introduction

• Ecoboost is a new generation of Ford petrol engines, which deliver

outstanding fuel economy, together with great fun to drive and refinement in

line with the Ford brand DNA.

• Ecoboost offers customers a genuine alternative between conventional

naturally aspirated petrol engines, and very efficient, but increasingly

complex and expensive Diesels.

• The new 1.0l engine is the fourth in the Ecoboost series, which started with

the 3.5 V6, launched in North America in 2009, continued with the 2.0 and

1.6 in 2010, and extends further with the 1.0 launch in 2012.

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Ecoboost Engine Families

1.0 I31.0 I3

1.6 I4

2.0 I4

3.5 V63.5 V63.5 V6

0

100

200

300

400

500

600

0 50 100 150 200 250 300

Power [kW]

To

rqu

e [

Nm

]

7

Ecoboost Family Philosophy

• All Ecoboost engines feature significant downsizing vs. naturally aspirated derivatives, as a means to enhance fuel economy. Downsizing offers numerous advantages:

• Lower mass: better performance, reduced real world consumption, improved dynamics, smaller tyres, less energy consumed by PAS.

• Less cylinders: lower cost, keeps technology accessible for consumer

• Reduced friction: fewer cylinders, bearings, less lubrication

• Significantly better warmup for both good fuel economy and rapid cabin heating.

• Key engineering challenge is to maintain, or enhance, performance and refinement, while delivering the fuel economy advantages of downsizing, as customers have shown that they are reluctant to compromise.

8

European Diesel share vs. performance.

• Diesel sales growth driven by performance gains, not FE advantage.

0

10

20

30

40

50

60

88 89 90 91 92 93 94 95 96 97 98 99 00 01 02 03 04

Year

Die

sel

Sh

are

[%

]

80

130

180

230

280

330

380

Peak T

orq

ue [

Nm

]

Diesel share (%)

Peak Torque [Nm]

9

Customer Performance Expectations

• Traditional petrol engine customers enjoy smooth, free-revving nature and

peak power figure high in RPM range.

• Diesel customers like high peak torque from low RPM, and relaxed cruising.

• Ecoboost engines offer both of these attributes, and careful matching to the

vehicle by means of gearing, means that Ecoboost engines appeal to wide

variety of customers, driving style and environments.

10

Engine Torque Comparison

Engine Torque Output

0

50

100

150

200

250

300

1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500

Engine Speed [rpm]

En

gin

e T

orq

ue

[N

m]

1.6 T/C Diesel

1.6 Petrol

1.0L Ecoboost

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1.0L Ecoboost Performance 6th Gear

Torque at Wheels - Top Gear Flexibility

0

100

200

300

400

500

600

700

20.0 40.0 60.0 80.0 100.0 120.0 140.0 160.0 180.0 200.0 220.0 240.0 260.0 280.0

Vehicle Speed [kph]

Wh

ee

l T

orq

ue

[N

m]

1.6 T/C Diesel

1.6 Petrol

1.0L Ecoboost

1.0L Ecoboost has

more torque at wheels

than 1.6 Diesel up to

80 KPH

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Ecoboost Technology

• Ecoboost engines feature three key enabling technologies:

• Turbocharging – allows much greater torque & power from smaller engine

• Direct injection – improves combustion efficiency

• Variable camshaft timing – increases bottom end torque, mid range

efficiency and peak power capability.

13 Ecoboost: Three Key Elements Working as a System

Turbocharging

- 50% engine size reduction for same power

- Proven, reliable, cost effective technology

- Matched for low speed response

Direct Injection

- Charge cooling for improved efficiency

- Higher knock limit/more torque at low RPM

- Enables scavenging action

Twin VCT - Scavenging for low RPM response

- Improved efficiency and stability at part load

- Higher peak output

14

Ecoboost Technology - Turbocharging

• Ecoboost focus is on responsiveness and low speed torque rather than very

high peak power figures.

• Torque at 1500 RPM, and time for torque to increase to maximum output are

key metrics.

• Achieved by utilising very small, low inertia turbochargers, capable of

running at very high speeds, up to 248,000 RPM on 1.0L

• Low inertia turbos greatly reduce “lag” in response when throttle is opened

from low RPM, a traditional problem with turbocharged engines

15

Ecoboost Technology – Direct Injection

• Fuel is injected directly into combustion chamber via high pressure solenoid

injectors, with 6 holes giving precise fuel targeting and mixing.

• High injection pressures (up to 150 Bar) give excellent atomisation and

mixing.

• Multiple injections per stroke are used at some operating points to optimise

fuel economy, emissions and stability

• Evaporation of fuel in cylinder cools mixture before combustion, reducing

tendency to “knock”.

• Allows higher Compression Ratio than normal for turbo engines, improving

part-load fuel efficiency.

• Eliminates transfer of fuel mixture from inlet to exhaust during valve overlap,

improving fuel consumption and reducing exhaust emissions.

16

Ecoboost Technology – Variable Cam Timing

• Variable cam timing on both intake and exhaust allows great flexibility to

optimise engine efficiency under all conditions, e.g.

• Moderate overlap at full load to improve breathing and output with

reduced boost level

• Low overlap at idle for stability

• Late exhaust valve opening at part load for fuel efficiency

• Greatest benefit is for low speed torque and responsiveness, where valve

overlap can be increased to allow scavenging effect.

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• At low speed & high load,

during the valve overlap period,

it is possible for the intake

manifold pressure to exceed the

instantaneous exhaust back

pressure due to turbo-charging.

• Under these circumstances,

“scavenged” air will flow directly

from the intake into the exhaust.

• Scavenging flushes residual

gases from cylinder, increasing

mass of following charge, and

cooling gas to reduce tendency

to knock. It also increases

turbo mass flow, helping spool-

up turbo.

• Intake Manifold Pressure > Exhaust Back

Pressure (due to boost)

Scavenging Effect

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Ecoboost – Low RPM Torque Benefit

Scavenging Torque Enhancement 1.0l Ecoboost

80

90

100

110

120

130

140

150

160

170

180

800 1000 1200 1400 1600 1800 2000

rpm

To

rqu

e/ N

m

Zero scavenging, stoichiometric

exhaust AFR

Steady state scavenging,

stoichiometric combustion AFR

Transient 'turbo spool-up'

scavenging, stoichiometric

combustion AFR

30Nm benefit at 1250RPM

40Nm benefit at 1400RPM

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1.0L 3-Cyl Ecoboost Technology Highlights

• Extremely compact block design, enabled by use of cast iron ilo

aluminium, small bore, long stroke geometry (71.9mm x 82.0mm),

and 6mm siamesed bore design. Total block length 286.2mm.

• Aluminium cylinder head with integrated exhaust manifold (IEM). 4V

layout with central injector & compact spark plug. 10.0:1 CR

• Rapid warmup due to small iron block, IEM, and split cooling system

with horizontally split head and controlled block/head circuits.

• ECU controlled variable displacement oil pump and low loss

lubrication system

• New Continental turbocharger with vacuum actuated wastegate,

allowing opening when off boost to reduce backpressure.

• Ultra-low friction design, with offset crank, coated pistons & tappets,

low tension rings, low friction crank seals.

• Cam drive via unique belt-in-oil design, giving full life belt, with

advantages of quietness & lightness vs. chain.

20

LHS engine Mount Velocity

0

8

16

24

32

40

48

56

64

Vertical Lateral

Baseline

Optimised

RHS engine Mount Velocity

0

4

8

12

16

20

24

28

32

Vertical Lateral

Baseline

Optimised

Force

Resultant engine

motion about

centre of gravity

In-line 3 cylinder engines

naturally develop a 1st order

(engine speed) couple resulting

in a combined pitch and yaw

motion

Vehicles are often sensitive to

this 1st order forcing and this is

manifested as a booming noise

and vibration in the vehicle

Balance shafts are conventional

technology to counteract out-of-

balance forces in a I3 engine.

However, they increase engine

weight and degrade friction thus

fuel economy and CO2

performance

Instead of

employing energy-

draining balance

shafts, Ford

strategy on the 1.0

engine is to

intentionally

“unbalance” the

flywheel and crank

pulley in

conjunction with

P/T mount

optimisation to

offset the primary

engine shaking

forces into a less

sensitive direction.

1st order balance

shaft

1.0L Ecoboost Balancing Strategy

• Patents applied for: DE102009047545.1, DE102011078356.3

21 1.0L Ecoboost Noise and Vibration Refinement

Modified

driveline to

achieve

optimum

balance between

vibration

transfer path

and

ride/handling

attribute

Engine mount system refined to decouple

shaking forces and provide best balance

between idle and pullaway vibration

performance

DMF (125PS) and clutch damper

tuning, flywheel inertia

optimisation (100PS) to minimise

torsional excitation – better

vibration characteristics and

rattle avoidance

120PS (DMF)

100PS (SMF)

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Ford 1.0L 120PS EcoBoost Full Load Radiated Noise Performance

60

65

70

75

80

85

90

95

100

105

1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000

Engine Speed (rpm)

So

un

d P

ressu

re L

evel

New Ford 1.0 I3 engine has been targeted to

achieve exceptional quietness for this power

density and out perform naturally aspirated

engines in the class above

Fuel injector

isolators and

fuel pump soft-

landing

strategy to

control high

frequency

noise content

Engine

structure

optimised for

best radiated

noise, stiffness

and weight

Integrated engine

mount bracket and

front cover for best

stiffness and weight

Belt-in-oil primary drive

system provides low

noise content and

controls any whine

character

Engine acoustic foam

cover to reduce top end

noise

1.0L Ecoboost Noise & Vibration Refinement

23

1.0L Ecoboost

• Outstanding performance, flexibility & responsiveness for 1.0 l engine

• Benchmark fuel economy

• Class leading refinement

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What You Need

• TO BE SAFE

• This is not a race, but hopefully an experience we will all enjoy...and all arrive in

one piece

• TO NOT SPEED

• Any speeding tickets will need to be paid for by the driver of the vehicle

• TO ASK QUESTIONS

• We have badges for the toll roads and maps etc but if we forget anything feel free

to ask

• TO ENJOY YOURSELF

Good scenery, good food, good driving and good company

If you need it the hashtag for the drive is #fordpowerdrive

25

In Geneva

• Ford Kuga –Rugged SUV provides more load space and

new technologies including hands-free tailgate lift

• Ford B-MAX– Ford’s ingenious new car with best in class

technologies, powertrains and all new ‘easy-access’ door

system

• Fiesta ST – Global production reveal of Ford’s small

car performance vehicle

• PLUS: Focus BEV, and the Transit Tourneo