Ford EcoBoost engine
Ford EcoBoost refers to a series of four-stroke gasoline engines, the car manufacturer Ford, which was presented with the Ford Iosis -MAX in Europe in 2009 and launched in early 2010 with the models Ford Mondeo, Ford S -MAX and Ford Galaxy for the first time. It involves three or four- cylinder in-line engines with four valves per cylinder and double overhead camshaft (DOHC ). There is also a six-cylinder V-engine, which is offered in various Ford and Lincoln models since 2009 for the North American market.
General
Since the motors were developed after the downsizing principle, they reach very high power levels, despite the relatively low displacement. To this end, they have direct fuel injection, turbocharging and Ti - VCT, a variable control of the two overhead camshafts.
Ford was planning in 2012 to produce 1.3 million EcoBoost engines for the European market in the period up to 2015, a further 800,000 engines for markets outside Europe. In September 2013, the two millionth EcoBoost engine rolled off the line, the planned production at this time for the full year 2013 already amounted to 1.2 million copies.
The EcoBoost engines also come in various Volvo models under the name GTDi (Gasoline Turbocharged Direct injection ) are used.
Already in 2001, was at the IAA in Frankfurt Zetec S 3 DISI (Direct Injection Spark Ignition, translated: Direct with electric ignition ) presented called motor prototype to the public. It was a three-cylinder gasoline engine with 1.1 liters, which contributed, through turbocharging and direct fuel injection 81 kW (110 hp). Vibrations decreased in this engine a balance shaft, the transmission was made using a specially developed automatic transmission. The fuel consumption was 15 to 30 percent lower than that of a 1.8-liter gasoline engine with similar performance. A launch of this engine, however, never took place because the engine and transmission calculated charge in the amount of DM 4,500 (~ € 2,300, € 2,800 in today's dollars ) were not considered marketable.
1.0-liter, three-cylinder
Development and production
The 1.0-liter EcoBoost engine is a joint development of Ford's development centers in Cologne- Merkenich and the British Dunton. Since the production stage the engine is running the engine plant in Cologne and since May 2012 in Craiova, Romania from the tape. Ford also announced that, to start the production of the engine in the new Ford engine plant in Chongqing, China, which opened in June 2013.
Ford announced in June 2013 announced the production of the 1.0 - liter EcoBoost engine in the engine plant in Cologne from mid-August 2013, more than 1,000 units per day to double.
By September 2013 284.000 copies of the engine were produced.
Technology
The engine is 74 kW (101 hp), 88 kW ( 120 hp ) and 92 kW ( 125 hp) and consumes 4.8 litres/100 km Ford Focus thereby, the CO2 emissions are 109 g / km. The engine is also available since October 2012 in the models B -MAX, C -MAX and Grand C -MAX and since January 2013 Fiesta. In future, use in the series Mondeo, EcoSport, Transit Courier, Courier Tourneo, Transit Connect and Tourneo Connect is also provided.
To reduce vibration of the engine, the flywheel was fitted with a precisely defined unbalance, which counteracts the type of construction tends to be uneven running of a three- cylinder targeted instead of balance shafts. Due to the small inertia forces of the most powerful constructed turbine of the turbocharger, the engine has virtually no turbo lag, the turbine thereby achieves top speeds of 248,000 min -1. By injecting the fuel at a pressure of up to 150 bar, a better atomization and distribution of the fuel-air mixture is achieved in the combustion chamber, moreover, the injection process can be split into several sub- sequences per combustion cycle. This provides a precise controllable and more complete ignition of the mixture is achieved.
The exhaust manifold is cast together with the aluminum cylinder head, and could be incorporated in this manner into the cooling circuit. This reduces the exhaust gas temperatures and permits operation with an optimum air -fuel ratio over a wider engine speed range, which leads to a significant improvement in the quality of exhaust gas and fuel consumption. By two separate cooling circuits for the aluminum cylinder head and the cylinder block from cast iron and the reduction of the distance between the combustion chambers to 6.1 mm, the warm-up period is shortened. Both drive belts are embedded in oil baths, causing the motor to run smoother, the timing belt cause less friction losses and are also much more durable. Moving engine components such as pistons and the crankshaft bearings are provided with special coatings, and lower, as well as the modified piston rings, the internal friction of the parts to a minimum. To lift the compact design of the engine, Ford advertises that the base of the motor fits easily on a DIN A4 sheet. The weight of the motor is 98 kg.
Even the accessories are designed for reducing energy demand, the air conditioning compressor and the oil pump work with variable controlled flow rates.
Awards
The trade magazine Engine Technology International gave the engine in June 2012 with the best ever score achieved the award " International Engine of the Year 2012", and the awards " Best New Engine " and "Best engine to 1.0 liters of displacement ." Consisting of 76 international automotive journalists jury took into account not only innovative engine developments and technologies as well as the drivability, the performance, the efficiency and smooth running of the motors. In June 2013, the engine again won two awards: " International Engine of the Year 2013 " and "Best engine to 1.0 liters of displacement ." This time there was a jury of 87 international automotive journalists from 35 countries.
In October 2012, the engine won the award " ÖkoGlobe " 2012 in the category " drives and the drive train ." This by the artist HA Schult called and developed jointly by TÜV Rheinland, the DEVK insurance and the ÖkoGlobe Institute of the University of Duisburg -Essen awarded international environmental award vehicles, propulsion technologies, production processes and ( mobility ) concepts are evaluated on the basis of ecological criteria.
The magazine test car recorded the 1.0-liter EcoBoost engine with the Innovation Award of the "Auto Test Winner 2013 ' from.
Others
In September 2012, Nick Tandy reached at the wheel of a converted Formula Ford racing car with a 1.0 -liter EcoBoost engine on the Nordschleife of the Nürburgring with 7:22 minutes elftschnellste the lap time of a road vehicle that has ever been measured there. The engine's power was increased to 151 kW ( 205 hp ), beyond the car with wheel covers, the correct lighting, turn signals, a horn and road traffic USEFULLY tires had to be fitted in order to obtain a UK road legal. This lap time was less than those of many supercars like Lamborghini Aventador, Ferrari Enzo or Pagani Zonda.
1.5 - liter four-cylinder
In April 2013 Ford announced that the EcoBoost engine family, to expand a 1.5 - liter four-cylinder, which was presented at the Auto Shanghai 2013, the public. First, he comes in the Chinese version of the new Ford Mondeo used later he will be available for the Ford Fusion in North America and also for the next generation Ford Mondeo and the Ford Focus in Europe.
This unit is the first Ford engine, in which the warm-up time is reduced by a controlled coupling of the motor control on the belt driving the water pump. In addition, the intercooler is cooled by water, which also makes for a more efficient thermal management of the engine. The engine block is unlike the 1.0 -liter engine, aluminum, gasoline direct injection with turbocharging, high injection pressures and variable camshaft adjustment, however, he shares with the other versions of the engine family.
The torque and power values are moving in a similar frame as the 1.6 -liter engine, but with even lower fuel consumption and resulting CO2 emissions. In Focus engine (150 hp) and 132 kW ( 180 hp ) will be available in two power levels of 110 kW.
The production of the 1.5 - liter engine has been held since April 2013 in Craiova, other production sites outside Europe however follow.
1.6 - liter four-cylinder
The 1.6 -liter EcoBoost engine is a further development of the Zetec SE and has been available since autumn 2010. It is available in three power levels: 110 kW ( 150 hp), 118 kW ( 160 hp ) and 134 kW ( 182 hp). Was first presented to the engine for the Lincoln C concept car in January 2009.
In contrast to the 1.0-liter EcoBoost engine is in this unit is a particularly lightweight, all - aluminum construction. The engine block is cast and attained by a central support and a torsionally rigid sump system a particularly resistant structure under high pressure. The two overhead camshafts are driven by a toothed belt. The valve is controlled via mechanical tappets. The piston rings have a low-friction coating, the surfaces of the cams are polished. As with the 1.0 -liter version, the oil pump is also working here with variable volume, also the electronic engine management system regulates the flow of coolant so the engine reaches its optimal operating temperature faster.
The direct fuel injection works bar with an injection pressure of up to 200, so that the fuel droplets are sprayed onto a size of less than 0.02 millimeters. The injectors with six -hole injectors are housed centrally in the cylinder head and spray the fuel into the combustion chamber optimized. Due to the denser and cooler fuel charge, the motor can with a higher compression ratio and a higher turbo boost pressure do.
The Borg Warner turbocharger type KP 39, thanks to smaller and lighter turbines has also very low mass forces achieved rotation speeds of more than 200,000 min -1, and is responsible for an increase in maximum torque by around 50 percent.
In addition, the rearrangement of the overhead camshaft (Ti- VCT) optimizes gas exchange in the combustion chambers. The control times of the intake and exhaust valves can be adjusted independently of one another by up to 50 degrees, the operation of the actuators takes place hydraulically. Here, the scavenging effect (translated: flushing) exploited the combustion chambers are thoroughly " flushed " when gas exchange by exploiting the differences in pressure between inlet and outlet channels. At low speeds, as more and cooler fresh air enters the cylinder, which results in more torque and faster speed gain of the turbocharger. Particularly at part load so the efficiency of the engine is significantly increased, which causes a significant reduction in the emission values .
The motors are manufactured at the Ford plant in Bridgend and are available for the third-generation Ford Escape and in various Volvo models in North America.
In addition, the 1.6 -liter engines have been used since the 2013 season in Formula Ford, they make there 147 kW ( 200 hp ) on the basis of an adjusted engine electronics.
View of the inlet side
Engine compartment of a Ford Focus with 1.6-liter EcoBoost engine
2.0 - liter four-cylinder
Even the 2.0 -liter engine is an all-aluminum engine with high-pressure direct fuel injection, turbocharger and variable early appealing controllable valve opening times (Ti- VCT). The direct injected here with pressures up to 150 bar the fuel into the combustion chambers. As with the 1.6 -liter engine, the openings of the injectors measure 0.02 millimeters, but each nozzle is equipped with seven instead of six openings. The opening times of the intake and exhaust valves are adjusted by the Ti - VCT system the current load situation by the camshafts can be rotated about oil pressure-controlled servo motors to a maximum of 50 degrees. Thus, the gas exchange in the cylinders is optimized at all engine speeds, which provides for increased energy efficiency, especially at partial load.
The 2.0 - liter engine with 149 kW ( 203 hp ) and 176 kW ( 240 hp) for several Ford and Volvo models, the stronger version in Ford models for the North American and Australian markets, as the Ford Taurus, the Ford Edge and the Ford Falcon, as well as for the Range Rover Evoque.
The Ford Focus ST engine thanks machined intake and exhaust ports and a different adjusted engine electronics even 184 kW (250 hp).
The 2.0 - liter version is produced exclusively in the Spanish plant in Valencia Almussafes. In addition, in 2014 the production of the engine start in Cleveland.
The Radical SR3 SL a modified version of the 2.0 - liter EcoBoost engine used since 2011, here is the engine delivers 224 kW ( 305 hp).
By September 2013, a total 532,000 engines were produced.
View from below
View of the outlet side
2.3-liter four-cylinder
At the 2.3 -liter engine also made the engine block and aluminum cylinder head, also the exhaust manifold integrated into the cylinder head. This results in the exhaust side of the inner and outer combustion chamber couple together separately and then to the turbocharger. This allows for a longer opening of the exhaust valves, which optimizes gas exchange and reduces fuel consumption alone by more than one percent.
The intake ports have been optimized, in addition, the engine has a special turbocharger housing. The drive of the blades in the turbocharger has been optimized, the turbocharger also has a two-tier Abgaseinströmöffnung, the so-called twin-scroll layout. This enables a faster pressure build-up in connection with a more direct response, similar to a turbo.
In March 2013 it was announced that from 2015 the available Ford Focus RS with a 246 kW ( 335 hp) 2.3-liter EcoBoost engine will have. The first time available in Germany from 2015 Ford Mustang will be available with a 2.3-liter EcoBoost engine, which (309 hp) 227 kW and has a maximum torque of 407 Nm. In addition, the engine with 202 kW ( 275 hp ) from the spring of 2014 at the Lincoln MKC is available, which is only offered in the North American market.
3.5-liter V6
In 2007, Ford 's Lincoln MKR a TwinForce mentioned 3.5-liter V6 engine from, which had 309 kW ( 420 hp ) and 542 Nm, the performance values of a 6 -liter V8 engine with around 15% lower fuel consumption. In 2008 Lincoln MKT featured the same engine was available, but was called by the name EcoBoost.
It is a bi-turbo engine with two Garrett GT15 turbochargers, reach the top speeds of 170,000 min -1. These loaders are quite small, thus the exhaust manifolds are also more compact and generate less heat. The high-pressure direct fuel injection system was developed in cooperation with Robert Bosch GmbH and injects the fuel at up to 150 a bar. The high-pressure pump is a nockenbetriebenene mechanical pump with a single piston, and an electronic valve that controls the flow of fuel to the injectors. This engine also has the Ti - VCT called, variable adjustment of the overhead camshafts.
The launch took place in July 2009 in the sixth generation of the Ford Taurus. Available is the engine that makes the 261-272 kW ( 355-370 hp) depending on the version, in various Ford and Lincoln models in North America. For the Ford F- 150, a version has been developed which delivers 569 Nm instead of 475 Nm significantly more torque. Ford produced the series version of these engines since May 2009 at Cleveland Engine Plant in Cleveland, Ohio.
In 2009, Ford before an ethanol variant of the 3.5-liter EcoBoost engine, which (321 hp) 236 kW made and delivered a maximum torque of 750 Nm. It was here, however an experimental engine.
Until September 2013 Ford produced a total of 635,000 units of the 3.5 - liter EcoBoost engine.
Ford Racing has developed a powered by a 3.5 -liter engine Daytona prototypes for the United SportsCar Championship, the chassis comes from Riley Technologies. For a record attempt at Daytona International Speedway on October 9, 2013 Colin Braun presented at the wheel with 40.364 seconds a new course record on, this corresponds to a speed of 222.971 mph ( 358.837 km / h ). In addition, Brown introduced new records for the replacement of 10 kilometers and 10 miles from the state.
View from front
Piston in a demonstration engine
Combustion chamber
View from behind