With new E.torQ family, FPT- Powertrain
Technologies gets high-technology midsize
engines onto the market
New powertrains reduce fuel consumption, improve performance
and add reliability, as well as reducing noise and vibration levels
Energy, Engineering, Emotion and Ecology have been brought together in the
new launch from FPT – Powertrain Technologies: the E.torQ powertrain
family. Made at the FPT facility in Campo Largo, the name of the new engines
was inspired by their main attribute – high torque at low revolutions. The
E.torQ family represents an expansion of the range of solutions offered by
FPT to the global market, with a global product, which has hit the ground
running as best-in-class in maximum torque and also as a reference point in
such aspects as performance, reliability, low levels of consumption, of
emissions, of noise and vibrations.
The engines were developed from the gasoline 1.6l 16v E0 from the former
Tritec Motors. Based on this, FPT has produced five new versions: 1.6l 16v
Flex-fuel and 1.8l 16v Flex-fuel – for the Brazilian market – and the 1.6l 16v
and 1.8l 16v E0 and a Sulev (Super Ultra Low Emissions Vehicle) version,
which is still under development.
The E.torQ family is the result of over 500,000 hours of development,
involving 20,000 hours of reliability testing in a dynamometer, 9,000 hours of
calculations, and 5 million kilometers of durability, reliability and application
testing. The project involved over 100 engineers from the FPT Engineering
Center in Betim (Brazil) and in Italy. In addition, 1,200 pre-series and
prototype engines were made before production began.
All this work has resulted in high-technology engines, with particular attention
on the following aspects:
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ENGINEERING
The engineering project was developed to make the most of torque at
low revolutions, with a capacity to meet global emissions standards
– assuring the global nature of the new line of engines from FPT. Other
focuses were reduced fuel consumption and reduced noise and
vibration levels, as well as increased reliability and a greater use of
components made in Brazil. The new powertrains are ready for the
future, prepared for technological evolution, using turbocompressors
and the MultiAir system of valve timing control.
To be sure of the modernity of its new powertrain family, FPT developed a
series of new features to add quality to the solid and technological base
offered by Tritec engines. In all, 70% of the engine is new, including
components such as blocks, crankshafts, connecting rods, pistons, intake
manifolds, valvetrains, electronic injection systems, engine wheels, water
pump and power steering, valve caps, cylinder heads and injection nozzles.
Computational and experimental techniques for the analysis of fluid, thermal
and structural dynamics allowed latest-generation technical solutions to be
included in the project. One example of this is the optimization of the
calculations for the injector spray, using 3D software called Virtual Engine
Modeling (VEM), which represents the state of the art in thermodynamic and
fluid dynamic simulation for internal combustion engines.
VEM can design the entire internal geometry of the engine, from the intake
manifold plenum to the first part of the exhaust manifold, using a mobile 3D
grid to simulate the movement of the piston and the valves. In the model, all
the gas and liquid movements, the formation of spray, the coalescence of
drops, temperature changes between fluids and between fluids and metal
surfaces, vaporization and fluid phase mixtures are represented.
This makes it possible to predict and optimize the behavior of the injector
sprays, optimizing the mixture in the cylinders and reducing the maximum the
formation of a fluid film in the conduits and valves. This means it is possible to
minimize the emission of unburned hydrocarbons, reducing fuel consumption
and improving combustion.
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In addition, the intake manifold went through computation fluid dynamics
(CFD) analysis to minimize loss of charge and volumetric yield symmetry
among the cylinders.
To reduce hydrocarbon (HC) emissions, 3.5mm tall Topland pistons
were used to reduce the crevice volumes. This involves volumes of fuel-air
mixtures that are trapped in crevices in the combustion chamber, preventing
their being burned. This means that unburned gases leave the exhaust,
increasing HC emissions. Using the 3.5mm Topland, the volume trapped in
the crevice between the first ring, the top of the piston, and the cylinder is
reduced, reducing emissions to a minimum.
The E.torQ engines have components that have been especially
planned with a focus on performance and reduced fuel consumption
and emissions – mainly due to reduced weight and/or friction. Examples are
the graphite, optimized, Evotec pistons, which are lighter and have
asymmetrical box walls, minimizing friction with the cylinders, as well as valve
trains.
The new forged, split, syntherized connecting rods are the lowest
mass on the market for this cylinder band. In the same way, the rings are
low friction with low tangential loads at heights of 1.2: and 2.41 mm, and are
among the lowest mass and friction on the market for this cylinder
band.
To reduce the deformation of cylinder jackets, the engine block has cylinder
head fittings separate from the cylinder jackets. In addition, the threads are
positioned in the upper part of the das water jackets and the connections
between the jackets and the outside were kept apart from the cylinder head
fittings. This made it possible to reduce deformation of the jackets caused by
twisting of the cylinder heads, so reducing friction and oil consumption.
The combustion chamber has a low surface/volume ratio and a central
sparkplug. This reduces combustion time and results in greater thermal
efficiency, which translates into performance gains and les fuel consumption.
Thermo-structural calculations were used to check and eliminate any
fatigue in the block, bedplate and cylinder heads. In addition, the same kind of
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calculation was used to design the new three-chamber metal cylinder head
gasket, preventing prior to construction of the prototype the pressure from
leaks between the gasket, block and cylinder heads.
Other content conserves the perfect functioning of the engine
throughout its working life. Examples of this are flat seal surfaces, which
optimize the performance of casings and guarantee no leaks; the new driveby-wire throttle with a contactless sensor, which eliminates mechanical
contact between internal components of the sensor; the maintenance-free
valvetrain, with hydraulic tappets; and the timing chain, which no longer
needs periodic maintenance.
For an even more significant increase in reliability, E.torQ engines have
crankshafts with a special microstructure, with greater resistance to
fatigue, and eight counterweights which reduce the effort required of the
bearings; optimized pistons with a reinforced hub, maximizing resistance;
and forged, split, syntherized connecting rods which offer, at the same
time, absolute precision of assembly, resistance, and maximum lightness.
Although blessed with a series of high-technology items, the new FPT
powertrain family is compact and has a simplified layout. All the
peripherals are mounted straight on the block, which also has the
water pump, power steering and engine support integrated. All of this
guarantees more versatility to the E.torQ family, allowing its application on
different platforms in various segments, as well as ease of
maintenance as a result of the free space in the engine bay.
The weight of the E.torQ engines is competitive, even compared to
the competitors that use an aluminum block. The block and cylinder
heads of the new line of engines have reduced masses compared with other
16v engines with the same cylinders. Also to this end, a plastic intake
manifolds and cylinder head gaskets were used, making them lighter.
The reduction of noise levels and vibration was also one of the aims of
the FPT engineering project. To achieve this, the front end transmission
was isolated. In addition, E.torQ engines use an aluminum oil pan,
which provides greater structural rigidity for the powertrain. With crankshafts
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with eight counterweights it was possible to achieve a 25% reduction in the
resultant balancing force.
The symmetry of flows between the four parts of the intake manifold,
conceived of using 3D fluid dynamic calculations, along with the design of the
cylinder head conduits and combustion chambers, allows exceptional
combustion symmetry between the four cylinders, enhancing the
smooth operation of the engine.
With reduced weight and optimized box walls, the engineering project
stabilized the movement of the pistons, also further reducing noise.
Finally, three classes of rod bearings were used for stricter gap tolerances in
the large connecting rod sockets. This guarantees the maintenance of low
noise throughout the engine’s working life.
ECOLOGY
The E.torQ engines are the best example that for FPT innovation and
conservation go hand-in-hand. The new powertrains have achieved a fuel
consumption and emissions reduction of around 5% compared with
the 1.8l used now by Fiat.
The level of emissions in the E.torQ family is up to 40% below that established
in Brazilian law. In addition, the powertrains have the electronic emission
control system OBD BR-1 and are now comparable with the next stage of
legislation, OBD BR-2.
The E.torQ engines have a recyclability index of 95%, and use an
ecological filter – in which only the paper and rubber filter elements are
changes, using the rest of the structure.
ENERGY
The energy of the E.torQ powertrains is expressed in their excellent
performance, both at high and low revolutions. Using ethanol, the 1.6l
16v Flex has a maximum power of 117 hp at 5,500 rpm and maximum
torque of 16.8 kgm at 4,500 rpm. The gasoline version develops 115 hp
at 5,500 rpm and torque of 16.2 kgm at 4,500 rpm. These figures make the
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engine the most powerful 1.6l flex-fuel on the market, as well as
having the highest torque among the engines with the same
number of cylinders.
The 1.8l 16v Flex version has maximum power of 132 hp at 5,250 and
maximum torque of 18.9 kgm at 4,500 rpm, when running on ethanol.
On gasoline, the power and torque figures are, respectively, 130 hp at 5,250
rpm and 18.4 kgm at 4,500 rpm. This is the highest torque among all 1.8
engines available on the Brazilian market.
Both the 1.6l and 1.8l versions present practically flat torque curves,
with 80% of the torque available at 1,500 rpm and 93% at 2,500 rpm.
EMOTION
Fun to drive is the most appropriate term to describe the feeling of driving a
car powered by E.torQ engines. Silent, smooth, and with great
performance and elasticity, the powertrain offers quick dynamic
responses to any kind of driving. In addition, their torque at low rpm – the
highlight of the new family – also helps reduce fuel consumption and
emissions.
The thrill of driving the E.torQ can be seen in the country’s racetracks, in
single-seat cars in Formula Future Fiat – a competition where the E.torQ
1.8l made its debut. Using a racing kit developed by FPT, the engine
reached 160 hp in a normally-aspirated version.
The acoustic performance of the new engine line highlights further the
pleasure of driving. Taking the 1.8l Flex-fuel version as a parameter, FPT
powertrains are superior to Brazilian-made competitors of the same
volumetric capacity in comparative testing, even with the E.torQ
using ethanol. In addition, the engine achieved noise levels markedly below
the approved level established by FPT in low gears.
Technical details E.torQ 1.6l 16v
Cylinders: 1.6l
Fuel: Ethanol/ Gasoline E22
Maximum power: 117hp @ 5,500rpm (ethanol)
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115hp @ 5,500rpm (gasoline E22)
Maximum torque: 16.8kgfm @ 4,500rpm (ethanol)
16.2kgfm @ 4,500rpm (gasoline E22)
Bore x Stroke: 77.0mm X 85.8mm
Compression ratio: 10.5: 1
Emissions: Proconve F-V
Technical details E.torQ 1.8l 16v
Cylinders: 1.8l
Fuel: Ethanol/ Gasoline E22
Maximum power: 132hp @ 5,250rpm (ethanol)
130hp @ 5,250rpm (gasoline E22)
Maximum torque: 18.9kgfm @ 4,500rpm (ethanol)
18.4kgfm @ 4,500rpm (gasoline E22)
Bore x Stroke: 80.5 mm X 85.8 mm
Compression ratio: 11.2 : 1
Emissions: Proconve F-V
About FPT - Powertrain Technologies
Present in ten countries in Europe and Latin America with 22 plants and 14 research and
development centres, FPT - Powertrain Technologies has a team of 20 thousand high trained
professionals. The strength of the brand can also be proven by the extensive number of distributors,
with over 1300 assistance and service centres that ensure the company's presence in more than one
hundred countries.
Synonymous of technology and reliability, FPT products are in Fiat Group companies such as Fiat
Automóveis, Iveco, Lancia, Alfa Romeo, Case IH, New Holland, Iveco Motors and Irisbus. With 9% of
non-captive customers in the automobile/light commercial sector and 33% in the maritime/industrial
sector around the world, the company also provides various applications for Ford, PSA Peugeot
Citröen, Tata-Daewoo, Suzuki, Mitsubishi, General Motors and Beijing Public Transportation
Corporation (BPTC), among others. Moreover, it has strategic joint ventures signed with Tata, in India,
with Saic, in China, and with Severstal, in Russia. In Latin America, FPT produces transmissions for
PSA Peugeot-Citröen, and has reached agreements to supply engines for TAC - Catarinense
Automotive Technology and Matefer / Agrinar.
The plant in Betim is the largest unit and has an annual production of over 1.5 million units between
engines and transmissions for cars. The plant in Sete Lagoas (MG) represents a model of flex
production, with a range of four families of diesel engines (F1; NEF, Cursor and S8000) for industries
of light and heavy commercial vehicles, buses, agricultural and construction machinery, and power
generators.
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The unit in Córdoba (Argentina), produces transmissions for PSA Peugeot Citröen, engines 1.9l 16v, as
well as C513 transmissions. Campo Largo unit, in the Metropolitan Region of Curitiba (PR), acquired
in 2008 by FPT, is responsible for the production of the E.torQ midsize engine family versions gasoline
and flex fuel.
FPT in numbers:
• Present in ten countries
• It has 22 factories and 14 research centres
• 20 thousand employees
• It had a worldwide billing, in 2009, of € 5 billion
• It produces 2.3 million engines and 2.2 million transmissions
CONTACTS
. Leonardo Werner
Mobile. - (31) 8373 7207
E-mail - [email protected]
. Tatiana Carvalho
Mobiles. - (31) 9382 5010 or (11) 8383 5028
E-mail - [email protected]
FPT - POWERTRAIN TECHNOLOGIES
Comunicação FPT Mercosul
Av. do Contorno da Fiat, 3455 G. 09 Sl. 05 – Betim - MG
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