Reports on the latest technological advances in the auto industry.
2006/1/30
@ 12:00 PM (45 months, 26 days ago)
While Ford Motor Company's new Beech Daly Technical Center may be the most sophisticated prototyping complex in the industry, the mediums they use may not seem like the stuff of rocket science. Sand castles, laser printers, and candle wax are used to quickly and efficiently build prototype parts used to test every nut and bolt on a new car. Housed in a rather unassuming building in Livonia, Mich., the center is capable of casting, machining, assembling and testing every major powertrain component, faster and more efficiently than ever. Prototype components are used in every stage of vehicle development, with the intent of making the product more reliable, more fuel-efficient, and more affordable for the consumer. The BDTC facility's rapid prototyping brings these benefits to the consumer faster, and more economically than ever. Five years ago, the time required to turn computer-aided design data into a functioning engine prototype could require more than six months. Today, Ford plans to build the first prototype of an all-new engine program from scratch in just 10 weeks. For Ford, this quick reaction time is expected to cut one to two years off of the typical time required to bring a powertrain to market. In addition, rapid prototyping eliminates the expense of tooling previously required to make functional components. This saves up-front costs, and significant costs as the engineering process drives design change. For example, the tooling for a small engine component could cost as little as $10,000. However, if nine design changes are required through the program, the cumulative cost of tooling alone could be $100,000. These cost savings increase exponentially with larger, more complicated components, such as engine blocks, cylinder heads and intake manifolds. "We believe the Beech Daly center is the most advanced prototyping facility in North America," says Todd Kloeb, manager, Engine Manufacturing Development Organization. "Paired with our sister facility in Dutton, England, Ford Motor Company now has the most sophisticated prototyping organization in the world. The center features proprietary technologies, but our advantage is not just in hardware and equipment. Rather, it's how we deploy that technology for significantly faster, cheaper prototype production." The BDTC relies on six techniques to produce prototype components. Two rapid casting techniques produce functional metal components that replicate sand-cast or high-pressure die-cast production components. Four rapid prototype technologies replicate functional plastic components, or non-functional, design-aid replicas. Here, computer data is translated into molds, built out of sequential layers of sand. These molds would humble the most elaborate sand castles, as these precise sand molds are filled with molten metal to make functional prototype pieces, such as an engine block. A pre-mixed layer of sand and activator is first applied to the entire build platform. Next, a printhead squirts a binding mixture onto the layer of sand. The activator and binder harden, creating the sand mold, one layer at a time, from bottom to top. Once the excess sand is removed, the mold can be filled with molten metal to cast the prototype piece. This makes very accurate, very intricate metal prototypes, such as transmission valve bodies. The begins by producing a rapid prototype master directly from CAD data. A silicone mold of the master is then filled with wax to create a pattern. These wax patterns are then dipped in ceramic. However, these ceramic pieces are not meant for display on a kink-knack shelf. After the ceramic hardens, the wax is replaced with molten metal to cast the prototype piece. SLS is used to make functional plastic components. For example, technicians at the center used SLS to develop functional intake and velocity stacks for use on Ford Racing's championship-winning FR500C Mustang. The Selective Laser Sintering process involves the production of a physical model by melting specific sections of powdered material, layer by layer. Like a laserjet office printer, the SLS laser beam scans each layer on the powder bed to fuse the fine particles into a solid area. Another layer of powder is then deposited and the next layer of the part is drawn. The solid sintered material forms the part, while the loose material acts as a support. When the build is finished, the loose material is removed to reveal the prototype piece. (click here for related story) Stereolithography can produce a very accurate, very inexpensive replica of a component in plastic. These are not functional pieces, and are usually used for design aid, or engineering models. For example, SLA replicas of metal castings are used to verify machining patterns and tool paths before the expensive metal components are cut. SLA components are made by curing a photosensitive liquid resin, which forms a solid surface when exposed to an ultraviolet laser. Each layer of the part is scanned onto the resin surface. Once a layer has been scanned, the build platform is lowered below the surface of the resin, and the process is repeated. When the build is complete, the part is raised out of the liquid resin, cleaned, and fully cured.
@ 10:19 AM (45 months, 26 days ago)
It's amazing what a room filled with radio-controlled cars, a 3-foot Statue of Liberty made of Legos and some comfy couches can do to stir the imagination. It may seem a place for fun and games, but to Ford Global Technologies, LLC, the Innovation Acceleration Center is a serious facility concerned with a serious goal: Brainstorming the future of Ford. Launched two years ago, the Innovation Acceleration Center invites groups from all areas of operations at Ford to use the facility to think not just outside the box, but even outside the car. "We offer a creative, off-site environment that is on-site at Ford," said Bill Coughlin, president and CEO, Ford Global Technologies, LLC. "When people come here they realize they aren't in Kansas anymore. They have the opportunity to push aside for awhile the typical constraints to think creatively and to see what may really be the best way forward." Located on the eighth floor of Parklane Tower, many different groups have taken advantage of the free facility -- which has break-out rooms and a small kitchen -- including marketing, product development and research and engineering groups. The drive of the Innovation Acceleration Center isn't just a place to think of a few idle ideas; it aims to do just hat its name implies: accelerate innovation at Ford. Ford Global Technologies, a wholly-owned subsidiary that manages all of Ford's intellectual property, encourages the development of patentable, innovative solutions. "Every aspect of our business can be improved in an innovative way to differentiate us from our competitors," said Greg Brown, manager of the center and IP counsel at FGTL. "So we hold sessions at the center on health care, diversity, incentive programs -- it's not just about steering nibble problems and hybrid vehicles. When you come play with us, our shtick is 'think outside the box; think game-changing. Think disruptive. Remember the Sony Walkman? Well, when Apple came out with the iPod, Sony's Walkman went the way of the 8-track tape. Sony's market was disrupted. "A sustaining technology means that it helps sustains the business just as it is," said Brown. "A disruptive solution means that it displaces prior solutions." These are the ideas FGTL staff seek, which is all about setting Ford products apart from the competition. "Desirable innovation is the key, because when we have a product that nobody else has we can command a premium," said Brown. "If you call a supplier every time you need a better widget, you won't get anything that differentiates your product. Taken to extremes, the styling of the vehicle is all you are left with, everything else is just a commodity." Another strategy is capturing IP early in order to have a broader market impact. "If you start to think about capturing IP just before production, you are too late in the game, and someone else will likely have patented the solution," said Brown. "Timing is fundamental in terms of the value of your IP." The earlier Ford can get its innovations patented, the broader their application can be, both inside and outside our industry. "The way we like to describe this is that instead of patenting an iPod compatibility device for an FM radio on a blue Focus, we would much rather broadly claim a radio with iPod compatibility," said Brown. "If you can claim a radio with iPod compatibility, you have something that everyone will want, whether they are building a blue Focus or purple Toyota." Through the center, FGTL's patent and marketing experienced people are able to get in on the ground floor of the innovation process. For example, a Ford researcher invents something really cool and FGTL might say this is great but let's try to build some more invention around it or help them take it to the next level. It's about building strategic patents around an invention, again, early. "We don't steer; the program directors steer us," said Coughlin. "We are there to facilitate and to assist with our expertise on the patent side. We explore with Ford's product teams problems they might face in the future, and then try to start solving them now and patent them."
2006/1/29
@ 12:11 PM (45 months, 27 days ago)
A year ago the Ford Volunteer Corps was just an idea waiting to be put into action, but when tragedy struck December 26, 2004, the Corps quickly became a reality. Like people across the globe, Ford Motor Company Chairman and CEO Bill Ford was horrified by the destruction of the tsunami, which killed approximately 275,000 people and left hundreds of thousands homeless. The company had to do something. Bill Ford initiated the Corps to make it more convenient for employees and retirees across the globe to volunteer for projects in their communities. The first major project was working with Habitat for Humanity International to rebuild housing in areas hardest hit by the tsunami. "I am very proud of the way this company and its people responded to the tsunami crisis," said Bill Ford. "The creation of the Ford Volunteer Corps helped us institutionalize that spirit." With the help of Ford volunteers, at least two communities that were destroyed by the 2005 tsunami started to rebuild. With volunteers from Ford Thailand and Ford India taking the lead, the Corps began with the village of Khao Lak located in the Southwestern region of Thailand, and with a fishing village 100 km South of Chennai in India. Since March, Ford Motor Company has sent 25 volunteers a week to Khao Lak - these volunteers often travel as far as 14-hours away by bus from their residence in Bangkok and Rayong. To date, more than 400 volunteers have given more than 25,000 hours to this effort and will extend into the new year. In India, Ford partnered with the Confederation of Indian Industry to adopt the 255 families of Panaiyur Periya Kuppam. To date, Ford of India has donated 25 new boats and fishing nets to support 75 families, paid school fees for children, conducted a summer camp for children, organized a children's club and started an engine repair training program for youngsters in the community. "People care so deeply and want to make a difference," said Executive Director, Ford Volunteer Corps, Jim Bright. Their mission: "We work to make a living. We volunteer to make a life." Throughout the world, the Corps partners with community groups that provide volunteer opportunities to Ford employees. It is estimated that more than 100,000 employees and 100,000 retirees worldwide participate in volunteer efforts each year. Habitat for Humanity projects, part of the company's 16-hour community service program for salaried employees, is one of the most popular causes. "Employees who donated their time and talents to help tsunami and hurricane survivors tell us the experience changed their lives," said Bright. The volunteers were instrumental in providing shelter and housing for displaced families. "I can't even begin to list all of our initiatives that have helped this vital region in the Gulf Coast begin to recover," said Bill Ford. "But I can say this: of course we donated money. But at times like this, people know that Ford does more than just write a check." "Heart is something that cannot be measured, but it is something that can very much be appreciated," he added. Besides being good corporate citizens during tragedies, Ford volunteers make a difference each day in their own communities in many ways, ranging from cleaning parks and public lands to mentoring children and young adults. Volunteers throughout the world touch lives, uncover needs and bring people together. "I am reminded daily of the spirit and deep commitment of our volunteers," said Nancy McCauley-Branstetter, manager-Ford Volunteer Corps. "I hear stories every day about employees who serve their community, and who take their families on vacation overseas to build homes for people in need."
Just as the 1965 Mustang was a runaway hit, so was its counterpart pedal car, selling over 93,000 units by Christmas of its first year in production. Four decades later, the pedal car with the Mustang logo is back and demand extends beyond kids, to their parents and grandparents as well - some of whom may have owned an original. "Mustang is an icon that appeals to kids of all ages. The pedal car gives our youngest fans a chance to get behind the wheel of their very first Mustang a bond that we hope continues for a lifetime," said Mark Bentley, Ford licensing manager. To start youngsters off right, Ford is donating 100 of the iconic Mustang pedal cars to the US Marine Corps Reserve Toys for Tots Program. Toys for Tots goal is to help needy children throughout the United States experience the joy of Christmas; to play an active role in the development of our nation's most valuable resource - our children. AMF Corporation sold he original pedal car tooling to a Mexican company in the early 70's and production ended in the early 80's when the company closed. The original equipment was left in a warehouse, where it remained untouched for nearly 20 years. Enter Mark Luzaich in 2004. As the owner of Warehouse 36, a small company in Windsor California, Luzaich started importing and producing pedal cars as collectables. Hearing about the original equipment, he flew to Mexico, bought it, and prepared to produce the original Mustang Pedal Car once again. With the exception of a few modifications to meet modern safety standards, the new models are nearly identical to the originals, with all-steel construction, adjustable rubber pedals and authentic Mustang markings. The biggest difference from the original pedal car is the price. While Ford dealerships sold them at a discount, in stores, they retailed for $25. But just as the cost of the Mustang has increased ten-fold over the last 40-years, so to has the price of the pedal car which now retails for around $250. "The Mustang became one of the hottest pedal cars of all time," said Bentley. "We hope the new one continues to offer nostalgia to kids of all ages."
2006/1/28
@ 11:54 AM (45 months, 28 days ago)
The cost of owning a hybrid vehicle becomes even more attractive in 2006. Beginning Jan. 1, buyers of the Ford Escape Hybrid and Mercury Mariner Hybrid - the world's cleanest, most fuel-efficient SUVs - can look forward to significant tax savings. "Our hybrid owners tell us how much they enjoy their Escapes and Mariners because of the way they look, the way they drive and their fuel economy," says Christine Biondi, Escape Hybrid marketing manager. "Now with these new credits, our customers can subtract directly from the money they owe the IRS. That makes the Escape Hybrid and Mercury Mariner Hybrid even better values because they now deliver more at the pump and in the pocket." Today's owners of an Escape or Mariner Hybrid can look forward to considerable deduction in April by being eligible for up to a $2,000 tax deduction, reducing their taxable income for an after-tax savings of up to $700. The deduction is being replaced in 2006 with a new sliding scale tax credit that can be used directly against the amount owed to the IRS. The Internal Revenue Service has not officially said how much the tax credits will be. However, Ford expects buyers of the Escape Hybrid and Mercury Mariner Hybrid to be eligible for a credit of $2,600 for two-wheel-drive versions and $1,950 for four-wheel-drive models. Hybrid buyers are encouraged to review state or local laws to determine whether there are further tax incentives related to hybrid ownership. In addition, Congress recently approved a new law that allows states to provide owners of hybrid electric vehicles access to High Occupancy Vehicle lanes. The Ford Escape Hybrid, the world's first hybrid SUV, is entering into its third year on the market. In addition to the Escape Hybrid, Ford sells the Mercury Mariner Hybrid, while Mazda has a test fleet of Tribute hybrids on the road today. Mazda will begin selling the Tribute Hybrid in 2007. In 2008, the three SUVs will be joined by the Ford Fusion Hybrid and Mercury Milan Hybrid. And by 2010, Ford will sell 250,000 hybrids globally and offer the option in up to half of its Ford, Lincoln and Mercury nameplates.
@ 06:27 AM (45 months, 28 days ago)
Sometimes, it's just as important to recognize a good idea and help bring it to fruition as it is to originate the concept. Such was the case a few years ago when Ford Motor Company learned of two experimental technologies at American universities - Selective Laser Sintering (SLS) and 3D Printing Sand - capable of producing prototype parts without expensive tooling. With Ford's help, those processes are at the forefront of rapid prototyping technologies, helping the company dramatically slash costs, improve time to market and better handle frequent product changes. "Those two technologies combined have saved millions of dollars since their launch just six to eight months ago," said Todd Kloeb, manager of Ford's Beech Daly Technical Center. "That doesn't include other benefits, such as much faster product development time and greater knowledge of the production processes necessary to mass produce the part." Ford's role in bringing SLS and 3D Sand Printing to the auto industry was to combine the materials experimentation in the U.S. with automation technology needed to utilize the materials being developed in Europe. Ford's Office of General Council navigated the legal waters, ultimately allowing Ford a head start on the competition. "Soon, other automakers will be able to use the technology, but because Ford did the leg work, we will have at least a year's advantage," Kloeb said. "These technologies completely revolutionize how we go through the product creation process. They are critical enablers of our new Global Product Development System." Both SLS and 3D Sand Printing literally grow prototype components in small sections, or slices, from a computer-aided design (CAD) model. Creating components this way results in extremely precise parts. In the case of SLS, a laser is used to sinter, or fuse, specific sections of powdered material. Three-Dimensional Sand Printing incorporates a print head - much like that used in inkjet printers - to distribute standard foundry binding material to layers of production sand. Unlike SLS, the print heads and build chambers are fully scalable and can be made as large as necessary to accommodate bigger components. Lasers become more difficult to manage once they reach a certain size. Both technologies are capable of producing production-ready components much faster than previous methods, at a fraction of the cost. "Three to five years ago, we would spend hundreds of thousands of dollars on a disposable prototype tool for a die cast part, and then wait a year to get the tooling to make the part," said Kloeb. "If we had subsequent changes to the part, that added more cost to change the tool and tacked on additional time to make each new part." Now, a prototype part can be produced within days of receiving the CAD drawing. The same goes for changes. The turnaround time is extraordinarily fast. And there are no prototype tool expenses. "These technologies can be leveraged in so many areas, such as to facilitate frequent changes," said Kloeb. "For example, every year, nearly all programs undergo changes to intake manifolds to accommodate new regulatory requirements. We can do that in a snap, now." Aircraft manufacturer Boeing already is using SLS to manufacture parts for some of the company's fighters. Kloeb says the technology could even be used on low-volume automotive products, such as the Ford GT. It becomes too expensive at higher volumes, though. According to Kloeb, Ford will launch another rapid prototyping technology in the first quarter of 2006 that will have just as much impact as SLS and 3-D Printing Sand.
