General Motors Company · NYSE:GM
General Motors — Technical Presentation (October 2012)
52 slides from General Motors's technical presentation, Oct 24, 2012
Slide 1: New Corvette Engine
LL-7/ media.gm.com/newcorvetteengine
Slide 2: Tadge Juechter, Executive Chief Engineer, Corvette
Tadge Juechter Executive Chief Engineer Corvette
Slide 3: The Small Block
eee The Small Block... , ae a Made high-performance attainable toa whole new generation of customers m Ushered in a new age of engine design and manufacturing m Helped make Chevrolet a formidable force in motorsports
Slide 4: Corvette and Small Block
Corvette and Small Block Corvette Production Cars = Corvette powered by Small Block for 57 years a Small Block power and performance are synonymous with Corvette Corvette Racing a Corvette won its first race at LeMans with a Small Block in 1960 = Corvette won its seventh championship at LeMans in 20
Slide 5: All-new Corvette Engine
All-new Corvette Engine Started by Asking What Do We Want in a Performance Car Engine = Compact a Lightweight = Powerful a Efficient = Durable = Best solution had all of these attributes v4
Slide 6: Corvette Frequently Asked Questions
—————EeeeEOEOeeeTTeteMe Corvette Frequently Asked Questions a Willitbea5.5L? a Will itbea Twin Turbo V6?
Slide 7: All-new Corvette LT1
All-new Corvette LT1 6.2L V8 with Next-gen Technologies a Corvette is lightweight, aerodynamic... makes it a great candidate for fuel-saving technologies a LT1is more powerful, more responsive, and more efficient than smaller displacement V8 u LT1is faster, more responsive, and more efficient than a
Slide 8: New LT1 is a Perfect Choice for Corvette
All-new Corvette LT1 New LT1 is a Perfect Choice for Corvette u LT1engine is 99.9% new, engineered to deliver * Tons of power and torque * Compact size * Lightweight * Fuel efficient
Slide 9: The New Corvette LT1 Objective
——————————————"— The New Corvette LT1 Objective: Improve performance, with 0-60 in under 4 seconds Improve efficiency, to make one of the most fuel efficient 450 hp vehicles you can buy nd 477
Slide 10: Jordan Lee, Chief Engineer and Program Manager
Lr y Jordan Lee Chief Engineer and Program Manager Small Block Engines
Slide 11: LT1 6.2L V8 Engine Program Objectives
LT1 6.2L V8 Engine Program Objectives Take a Great Engine and Make it Better High performance engine for Corvette Optimize performance and efficiency Extremely compact engine size — low mass, low hoodline, better driver visibility LT1 is a purpose-built high performance engine = Allnew Gen 5 engine
Slide 12: LT1 6.2L V8 Engine Program Objectives
LT1 6.2L V8 Engine Program Objectives Take a Great Engine and Make it Better The LT1 was engineered to be best in class in many categories a Incorporate Next-Gen technologies that improve performance and efficiency = Avery high performance and fuel efficient engine = Maintain an extremely compact an
Slide 13: Unprecedented Technology Combination
——————— LT1 Unprecedented Technology Combination = Direct injection = Active Fuel Management = Continuously variable valve timing = Radically new combustion system with 11.5:1 compression ratio = Resulting in greater performance, efficiency and refinement in an extremely compact engine size nd 47y
Slide 14: LT1 Overall Results
LT1 Overall Results Best Power, Torque, Acceleration and Fuel Economy Ever for Standard Corvette Preliminary 450 horsepower Preliminary 450 lb-ft torque 0-60 in under 4.0 seconds More than 26 mpg 47d
Slide 15: LT1 vs. BMW: Power Density
—————EeeeEOEOeeeTTeteMe LT1 vs. BMW Power Density BMW 4.4L Twin Turbo (5 Series, base V8 engine) LT16.2L V8 preliminary 450 hp / preliminary 450 lb-ft torque 400 hp / 450 Ib-ft torque mass = 465 pounds (211 kg) mass = 503 pounds (228 kg) WF (source: BMW technical paper) 477
Slide 16: LT1 vs. BMW: Packaging Efficiency
mT LT1 vs. BMW Packaging Efficiency Base Engine Comparison GRAY IS THE SIZE OF BMW ENGINE (BMW dimensional data from BMW technical design paper published in MTZ 11/2008 Volume 69) 7 477
Slide 17: Corvette LT1 Efficient Output
Corvette LT1 Efficient Output One of the most fuel efficient sports cars on the market Model HP Torque (Ib-ft) 0-60 (seconds) MPG (highway) Corvette Coupe v4 Est. 450 Est. 450 Under 4.0 More than 26 Porsche 911 a 350 287 4.6 27 BMW M3 Coupe 414 295 48 o * A 47d
Slide 18: LT1 6.2L V8: Unique Solution Set: Next-Gen Technologies
—————————————"— LT16.2L V8 Unique Solution Set: Next-Gen Technologies
Slide 19: The Most Beautiful Part Of The Corvette
The Most Beautiful Part Of The Corvette: That Customers Will Never See -™, C ~~
Slide 20: LT1 Advanced Combustion System
LT1 Advanced Combustion System Most Intensely Analyzed, Developed and Optimized System in GM’s History = Hundreds of iterations of combustion systems analyzed = Over 6 million hours of CPU time dedicated to combustion system optimization * Over 10 million hours of CPU time dedicated to all Gen 5 ana
Slide 21: LT1 Advanced Combustion System: Leading Edge Design Process
LT1 Advanced Combustion System Leading Edge Design Process Parametric design tools Steady-state airflow assessment = Three-dimensional Computational Fluid Dynamics (CFD) analysis = Airflow bench testing One-dimensional engine cycle simulation Geometric flame propagation analysis Three-dimensional mi
Slide 22: Analysis of Airflow and Combustion
—————EeeeEOEOeeeTTeteMe LT1 Advanced Combustion System Analysis of Airflow and Combustion
Slide 23: LT1 Advanced Combustion System
LT1 Advanced Combustion System The Gen 5’s Advanced Combustion System assures every drop of fuel is converted to energy to maximize fuel efficiency, reduce emissions and reduce knock sensitivity Even in the most extreme climatic conditions
Slide 24: LT1 Torque Analysis
LT1 Torque Analysis Powerful & Efficient Better — preliminary 450 Ib-ft (1236 kPa BMEP) horsepower/liter ne than LS7 — 2014Corvette 6.2L LT1 lb-ft — 2013 Corvette 6.2L LS3 lb-ft — 2013 Corvette Z06 7.0L LS7 Ib-ft -- LT1hp == LS3 hp Torque (Ib-ft)/Power (hp) 1000 2000 3000 4000 5000 6000 7000 wf RPM
Slide 25: Legendary Durability
mT Legendary Durability if | The Gen 5 LT1 has been | aa pushed further than any mm of its predecessors with fe dyno testing. We are now # using a more aggressive # and advanced high = speed, high load = durability test based on extremely aggressive driving conditions. A
Slide 26: Legendary Durability
Legendary Durability Each hour of durability testing is the equivalent distance of 40 laps around the Nirburgring’s sia Nordschleife (12.9 mile length) £ Each test has over 20,000 “0-60” mph passes at extreme oil and coolant temperatures 47d
Slide 27: Legendary Durability
mT Legendary Durability : The Gen 5LT16.2L engine will = 3 have accumulated an equivalent of over 1.5 million miles of validation testing ye =u 60 times around the world v4
Slide 28: Legendary Durability
Legendary Durability Extensive thermal cycling performed to simulate over 10 years of extreme operating conditions Repeated cycling between approximately -4°F (-20°C) to 239°F (115°C) coolant temperature while running the engine under max power conditions 477
Slide 29: Tonawanda Engine Plant
Tonawanda Engine Plant Engine Manufacturing Experience for Almost 75 Years Built in 1937 Original 1955 Small Block built here Designed by Albert Khan (famous industrial architect) Holds world record single day engine production (8,832 engines) Converted to make aircraft engines during World War II
Slide 30: Tonawanda Engine Plant: State of the Art Manufacturing
Tonawanda Engine Plant State of the Art Manufacturing Facility Technology didnt end with the engine design: m Block machining: 25 CNC machines per module capable of fully machining over 400 features including bores. u Cylinder head machining: 11 CNC machines per module use 15 spindles and 44 unique
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Slide 32: John Rydzewski, Assistant Chief Engineer
Lory So John Rydzewski Assistant Chief Engineer Small Block Engines
Slide 33: Direct Injection Fuel System
Direct Injection Fuel ry = Directinjection u Compact fuel system hidden ar under intake manifold, injectors FS. . Fuel Charging Flowsiieten eee ATOM under intake ports Re, Assembly = Single high output fuel pump 5 7 = Injector spray and droplet design 7 a <I integrated to mixture dynamics § nS u Fue
Slide 34: LT1 Valvetrain and AFM
LT1 Valvetrain and AFM New Splayed Valve Geometry 2mm Taller Ls3 — (er) 6600 rpm eae! poiber | <— Splayed 2.5 Degrees Non-offset Common Springs \ ( bi = = Rocker for Inlet/Exhaust (1.8 ratio) Head Mounted Individual Rocker Arm Pivot Saddles be Exhaust 40.4mm Pad Sodium Filled Intake 54mm J Stiffer 8
Slide 35: Valvetrain: Camshaft and Continuously Variable Valve Timing
i Va Ivet ra | n Lash Adjusted Valve Lift vs. Crank Angle Camshaft and Continuously “4 - Variable Valve Timing ~~ 5, peter : Ls3 a LT1 camshaft design based onLS3’s_ | =\ og ® cam tuning (14mm gross intake lift) ™\y 45 ‘ a Variable valve timing / capability i 2 (62 crank degrees of cam ~~ ol phasing
Slide 36: Gen 5 Combustion
49 Gen 5 Combustion a Every mm of every design feature carefully developed to support the most ideal combination of direct injection, AFM and continuously variable valve timing = Twisted shaped high flowing intake and exhaust ports = Splayed intake and exhaust valve = Compact combustion chamber a Pr
Slide 37: LT1 Cylinder Head
LT1 Cylinder Head Combustion chambers sized for Spark plugs moved closer to higher C.R center for optimal ignition, 9 ae reduce knock Intake and exhaust valves reversed in Gen 5 cylinders Gen 4 Ses =~ Allhead boltsnow M12 Intake ports raised for fuel IN >) A) (vs. M11 in Gen 4) r yf economy) % power
Slide 38: Intake Manifold Features
Intake Manifold Features = “Runners in a Box” architecture m 4-piece molded and welded composite intake manifold; lightweight and thermally efficient design a Integral manifold cover with copolymer filled acoustic barrier = 87mm digital throttle body with low restriction = Dynamic Air flow improved
Slide 39: LT1 Tuned Exhaust
—————EeeeEOEOeeeTTeteMe LT1 Tuned Exhaust = LT1 uses a similar yet cast version of the “four-into-one” short-header exhaust manifold used on the LS7 and LS9 m Runner geometry was further optimized using the latest analysis software to develop cross sections which minimize restriction and maximize vo
Slide 40: LT1 Piston / Rod Features
LT1 Piston / Rod Features High Compression Direct Injection Fuel ‘Bowl’ ‘Pop-up’ = (11.5 :1C.R.) Valve Relief (apered / Wide Pin End <or Cain percharged Type) Phasing High Strength PM Forging (Supercharged Material) High Strength Al LS3 Style (Supercharged Material) Ring Pack a ‘ ‘ y) Skirt Notch fo
Slide 41: LT1 Block
Dé LT1 Block f' aees ¥. x, wh bs a Aluminum - 319 Precision Cast é pias * = 103.25mm Bores with cast-in-place liners; Front @ ‘a gt induction liner heating for dimensional control be 3m a All aluminum deck face (cast over liners) - “EO 3 SO 4 = Nodular iron main caps (were powder metal) we %) A Ss '
Slide 42: LT1 Crankshaft & Bearings
LT1 Crankshaft & Bearings = Steel forged crankshaft Mali Reng * Polymer Coated Bi-metal eccentric = Polymer main and rod bearings * Upper groove narrower than Gen 4 for increase bearing area/oil films « . . . : Gen5 Gen4 ~ <— \5 ( > ( > 40mm 5.5mm a - at " Rod Bearings: q J * Polymer Coated Bi-metal
Slide 43: LT1 Lube Circuit
450 Characteristic Oil Pressure @ 110C J : LT1 Lube Circuit —— Rear of Lifter Gallery a Variable-displacement oil pump = 00 continuously adjust oil flows to 2 F iioeL INE: GENRE) . : : . Ss maintain proper oil pressure at bearings a oa = Dual-pressure capability aq 160 + Very efficient oil pressure
Slide 44: Lube and Vent System
Rocker Cover with integral fresh air separator Lube and Vent System m Rocker cover dome features between direct-mount ignition coils; domes contain baffles (impacters) which separate oil Oo and air from the crankcase gases ; a 3times enhancement in oil/air separation capability LOMA with a Patent-pe
Slide 45: LT1 Dry Sump System
Gerotor LT1 Dry Sump System sr. — Pump = New variable vane oil pump coupled to anew higher output gerotor scavenge pump m New Scavenge pump with capacity increase from 20.9 to 26 cc/rev = Higher output oil cooler (coolant-to-oil) mounted on oil pan m Enhanced pan and windage tray — a Enhanced oil pi
Slide 46: Lube and Vent System
Lube and Vent System = Wet or dry sump systems available within compact design = Track capable in the hands of the most capable drivers a Lube designed thru extensive “Tilt Rig” and “MRC” development GM “Tilt Rig” Pontiac GMPMRC? billford ..fapidly tilts the engine during extreme operation to simula
Slide 47: Summary
Summary One Of The Most Technologically Advanced Engines In The World All new high performance engine designed for Corvette Next-Gen technologies featuring a radically new combustion system One of the most compact, power dense engines in the world Highest standard power, torque and fuel economy ever
Slide 48: Dave Mooty, Lab Manager, Powertrain Development Center
Lr y Dave Mooty Lab Manager Powertrain Development Center
Slide 49: Powertrain Development Center
—————————————"—" Powertrain Development Center u Largest and most technically advanced powertrain development center in the world m 450,000-square-foot facility u Two test wings with 120 flexible dynamometer test cells = More than 100 powertrain component test stands m 250,000 gallon fuel capacity =
Slide 50: Powertrain Development Center
——— Powertrain Development Center Maintenance Inspection Shipping & Non-Firing Receiving r Spin Cells Experimental Teardown Build Advanced Build and Garage Test Wing 1- Transmission & Diesel Test Wing 2- Gas & Diesel Engine Fired Cells Engine Fired Test Cells
Slide 51: First Floor Layout
eeeEeEO———eeeeeee First Floor Layout Test Cell Key F1- PT FWD/RWD F2 - PT AWD F3 -Cold Room F4 - Calibration Engine F5 — Engine Development F6 — Engine Tilt F7 - Certification F8 - Specialty Tests F9 — PT Calibration WORK PREP NF1- Unloaded Spin efefeleley ie i ‘sueenno NF2 - Loaded Spin Testing NF3
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