MCE-5 direct costs

When speaking about final cost of the MCE-5 technology, it is important to keep in mind that MCE-5 is not a complete engine, but only a VCR engine block. Even if they are adapted to specific VCR requirements and specific power and torque, other components of the engine remain unchanged from the technical point of view (cylinder head, pipes, peripherals). The MCE-5 VCR engine block integrates 3 types of components: (1)   Components that remain conventional from the industrial point of view; 2   A crankcase which casting and machining process is slightly different compared to those of conventional crankcases; 3   Innovative components, which mass-production process remains simple and constitutes no particular industrial challenge; 4   Innovative components, which mass-production is the subject of specific studies while having recourse to advanced machining processes.

Conventional parts

Mass producing these components does not constitute any particular challenge:

The crankshaft

Its crank radius is divided by two. As a result, this crankshaft is more compact than conventional ones. Its casting, forging and machining remain conventional.

The connecting rods

The MCE-5 rods are shorter and assume higher tensile force than those of conventional engines. For this reason, they present specific dimensions. Their forging and machining remain conventional.

Crankcase

Casting the MCE-5 crankcase does not constitute any particular challenge. Depending on expected production quantities, this crankcase can be machined on two installation types:

1)

On flexible machining lines (machining centers). In this case, machining the MCE-5 crankcase induces extra costs of about 10% (increased machining duration), but it implies no particular challenge or investments.

2)

On transfer lines, machining the MCE-5 crankcase implies inserting new machine tools in existing lines, notably to machine specific surfaces such as control jacks bores or side holes.

Innovative parts

Mass-production of these components is the subject of specific studies carried out by several European manufacturers.

Gear-wheel and racks

These components will be made of forged steel. Forging the gear-wheel while limiting the need for machining constitutes a real challenge (forge process definition), however, finishing this component does not imply particular studies. Grinding this component is required to reach the expected gear quality class 7 (ISO norm 1328). The situation is exactly the opposite for the racks: forging these components is easier, but finishing them while obtaining the required quality level and tolerances implies using high precision electrochemical machining (gear teeth surfaces), and grinding (rolling surfaces). High precision electrochemical machining process is already used in mass-production and is applicable to MCE-5 racks (about 2mn to bring rack’s teeth from quality class 9 to final quality class 7).

Piston

The MCE-5 piston is made of cast aluminium and does not present any particular technical challenge.

Control Jacks

This component integrates simple components: springs, valves, sticks. It is covered with a specific but relatively simple jack-cylinder head. Its manufacturing presents no particular challenge. A low power servomotor permits controlling all the cylinders together.

The MCE-5 innovative parts can be manufactured and provided to carmakers by existing Automotive OEMs and suppliers as it is already the case for other engine components such as pistons, rings, valves or bearings.

Final extra cost

Final extra cost for the MCE-5 VCR engine block has to be calculated taking into account both VCR negative costs (see: VCR negative costs) and MCE-5 negative costs (see: MCE-5 negative costs). Indeed, carmakers do not sell engines, they sell vehicles. Final balance has to take into account the cost price per kW and cost per percent of fuel economy in comparison with other strategies and technologies (see: VCR cost price - general approach for VCR cost determination).

However, the absolute extra cost for the MCE-5 VCR engine block compared to a conventional engine block of equivalent capacity will be between:

		Optimistic hypothesis: 200 Euros
		Conservative hypothesis: 300 Euros

Depending on the case, MCE-5 extra cost could be nil (example: when replacing a 6 cylinder by a 4 cylinder), or highly negative (about 1,000 Euros less expensive when replacing a Diesel in 2010 at same performance, Fuel Consumption and emissions).

However, as it is the case for all technologies, the MCE-5 VCR engine block cost price will decrease in the future as its mass-production techniques will become better mastered and optimized (that’s why equipments that could only be found on luxury vehicles in 1980 can be found on common small vehicles in 2005):

This principle will permit to progressively implement the MCE-5 VCR technology in an increasing range of vehicles in the future, even in low-cost small-class vehicles.