• + VNT™ DualBoost provides twin-turbo performance in single turbo package
  • + Honeywell innovation helps Ford’s Power Stroke engine lead the way in performance and emissions reduction

World’s First Dual Compressor Turbo

Posted 04.08.2011

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It’s the cleanest and most fuel-efficient Power Stroke engine ever – but still provides class-leading performance and increased levels of refinement. With class-leading power rated at 400hp and 800lb-ft of torque, the Ford F350 Super Duty embodies North America’s love affair with medium-duty trucks, a segment where performance reigns supreme. Yet the new Super Duty’s Power Stroke engine achieves this while boosting fuel economy by 20% (according to Ford) and meeting emissions standards that mandated an 80% reduction in NOx. It’s no wonder Ward’s Auto magazine considers the 2011 model Super Duty to be “arguably the finest heavy-duty pickup diesel of the modern era.”

World’s First Dual Compressor TurboThe new 6.7 liter V8 diesel engine is also Ford’s most advanced Power Stroke yet, bristling with innovations and boosted by one of the most significant turbocharger breakthroughs in a generation – Honeywell’s VNT™ DualBoost turbo. The heart of the turbo’s many innovations is a dual-sided compressor wheel that delivers twin turbo performance in a single turbo package.

For its new Power Stroke program, Ford had a number of challenging goals: improving engine performance, lifting fuel economy, minimizing NVH (noise vibration harshness)—all while cutting NOx and PM emissions. To meet these targets, Ford reversed the conventional intake and exhaust flow through the cylinder heads, with the exhaust gas exiting inboard directly to the turbo.

The engine design led to some creative thinking on the part of Honeywell engineers, who came up with a winning turbo solution that covers a wide operating range, yet still fits between the banks of the V engine. Befitting Ford’s innovative engine design, Honeywell pursued the industry’s first dual-sided compressor wheel to get the performance needed in a smaller package. The unique configuration not only succeeds in driving EGR at low engine speeds, it does so while enhancing throttle response and contributing to fuel efficiency.

The contribution made by VNT DualBoost is aided by several Honeywell design innovations, including a ball bearing system that reduces mechanical loss and improves responsiveness and fuel economy; a wastegate-on-VNT bypass valve that allows a high power point; and a pedestal mounting that reduces NVH (Noise, Vibration & Harshness) to best-in-class levels.

DualBoost TurbochargerFord’s journey to the new Power Stroke began when the company established a dedicated center of engineering excellence specifically for this program. Honeywell was engaged from the outset, providing a multi-disciplined team of engineering and manufacturing experts. Once design qualification had been achieved, Honeywell undertook detailed process and capacity planning to meet delivery commitments to Ford.

“VNT DualBoost is helping Ford’s new Power Stroke engine set new standards in performance and refinement for medium-duty trucks,” says Steve McKinley, Americas VP of Engineering at Honeywell Turbo Technologies. “But its application goes far beyond the pick-up truck segment as this technology can be applied to any gas or diesel engine with requirements approaching dual turbo performance, but can benefit from the size and efficiency of a single unit.”