Ford 1.0-Liter EcoBoost Engine Sets the Standard for Smoothness and Quietness in Small Engines

Engineerblogger
Jan 7, 2013

Ford CEO Alan Mulally kissing 1.0-liter EcoBoost engine

• Innovative engine mounts, flywheel and pulley in the new 1.0-liter Ford EcoBoost^® engine combine to dramatically reduce the vibrations that are inherent in three-cylinder engines

• Super-stiff block, isolated fuel injectors and oil-immersed timing belts help make 1.0-liter EcoBoost engine one of Ford’s quietest engines

• 1.0-liter EcoBoost engine debuts in North America in the redesigned 2014 Ford Fiesta

Start up Ford’s patented new 1.0-liter three-cylinder EcoBoost® engine and chances are you’ll have to look at the tachometer to verify that the engine is running.

Ford engineers always knew they could build a powerful, fuel-efficient three-cylinder engine. The real engineering magic would be solving the problem that has often sunk previous three-cylinder automobile engines – conquering the unpleasant vibrations that come from having an odd number of cylinders under the hood.

For Ford’s new three-cylinder engine to be successful, it would have to be a no-compromise engine. It could not force customers to choose between performance versus economy or responsiveness versus smoothness. It had to deliver it all and it had to be affordable.

The traditional way of reducing shaking forces in small-displacement engines is to install a counter-rotating balance shaft inside the motor that cancels out most vibrations. But the problem with a balance shaft, explains Andy Delicata, Ford of Europe manager of Powertrain Noise, Vibration and Harshness, is that it is heavy, expensive, and it reduces fuel economy.

The 1.0-liter’s NVH engineering team, led by Delicata at Ford Technical Centres in Dunton and Dagenham, England, attacked the problem by focusing on two areas – the engine’s front pulley and rear flywheel, and the mounting system that connects the powertrain with the car’s body.

The pulley and flywheel are unbalanced with weights that are placed precisely to counteract the natural shaking forces of the engine and drive the energy in a less sensitive direction. The engine mounts are designed to decouple as well as absorb the engine’s shaking forces, Delicata explained.

The result is one of the smoothest and quietest engines in Ford’s global lineup. “We like to compare the refinement of the 1.0-liter EcoBoost engine with what you would typically experience in a vehicle two or three classes up from Fiesta and Focus,” said Delicata.

The smoothness of the engine is complemented by class-leading quietness. Engineers in Dunton and Dagenham attacked engine noise at its many sources.

For instance, a super-compact, highly stiff cast-iron block structure and an integrated engine mounting bracket are crucial in absorbing noise energy. In addition to immersing the engine’s toothed rubber timing belts in oil, isolated fuel injectors electronically controlled for soft landing and a foam-covered engine collectively help keep noise and vibration from reaching the driver.

The 1.0-liter EcoBoost engine is off to a fast start in Europe. Since its launch in March in the Focus, the 1.0-liter EcoBoost engine has won four major international awards. In the Focus, the 1.0-liter engine accounts for about 30 percent of sales, no small feat in a part of the world where the diesel engine is king.

The 1.0-liter is just now launching in B-MAX and C-MAX, and will be available in North America next year in the redesigned 2014 Ford Fiesta.

Source: Ford Motor Company

Additional Information:

•   2014 Ford Fiesta Press Kit
• Ford’s 2.0-Liter EcoBoost Engine Wins Second Consecutive Ward’s 10 Best Engines Trophy; GT500 Engine Also Honored 

Leah Buechley: How to “sketch” with electronics

Engineerblogger
Jan 6, 2012


Designing electronics is generally cumbersome and expensive -- or was, until Leah Buechley and her team at MIT developed tools to treat electronics just like paper and pen. In this talk from TEDYouth 2011, Buechley shows some of her charming designs, like a paper piano you can sketch and then play.

Leah Buechley is an MIT electronics designer who mixes high and low tech to create smart and playful results.



Source: TED

Additional Information: 

• Leah Buechley bio

Building a better machine: Students use creativity to improve the heat engine

Engineerblogger
Jan 4, 2012

Photos by Kris Snibbe/Harvard Staff Photographer

Elizabeth Kane looks at a Sterling heat engine model that eliminates the standard piston system. The presentation was part of the “Physics and Applied Physics Research Freshman Seminar." The seminar challenged students to study and improve upon the Sterling heat engine constructed by last year’s seminar students.

When Roman Berens signed up for the “Physics and Applied Physics Research Freshman” Seminar, he wasn’t sure what to expect.

“Initially, I really had no idea what it was about,” he said. “But I’m majoring in physics, so I thought having lab experience would be really valuable.”

Berens and other freshmen in the seminar discussed their research at a presentation at the Rowland Institute on Dec. 12. Using a handmade, laboratory-scale, Sterling heat engine, the team of students was able to generate enough electricity to power several light-emitting diodes, or LEDs, and a laptop computer.

“I’m amazed and invigorated by what our freshmen are capable of,” said Jene Golovchenko, Rumford Professor of Physics and Gordon McKay Professor of Applied Physics, and professor to the freshman seminar. “This year’s class has a wonderful collection of students who were admitted by interview to assure they were ready to take advantage of the high level of support provided them by the Rowland Institute. They are all prime candidates to concentrate in either in physics or SEAS,” the School of Engineering and Applied Sciences.

The seminar challenged students to study and improve upon the Sterling heat engine constructed by last year’s seminar students. Participants were tasked to improve on the existing model, turning it into a scientific instrument — embodying the laws of classical mechanics and thermodynamics.
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How a computer game could radically alter manufacturing

Engineerblogger
Jan 4, 2013

Here at The Engineer we’re used to explaining difficult concepts, whether it’s nuclear fusion or spintronics (actually I’m still not sure about that one). It helps that we have a receptive and enthusiastic audience and are tackling subject material that is usually instantly exciting.

But what if you had to explain something with less obvious appeal to people who think you might be wasting their time, for example, a complex new manufacturing business model to a group of sceptical bean counters? It’s probably not a conversation you’d want to have at a dinner party.

The answer to this might be to make the explanation into a game, according to one research group at least. Make the process fun, entertaining and engaging, and the audience might be more likely to understand and remember the concept, and perhaps even become more enthusiastic about it.

A team led by Aston University Business School are about to do just this by starting a five-year research project on the gamification of explaining servitisation. Now comes the bit where I explain what this boring and complicated-sounding concept actually is.

A product service system (PSS) is a business model where a firm offers both products and services. Rolls-Royce, for example, is well known for earning around 50 per cent of its revenue through service and support contracts, providing things such as maintenance and advice to customers that also buy its goods. Simply put, servitisation is when a straightforward manufacturing company adopts this model.

Particularly in developed marketplaces and economies, servitisation offers companies a chance to make more money than they would simply by selling products and competing against other manufacturers. Described like this, it sounds rather simple and very attractive. But making it a reality is a far more complex procedure with many barriers, and so servitisation of manufacturing firms has been slow.

Prof Tim Baines of Aston University argues that one of the biggest barriers to adoption of PSS is just explaining how the process of servitisation works. ‘To try to get those ideas across to someone in a manufacturing company in five or 10 minutes in a way that makes sense to them is quite challenging,’ he says.

This is where he believes gamification could come in. This is another slightly off-putting piece of jargon that basically means turning a process into a game. It’s not a new concept but has found growing popularity in recent years thanks to the growth of the internet and smartphones. There are any number of websites and apps that encourage you to do something by making it a game and rewarding you in some for participation.

For example, if you want to get fit but struggle to find the motivation, an app on your phone can monitor your progress to give you encouragement, telling you how many calories you’ve burnt or giving you badges for completing certain levels. One app even asks you to image you’re being chased by zombies and the only way to escape them is to run to a certain place.

But how will this work for explaining servitisation? Baines is planning to work with the Serious Games Institute at Coventry University and Sheffield’s Advanced Manufacturing Research Centre to create a computer simulation of a business adopting PSS. Companies, including Ford and Xerox, will then be brought in to test the game. ‘One of the big barriers is understanding, getting across the basic ideas and the language used, an appreciation of what it can actually mean,’ says Baines.

‘We’ll create a demonstration first of all so that we can communicate to the gaming community what we’re trying to do. The big hurdle is translating between these two communities, explaining to the gaming community what it is that we’re trying to model and them explaining to us what makes an engaging game. We’ve got to try to find the middle ground and from that we’ll create the basics of the game.’

It would be easy to write this concept of gamification off as a fad or a buzzword. For one thing, it doesn’t sound like the most fun idea for a game but, then again, there have been whole series of popular computer games designed around simulating real-life industries (Sim City, for example). And this won’t be the first time games are used to explain manufacturing concepts. Team games have been used before to demonstrate and introduce Western manufacturers to the Japanese-originated ideas of lean manufacturing.

Perhaps it will take more than a computer game to persuade companies to adopt dramatically different business models, but Baines hopes the game will do more than just change individual’s minds. ‘I would like it to be something quite pervasive that people inside the organisation become aware of and have a go at it, and for the top managers to hear about it not just from academics but also from people within the organisation who get to know about this thing called servitisation from playing the game.’

The game will also serve as a way for academics to further study servitisation so they can better understand the barriers to adopting PSS when it is attempted by real companies.

With gamification spreading even into business management techniques, it’s interesting to consider how else it could be used in manufacturing or other parts of the economy. Perhaps games could become a more common sight at work, motivating people to complete tasks or reach certain levels of achievement. On the other hand, you could argue we already run such a reward system. It’s called getting paid.

Source: The Engineer

Jumping droplets help heat transfer

Engineerblogger
Jan 4, 2013

Many industrial plants depend on water vapor condensing on metal plates: In power plants, the resulting water is then returned to a boiler to be vaporized again; in desalination plants, it yields a supply of clean water. The efficiency of such plants depends crucially on how easily droplets of water can form on these metal plates, or condensers, and how easily they fall away, leaving room for more droplets to form.

The key to improving the efficiency of such plants is to increase the condensers’ heat-transfer coefficient — a measure of how readily heat can be transferred away from those surfaces, explains Nenad Miljkovic, a doctoral student in mechanical engineering at MIT. As part of his thesis research, he and colleagues have done just that: designing, making and testing a coated surface with nanostructured patterns that greatly increase the heat-transfer coefficient.

The results of that work have been published in the journal Nano Letters, in a paper co-authored by Miljkovic, mechanical engineering associate professor Evelyn Wang, and five other researchers from the Device Research Lab (DRL) in MIT’s mechanical engineering department.

On a typical, flat-plate condenser, water vapor condenses to form a liquid film on the surface, drastically reducing the condenser’s ability to collect more water until gravity drains the film. “It acts as a barrier to heat transfer,” Miljkovic says. He and other researchers have focused on ways of encouraging water to bead up into droplets that then fall away from the surface, allowing more rapid water removal.

“The way to remove the thermal barrier is to remove [the droplets] as quickly as possible,” he says. Many researchers have studied ways of doing this by creating hydrophobic surfaces, either through chemical treatment or through surface patterning. But Miljkovic and his colleagues have now taken this a step further by making scalable surfaces with nanoscale features that barely touch the droplets.

The result: Droplets don’t just fall from the surface, but actually jump away from it, increasing the efficiency of the process. The energy released as tiny droplets merge to form larger ones is enough to propel the droplets upward from the surface, meaning the removal of droplets doesn’t depend solely on gravity.

Jumping-droplet superhydrophobic condensation shown on a nanostructured CuO tube.
Image courtesy of the researchers

 Other researchers have worked on nanopatterned surfaces to induce such jumping, but these have tended to be complex and expensive to manufacture, usually requiring a clean-room environment. Those approaches also require flat surfaces, not the tubing or other shapes often used in condensers. Finally, prior research has not tested the enhanced heat transfer predicted for these types of surfaces.

In a paper published early in 2012, the MIT researchers showed that droplet shape is important to enhanced heat transfer. “Now, we’ve gone a step further,” Miljkovic says, “developing a surface that favors these kinds of droplets, while being highly scalable and easy to manufacture. Furthermore, we’ve actually been able to experimentally measure the heat-transfer enhancement.”

The patterning is done, Miljkovic says, using a simple wet-oxidation process right on the surface that can be applied to the copper tubes and plates commonly used in commercial power plants.

The nanostructured pattern itself is made of copper oxide and actually forms on top of the copper tubing. The process produces a surface that resembles a bed of tiny, pointed leaves sticking up from the surface; these nanoscale points minimize contact between the droplets and the surface, making release easier.

Not only can the nanostructured patterns be made and applied under room-temperature conditions, but the growth process naturally stops itself. “It’s a self-limiting reaction,” Miljkovic says, “whether you put it in [the treatment solution] for two minutes or two hours.”

After the leaflike pattern is created, a hydrophobic coating is applied when a vapor solution bonds itself to the patterned surface without significantly altering its shape. The team’s experiments showed that the efficiency of heat transfer using these treated surfaces could be increased by 30 percent, compared to today’s best hydrophobic condensing surfaces.

That means, Miljkovic says, that the process lends itself to retrofitting thousands of power plants already in operation around the world. The technology could also be useful for other processes where heat transfer is important, such as in dehumidifiers and for heating and cooling systems for buildings, the authors say.

Challenges for this approach remain, Miljkovic says: If too many droplets form, they can “flood” the surface, reducing its heat-transfer ability. “We are working on delaying this surface flooding and creating more robust solutions that can work well [under] all operating conditions,” he says.

Yi Cui, an associate professor of materials science and engineering at Stanford University, calls the concept behind this work “an excellent idea,” and adds, “The studies here can lead to better atmospheric water-harvesting and dehumidification, and efficient heat transfer.” Cui adds that the fact that this team was able to make direct measurements of the actual heat-transfer enhancement from these treated surfaces is “interesting and important.”

The research team also included postdocs Ryan Enright and Youngsuk Nam and undergraduates Ken Lopez, Nicholas Dou and Jean Sack, all of MIT’s mechanical engineering department. The work was supported by MIT’s Solid-State Solar Thermal Energy Conversion Center, the U.S. Department of Energy, the National Science Foundation and the Irish Research Council for Science, Engineering and Technology.

Source: MIT

New 2D material for next generation high-speed electronics

Engineerblogger
Jan 4, 2013

Artist impression of high carrier mobility through layered molybdenum oxide crystal lattice. Credit: Dr Daniel J White, ScienceFX

Scientists at CSIRO and RMIT University have produced a new two-dimensional material that could revolutionise the electronics market, making “nano” more than just a marketing term.

The material – made up of layers of crystal known as molybdenum oxides – has unique properties that encourage the free flow of electrons at ultra-high speeds.

In a paper published in the January issue of materials science journal Advanced Materials, the researchers explain how they adapted a revolutionary material known as graphene to create a new conductive nano-material.

Graphene was created in 2004 by scientists in the UK and won its inventors a Nobel Prize in 2010. While graphene supports high speed electrons, its physical properties prevent it from being used for high-speed electronics.

The CSIRO's Dr Serge Zhuiykov said the new nano-material was made up of layered sheets – similar to graphite layers that make up a pencil's core.

"Within these layers, electrons are able to zip through at high speeds with minimal scattering," Dr Zhuiykov said.

"The importance of our breakthrough is how quickly and fluently electrons – which conduct electricity – are able to flow through the new material."

RMIT's Professor Kourosh Kalantar-zadeh said the researchers were able to remove "road blocks" that could obstruct the electrons, an essential step for the development of high-speed electronics.

"Instead of scattering when they hit road blocks, as they would in conventional materials, they can simply pass through this new material and get through the structure faster," Professor Kalantar-zadeh said.

"Quite simply, if electrons can pass through a structure quicker, we can build devices that are smaller and transfer data at much higher speeds.

"While more work needs to be done before we can develop actual gadgets using this new 2D nano-material, this breakthrough lays the foundation for a new electronics revolution and we look forward to exploring its potential."

In the paper titled 'Enhanced Charge Carrier Mobility in Two-Dimensional High Dielectric Molybdenum Oxide,' the researchers describe how they used a process known as "exfoliation" to create layers of the material ~11nm thick.

The material was manipulated to convert it into a semiconductor and nanoscale transistors were then created using molybdenum oxide.

The result was electron mobility values of  >1,100 cm2/Vs – exceeding the current industry standard for low dimensional silicon.

The work, with RMIT doctoral researcher Sivacarendran Balendhran as the lead author, was supported by the CSIRO Sensors and Sensor Networks Transformational Capability Platform and the CSIRO Materials Science and Engineering Division.

It was also a result of collaboration between researchers from Monash University, University of California – Los Angeles (UCLA), CSIRO, Massachusetts Institute of Technology (MIT) and RMIT.

Source:  CSIRO

Doris Kim Sung: Metal that breathes

Engineerblogger
Jan 4, 2013

Modern buildings with floor-to-ceiling windows give spectacular views, but they require a lot of energy to cool. Doris Kim Sung works with thermo-bimetals, smart materials that act more like human skin, dynamically and responsively, and can shade a room from sun and self-ventilate.

Doris Kim Sung is a biology student turned architect interested in thermo-bimetals, smart materials that respond dynamically to temperature change.



Source:  Ted

Additional Information:

• Doris Kim Sung bio