Ford Otosan New Powertrain Test Facility - Part 1: Design & Construction of Engine Emission Development Cells

Ford Otosan the New Powertrain Test Facility project was started as an extension of existing Engine Test Facility in order to cover extra capacity requirement for future Euro 6 emission development programs. Adjacent vehicle workshop was utilized to build new test cells due to space unavailability in neighboring area of the existing facility with four engine test cells. With first phase of the construction, six new multipurpose dynamometer test cells and infrastructure for a 4×2 Powertrain NVH test cell was completed. Lean facility operating concepts were applied in facility design process to improve testing flexibility and efficiency, while minimizing investment costs at the same time. The new test automation systems were equipped with Real-Time testing tools enabling utilization of in-house built engine models in calibration development process. This paper provides a description of the new facilities and an overview of the issues associated with converting an existing building to a functional facility enabling realization of corporate efficiency & utilization objectives.