Forum at Transilvania University of Brasov

01 November 2011
Brasov (Romania)

Inside Ferrari:
scouting the engineering motivation of
a very successful story

DE
ETC

Giovanni Cipolla
DECET (Torino, Italy)
Development
Engineering
Consulting
for Energy
in Torino

Past GT Powertrain Director

Ferrari (Maranello, Italy)

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 dellAutomobile)

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

G. Cipolla - DECET

26 maggio 2011

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

DE
ETC

Virtual visit of Ferrari Gallery

GeS & GT stories strongly connected

GeS the R&D for GT

All Ferrari engines (1947/2002)

In 55 years

V12
V10
V8
L6/4
R&S

36 +
7+
20 +
7+
11 =
-------81 engines

i.e. 1 engine every 8 months !!!

575
Maranello

2001

The V12 Ferrari

Engines
1995

F50

TESTAROSSA

1984

1976

512 BB

1969

365 GTB4 DAYTONA

1956

1947

410 SUPER AMERICA

125 S
8

The V12 Ferrari

Engines

125 S

(1947)

1496,77 cm3
100 CV @7000 rpm

The V12 Ferrari

Engines

410 SUPER (1956)

AMERICA

4961,57 cm3
340 CV @6500 rpm

10

The V12 Ferrari

Engines

365 GTB4
DAYTONA

(1969)

4390,35 cm3
352 CV @7500 rpm

11

The V12 Ferrari

Engines

512 BB

(1976)

4942,10 cm3
340 CV @ 6800 rpm
12

The V12 Ferrari

Engines

TESTAROSSA (1984)

4943 ,04 cm3

385 CV @ 6800 rpm
13

The V12 Ferrari

Engines

F50

(1995)

4699.2 cm3
520 CV @ 8500 rpm

14

The V12 Ferrari

Engines

575 Maranello

(2001)

V 12 65 5749 cm3
515 CV @ 7250 rpm
600 Nm @ 5250 rpm
15

The V8 Ferrari
Engines

360
Modena

2001

1994

355 Spider

1989

348 TS

F40

1987

1982

1974

308 4V

Dino 308 GT4

16

The V8 Ferrari
Engines

DINO 308 GT4

(1974)

2926,90 cm3
250 CV @ 7700 rpm

17

The V8 Ferrari
Engines
308 4V

(1982)

2926,90 cm3
235 CV @ 7600 rpm

18

The V8 Ferrari
Engines

F 40

(1987)

2936 cm3
478 CV @ 7000 rpm

19

The V8 Ferrari
Engines
348 TS

(1989)

3404,70 cm3
300 CV @ 7500 rpm

20

The V8 Ferrari
Engines
F 355 Spider

(1994)

3495,50 cm3
380 CV @ 8500 rpm

21

The V8 Ferrari
Engines
360 Modena

(1994)

8V 90 3586 cm3
400 CV @ 8500 rpm
373 Nm @ 4750 rpm
22

Physic Laws & Basic Mechanics ...

... are independent from Engine Pedigree !
cS kRT

F ma

pv RT
i 1

M l
I

k 1

id 2 3 2

pme V n
N
J T

23

Drivers for a FERRARI car client choice

Technology as a Premium asset!
PERFORMANCE

Racer
Colt
COMFORT

MISSION

A must
Important

HP car
owners

Marginal

Utility

Optional

Niche

Relevant
Decision
COST FOR Issue

Pusher

Hobby

Serial

Mass
Utility

CUSTOMER

Salesman
MILEAGE

Fun to
Sport drive

PRODUCTION
VOLUMES

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
GT: 365 GT4 BB (1973)
GeS: 512 F1 (1964)

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
GT: 208 GTB Turbo (1982)

GeS: 126 CK (1980)

30

Innovation Transfer from GeS to GT:

DRY SUMP
GT: F40 (1987)
GeS: 126 CK (1980)

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

the technology

126 CK Comprex (1980)

CX

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

HPEs development:
Evolution not Revolution
Performance

(Cv/lt)

Weight

(Kg/CV)

100

0.9

75
0.6

50
0.3

125S-1947

TR-1984

Enzo-2002

125S-1947

Piston velocity (m/s)

(rev/s) Rot.Speed

TR-1984

Spec.Displacement

Enzo-2002

Compression Ratio

(lt)

10

0.5

7.5
8000

20

7000
15

6000

5
0.25

10
0.125

125S-1947

TR-1984

Enzo-2002

125S-1947

TR-1984

Enzo-2002

42

Sump Volume Reduction Trend

in Ferrari Engines Design

157
mm

115
mm

129
mm

Ferrari V12

Ferrari V8

(575 Maranello)

(360 Modena)

* LOWEST OIL SUMP INTERNAL LEVEL

Maserati V8
(Coup, Spyder, Quattroporte)

&
Ferrari V8

(430 Modena)43

The Evolution Criteria

in Ferrari Engines Development
V12
Engine

Configuration

Valvetrain

Single Camshaft &

Rocker Arm

Double Camshaft &

Mech. Followers

Double Camshaft
HLA & VVT

Fuelling

Multibody Carburettor

Mechanical PFI

Electronic PFI

Control

Mech Throttle
& Ignitor

Throttle Body &

Mech Injectors

Drive-by-Wire &
Electronic Injection
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

GT vehicles assembly
GT testing & Logistics

GeS mechanical production

GeS composites production

Comune di Maranello:
Total area :
Covered area:
Future availability:
Comune di Fiorano:
Total area :
Covered area:

m2 264.931
m2 133.568
m2 72.774
m2 245.800
m2 4.163

GT engines assembly

Light alloy foundry

GeS wind tunnel

Ecologic area
GT mechanical production

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

V12 Fx engine block

Plant view

V8 engine crankshaft

49

V8 engine cylinder head

V12 engine crankshaft

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 ?