The latest Ford F-Series Super Duty trucks look to be the greenest versions of the vehicles yet thanks to new diesel and petrol engine powertrains.

Now before you say that being the greenest truck is hardly worthy of an environmental stamp of approval, consider the strides that have been taken. The 6.7litre Power Stroke V-8 Turbocharged diesel engine, for example, averages an 18 per cent improvement in fuel economy for pick-up models and up to 25 per cent improvement for chassis cabs compared to 2010 models. Indeed trucks equipped with the basic 6.2litre V-8 petrol engine average a 15 per cent improvement in fuel economy when compared to the 2010 models. 

There’s no compromise with power to achieve these improvements, however. The 6.7litre Power Stroke V-8 produces a best in class 997Nm of torque at 1,600rpm; while the new 6.2litre V-8 also boasts best in class numbers at 549Nm at 4,500rpm. Indeed the new diesel engine is also B20 biodiesel compatible, while the petrol engine is E85 compatible.

According to Al Bruck, the transmission engineering manager, the new transmission is a clean-sheet design that has been developed to handle increased torque and higher rotational speeds. It can deliver power to the wheels seamlessly and efficiently.

Among the enhancements that have been made to the transmission are an optimised shift and converter lock-up schedule; gearing and double-overdrive; optimised pumping pressure; optimised drainback to reduce spin losses; and a warmer operating temperature.

A range extended electric conversion of the Ford F-150 has been revealed as part of the 2010 National Truck Equipment Association Work Truck Show and Green Truck Summit.

The vehicle, developed by Michigan-based electric powertrain company ALTe LLC includes a Ford 2.0litre, four-cylinder normally aspirated petrol engine that powers an 82kW Remy DC generator. It includes two Remy DC drive motors that run at 320V and deliver 400Nm maximum torque.

The battery pack has been assembled into a saddlebag configuration with a 52mile all-electric range. Fuel economy in charge sustaining mode is 32mpg and the entire range extended electric system adds around 200lbs to the vehicle’s net weight. 

According to ALTe CEO John Thomas, the company is in discussions with several car manufacturers at the chairman and CEO level and is also in discussions with a major retail chain that is interested in becoming a nationwide centre partner.

Thomas hopes that his company might be the one that offers Freightliners, manufacturers and their customers the range-extended solution to complement the existing battery electric vehicles in the field.

Ford’s European engine product range has been revamped with the emphasis placed clearly on offering more efficient petrol and diesel engines.

At the top of the list is the introduction of two four-cylinder Ford EcoBoost petrol units that combine high pressure direct injection with advanced turbocharging and twin variable valve timing. This maximises combustion efficiency and both 1.6litre and 2.0litre models will be made available.

The 1.6litre version is scheduled to be launched in the all new Ford C-MAX and Ford Grand C-MAX models that are due to debut later this year as well as being included in the next-generation Ford Focus from early 2011. Meanwhile, the 2.0litre engine will makes its debut in the latest 2010 S-MAX, Galaxy and Mondeo models.

Also making its first appearance for Ford is an updated Duratorq TDCi diesel engine that delivers high efficiency with improved performance and better fuel economy. Both the 1.6litre and 2.0litre versions are enhanced by a next generation combustion system with a lower compression ratio; a higher pressure common-rail fuel injection system with advanced multi-hole injectors; and smaller, low-inertia variable geometry turbochargers. The engines now meet Euro 5 emission standards and, according to Ford, the 1.6 TDCI engine can reduce CO2 emissions by as much as six per cent compared to the previous model; while the 2.0litre version cuts emissions by seven per cent. The 1.6litre TDCI will be included in the all-new C-MAX, Grand C-MAX and the next generation Focus; while the 2.0litre model will also be offered in the C-MAX and Grand C-MAX as well as the 2010 Kuga, Mondeo, Galaxy and S-MAX models.

The entire TDCi Ford range will also boast ECOnetic derivatives that are optimised specifically for fuel economy and low CO2 emissions. From this year, Ford will launch an updated Focus ECOnetic that can be specified with Ford’s auto start-stop system and can take emissions down to a class-leading 99g/km.

Also lined up by Ford is a host of new transmissions including an advanced Ford PowerShift six-speed dual clutch automatic and a new six-speed manual gearbox. The six-speed transmission is light and compact with real world fuel economy reduced by three-five per cent compared to the five-speed manual gearbox.

Having established its global electric vehicle plans, Ford has now revealed its intentions for the European market.

The company will introduce five full electric or hybrid vehicles across the C, CD and light commercial vehicle ranges by 2013. This will include two zero-emission battery electric vehicles including the Ford Transit Connect Electric in 2011 and the Ford Focus Electric in 2012. Three additional vehicles will also be introduced including two next-generation hybrids and a plug-in hybrid.

Unsurprisingly, the Focus Electric will be based on the next-generation Ford Focus and will be one of at least 10 vehicles created on the company’s C-car platform. It will debut in the US and Canada in 2011 followed by Europe in 2012. The Ford Transit Connect Electric meanwhile goes on sale in North America later this year.

Ford has already established a hybrid presence in North America with both the Ford Escape and Ford Fusion Hybrids and is planning to expand its presence into Europe – further details of its hybrid offerings will be revealed closer to launch.

Also planned are two specific European trial initiatives that aim to demonstrate the technology in real world driving conditions and generate feedback. In the UK, Ford has formed a consortium with Scottish and Southern Energy (SSE) and Strathclyde University with plans to introduce a fleet of Ford Focus electric vehicle prototypes using elements of the technology under development for the new Focus Electric. They will be evaluated by both SSE staff members and fleet and private customers.

Meanwhile, in Germany, Ford has announced its participation in the Cologne-Mobil project to research the impact of electric vehicles on urban air quality and to look into electricity supply infrastructure. It is one of four partners in the project, the others being utility company RheinEnergie AG, the City of Cologne and the University of Duisburg-Essen.

The Green Piece Column. Tuesday 23 February 2010

Steeped in tradition, having been established in 1905 and now set for its 80^th edition, the Geneva International Motor Show has always been one of the highlights of the automotive calendar.

Regarded as a level playing field for the world’s car manufacturers as Switzerland lacks an automotive industry of its own, exotic supercars usually steal the spotlight at the event but this year, after turbulent times for the industry, the focus is on green cars and the future of the business. With that in mind here we look at the top 10 most exciting green cars expected to be unveiled at the show.

1. BMW Concept ActiveE

Making its European debut in Geneva, the BMW Concept ActiveE is a fully electric drive vehicle based on the BMW 1 Series (see article). It features a specially developed motor that delivers 125kW/170hp with a maximum torque of 250Nm.

It is capable of accelerating from 0-60mph in 8.5 seconds and has a range of 100 miles on a single charge.

2. New 2011 Ford Focus

Already unveiled to North American audiences in Detroit in January, the 2011 Ford Focus will make its European debut in Geneva with fuel consumption savings of 10-20 per cent compared to outgoing models (see article).

The new Focus is expected to include the next generation Focus ECOnetic technologies including automatic stop-start, smart regenerative charging and low tension front end accessory drive to bring emissions down to a targeted 99g/km with fuel economy at 74.2mpg.

3. Citroen DS High Rider

A brand new hybrid concept, the Citroen DS High Rider hopes to capitalise on the higher efficiency of a diesel combined with an electric motor and is capable of operating by diesel or electric power separately dependent on the conditions (see article).

Details of fuel economy and emissions of this exciting prototype are remaining under wraps until the Geneva Motor Show opens its doors.

4. Peugeot SR1

A new concept car by Peugeot, the SR1 uses the Hybrid 4 technology that is expected to be launched in the Peugeot 3008 in 2011. A 1.6litre THP petrol engine is combined with a rear electric motor that develops 70kW and with the two powertrains operating simultaneously the SR1 can deliver power as high as 230kW.

Its combined fuel cycle performance is 58mpg, with CO2 emissions at 119g/km.

5. New 2011 Audi A1

A new super-mini from the German carmaker, the Audi A1 boasts CO2 emission figures as low as 102g/km according to preliminary figures (see article).

 

Though Audi is shrinking in size to meet green car market demand, the A1 retains its signature sleek, streamlined look and can develop 160Nm of peak torque that enables it to race from 0-62mph in 12.1 seconds with a top speed of 111mph and fuel efficiency in the region of 55.4mpg.

6. New 2011 Bentley Continental SuperSports Convertible

As part of Bentley’s ongoing commitment to biofuels, the manufacturer will debut its flex-fuel capable Continental SuperSports Convertible at the event (see article).

With flex-fuel in full use, CO2 emissions fall by as much as 70 per cent and yet the vehicle still produces remarkable sports car figures, racing from 0-60mph in 3.9seconds and with a top speed of 202mph.

7. New 2010 Volkswagen Polo BlueMotion

Simply one of the greenest cars to date, the new Volkswagen Polo BlueMotion will be the second cleanest conventionally fuelled diesel on the market (behind the Smart ForTwo) with emissions at just 91g/km and fuel efficiency as high as 80.7mpg (see article).

This remarkable small car has certainly stood the test of time but with a new advanced 1.2litre TDI engine, automatic stop-start technology and regenerative braking, it takes the carmaker to an all-time high in fuel efficiency.

8. Vauxhall/Opel Flextreme

The Vauxhall/Opel Flextreme is a diesel plug-in hybrid car that can travel 34miles on its lithium-ion batteries before a small diesel engine starts to charge the batteries (see article). This range-extended concept is a rebadged version of the Saturn Flextreme first introduced in 2008 and is expected to emit 40g/km of CO2 or less based on European test procedures for range extended vehicles.

Its total range is expected to be more than 300miles with average fuel consumption at 174mpg.

9. “5 by Peugeot”

Another Peugeot debutant at the event will be the “5 by Peugeot”, a new concept car that expresses the carmaker’s desire to establish itself in the luxury sector (see article).

With Hybrid 4 technology it has an overall maximum power of 200bhp with super low fuel consumption at 74.3mpg. Its CO2 emissions, although not yet confirmed, are expected to be a meagre 99g/km placing this car right at the top of its sector.

10. New 2011 Lotus Elise

With all the hallmarks of a super car, the new Lotus Elise certainly isn’t the average green car, but thanks to a number of technological advances it manages to combine performance with efficiency (see article).

Thanks to a new 1.6litre engine that is 200cc smaller than the previous Elise model but still produces similar power at 160Nm at 4,400rpm, it has the lowest CO2 output of a petrol sports car in the world with emissions at less than 155g/km of CO2 and fuel economy at 38mpg. Nevertheless it still manages to race from 0-60mph in 6.0seconds with a top speed of 124mph.

The Geneva Motor Show opens to the Press on March 2 and to the public on March 4. We’ll bring you all the latest information from the event in our news section.

Faye Sunderland

The Cologne-Mobil project was launched in Cologne on Monday with Smith Electric Vehicles providing 10 of its Edison electric vans to Ford of Europe to assist with the trial.

The Smith Edison is a pure electric version of the Ford Transit van that is powered by lithium-ion batteries. In urban operations it delivers a range of up to 100miles on a full charge and it boasts a top speed of 50mph.

The company has been producing the van with Ford since 2007 and as part of this latest project will build seven Edison panel vans for delivery services companies, as well as two Edison minibuses for shuttle services and an Edison chassis cab for municipal use.

The aim of the initiative is to research the impact of electric vans and cars on urban air quality, as well as electricity supply infrastructure and their effects on traffic safety. The plan is for scientists to scale up results and examine the true benefits of an electric future for the German city. It is expected that the results of the trial could impact Germany’s efforts to deploy one million zero emission vehicles by 2020.

Ford will supply the final vehicles to clients and will also deploy several Ford Focus battery electric vehicle passenger cars at a later point. It is one of four partners involved in the project that is partly funded by the German government – other members are utility company RheinEnergie AG, the University of Duisburg-Essen and the city of Cologne.

Having ramped up production of green cars with a host of small, efficient vehicles in the works, Ford is now attempting to bring its environmental outlook into its dealerships.

In the US, the company has established the “Go Green” sustainability programme, a voluntary initiative aimed at helping Ford and Lincoln Mercury dealers improve both their energy efficiency and running costs.

As part of the programme, Ford will team with the Rocky Mountain Institute, an energy efficiency organisation, to trial new architectural designs and technologies in dealerships in Florida, New York and Nevada. Dealers that sign up will get a full energy assessment and then be given a number of options to help improve the energy efficiency of existing and new facilities. The company will also offer advice on both state and Federal tax credits and incentives.

According to Sue Cischke of Ford, the initiative means that dealers will soon reflect the same techniques and principles that the company employs to reduce energy use at large.

The Green Piece Column, Tuesday 16 February 2010

Anyone who hadn’t heard of regenerative braking before has surely heard the term now after a host of issues surrounding the hybrid cars produced by both Toyota (see article) and Ford (see article).

So is this technology, that’s meant to boost both fuel efficiency and performance, actually littered with technical issues that are threatening the reputation of vehicle electrification?

How does regenerative braking work

Most people know the basic purpose of regenerative braking – it captures the vehicle’s kinetic energy when you brake and stores it in the battery pack for use during acceleration. However, what is the technical process behind the theory?

Regenerative braking occurs by allowing a vehicle’s electric motor generator to spin freely, which then generates an alternating current which is rectified to direct current to charge a vehicle’s battery pack. The motor generator must be connected to the vehicle’s final drive so that the coasting motion causes it to rotate. The rate of regenerative braking is restricted by both the size of the motor-generator and the amount of charge the battery pack can accept.

With some early hybrids, regenerative braking is employed alongside a conventional hydraulic braking system – hydraulic braking was applied to slow the vehicle when the driver applies the brake pedal and this was supplemented by regenerative braking. However, this system limited the recuperation of brake energy and was deemed effectively redundant by the technology employed by most of today’s hybrid cars that combines friction braking with a control strategy that allows the vehicle to be slowed by as much regenerative braking as possible.

Friction and blended braking

In a non-hybrid vehicle with an electro-hydraulic braking system, pedal force is read by pressure sensors that transfer a signal to a brake control unit which will typically use a motor-driven hydraulic pump and control solenoids to calibrate brake force.

However, with a hybrid vehicle that blends friction and regenerative braking, the applied brake force data must be transferred to a power control unit which calculates the friction-to-regenerative ratio. With the control parameters continually changing – such as the steering angle, rate of deceleration, applied brake force and battery state of charge – and a greater number of control units contributing data, software design can be problematic.

The problem is in the software

Both Toyota and Ford have indicated that their recent issues will be resolved with software changes.

Many of the reports of irregular braking in the 2010 Toyota Prius and some 2010 Ford Fusion and Mercury Milan Hybrids seem to be focused on the activation of ABS with Prius drivers reporting an inconsistent brake pedal feel and a reduction in braking force as they transition from high-traction surfaces to low traction surfaces. Toyota has reported around 200 complaints and four incidents but has not stated whether there have been any injuries – Ford meanwhile, has not cited the number of complaints but has stated there have been no injuries. Toyota has since decided to adopt ‘full disclosure’ of complaints and issues surrounding its vehicles following criticism of its handling of the situation (see article).

How will these issues affect electrification? Our verdict

With Toyota recalling vehicles and Ford informing its customers of potential problems via mail, questions have accumulated about whether the prospects for hybrid electric vehicles and battery electric vehicles have been harmed by this negative publicity.

Certainly a recall is a bump in the road, but to TheGreenCarWebsite.co.uk it is likely to only be a short-term issue. The technology surrounding regenerative braking has been successfully used for more than a decade in the Toyota Prius, as well as in many non-Toyota models, and Toyota itself had previously earned a stellar reputation for quality.

The close scrutiny and media uproar surrounding these issues is not so much an issue about electrification as it is about a catalogue of events that have brought questions about Toyota’s quality. It is likely that it is the company’s reputation that has taken the most severe blow rather than that of hybrid cars in general – and with time, chances are that even Toyota itself will re-emerge and the problems will be a distant memory.

The need for electrification remains strong – there is an urgent need to reduce fuel consumption and CO2 emissions; oil price and supply issues continue to resonate; and, perhaps most crucially, all of the leading car manufacturers have recognised a strategic need to develop hybrid, plug-in hybrid and electric vehicles. With prices too expected to tumble over the next 10 years thanks to a reduction in lithium-ion battery costs, the road remains clear for the era of electrification to continue at full speed.

Faye Sunderland

The Chicago Auto Show will mark the first application of Ford’s global 2.0litre EcoBoost I-4 engine as part of the refreshed 2011 Ford Edge line-up.

Thanks to the use of the EcoBoost system, fuel economy for the new Ford Edge is 30 per cent better than it was when the vehicle was launched in 2006. It also promises 15 per cent fuel economy improvements when compared to the current 3.5litre V-6 engine.

According to Ford, the 2.0litre I-4 engine with direct fuel injection and a single turbocharger has fuel economy benefits that are at least 10 per cent better than a comparable V-6. Just like the first generation EcoBoost system, the I-4 can move quickly to maximum torque and maintain it from a range estimated to span from 2,000rpm to 5,500rpm. It also adds Ti-VCT (Twin Independent Variable Camshaft Timing) technology and the combustion system has been completely redesigned to take advantage of the EcoBoost system’s performance.

Also available with the new Ford Edge will be a 3.5litre V-6 and Edge Sport 3.7litre V-6. The 3.5litre produces 285hp while the 3.7litre produces 305hp. All three engines are also mated to a six-speed automatic transmission with the 2.0litre EcoBoost engine benefiting from a transmission that has been specially calibrated.

There are other features that contribute to the vehicle’s improved fuel economy including: aggressive deceleration fuel shut-off and torque based deceleration control, which shuts off the engine when the customer doesn’t command engine torque to help save fuel; and battery management smart charging which allows the battery to be charged or discharged at optimal opportunities with smart charging increasing the alternator output when the vehicle brakes or decelerates converting the kinetic energy into electrical energy without the need for additional fuel.

The Chicago Auto Show, which opens to the Press today, is the venue for the unveiling of the all-electric version of the Ford Transit Connect.

The vehicle will be powered by a liquid-cooled 28kWh lithium-ion battery pack from Johnson Controls-Saft and has an electric powertrain that includes a Siemens model 135 induction motor, a Borg-Warner 31-03 single speed transmission, the 28kWh lithium-ion battery pack, and a pack voltage range of 215-390V.

The electric Ford Transit Connect will be able to accelerate at approximately the same rate as the petrol-powered vehicle with a top speed of 75mph and a targeted range of 80miles. Owners of the vehicle will also have the option of recharging the vehicle with either a standard 120V outlet or a 240V charge station installed at the user’s base of operation for optimal recharging in six-eight hours.

Just like the standard version of the model, the electric Ford Transit Connect will boast 135 cubic feet of cargo volume; 72.6 inches of load space; split rear cargo doors that open at a standard 180 degrees or an optionally available 255 degrees; a lift-over height of less than two feet when the vehicle is unloaded; and power-assisted rack-and-pinion steering. It has a projected life of 120,000 miles.

Ford has also announced the Ford Transit Connect Taxi that will go into production and arrive in dealerships later this year. According to Mark Fields, Ford’s president of The Americas, there is considerable interest in vehicles that run on alternative fuels and this taxi Transit is designed to meet those needs.

In addition, Ford is planning to bring three more electrified vehicles to the market by 2012 – the Focus Electric in 2011, a plug-in hybrid electric vehicle in 2012 and a next-generation hybrid in the same year.