Dr. Gizmo's Auto Blabber: 2012

Monday, December 31, 2012

Ford C-MAX Is the Fastest-Selling Hybrid Ever at Launch

Ford C-MAX has become the fastest-selling hybrid ever at launch, with 8,030 units sold in its first two months of sales in October and November, outpacing Toyota Camry Hybrid’s 7,300 sales in its first two full months in May and June 2006

C-MAX Hybrid and C-MAX Energi plug-in hybrid are selling three times faster than the combined launch sales of Toyota Prius and Honda Insight in 2000

Ford achieved its best electrified vehicle sales month ever in November with 7,157 units sold, with C-MAX Hybrid and C-MAX Energi plug-in hybrid outselling Prius v and Prius Plug-in combined by nearly 10 percent

Ford is projecting an all-time record quarter for hybrid sales at December close, with more than half of hybrid sales this year expected to come in the fourth quarter

DEARBORN, Mich. – Ford’s all-new C-MAX has become the fastest-selling hybrid ever at launch, with 8,030 sales in its first two full months on the market in October and November. This significantly outpaces Toyota Camry Hybrid’s 7,300 sales in its first two full months in May and June 2006.

C-MAX hybrids also are selling three times faster than the combined sales for the Toyota Prius and Honda Insight when launched in 2000.

Ford sold 8,999 C-MAX hybrids through November, a figure projected to surpass by 40 percent through December the combined Prius and Insight launch sales of 9,350 in 2000. C-MAX sales would represent four months compared to the initial combined 18 months of Prius and Insight sales.

“Dealers are seeing an overwhelmingly positive response to C-MAX hybrids and are excited to finally take on Prius, with some offering comparison test drives right on their lots,” says C.J. O’Donnell, group marketing manager, Electrification. “Our customers also are excited to have a fresh hybrid option, with leading fuel economy that does not sacrifice driving fun, performance and technology – choices typically not offered with hybrids.”

Ford achieved its best electrified vehicle sales month ever in November with a total of 7,157 sales, with C-MAX hybrids acting as the driving force behind the milestone. Ford is projecting an all-time record quarter for hybrid sales at December close. More than half of Ford’s hybrid sales this year are expected to come in the final quarter of the year as the company continues to ramp up production of Fusion Hybrid and Fusion Energi plug-in hybrid.

C-MAX hybrid sales totaled 4,848 in November, up 52 percent month-over-month. November marked the first month both C-MAX Hybrid and C-MAX Energi plug-in hybrid were available on dealer lots.

Fuel economy, hybrid demand grows

New vehicle buyers across the industry rate good fuel economy as the No. 1 purchase reason according to Ford research conducted by Maritz.

Consumer adoption of hybrid technologies has slowly grown over the last several years, but research shows 60 percent of today’s buyers are considering hybrid vehicles. And, for the first time ever, electrified vehicle sales captured nearly 4 percent of the total industry in November.

“Fuel economy has become the No. 1 purchase consideration as customers try to save money at the pump,” says O’Donnell. “C-MAX hybrids highlight Ford’s commitment to offer customers the power to choose leading fuel economy across our lineup.”

With the highest conquest rate in the Ford lineup at 64 percent, C-MAX hybrids continue to draw new customers to the Ford brand. Toyota Prius is the No. 1 competitive trade-in, followed by Honda CR-V – demonstrating early appeal with both hybrid buyers as well as more mainstream customers.

C-MAX Hybrid and C-MAX Energi plug-in hybrid comprise Ford’s first-ever dedicated hybrid range. C-MAX hybrids headline Ford’s transformed lineup, which features eight models with 40 mpg or more, building on the company’s commitment to give fuel-efficiency-minded customers the power of choice.

More information about C-MAX Hybrid and C-MAX Energi can be found here.

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About Ford Motor Company

Ford Motor Company, a global automotive industry leader based in Dearborn, Mich., manufactures or distributes automobiles across six continents. With about 172,000 employees and 65 plants worldwide, the company’s automotive brands include Ford and Lincoln. The company provides financial services through Ford Motor Credit Company. For more information regarding Ford and its products worldwide, please visit http://corporate.ford.com.

Recall Recap For The Week Of December 24 - 28, 2012

The National Highway Traffic Safety Administration has issued its recall recap for last week. Four recalls were issued.

To find out more about the recalls click on the NHTSA ID Number.

If your vehicle is affected please have it repaired as soon as possible. Repairs to correct issues covered by a recall are performed at no charge.

Happy New Year to all of you!

NHTSA Campaign ID Number :	12V598
Manufacturer :	Jerr-Dan Corporation
Make / Model Years :	JERR-DAN / 2009-2012
Subject :	Loose Mounting Hardware

NHTSA Campaign ID Number :	12V597
Manufacturer :	American Suzuki Motor Corp.
Make / Model Years :	SUZUKI / 2007
Subject :	Fuel Pump Module May Crack

NHTSA Campaign ID Number :	12V596
Manufacturer :	Airstream, Inc.
Make / Model Years :	AIRSTREAM / 2008-2013
Subject :	Sofa Components may Contact Electrical Components

NHTSA Campaign ID Number :	12V593
Manufacturer :	Thor Motor Coach
Make / Model Years :	CHAMPION / 2006,2008-2013 CHAMPION BUS / 2009-2013
Subject :	Wheelchair Lift Armored Cable Short Circuit

Thursday, December 27, 2012

Chevrolet Volt Owners Surpass 100 Million Electric Miles

5 million gallons of fuel saved; $1,300 a year in fuel costs avoided

DETROIT – Chevrolet Volt owners collectively have driven more than 100 million all-electric miles since the vehicle went on sale two years ago this month. The average Volt owner travels more than 65 percent of the time in pure electric mode as the car was designed – only using the gasoline-powered generator for longer trips.

By charging regularly, Volt owners drive approximately 900 miles, or a month and a half, between fill-ups. However, many Volt owners quickly exceed that average, based on an EPA-estimated 98 MPGe that puts electric-only range at 35 mpg city and 40 mpg on the highway. Andrew Byrne from Los Angeles is one of these drivers.

“Since my daily driving is all electric, I only really need to buy gas for long road trips,” Byrne said. “I drove over 1,900 miles on my last tank of gas.”

With each avoided trip to the gas station, Volt drivers continue to increase their return on investment. Based on EPA estimates and compared to the average new vehicle sold in the United States, Volt owners are saving about $1,370 a year in fuel costs.

“The best sign of a great product is when your customers are the most satisfied in the industry,” said Cristi Landy, Chevrolet Volt marketing director. “Volt owners have found the Volt is not only fun to drive, but provides technology and performance where consumers need it most.”

This is the second year in a row the Volt has topped the satisfaction survey of one of the leading consumer testing organizations in the United States.

“My commute is 55 miles round trip, but with the Volt I use 80 percent less gas and save over $150 each month,” said Farris Khan from southeastern Michigan. “Plus the Volt is really fun to drive because of its instant torque; driving anything else feels like yester-tech!”

For the typical driver, the average Volt savings equates to:

Nine weeks of groceries at $151 per week
228 car washes at $6 per car wash
137 movie tickets at $10 per ticket

The 5 million gallons of gas saved is equivalent to $21 million in gasoline costs averted overall based on $4 per gallon of premium, or more than two supertankers of gas.

For the first 38 miles, the Volt can drive gas and tailpipe-emissions free using a full charge of electricity stored in its 16.50-kWh lithium-ion battery. When the Volt’s battery runs low, a gas-powered engine/generator seamlessly operates to extend the driving range another 344 miles on a full tank.

Founded in 1911 in Detroit, Chevrolet is now one of the world's largest car brands, doing business in more than 140 countries and selling more than 4 million cars and trucks a year. Chevrolet provides customers with fuel-efficient vehicles that feature spirited performance, expressive design, and high quality. More information on Chevrolet models can be found at www.chevrolet.com.

Recalls Of The Day, December 27, 2012

The National Highway Traffic Safety Administration has issue two recalls. These could burn you, literally.

The first is for a vehicle with a faulty electrical cable. The second is for a sofa that has structures that could contact electrical components. Both issues could result in fire and toast your buns.

Vehicle Make / Model:		Model Year(s):
CHAMPION / AMERICAN CRUSADER		2009
CHAMPION / CHALLENGER		2006 2008-2013
CHAMPION / CRUSADER		2009-2011
CHAMPION BUS / DEFENDER		2009-2013
Manufacturer: Thor Motor Coach		Report Receipt Date: DEC 18, 2012
NHTSA CAMPAIGN ID Number: 12V593000		N/A NHTSA Action Number: N/A

Component: EQUIPMENT

Potential Number of Units Affected: 73

Summary:

Champion Bus is recalling certain model year 2006, and certain model year 2008-2013 buses, models: American Crusader, Challenger, Crusader, and Defender; manufactured September 30, 2006, through November 16, 2012. The buses are equipped with a Ricon manufactured wheelchair lift which has an optional armored pendant cable. The cable may have been installed such that it doesn't clear the wheelchair lift and without a protective cover, or a misinstalled protective cover.

Consequence:

The cable may contact the power lug at the base of the wheel chair lift causing a short circuit that could result in a fire.

Remedy:

Champion Bus is working with Ricon to notify owners. Ricon will provide a supplemental cover kit with instructions, free of charge. Owners may contact Champion Bus at 1-819-724-6474 or Ricon at 1-818-267-3000.

Notes:

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

Vehicle Make / Model:		Model Year(s):
AIRSTREAM / INTERSTATE		2008-2013
Manufacturer: Airstream, Inc.		Report Receipt Date: DEC 20, 2012
NHTSA CAMPAIGN ID Number: 12V596000		N/A NHTSA Action Number: N/A

Component: ELECTRICAL SYSTEM

Potential Number of Units Affected: 576

Summary:

Airstream is recalling certain model year 2008-2013 Interstate motorhomes manufactured August 2007, through December 2012 and equipped with the rear sofa floor plan. The electrical equipment underneath the sofa may come in contact with the seat belt buckle or metal cables from the seat.

Consequence:

If the metal sofa components come in contact with the electrical components, electrical arcing could occur. Arcing may lead to a vehicle fire.

Remedy:

Airstream will notify owners, and dealers will install a cover over the electrical components, free of charge. The recall is expected to begin by late January 2013. Owners may contact Airstream at 1-877-596-6111.

Notes:

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

Wednesday, December 26, 2012

Cadillac ATS Lightweighting Heavy on Chemistry

Periodic table helpful in understanding how the pounds came off

DETROIT – Engineers on the Cadillac ATS took a chemistry-lab approach to deliver the brand's first entry into the compact luxury sedan segment. Metals such as Martensitic alloys and ultra-high strength steel, among other materials, help make ATS one of the lightest vehicles in the class.

Still, the ATS is among the safest, earning a 5-star overall crash test rating in the New Car Assessment Program run by the National Highway Traffic Safety Administration.

Cadillac has been a leading luxury auto brand since 1902. In recent years, Cadillac has engineered a historic renaissance led by artful engineering and advanced technology. More information on Cadillac can be found at media.cadillac.com.

In Transit to 3D Printing Boom, Ford a Major Player in Digital Revolution

3D rapid prototyping enables Ford engineers to create workable parts right at their desks digitally – increasing global efficiency, greatly reducing development time and time to market, and saving cost

Ford is a leader in 3D printing, investing in efforts not only to enable engineers to create an entrepreneurial spirit through experimenting at their workstations, but also investing in one of the newest forms of 3D printing with sand to help develop production-representative parts

Manufacturing and desktop rapid prototyping converge as each Ford EcoBoost^® engine – now available in the upcoming Transit Van, all-new Fusion, 2014 Fiesta and full-size F-150 pickup – utilizes the technology to develop parts

DEARBORN, Mich. – In Ford’s Silicon Valley Lab, Dave Evans creates a custom vehicle gauge and emails the 3D design to Zac Nelson in Dearborn. Nelson uses the MakerBot^® Thing-O-Matic^™ at his workstation and prints up a physical prototype. The future of research and development is happening right here and now at the desks of these Ford engineers.

Click here to see Nelson, a Ford engineer in Research and Innovation, explain and use the MakerBot Thing-O-Matic at his workstation.

Just like laser printers today, expect 3D printers to be commonplace tomorrow. Engineers throughout the industry will have the ability to visualize a design on a computer screen and have the physical prototype show up at a colleague’s desk on the other side of the country in minutes. With this capability, the most qualified experts in each domain can make changes that feed into a tangible model. They can then share a 3D CAD design with the improvements.

“We’ve been shifting from the tangible world to the computer world, and the reality is that a hybrid model works best,” says K. Venkatesh Prasad, senior technical leader, Open Innovation, and a member of Ford’s Technology Advisory Board, Research and Innovation. “There is nothing like having a tangible prototype, but it has always been time consuming and expensive to create.

“Now, at the press of a button, you can have the product or component at your fingertips,” he adds. “With a model in one hand, you can then input your changes back into the computer model. The best decisions are made from the highest quality engineer and at the best pace.”

Currently thought of as a do-it-yourself tool for independent entrepreneurs and hobbyists, MakerBot enables users to design and produce products in various plastic materials. Ford is using this low-cost 3D printing in similar ways to other technology companies, mainly for small developments like shift knobs, gauges and display modules.

“We encourage our engineers to have the same entrepreneurial and creative spirit that started this movement,” says Prasad. “When we first got the machine, we made a scaled-down replica Model T and engineers have even made superheroes. We like that people are having fun with it and experimenting for it is that type of creativity that will lead to great uses and discoveries.”

Where we are now

Ford is using 3D printing in the manufacturing world, bridging the gap between abstract and practical.

Large industrial rapid prototyping machines have made significant gains in the manufacturing world, and Ford is fully invested in the latest commercial 3D printing innovations.

Recently, many of the components for the 3.5-liter EcoBoost^® engine in the all-new Transit Van were developed with the aid of 3D rapid manufacturing. Cast aluminum oil filtration adaptors, exhaust manifolds, differential carrier, brake rotors, oil pan, differential case casting and even rear axles were prototyped with the technology, specifically utilizing selective laser sintering, stereolithography and 3D sand casting.

Additionally, Ford is a leader in a new variation on this technology: 3D printing with sand allows for the creation of casting patterns and cores with multiple printers in-house.

The technology enables engineers to quickly create a series of evolving testable pieces with slight variations to develop the absolute best vehicle for mass production. This results in improved efficiency and time to market, reduced time spent waiting on iterations and increased cost savings.

Examples of 3D sand printing include:

C-MAX, Fusion Hybrid: Rotor supports, transmission cases, damper housings and end covers for the new HF35 hybrid transmission built at Van Dyke Transmission Plant in suburban Detroit
Escape: EcoBoost four-cylinder engines in the 2013 Escape built at Louisville Assembly Plant
Explorer: Brake rotors for the 2011 Explorer built in Chicago. The rotors were modified late in development to address a brake noise issue discovered in durability testing
F-150: Exhaust manifolds for the 3.5-liter EcoBoost built in Cleveland and used in F-150

Where this could lead

In the not-so-distant future, if a part breaks on your refrigerator, you may be able to scan the barcode or a model number, take the information to an in-home rapid manufacturing machine, and actually print up a useable replacement piece.

“Many have referenced this technology as ushering in a third industrial revolution,” says Harold Sears, Ford additive manufacturing technical specialist. “While that is yet to be determined, we do know manufacturing is continuing to go digital, the speed of these technologies is increasing, and the variety of materials is expanding. This all leads us to believe the potential of micro-manufacturing presents great opportunity for the manufacturing industry overall.”