GQEBERHA, South Africa, 8 September 2022 – In preparation for the upcoming launch of the Next-Generation Ford Ranger later this 12 months, the Ford Struandale Engine Plant in Gqeberha has commenced manufacturing of the newest addition to its engine household – the three.0L V6 Diesel, which can energy the range-topping Ranger pick-up fashions to be produced on the Silverton Assembly Plant in Pretoria.
This varieties a part of Ford’s R600-million funding within the Struandale Engine Plant operations, which has additionally facilitated upgrades to the prevailing meeting line for the two.0L Single Turbo and Bi-Turbo diesel engines. Design modifications and extra derivatives of the engines have been added for the Next-Gen Ranger, which shall be offered domestically and exported to greater than 100 world markets.
“The modernisation and upgrades to the Struandale Engine Plant began in July 2021, and the construction was completed on time in December, ready to begin our tooling trials and pre-production runs this year in preparation for Job 1 for both engine programs commencing in August,” says Shawn Govender, Plant Manager of the Ford Struandale Engine Plant.
“In its updated and extended format, the assembly line that is now producing the new 3.0L V6 turbodiesel continues with production of the existing 2.2 and 3.2 Duratorq TDCi engines, making it the only facility of its kind in the Ford world that produces both V-configuration and in-line engines on the same line,” Govender says. “Although this was a major challenge for our team and required a lot of creative and innovative thinking, it was essential to make optimal use of our facilities to contain the total investment required, and ensure that we are competitive from a cost-per-unit perspective.”
Struandale Engine Plant manufacturing begins
Relying on a versatile manufacturing format, with scheduled batches of the 2 totally different engine packages being assembled, the road incorporates 40 stations which are frequent to each models and an additional 25 stations which are distinctive to the three.0L V6 Diesel. The whole put in capability for this line is 130 000 engines per 12 months.
“The investment in extending and retooling this assembly line allowed us to modernise the facility by introducing the latest advancements in traceability and quality management technologies, including highly accurate GPS tool positioning systems, torque-to-turn monitoring for every bolt on the engine, and multiple camera stations that validate and record the accurate fitment of parts throughout the production process,” Govender explains. “This ensures that each engine we produce is of the best high quality, and can complement the numerous enhancements in efficiency, effectivity and refinement that shall be hallmarks of the Next-Gen Ranger.
“Our employees have undergone extensive training with our in-house team and global Powertrain Manufacturing Engineering specialists to ensure that they are fully equipped to manage the complexity and maximise the efficiencies of the flexible production format for the two engine programs.”
The Struandale Engine Plant can be accountable for machining of the cylinder heads for the three.0L V6 Diesel, which is carried out in a very revamped facility utilizing new and redeployed machines which were up to date with the newest tooling, working and high quality management methods.
2.0L Single Turbo and Bi-Turbo
The R600-million Struandale Engine Plant funding launched quite a few modifications for the newest variations of the extremely rated 2.0L Single Turbo and a couple of.0L Bi-Turbo diesel engines that would be the core line-up for the Next-Gen Ranger. Around 23 design modifications had been carried out for the new utility, whereas the variety of derivatives produced on the devoted meeting line for this engine program has elevated from 9 to 13.
“Most of the updates introduced were to accommodate the design of the Next-Gen Ranger, while further improvements have been made to the noise, vibration and harshness (NVH) characteristics of the engines for even greater comfort and refinement,” Govender says. “The quality, reliability and durability of this engine program is exceptional matched to superb fuel economy, and these are traits that will shine through in the Next-Gen Ranger.”
To help the elevated demand for the two.0-litre diesel engines, the plant has gone from the earlier two shifts to 2.5 shifts, with a complete put in capability for producing as much as 120 000 engines per 12 months.
Tested to the restrict
As with any new or up to date engine program, the new 3.0L V6 Diesel and newest specification 2.0L Single Turbo and Bi-Turbo engines are subjected to exhaustive in-process and off-line testing. Additionally, the prevailing Duratorq TDCi engines have additionally undergone in depth exams to make sure that the superior manufacturing methods, tooling and applied sciences used on the modernised versatile meeting line are inside specification.
Using probably the most superior engine dynamometer to be put in on the Struandale Engine Plant so far, the three.0L V6 Diesel endured a rigorous testing regime, together with a collection of 10 conformity of manufacturing (COP) exams spanning 20 hours every. This is a standardised management check used to qualify autos or elements all through the world.
Three 275-hour engine fatigue exams (EFTs) had been performed, with the accelerated check evaluating the engine’s robustness in opposition to structural fatigue attributable to repetitive mechanical loading at excessive speeds and cylinder pressures. An additional 100-hour engine fatigue check was additionally accomplished as a part of the validation course of.
Thereafter a 115-hour GloTherm accelerated dynamometer check was carried out to validate the engine sealing system (together with the cylinder head gasket) and sure structural engine elements by publicity to excessive thermal biking. And, lastly, a 150-hour GloSys check was carried out to guage the sturdiness and reliability of the engine below simulated buyer driving situations.
On the up to date 2.0L SiT/BiT engines a complete of 4 20-hour COP exams had been carried out, together with three 275-hour engine fatigue exams, and two 100-hour GloSys exams. Similarly, the Duratorq TDCi engines underwent three 20-hour COP exams and a 154-hour sturdiness check.
“The extensive and rigorous dynamometer tests are essential in validating the training of our employees, the application of the production processes and systems, as well as the performance and durability of the engines as part of our commitment to delivering world-class quality for our customers,” Govender says.
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