Report by the Committee on Motor Vehicle Emissions (1973) / Chapter Skim
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5 Manufacturing, Costs, and Producibility
5 Manufacturing, Costs, and Producibility
Pages 87-103
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From page 87... ...
5.1.1 The Dual-Catalyst System In response to California and federal regulations over the years, the automotive industry has progressively added to the emissionscontrol devices on automobiles. Due in part to a determined effort to preserve as much of the technology of the carbureted internal-combustion engine as possible, the approaches to emissions control have consisted of add-one and relatively minor engine modifications.
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From page 88... ...
i, k) Electronic Ignition Improved Timing Control Oxidizing Catalytic Converter Pellet Charge Increased Cooling System Improved Underhood Materials Body Revisions Model Year Most Cordon Configuration 1976 a)
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From page 89... ...
If this type of system is to be massproduced in the 1976 model year, the following must have been accompl ished by mid- 1973: · Freeze design for production · Build catalytic converter plant and line · Commit to plant and equipment for substrate ~ Commit to new carburetor production design · Freeze design of early fuel-evaporation system 5.1.2 Diesel Engine Some light-weight diesels are currently being produced for passenger cars, mainly in Europe and Japan. However, because it is difficult to make a diesel engine meet the 1976 NOx standards, and, for other reasons discussed in Section 6.1, there is no serious effort to develop the diesel engine for large- scale mass-production as a passenger-car engine.
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From page 94... ...
TABLE 5-3 Summary of Sticker Prices for Emissions Hardware from 1966 Uncontrolled Vehicle to 1976 Dual-Catalyst System Year Sticker Price Increase Cumulative Price 1966 1968 1970 1971-72 1973 1974 1975 1976 1972 Dollars $ 3.00 15.00 8.00 14.00 60.00 20.60 138.20 134.00 - 94 $ 3.00 18.00 26.00 40.00 100.00 120.60 25 8.
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From page 95... ...
Freeze design for production Arrange for transfer of European light-duty diesel technology Build low-volume production tooling · Plan for conversion of gasoline engine lines for diesel engine production Plan body changes Arrange for supply of turbochargers (if used)
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From page 96... ...
Two to four more years will be required on its development before it can be cons idered a competitor to the larger V-8. The manufacturing requirements for the Wankel engine are concentrated around the following significant equipment: a trochoid grinder for the rotor housing, a rotary grinder for finishing of the end housings, an eccentric grinder for the rotor, some special plating equipment combined with surface-preparation equipment, and special equipment for pressing and sintering the apex seals.
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From page 97... ...
For another manufacturer to mass-produce this system in model year 1976 would require the following accomplishments by mid-1973: · Transfer technology from Honda Motors · Freeze des ign for production · Decisions made and orders placed for new transfer lines for cylinder heads, mans fold systems, and carburetors · Design new camsha£t-production line 5.1.5 A Typical Feedback-Controlled System Because of the apparent potential for emission reduction and ease of maintenance, which might result with further development of some of the feedback-controlled systems, manufacturability and costs of one of these systems were evaluated. The configuration studied !
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From page 98... ...
. Freeze design for production · Commit to pump and nozzle plants · Build low-volume production tooling and vehicles Field test low-volume production vehicles · Commit to electronic emissions control unit plant and tooling 5 2 Manufacturabil ity and C as ts of Automotive Exhaus t Catalys ts As discussed previously, most manufacturers plan to use a dual-catalytic system for 1976 model year vehicles.
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From page 99... ...
Thus, there would be a demand of as much as 3 million ounces for the initial installation of the catalytic converters required, a figure comparable to the world production in 1970. Ruthenium is the most promising NOx catalyst, although it is in short supply.
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From page 100... ...
These figures include not only the direct cost of emissions hardware, but also associated costs of redesign of the rest of the car to accommodate the new systems. These associated costs include weight penalties, which can be quite significant in either direction; e.g., diesel-powered cars will be relatively heavy, whereas an automobile designed around the compact Wankel end ne can be appreciably lighter than present cars.
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From page 101... ...
at o o o u, o 1 ~ us o ~ cq co cO Em O o c)
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From page 102... ...
~ The following are the assumptions used: 1. The modified carbureted piston engine equipped with an oxidation catalyst will be produced only In model year 1975 and no modif fed carbureted p is ton engine using catalytic control of emis signs will be produced in model year 1976.
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From page 103... ...
These numbers were developed giving due consideration to expected product life and normal industry amortization practices. The expected sticker-price increases to return the capital investment in new production lines, old production-line tearup, assembly-line change, and new facilities were found to range (even with such a drastic change in engines and control systems in such a short time)
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