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Production launch of new Mercedes-Benz engine generation at the Mannheim plant

Production launch of new Mercedes-Benz engine generation at the Mannheim plant

Mar 17, 2011
  • New BlueEFFICIENCY Power commercial vehicle engine family meets Euro VI emission limits
  • New benchmarks for fuel consumption, robustness, and longevity
  • First “assembled” camshaft for heavy-duty truck engines
  • Absolute perfection throughout the production process
  • Several hundred million euros invested in the “synchronous factory”
MANNHEIM – Daimler Trucks is presenting an all-new generation of heavy-duty engines for the first time today at the Mercedes-Benz commercial vehicle engine plant in Mannheim. The unveiling of the new Mercedes-Benz engine family that goes by the name of “BlueEFFICIENCY Power” simultaneously marks the launch of series production of the new units.
Production in Mannheim is being launched with the 12.8-liter Mercedes-Benz OM 471, which like all other engine variants is designed as a six-cylinder in-line unit.
The engine family utilizes a common basic technical concept. The series is considered a new benchmark in terms of fuel consumption — thanks to, among other things, the unique X-PULSE fuel injection system featuring a pressure booster.
New engine generation certified according to the Euro VI emission standard
The Mercedes-Benz OM 471 is the first available engine in its class to meet the future Euro VI emission standard. Euro VI will lead to a further dramatic reduction of exhaust gas emissions, especially of particulates and nitrogen oxides.
In order to comply with the Euro VI standard, the engines are equipped with a sophisticated exhaust gas treatment system. BlueTec engine technology has been used very successfully for six years now at Mercedes-Benz. BlueTec is an exhaust gas purification system that employs SCR (selective catalytic reduction) technology in a process in which AdBlue (which is now available on the market everywhere) is added to the exhaust gas system. This fluid transforms harmful nitrogen oxides into harmless water and nitrogen in a downstream SCR system. BlueTec technology from Mercedes-Benz enables optimal combustion and has also been proven to result in outstanding fuel economy.
Mercedes-Benz engineers develop unique common-rail system
Clean and efficient combustion of fuel is ensured in the OM 471 by a flexible common-rail injection system that is completely electronically controlled.
Flexibility is delivered by the new X-PULSE injection system that was developed exclusively at Daimler Trucks. This system ensures that the fuel injection rate is just as variable as the injection pressure, injection time, and injection volume. High-pressure injection with a common-rail system generally leads to relatively quiet and smooth-running engines.
Six-cylinder in-line engine with a compact and robust design
The new Mercedes-Benz OM 471 is an upright six-cylinder in-line engine. Such a design platform ensures smooth engine operation. Moreover, because of its compact dimensions (the length is 1,531 millimeters), the engine fits perfectly underneath the cabin of cab-over-engine trucks.
In line with the requirements in the segment for high-powered heavy-duty trucks, the engine boasts low fuel consumption and exceptional robustness and longevity — not to mention other outstanding features. All of this can actually be seen in the unit’s basic design.
Absolute perfection throughout the production process
Several hundred million euros were invested in a new facility in Mannheim so that every manufacturing detail could be optimized for the production of the new engine family.
The operation system in Mannheim is referred to by Mercedes-Benz production logistics engineers as the “ synchronous factory.” What this means is that the three production sections — foundry, machining, and assembly — operate as a unit in a continuous production flow.
The system excludes errors, thanks to highly skilled employees, the sophisticated production system, top-of-the-line machinery, and a wide range of statistical quality checks. All of the production units cooperate closely with one another with regard to content. They are also located in close proximity to each other, and the internal supply lines for components are extremely short.
Top quality achieved through the highest levels of precision
The extreme precision of the production process can be clearly seen even at the beginning of the process chain. The foundry in Mannheim is considered the most advanced in the world and displays both the highest productivity and lowest reject rates. For example, in a first for the industry, robots produce the core packets from sand cores in a very technologically challenging process.
Mannheim plant is the hub of a global network
The Mannheim plant stands at the center of a worldwide production network for heavy-duty commercial vehicle engines from Daimler Trucks. The facility manages all of the logistics and quality processes within this production network, thereby ensuring the quality and availability of parts and components around the globe. Mannheim sets the production and quality standards and defines the manufacturing processes and equipment to be used. The plant also coordinates regional supplier management activities.