Inside Ferrari: scouting the engineering motivation of

a very successful story

Giovanni Cipolla DECET (Torino, Italy)

Past GT Powertrain Director

Ferrari (Maranello, Italy)

D E E C T

Development

Engineering

Consulting

for Energy

in Torino

Forum at Transilvania University of Brasov

01 November 2011

Brasov (Romania)

26 maggio 2011 2 G. Cipolla - DECET

SHORT CURRICULUM VITAE

Giovanni CIPOLLA

1947 born in Torino-Italy

1971 graduated in Mechanical and Automotive Engineering at Politecnico di Torino

1972 at FIAT Research Centre in Orbassano (Turin), where he was involved in several engine

R&D programs and finally managed the Racing Engines Research Center

1994 at Elasis in Pomigliano (Naples), as Powertrain Director of the R&D Center

1998 at Ferrari in Maranello (Modena), as Powertrain Director of the GT Division

2004 at FIAT-GM Powertrain joint venture (Turin), as Advanced Engineering Director

2005 at GM Powertrain Europe, at start-up as Diesel Engines Director & afterwords

as Advanced Engineering Director & Site Manager AE Italy

2010 at GM Diesel Hybrid Center (Torino) as Chief Technical Officer (CTO) & Engineering Director

2011 at PoliTo (Torino) as GM-PoliTo IARE (Institute for Automotive Research & Education ) Director &

Alternative Propulsion System professor

1996 vice president of ATA (Associazione Tecnica dell’Automobile)

2007 member of PTNSS ((Polish Scientific Society of Combustion Engines)

2008 co-founder & member of SAE Torino (Society of Automotive Engineering, SAE International)

2003 Honorary Professor at Zwickau University (Germany) for Advanced Powertrain Concepts

Summary

Virtual visit of Ferrari Gallery

Ferrari engines Story book

Engineering peculiarities

Innovation Transfer from GeS to GT

R&D supporting actvity at prototype level

ICE development: “Evolution”, not “Revolution”

HighTech Production

Lessons learned during the visit

D E E C T 3

Virtual visit of Ferrari Gallery …

GeS & GT stories strongly connected

“GeS the R&D for GT”

5

6

“All” Ferrari engines (1947/2002)

In 55 years…

V12 36 +

V10 7 +

V8 20 +

L6/4 7 +

R&S 11 =

--------

81 engines

…i.e. 1 engine every 8 months !!!

7

1984

1956

1947

1976

1969

125 S

410 SUPER AMERICA

365 GTB4 DAYTONA

512 BB

TESTAROSSA

1995 F50

575

Maranello 2001 The V12 Ferrari

Engines

8

(1947) 125 S

1496,77 cm3

100 CV @7000 rpm

The V12 Ferrari

Engines

9

410 SUPER

AMERICA (1956)

4961,57 cm3

340 CV @6500 rpm

The V12 Ferrari

Engines

10

365 GTB4

DAYTONA (1969)

4390,35 cm3

352 CV @7500 rpm

The V12 Ferrari

Engines

11

(1976) 512 BB

4942,10 cm3

340 CV @ 6800 rpm

The V12 Ferrari

Engines

12

TESTAROSSA (1984)

4943 ,04 cm3

385 CV @ 6800 rpm

The V12 Ferrari

Engines

13

F50 (1995)

4699.2 cm3

520 CV @ 8500 rpm

The V12 Ferrari

Engines

14

575 Maranello (2001)

The V12 Ferrari

Engines

V 12 65° 5749 cm3 515 CV @ 7250 rpm

600 Nm @ 5250 rpm

15

1994

1989

1982

1974

355 Spider

Dino 308 GT4

348 TS

308 4V

1987 F40

360

Modena 2001 The V8 Ferrari

Engines

16

(1974) DINO 308 GT4

2926,90 cm3

250 CV @ 7700 rpm

The V8 Ferrari

Engines

17

(1982) 308 4V

2926,90 cm3

235 CV @ 7600 rpm

The V8 Ferrari

Engines

18

(1987) F 40

2936 cm3

478 CV @ 7000 rpm

The V8 Ferrari

Engines

19

(1989) 348 TS

3404,70 cm3

300 CV @ 7500 rpm

The V8 Ferrari

Engines

20

(1994) F 355 Spider

3495,50 cm3

380 CV @ 8500 rpm

The V8 Ferrari

Engines

21

(1994)

The V8 Ferrari

Engines

360 Modena

8V 90° 3586 cm3 400 CV @ 8500 rpm

373 Nm @ 4750 rpm

22

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11

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Physic Laws & Basic Mechanics ...

... are independent from “Engine Pedigree” !

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23

MILEAGE

PERFORMANCE

COST FOR

CUSTOMER

PRODUCTION

VOLUMES

MISSION COMFORT

Drivers for a FERRARI car client choice …

Sport

Utility

Fun to

drive

Colt

Pusher

Racer

Salesman

Utility

Hobby

Mass

Serial

Niche

A must Important

Marginal

Decision

Issue

Relevant

Optional

HP car

owners

… Technology as a Premium asset!

24

Innovation Transfer from GeS to GT:

HIGH REVs

GeS: 125S (1947) GT: 166 Inter (1948)

25

Innovation Transfer from GeS to GT:

V12 BOXER

GeS: 512 F1 (1964)

GT: 365 GT4 BB (1973)

26

Innovation Transfer from GeS to GT:

STRUCTURAL POWERTRAIN

GeS: 158 (1964) GT: F50 (1995)

27

Innovation Transfer from GeS to GT:

MECHANICAL INJECTION

GeS: 330 P4 (1967) GT: 308 GTBi (1980)

28

Innovation Transfer from GeS to GT:

TRANSVERSAL GEARBOX

GeS: 312 T3 (1978) GT: 348 TB (1989)

29

Innovation Transfer from GeS to GT:

TURBO

GeS: 126 CK (1980) GT: 208 GTB Turbo (1982)

30

Innovation Transfer from GeS to GT:

DRY SUMP

GeS: 126 CK (1980)

GT: F40 (1987)

31

Innovation Transfer from GeS to GT:

ELECTRONIC INJECTION

GeS: 156-85 (1985) GT: 348 TB (1989)

32

Innovation Transfer from GeS to GT:

the ROBOTIZED GEARBOX

GeS: F1-89 (1989) GT: 355 GTS (1997)

33

Innovation Transfer from GeS to GT:

VARIABLE INTAKE MANIFOLD

GeS: 412 T1 (1994) GT: 140-Fx (2002)

34

R&D supporting actvity at prototype level:

MECHANICAL DIRECT INJECTION

158 F1 (1964)

the technology

35

R&D supporting actvity at prototype level:

W-18cyl ICE

P3C (1967)

the technology

36

R&D supporting actvity at prototype level:

WAVES CHARGING

126 CK Comprex (1980)

CX

the technology

37

R&D supporting actvity at prototype level:

GEARED VALVETRAIN

033E (1987)

the technology

38

R&D supporting actvity at prototype level:

ELECTRO-HYDRAULIC VVA

F1-89 (1989)

the technology

39

R&D supporting actvity at prototype level:

TWO STROKE ENGINE

F134 (1994)

the technology

40

R&D supporting actvity at prototype level:

DOUBLE-V CRANKSHAFT

F135A (1994)

the technology

41

HPE’s development:

“Evolution” not “Revolution”

Rot.Speed (rev/s)

125S-1947 Enzo-2002 TR-1984

6000

7000

8000

Compression Ratio

10

5

7.5

Piston velocity (m/s)

10

20

15

125S-1947 Enzo-2002 TR-1984

Spec.Displacement (lt)

0.25

0.5

0.125

125S-1947 Enzo-2002 TR-1984

100

50

75

Performance (Cv/lt)

125S-1947 Enzo-2002 TR-1984

Weight (Kg/CV)

0.3

0.6

0.9

42

Sump Volume Reduction Trend

in Ferrari Engines Design

Ferrari V12 (575 Maranello)

Ferrari V8 (360 Modena)

Maserati V8 (Coupè, Spyder, Quattroporte)

&

Ferrari V8 (430 Modena)

157

mm 129

mm

115

mm

* LOWEST OIL SUMP INTERNAL LEVEL 43

The Evolution Criteria

in Ferrari Engines Development

V12

Engine

Configuration

Valvetrain

Fuelling

Control Mech Throttle

& Ignitor

Throttle Body &

Mech Injectors

Drive-by-Wire &

Electronic Injection

Multibody Carburettor Mechanical PFI Electronic PFI

Single Camshaft &

Rocker Arm

Double Camshaft &

Mech. Followers Double Camshaft

HLA & VVT

44

The New Ferrari Engines Family…

with common

DESIGN

solutions…

… but with brand specific features & feeling

45

Ferrari GeS & GT location in Maranello

GeS dept.

Fiorano proving ground

GT Body painting

Light alloy foundry

GT mechanical production

GeS mechanical production

GeS composites production

GeS wind tunnel

GT vehicles assembly

Ecologic area

Comune di Maranello: Total area : m2 264.931 Covered area: m2 133.568 Future availability: m2 72.774 Comune di Fiorano: Total area : m2 245.800 Covered area: m2 4.163

GT testing & Logistics

GT engines assembly

46

Ferrari light alloy foundry in Maranello

V8 engine block

Chassis component Foundry overview 47

Tomographic inspection of defects

in Ferrari foundry

48

Ferrari mechanical workshop in Maranello

Plant view

V12 Fx engine block

V8 engine cylinder head

V8 engine crankshaft

V12 engine crankshaft 49

Ferrari engines assembly & testing in Maranello

“short-block” assembly line Powertrain installation in vehicle

EoL engines testing facility Engine test rig

50

FERRARI cars are a “niche” product …

… for “exclusive” use “object of desire” &

51

…& “key ingredients” for ENGINE development !

Skill & … Passion

52

In other words, the Ferrari receipt is…

a “strong & motivated” team …

with “right competence” people …

… in “right responsability” position ! 53

… did you enjoy the virtual visit

of Ferrari Gallery ?