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FORD GOES FURTHER WITH PROTOTYPE ELECTRIC KA
Ford Motor Company today announced the development of a prototype electric Ka small car, powered by a new generation of lithium ion high-tech batteries. Ford is the first manufacturer to produce an electric vehicle using this type of battery propulsion.
The e-Ka has the performance of a petrol engine car and a range of 95 miles (150
kilometres) thanks to second-generation lithium ion batteries, and retains the zero emissions benefits of electric vehicles while extending considerably their
conventional limits.
The e-Ka has been developed at Ford's Reseaarch Centre in Aachen, German(known as FFA) to demonstrate the capabilities of new "dedicated soft lithium ion
water-cooled battery technology.
Appropriately based on the Ford Ka, which is renowned for its luturistic exterior and interior design, the e-Ka's body has been lightened by 45 kilograms to optimise the performance of its electric powertrain. The lithium ion battery pack (total weight 280 kg) is approximately 70 percent lighter than an equivalent pack using conventional lead acid technology.
The result is that the e-Ka can sprint to 62mph (100 km/h) in 12.7 seconds (0-
31mph/5O km/h in 3.9 seconds) and can reach a maximum speed of 82mph (130km/h). At a constant speed of 50mph (80 km/h), the e-Ka will travel more than l25miles (200 kilometres) before needing a recharge.
A particular advantage of lithium ion battery technology is its tolerance to high electric current when recharging. The e-Ka can go from zero to full charge in just six hours and, unlike other battery systems, it is immune to the so called "memory effect" and retains its lull charging capacity regardless of usage. The on-board recharger ensures that - after a complete discharge - the battery will be fully operational again after six hours.
Powering the e-Ka
The Ford e-Ka battery pack consists of a total of 180 cells. These are divided into three separate battery 'troughs'. One trough is located in the engine compartment and two others directly behind and one in front of the rear axle. The entire bundle of lithium ion batteries weighs only 280 kilograms, which is 70 percent less than normal lead-acid batteries.
The battery troughs are divided into modules each containing six lithium ion cells. An on board Battery Management System (BMS) constantly monitors each of the 30 modules, both during operation and while it is being recharged. Cell voltage, battery charge status, and the operating temperature of the battery module are all monitored and this data is passed to the central control unit, the Vehicle System Controller (VSC), through thL on board communications network (CAN data bus).
Safety and Comfort
The flow of electricity from the battery unit is automatically cut off if the system is turned off, or in the event of an accident. The e-Ka is equipped with crash sensors, which trigger the shut down. The e-Ka also has two independent coolant systems that prevent overheating. One is for the drive system(consisting of electric engine, transmission, and differential), and the other is dedicated to the Lithium ion battery pack. The three battery troughs in the system are completely sealed.
The e-Ka retains all of the dynamic abilities for which the Ka itself is so well
regarded. To achieve this with the heavier e-Ka, Ford engineers have equipped the vehicle with Electric Power Assisted Steering (EPAS). EPAS is equipped with
sensors that are able to register the torque, as well as the current position of the steering wheel. This data is continually conveyed to an electronic module, which controls the precise amount of electrically powered assistance required. The advantages of the EPAS system, compared to conventional power steering
(hydraulic) systems, include compact construction, reduced weight, and environmental benefits. The e-Ka is also equipped with an electric brake booster and ABS.
Vehicle Management System
A vehicle management system (VSC - Vehicle System Controller) has been developed especially for the e-Ka to ensure optimum operation of the battery charger, the battery itself, and the electric motor. The end result is that despite its
state-of-the-art technology the e-Ka can be driven in the same manner as a
"conventional" abtomobile.
Weight Reduction with Aluminum
Selective use of aluminum and aluminum composites has taken weight out of the
e-Ka without compromising strength or refinement. A composite material called
Hylite=AE, consisting of two aluminum sheets sandwiching a layer of thermoplastic (polypropylene), is used for the roof (weight reduction: 5.5 kg) and the hood (-5.3kg). Overall weight reduction is 45 kilograms. Hylite is up to 65 percent lighter than aluminium or steel of comparable stiffness. Weight was also reduced through the use of aluminium for the rear axle (-12 kg), wheel rims (-12 kg), and brakes (-10 kg).
The e-Ka is also equipped with low rolling resistance tyres to maximise the vehicle's range.
Contact: Philip Hale Tom Malcolm
+44 1277 252407 +44 1277 252957
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