Ford Previews Next-Generation Hybrids
14 February 2008
by Jack Rosebro
Speaking at the 2008 SAE Hybrid Vehicle Technology Symposium in San Diego yesterday, Sherif Markaby, Global Core Engineer for hybrids at Ford Motor Company, provided some technical details of the coming 2009 Ford Fusion and Mercury Milan hybrids, due at the end of the year, as well as of the 2009 Escape and Mariner hybrids, which are scheduled to be released in a few months.
All four hybrids will share a new powertrain that combines a 2.5L inline four-cylinder engine with a series-parallel transaxle. While the basic layout and packaging of the powertrain and related components remains for the most part unchanged from the 2005-2008 Escape component architecture, many of those components have been redesigned for improved efficiency.
Markaby also noted that Ford has sold 70,000 Escape hybrids to date, and that some units have reached 200,000 miles in service with no service problems.
The next-generation hybrid system applied in the Fusion, for example, will provide a more than 60% improvement in city cycle fuel economy over a non-hybrid I4 engine, Markaby said, and a more than 80% improvement over a V6 on the city cycle.
Variable-Voltage Converter (VVC). The new powertrain’s inverter assembly utilizes a DC-DC buck-boost converter, which Ford refers to as a Variable-Voltage Converter, to step up the voltage potential of current from the battery pack before it is synthesized into a three-phase AC waveform to power the transaxle’s two electric motor-generators.
Every model-year 2004 and up Toyota/Lexus hybrids utilizes a buck-boost converter; however, this is the first time that the architecture has been employed in a mass-produced passenger hybrid vehicle built by another manufacturer.
Stepping up voltage allows the powertrain to produce a given output using less current, which reduces resistance losses and increases efficiency. It also allows the manufacturer to use a smaller, lighter battery: the 275V, 5.5Ah, 27 kW peak power NiMH battery pack used in the new Fusion/Milan hybrids features improved cell chemistry, and is more compact, for example, than the 2005-2008 Escape hybrid’s 330V battery pack.
One of the most important attributes of VVC, according to Markaby, is “reducing the cost of the battery.” Previous Escape and Mariner hybrids used a stand-alone air conditioning loop to cool the battery pack during peak operating temperatures: the new powertrain uses only a forced-air ventilation system.
High-Efficiency Internal Combustion Engine (ICE). The 2.5L iVCT I-4 engine gets variable valve timing on the intake side (Intake Variable Cam Timing, iVCT), as well as a wide-band lambda sensor in place of a conventional oxygen sensor. The compression ratio in the engine is 12.3:1.
Idle-stop and start events are much quicker, and enable greater efficiency with as many as two times the starts and stops in a given driving cycle as the previous system. The quicker engine shut-downs and pre-positioning (for the next start) also reduces O2 build-up in the engine’s catalyst. Decel Fuel Shut-Off (DFSO) mode and electric-only mode have also been expanded.
High-Efficiency DC-DC Converter. The conventional DC-DC converter, which steps down system voltage to run the vehicle’s 12V accessory bus and charge the auxiliary 12V battery, has been redesigned to operate at higher temperatures. The unit remains liquid cooled, and can switch at higher frequencies.
The VVC variably boosts traction battery voltage to operate the motor and generator more efficiently. Click to enlarge. |
High-Efficiency Transaxle. The maximum RPM of the new transaxle’s permanent-magnet synchronous motor-generators has been increased, and a new low-drag transaxle fluid has been formulated. The higher available voltages from the variable-voltage converter allow greater torque at higher speeds. Typically, such voltages also enable a more efficient recuperation of kinetic energy via regenerative braking.
Update on the SCE PHEVs. Markaby also made mention of the plug-in hybrid Escapes that Ford is delivering to Southern California Edison (SCE) for V2G research. The PHEV Escapes use a 10kWh Li-ion battery pack, and are getting as much as 120 MPG in testing. The PHEV powertrain operates in three distinct modes: electric drive (ED) mode, blended mode (a combination of engine operation and charge-depleting electric drive), and conventional hybrid mode.
"..with a series-parallel transaxle."
Does this mean that is can run as either a series or parallel hybrid like the BYD? I could do with less marketing speak and more straight talk when it comes explaining their new products.
I would assume that they mean that it is a full hybrid that can run in EV only mode. However, that EV only mode may be under 35 mph for a few miles. This is not exactly a worthwhile "feature".
Now, if it could run in series hybrid mode with the engine and alternator running as a genset powering the motor and charging the batteries in a range extender configuration and go faster than 35 mph, I would be interested.
Posted by: sjc | 14 February 2008 at 12:33 PM
"The PHEV Escapes...are getting as much as 120 mpg in testing."
Now your talking!!! Put me down for one of those!
Posted by: Schmeltz | 14 February 2008 at 12:45 PM
"The PHEV Escapes...are getting as much as 120 mpg in testing."
Is that 120 mpg energy equivalency or are they ignoring electrical consumption and merely tabulating the gasoline use?
Posted by: Mark Gutting-Kilzer | 14 February 2008 at 12:53 PM
@ sjc -
I'm guessing there are two electric motors on either side of a clutch in the transaxle. If the clutch is open, you're in series hybrid mode, useful for low speeds, reverse gear emulation and recuperative braking. Once you close it, you're in parallel mode, which saves fuel and increases available boost torque at higher speeds.
Of course, in Ford's private dictionary, the term could also refer to a Toyota-style single-mode compound hybrid. In that setup, part of the engine power is always routed electrically and the rest mechanically to deliver a continously variable transmission ratio using just one set of planetary gears.
@ Mark Gutting-Kilzer -
they are almost certainly ignoring the fuel inputs at the power stations, because (a) they vary by region/country and (b) marketing types like big numbers regardless of what they really mean. There is as yet no agreed-upon technical standard for measuring the aggregate fuel economy of a PHEV or E-REV.
Posted by: Rafael Seidl | 14 February 2008 at 01:33 PM
Will the hybrid fusion also be made in Mexico?
Posted by: Chad | 14 February 2008 at 01:36 PM
I know that single-digit range or low-speed restrictions of "EV mode" seems like a useless feature to many, but I personally value it as a nice complimentary feature. One may not be able to use EV mode all the time, but it's a feature that is certainly useful in traffic jams, parking lots, and driving around residential areas.
I'd love to see that perfect EV some day, but for now, hybrids with some EV features will probably be the right-now vehicle that can appeal to masses. It took almost a decade for hybrids to get to where it is today, and I think pure-EVs will take some time to gain some traction in the mainstream.
Posted by: Charles S | 14 February 2008 at 01:48 PM
You can bet that 120 mpg figure ignores the energy used in creating the electricity. When I hear 120 mpg, I think more in terms of 60 mpg costs and even less in equivalent energy.
Posted by: sjc | 14 February 2008 at 02:31 PM
Ford is licensing the Toyota patents, so it's a planetary transmission that blends the properties of series and parallel hybrids. The list of improvements planned sounds just like the list of improvements that Toyota released in the 2004 Prius.
Posted by: Wes | 14 February 2008 at 02:42 PM
"Ford is licensing the Toyota patents, so it's a planetary transmission that blends the properties of series and parallel hybrids. The list of improvements planned sounds just like the list of improvements that Toyota released in the 2004 Prius."
Maybe a couple Wes,
But you didn't see the Ford internal memo disputing this 3 or 4 years ago. Please stop this canard, Fords Patents on this system is over 200 homegrown ideas, it mayb ebe over 300.
Give credit where credit is due....
Posted by: Egeek | 14 February 2008 at 02:50 PM
This is just solid engineering producing improvements. Its nice to see it occurring. As 21st century Science deflates the power of GHGs to only a tenth of a single degree or so per century, and so deflates concerns over AGW caused by GHGs, nonetheless there is a definite and valid concern for hydrocarbon fuel availability to provide enough for the entire world. There is simply not enough to go around for everyone if that is the only choice.
But it is not. Substitution is finally arriving for Ground Transport.
Reducing hydrocarbon demand from 20 mpg to 120 mpg for liquid hydrocarbons is a reduction of some 600%, of that commodity,even as electrical demand grows. If the US demand for Oil fell by 600% with an automotive fleet of such vehicles, the US demand would drop from 21 million BBD to around 3.5 million BBD.
It becomes not only possible, but probable to envision the US becoming independent of the Oil Sheiks and the Commissars who bottleneck petroleum supply while stealing their citizen's wealth.
I must say I can't think of a better reward to the Chavez's and Putin's and the House of Saud.
Even if the present US electrical supply is currently produced with about 70% total hydrocarbons, almost exclusively coal and gas, that will change in the next decade. While such PHEV vehicles also replace current vehicles in the US automotive fleet. By then, the US will be generating only 50% of its electricity from coal and gas. Half or more of US electricity will be supplied by a last generation of uranium,(doubling to 40%), falling water, essentially constant, and assorted miscellaneous other sources adding a per cent or even a percent and a half of supply. We will then be well positioned to harness clean,inexhaustible, Fusion when it starts getting practical around 2030 or so.
We will have clean air in the US in only a half a decade, at most. That is a triumph that merits a a national holiday, as it was a bi-partisan effort over 40 years in the creation. Too Bad the EU is a couple of decades away from such progress. We will have clean air, and clean inexhaustible energy for all.
It is so refreshing to see the world getting better, in spite of the Leftist propaganda attempts to depress and convince everyone that they must submit to sharing the misery. While putting the commissars in charge, to supervise the equal misery for all,(except themselves, of course!).
Posted by: Stan Peterson | 14 February 2008 at 03:16 PM
To add to Stan's diatribe:
The demand for oil won't be replaced as quickly by China, they will adopt some of the most efficient technologies and techniques (even if manufacturing limitations prevents the same level of efficiencies it will make an impact). Of course China will adopt them in the best way they know how...steal the technology...
Posted by: Patrick | 14 February 2008 at 04:07 PM
@Patrick,
The technology will be available and the Chinese companies may actually be building it for export to the US. But China is about two years behind the Japanese in adopting emissions standards internally. The Japanese, in turn, are about half a decade behind the EU in implementing emissions standards internally; and they pattern their standards after the EU model.
Since the EU is almost two decades behind America, it may be three decades before the Chinese actually equip their domestic fleet with emissions abatement equipment that they may be exporting to America in only a half dozen years or less.
Too Bad.
Posted by: Stan Peterson | 14 February 2008 at 05:29 PM
All four hybrids will share a new powertrain that combines a 2.5L inline four-cylinder engine ...
How nice is it to see an American car company choosing to use I4 vs v6 and v8, like we are seeing from many other American "green" car offers.
Maybe a corner really is being turned...?
Posted by: Mike L | 14 February 2008 at 09:13 PM
At least Ford is trying to produce full hybrid sedans. Unlike the less than innovative green vue line. The battery for the Fusion/Milan is only 5.5 Ah compared to the Prius 6.5 Ah battery. At a 60% increase in city mileage means from 24 MPG to around 38 MPG. Don't know if it is the old EPA figures or new ones. The Prius new EPA figures around the 44-46 MPG.
Stan's off in his own world again. 40% nuclear? Really? From what? There's only 6 applications for COL licenses so far and that doesn't mean that they will even be built.
To do what you believe nuclear is going to be in a mere couple of decades would require the building of at least 90 GWe worth of reactors. In an era when the economy might turn down, the utilites are going to mass build them? This isn't field of dreams. Try going to any board with the idea of build it and they will come and they'll rightly toss you on your behind.
All this in the 15-20 years before your crystal ball belief that nuclear fusion will come and save the world? Right Stan. There is no evidence that a viable commercial fusion reactor will be built by then.
Great planning ability there, hope that something new emerges that doesn't really exist now. Heck, why not say that nanotechnology will be around by 2030 too while your at it, so that we can keep pigging out in our non sustainable lifestyles.
If the air is so great in the US, why are the north eastern states suing the US industrial heartland? Because of all the clean air? You keep saying that Europe is behind the US in emmissions by decades? Where does this come from?
Leftist propaganda? Stan, most of the clean air act was created by "leftists" and is still considered by many conservatives to be propaganda. What makes it anything that disagrees with you leftist? In fact, there is little fact in your diatribe but there is many emotional appeals and barbs. Commissars, Stan? Painting a picture that your viewpoint is american as apple pie and anything that isn't such as any hint socially oriented programs is part of some communie plot? Geez, McCarthy would be proud of you.
I don't believe in a future utopia and yours, like most, is totally unanchored in any reality but your own.
http://www.eia.doe.gov/cneaf/electricity/epa/epat1p1.html
http://www.eia.doe.gov/cneaf/nuclear/page/nuc_reactors/com_reactors.pdf
Posted by: aym | 14 February 2008 at 09:27 PM
Aym
Don't bother, Stan Peterson like to please himself with his utopia and ridiculous faith that american car technology is so good that is going to save us from the next energy crisis. Technology and especialy american technology is going to save us, well what he forgot in is blind naive way of thinkin is that technology doesn' make energy is quite the opposite inded : energy makes technology. What he also forgot in his primitive anti-leftiste conviction is that the most advanced car technology happened to be in leftiste oriented countries (Germany, Sweeden, Japan)where social policy means something and where people have a decent level of education because more money is put in schools than in weaponry unlike america were people are on average shamely ignorant and clueless about everything.
american car industry is crapy, inefficient, ugly unproductive and unsustainable. GM, Ford and Chrysler are just starting to meeet quality standards that Japaneses companies met 15 years ago.
Europe behind america when it comes to environment ? most of the chemical in food industry or cleaning stuff that you can freely buy here in america couldn't be sold in europe because they don't pass safety and inocuity regulation in europe. If cars emissions ar so advanced in US compared to europe you can thanks the "leftiste corrupted california"
Posted by: Treehugger | 14 February 2008 at 11:27 PM
WOW Treehugger very emotive diatribe of your own. Come on the US auto industry is not solely to blame. Mostly they make cars for Americans that like big cars and trucks. Now why is this.
You could say they just want to rip the consumer off and destroy the environment. If they just did that they would of quickly gone out of business years ago. Their image is set by their product path, consumers, media, and their business model. They have been stuck in the role worse than your favorite TV role has his.
Now convince people to buy small cars or hybrids and every manufacturer will make them. No company has such a big technical leap in this area and the others can't follow. Lets support any greener alternative that any car produces. If you gotta have your big car a hybrid Escape or in 2009 Fusion you might be a good choice.
Posted by: Mike H | 15 February 2008 at 12:27 AM
Treehugger,
Once again, while somewhat entertaining, your comments are unproductive and completely off base. I cannot recall a single instance of anything you have ever said to be useful, let alone factual. You seem most focussed on baseless personal attacks on others and making generalizations about things for which you have proven to know very little about.
"Energy makes technology"? I love how you attempt to make some profound statement and then elect not to explain it at all, as if that statement was in any way intuitive.
I could pick you apart on a number of other things (SwEEdish car tech, the food industry/chemical stuff, your inability to grasp the geographic definition of Europe), but I am not going to this time. I have concluded that you are just an angry person who needs to vent somewhere, and you have simply chosen to use this site to do so. I just wish you would tone it down a bit.
Posted by: Angelo | 15 February 2008 at 04:07 AM
"Since the EU is almost two decades behind America... in adopting emissions standards internally..."
Hmm, I think you ought to back that one up Stan.
I assume you are talking about the red herring NOx restrictions motivated by smog in unusual climate areas (like coastal california) rather than CO2 emissions per mile tragets on auto production. Whos leads on the latter?
If the residents of west coast america were not putting down quite so many miles in their cars, they might not need the T2B5 restrictions for clean air in the first place...
I agree that the targets of Euro V and T2B5 are a good push to improve local atmospheric conditions for the public, but when it comes to energy consumption per household - Europe is very gladly behind on that one.
Posted by: Tim | 15 February 2008 at 07:33 AM
I have nothing against america or europe or for any belief in something. In the history of things, everything is tainted to some degree and less than idealistic to some extent or another. There is nothing really evil, it's systemic from the ways things are, but there is certainly nothing virtuous either.
I don't believe quite that larger cars are the natural evolution of an increasingly affluent society. True costs of energy are being shielded by policy and by how we account for things. This distorts choices so that the US which has relied on cheap energy has created an infrastructure which requires cheap energy to work and it lacks the political/social will to realize it and change. From short term energy solutions like water heaters to larger cars & SUVs to urban sprawl.
Europe has tried to be less dependent on foreign sources of energy. This had led to higher energy intensities (J/GDP $). Japan which has to import virtually everything has done the same policy.
These are social choices which have economic impacts, in the short and long term to individual countries and with globalization to the world based on policy implementations. These policy implementations affect public viewpoints and affect the market. Whether they affect the market like in europe or like the US is in the end a choice especially since we elect the people who create policy.
Posted by: aym | 15 February 2008 at 07:51 AM
aym,
I think I understand what you're trying to say in a very long-winded way - that in a free market economy society develops according to the financial pressures on it - basic capitalist concept - fair enough and I agree. But this site is devoted to 'Green Cars' - that means, the interest and aim of the contributors and readers is the reduction of the impact on the environment of vehicles.
I think it is very important to have the debate over how the metrics Nox emissions per BHP.hour and co2/unit benchmark distance are used to measure the greeness of a vehicle.
If the g Nox per BHP.hour of a vehicle is low, but vast volumes of fuel are used to propell a single person a few miles in slow traffic - that is not green to me.
While I understand the value of very low pollutant concentrations to the high quality of life expectations in small areas of the planet - the consumed fuel must obviously come into the value of the car somewhere too - as those emissions are thought to have much longer lasting and further reaching effects. Most people posting here agree with me on that, I'm sure.
I get very upset when european technology is rejected on the basis of air purity restrictions, when it is using vast amounts of energy less that the vehicles that meet these standards.
You only have to look at the European vehicles engineered to meet these US standards to see the difference in emphasis either side of the water: most are large and use V8 spark ignited engines, and all have greater cylinder capacity than european versions.
The market pressures are changing, and one simple solution, that nicely compliments all the technologies presented here is simple - *drive smaller lighter cars*.
Posted by: Tim | 15 February 2008 at 08:42 AM
Sorry for all the splurge, guys.
I just want to add that I agree with Mike H among others that I do think that the Hybrid SUV is a great addition to US offerings. If you are going to accelerate a large chunk of metal, at least do it more efficiently. If the long range, large vehicle habit can't be broken, I hope Hybrids get market take-up in this sector.
Posted by: Tim | 15 February 2008 at 08:57 AM
"america were people are on average shamely ignorant and clueless about everything."
Especially English.
Posted by: sulleny | 15 February 2008 at 02:21 PM
Stan,
I don't doubt that the Chinese won't pay too much attention to toxic emissions but I bet they do care about efficient engines for energy price reasons. Toxic emissions will probably be reduced as a byproduct of this and not an effort for health of the population.
Posted by: Patrick | 15 February 2008 at 03:10 PM
aym,
I don't know from where you get your numbers but there are 32 nuclear power plants in the early pipeline, preparing for or seeking COLs, or getting ready for them. Please check the NRC web pages such as:
http://www.nrc.gov/reactors/new-reactor-licensing.html
Those 32 plants would be equivalent to about 60 of the 100 odd current running plants. The current plants are bifurcated in power output, with a earlier first and later second wave of designs. Since these new standard designs are about a third larger in output than the current running second wave plants; and two thirds larger than the first wave of current plants.
They won't double nuclear generation to 40%, all by themselves, but will easily raise it to well over 30% and there surely must be a few more plant orders that will emerge in the next decade and a half. After all, this backlog has developed from zero in only two years.
All but a couple are sited in currently existing nuclear sites with other existing nuclear plants, so siting opposition will be less. In fact, most of the opportunity for obstructionism is now already done with, as the Westinghouse designs are now already approved as "standard designs"; and the GE designs are almost finished with their multi-year approvals as "standard designs". While other standard designs are being sought, they represent little of the existing base of current plants.
No more construction delaying critiques are allowed under the new laws, except for NRC itself, and provable malfeasance by not following construction standards.
This is much less likely, as the plant manufacturers are undertaking to supervise the construction under fixed price, fixed delivery, contracts. This is totally unlike the environment in which we principled critics, could, and did, critique the one-off designs, sloppy construction, and rump construction contracts often done by firms who had never undertaken to build a nuclear plant before. Today you simply can't tie up construction, under the revised laws, like we could back then.
So they are in th pipeline, and they will be built, and built in under 4 years from first concrete; and operating generating electricity in under 5 years.
Posted by: Stan Peterson | 15 February 2008 at 04:41 PM
Angelo
Why should I lower my tone when Stan Peterson is allowed to post provocative, anti-european, anti-leftiste, anti-environmetalist, global warming denial and above all politicaly biased opinion ?
It is not because I am angry against Stan than I am angry in general and I welcome progresses in fuel efficiency and renewable energy which is what I am looking here.
You are not knocking the right door
Posted by: Treehugger | 15 February 2008 at 05:09 PM