Ford begins production of hydrogen internal combustion engine
Ford will become the first automaker to sell a hydrogen internal combustion engine when it begins deliveries of its E-450 shuttle buses later this year. Unlike a hydrogen fuel cell -- which provides power to an electric motor -- the hydrogen combustion engine burns hydrogen in the same manner a conventional gasoline engine. Production of the 6.8-liter V10 engine began today, the automaker said. "This engine represents a significant milestone in Ford's research efforts in hydrogen technology," said Dr. Gerhard Schmidt, vice president, Research & Advanced Engineering, Ford Motor Company. "We have learned a great deal about hydrogen powered internal combustion engines during the development phase of this engine."
Ford's 6.8-liter V-10 engine is specially prepared to burn hydrogen as a fuel but is based on the same modular engine series that powers many Ford vehicles. It produces 235 horsepower at 4000 rpm and 310 lb-ft of torque at 3000 rpm. Redline is 5000 rpm.
Hydrogen fueled internal combustion engines have many advantages including high efficiency, all-weather capability, and near zero emissions of regulated pollutants and greenhouse gases (CO 2). They can also be easily hybridized for further gains in fuel efficiency.
While the hydrogen internal combustion engine shuttle buses will provide valuable real-world experience, Ford is also conducting research into next generation hydrogen internal combustion engines, including features such as direct injection to enhance power and fuel economy. "We have only scratched the surface in terms of what can be achieved with hydrogen internal combustion engine technology and are serious about maintaining our edge in this field," said Vance Zanardelli, chief engineer, Hydrogen Internal Combustion Engines, Ford Motor Company.
Ford's hydrogen internal combustion engine is much more than just a converted production engine. This 6.8-liter V-10 engine is specially prepared to burn hydrogen as a fuel but is based on the same modular engine series that powers many Ford products. Significant efforts were made to optimize this engine for hydrogen fuel to achieve maximum efficiency and robust durability in the customer's hands.
Prior to production, more than 7,000 hours of development and testing was performed on engine dynamometers to ensure optimum durability and performance when vehicles reach customers later this year. The engine development process replicated the same stringent durability standards applied to other Ford engines.
Specialized components in the engine include:
- Valves and valve seats - special hardened materials are used to compensate for hydrogen's reduced lubricating properties compared to gasoline or natural gas
- Spark plugs - Iridium tipped plugs allow for increased spark plug life
- Ignition coils - high energy coil-on-plug coils, to manage unique ignition characteristics
- Fuel injectors and fuel rail - Fuel injectors designed specifically for hydrogen and high volume fuel rails
- Crank damper - tuned for hydrogen fuel to ensure smooth operation
- Pistons, connecting rods and piston rings - high output designs to accommodate the higher combustion pressure of hydrogen combustion
- Head gasket - accommodates increased combustion chamber pressures
- Intake manifold - all-new to accommodate twin screw supercharger and water-to-air intercooler
- Twin screw supercharger and water-to-air intercooler - added to improve power output and maximize efficiency
- Engine oil - full-synthetic formulation developed in partnership with BP/Castrol optimized for hydrogen combustion properties