DEARBORN/COLOGNE - Day to day researchers, scientists and engineers are hard at work brainstorming ideas to help Ford Motor Company stay on top with cutting-edge technologies.
These innovation leaders have been recognized for their achievements in developing the best and brightest innovations at the 2011 Henry Ford Technology Awards. The North American ceremony was held in Dearborn, while the European awards were presented at a ceremony in Cologne.
Allan Mulally, president and CEO, said these awards are significant because they follow Henry Ford's dream to "open the highways for all mankind."
"It really is about celebrating innovation – one innovation after another that helps make lives easier," said Mulally.
The Henry Ford Technology Award program was established to celebrate the exceptional technical contributions of Ford employees globally. Each year, recipients of this prestigious award are recognised for their ground-breaking developments that help pave the way in the automotive industry.
Easing the way are developments like the Compact Hybrid Paint System - the world's most compressed paint application system - FG2: Global Front Seat Structure Architecture - Ford's first global in-house engineered front seat structure architecture - Curve Control - the new vehicle stability control system – and the development and integration of CO2 Glide Paths – a scientific foundation for reaching future corporate sustainability targets. These are just a few examples that were honoured at the award ceremonies.
"Innovation is the heart of our company," said Paul Mascarenas, vice president, Ford Research and Innovation. "It's what we do. The Henry Ford Technology Award is really important for us. It's the highest, most prestigious technical award we have in Ford.”
Awards were presented for innovations in the areas of manufacturing, product development and research. Below is a brief summary of each award and its team members.
The development and integration of CO2 Glide Paths: A Scientific Foundation for Corporate Sustainability Targets
David Chock – Retired Senior Technical Leader, Ford R&A; Timothy Wallington – Technical Leader, Ford R&A; Sandra Winkler – Senior Researcher in R&A, Heiko Maas - Research Engineer. Ford R&A, Heinz Hass - Manager, Ford R&A
A model for CO2 and associated future glide paths has been developed providing the gCO2/km requirements for new vehicles in NA, SA, EU, and China over the period from 2010 - 2050, consistent with stabilization of CO2 at 450 ppm in the Earth's atmosphere used in our Ford sustainability plan
The development and implementation of Mash Seam Welded Blanks 3
Team members: Hubert Adamietz, Alfred Czogalla, Gerd Frehsdorf, Achim Hecht and Norbert Kühne
A process has been developed and implemented which uses mash seam welded technology for blanks where the established blanking facilities fail to deliver high material utilisation. With steel raw material costs rising, the project is helping to achieve material utilisation and cost savings targets.
The development and implementation of Platinum/Palladium Alloy Catalysts on Stage IV non-DPF Applications
Mark Brogan – Aftertreatment Supervisor, Ford of Europe
This innovation substitutes palladium for some of the platinum loading on alloy catalysts. Prior to this work all Ford diesel vehicles had catalysts where the only active metal was platinum, as palladium was thought not to have been durable throughout the useful life of a vehicle. In 2007, platinum was roughly three times the cost of palladium, so this development has allowed significant cost savings to be achieved; Ford of Europe has saved at least $200 million since 2007.
Development and implementation of the Compact Hybrid Paint System
Team members: Gerald Berger – Technical Specialist, Paint Robotics, VOME; Salvador Burgara – Application Process Unit Manager, Mexico; Richard J. Burt – Supervisor of Paint Planning Section, VOME; Aaron M. Fiala – Technical Specialist, Paint Application, VOME; Dennis L.Havlin – Technical Specialist, Paint Materials, VOME
The Compact Hybrid Paint System is the world's most compressed paint application system. It was developed by utilizing a compressed booth design with an, innovative utilization of automation application, and leveraging the materials developed for Ford's 3 Wet System.
The development and implementation of the Springback CAE for Advanced High Strength Steels
Team members: Laurent Chappuis – Technical Expert, Lightweight Stampings; Jizhou Chen – Stamping Engineer, Ford Stamping Activity; Nand Kochhar – Executive Technical Leader, Global CAE and Chief Engineer, Global Materials Engineering & Standards; Cedric Xia – Technical Leader, Global Materials CAE, Ford R&A; Danielle Zeng – Research Engineer, Ford R&A
Springback Computer Aided Engineering for Advanced High Strength Steels is a suite of computerized tools, methods and material test processes that provide accurate predictions of material “springback”. Stamping Engineering has used this modeling suite since 2009, significantly reducing die re-cuts on the C346, U502, C520, C344 programs, plus many others.
The development and implementation of Innovative Vibration Testing on Production Test Systems
Team members: Gino Catenacci – NVH Test Engineer, Warranty & Test Garage Supervisor, Axle Manufacturing; Douglas Grimes – Technical Expert, NVH Transmission Test, Powertrain Operations; Flynn McCabe – RDU Lead Test Engineer for P473, Powertrain Operations; Matthew Sroka – Master Black Belt, Axle Manufacturing
This is an industry-first measurement technology that was developed, validated and implemented for in-process axle measurement of Pitch Line Run-Out (PLRO) and Transmission Error (TE), using torsional vibration sensors.
Development of Collision Mitigation Support 1.0 Plus
Team members: Christopher Nave – Development Engineer, Ford R&A; Rebecca Seiler – Research Engineer, Ford R&A; David Smit – Research Engineer, Ford R&A; Roger Trombley – Algorithm Developer for Ford R&A; Andrew Waldis – Computer Applications Engineer, Ford R&A
Collision Mitigation Support 1.0 Plus is the first radar-only collision mitigation system on a high-volume brand that is compliant with the National Highway Transportation Safety Administration's MY2011 Forward Collision Warning rules and regulations. The technology includes driver warning and autonomous braking for moving and stationary vehicles.
The development, integration and launch of the Mega-Knock Detection and Mitigation Strategy
Team members: Robert Baskins – Ignition Subsystem & Feature Engineer; Kelvin Dobbins – Technical Specialist, Engine Controls, Ford R&A; Christopher Glugla – Controls Technical Expert, Ford R&A; James Kindree – PT Calibration Technical Expert, PCCN; Christopher Weber – Product Development Supervisor
Mega-Knock is an innovative remedy (and industry first for full size trucks) for an objectionable NVH and component damaging knock that may occur when an EcoBoost engine runs on regular fuel at high load. It is an essential part of our EcoBoost engine control strategy.
The development and implementation of Curve Control
Team members: Daniel Eisele – Algorithm Engineer in NAE Brake Control; Moses Fridman – Supervisor, Chassis Controls; Scott Gridley – Brake Controls Development Engineer; David Messih – Senior Engineer in PD; Albert Salib – Brake Software Engineer in PD
Curve Control is a new vehicle stability control system. First implemented on the MY11 Ford Explorer, it will rapidly reduce vehicle speed by reducing engine torque and applying differential braking when a curve is taken too fast.
The development of the FG2: Global Front Seat Structure Architecture
Majid Arefi – Structure Engineer for Seating in PD; Khaled Ayyash – Seat Structure Supervisor for PD Seating; Shawn Dixon – Structures Engineer, PD Seating; Johnathan Line – Technical Specialist, PD Seat Systems; Michael Medoro –Seat Structures Engineer, PD
This is Ford's first global in-house engineered front seat structure architecture. It delivers on average $19 / vehicle price reduction and 10 lbs / vehicle mass reduction vs. outgoing structures. FG2 structure will be migrated to over 4 million vehicles by 2016.
The development of Powershift Hill Launch Control Using a Zero-Prototype, VIRTTEX-Based Environment
Team members: Michael Blommer – Technical Leader, VIRTTEX; Ronald Boudia – Product Development Engineer; Michael Fodor – Technical Expert; Gregory M. Pietron – Technical Expert; Eric Tseng – Technical Leader
This is a simulation system and powertrain strategy that allow the optimization between launch feel, clutch protection, and driver feedback are developed to enable Ford as the first OEM to bring Dry-clutch PowerShift (DPS) to North America.
An additional award, The President's Technology Award, was given to recognize a diverse cross-functional team for the following technology:
Institutionalization and production launch of Smart Inventory Management System (SIMS)
Team members:John Bradley – Ford & Lincoln Dealers; Adam Haas – Information Technology; Linda Jakubowski – Marketing Sales and Service; Gint Puskorius – Research and Advanced Engineering
SIMS is a business process technology that is used to recommend orders for dealers to re-stock inventory. Successful development, implementation and deployment was realized through the cross-functional efforts of MS&S, IT, R&A and the Dealer Network.