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Ford finds flex-fuel engine design plays big role in emissions output

How bad is ethanol for your engine? There's been a lot of debate on this issue as the US considers upping the biofuel content in the national gasoline supply from 10 percent (E10) to 15 percent (E15). The ethanol industry and some scientists say higher ethanol blends show no "meaningful differences" in new engines while the oil industry says ethanol creates health risks. Researchers working at the Ford Research and Innovation Center decided to take a closer look at how a wide range of gas-ethanol blends - E0, E10, E20, E30, E40, E55 and E80 - affected the emissions coming out of a flex-fuel 2006 Mercury Grand Marquis. To see the full report, printed in the journal Environmental Science & Technology, requires payment, but there is an abstract and Green Car Congress has some more details. The gist is that, "with increasing ethanol content in the fuel, the tailpipe emissions of ethanol, acetaldehyde, formaldehyde, methane, and ammonia increased." At least NOx and NMHC emissions decreased. The researchers say that the effects are due to the fuel and "are expected for all FFVs," but that the way that a manufacturer calibrates the engine will affect NOx, THC, and NMOG emissions. It's this last bit that's important, since the researchers found, "Higher ethanol content in gasoline affects several fundamental fuel properties that can impact emissions. ... These changes can have positive or negative effects that can depend on engine design, hardware, and control strategy. In addition to direct emissions impacts, higher ethanol content fuel can also provide more efficient combustion and overall engine operation under part-load conditions and under knock-limited higher-load conditions." So, as we head towards more ethanol in our fuel supply (maybe), manufacturers are going to need to learn how to burn it most efficiently.

Ford opens research center in Silicon Valley

These days, the software running a vehicle's myriad of electronic systems seems to be getting nearly as much development focus from automakers as the traditional mechanical parts that keep a car going. Constantly improving that technology requires a lot of experimentation, though, and Ford is expanding its presence in Silicon Valley with the just-opened Research and Innovation Center Palo Alto to make that progress possible. Ford opened its first office in the country's technological hub in 2012 to draw talent and devise ways to deal with vast amounts of sensor data. Apparently, setting up shop in Silicon Valley was deemed a success because the Blue Oval decided to create this new lab in the Stanford Research Park to focus on five areas: connectivity, mobility, autonomous vehicles, customer experience and analytics. Among the center's potential projects, Ford is hoping to develop better natural speech recognition, which is absolutely vital for improving infotainment systems. Assuming the tech eventually works well enough, your voice might even be used to adjust a vehicle's power seats, according to the automaker. The Blue Oval is also letting engineers from Stanford University test autonomous driving algorithms on a self-driving version of the Fusion. In a smaller stakes venture, researchers are working to get a Nest smart thermometer to automatically adjust the temperature at home depending on if an owner's vehicle is leaving or coming back. To really show that its serious about these ventures, Ford hired Dragos Maciuca away from Apple as the center's technical leader. The automaker also wants to have 125 researchers at work there by the end of the year.

Ford reveals new rapid prototyping and low-volume production techniques [w/video]

It's called "F3T," and that stands for Ford Free-form Fabrication Technology. The process that The Blue Oval has developed means being able to sidestep the weeks-long process of tool-and-die making when engineers want to construct a new part, allowing them to fabricate a three-dimensional part from a two-dimensional sheet of metal in just hours.
While F3T is being developed it is limited to "low-volume prototyping or even low-volume niche vehicles," but the next step is to evaluate it for use in Ford's global manufacturing facilities. You can find out more about it in the video and the press release below.