Dave,
Very interesting Q & A session and some interesting information:
Q: Better breathing with flat planes? (Strange question as to influence of the Flat Plane Crank (FPC) on the “intake” side? Should not have any effect. Pistons moving up/down in the bore have no idea if they are controlled by a FPC or a Cross Plane Crank (CPC). But it does have an influence on exhaust scavenging (two 4-cyl engines mated) and rotor dynamics. Just as Ford answered below.)
A: It’s the rotational inertia that it reduces and also from an exhaust standpoint because you’re going side to side, you’re never disturbing the next cylinder’s firing.
Q: This is a pretty big motor for a flat plane crank (big displacement). What have you done in terms of crankshaft damping? (This is a BIG deal and is a very significant accomplishment for Ford engineers. FPC utilization is mostly found on smaller displacement engines where managing the rotor dynamic loads caused by the FPC architecture is a little less challenging. To attempt utilization of a FPC in a large displacement engine without having the engine shake itself apart is a significant engineering achievement.)
A: There’s almost 30 things we did (outside the block) to compensate for it. It’s going to be a whole other story on how we did that.
Q: Challenges with emissions compliance with a flat plane crank?
A: It was harder than usual. (It would be interesting to hear why? Possibly the exhaust pulses of the CPC architecture help backpressure adjacent cylinders and assist in Exhaust Gas Recirculation (EGR) which you do not have in a more free exhaust breathing FPC design.)
Q: Tell us about the variable loading exhaust valve?
A: It’s got an electric valve. So the valve, depending on what driver mode you’re in, the valve will either be open all the time (track mode) or it will open under certain conditions. (Another interesting topic. Implied is removal of parasitic mechanical losses associated with the camshaft and lifters relegating that to electronics. And you can program any valve opening schedule you want with that type of system. But it is unclear why you would want to have the exhaust open “all the time”. Seems to defeat the premise of wanting high Break Mean Effective Pressure (BMEP) throughout the full Otto cycle. And may hurt emissions by allowing unburned air/fuel out the tailpipe.)
Q: How much were you able to share with the 5.0L?
A: There are little common parts (i.e. things in the valve train), but it’s pretty much an all-new engine: new heads, new casting, new intake, new crank, new pistons, new rods, new halfshafts. (So this is interesting- halfshafts. Increased engine weight by their inclusion but necessary for engine balancing because of the FPC. Parasitic losses associated with turning them perhaps offset by removing the losses associated with camshaft/lifer removal.)
Q: Is factory top speed software-limited?
A: No, it is drag-limited. (Good question and interesting response. Vehicle speed is easy to obtain and an often used data variable within the vehicle’s computer systems. Drag on the other hand is not an easy variable to calculate unless in a wind tunnel and varies by a square function of the car through air. Must be some reason to limit vehicle performance by drag over speed. Perhaps there is some aerodynamic instability at certain drag loads with particular atmospheric conditions that should be avoided...? Interesting limitation concept).
Thanks for posting the transcript!