Ford EV Boasts Speedy Charge Time

Ford Motor Co. says the upcoming Focus electric-vehicle's speedy charge time will differentiate it from competitors and define the EV “ownership experience.”

Unveiled at the 2011 Consumer Electronics Assn.'s annual tradeshow in Las Vegas, the Focus EV, launching in North America later this year, will be able to recharge its batteries in about three hours using a 240V outlet.

That's about half the time of top competitors, including the Nissan Leaf, says Sherif Marakby, Ford's chief engineer-global core HEV propulsion system engineering. The secret is the vehicle's onboard charger.

“Our charger is 6.6 kW, while many competitors are using 3.3 kW,” Marakby tells Ward's “The 6.6 charger is a really new technology.”

When plugged in, the onboard charger converts AC power from the electric grid to DC to charge the car's liquid-cooled/heated lithium-ion 23 kW/h battery pack.

However, opting for the larger charger comes with trade-offs, as the 6.6 kW charger is heavier, and more difficult to package than the lighter 3.3 kW version. But in the end, it was decided the “trade-off was worth it,” Marakby says.

Battery recharging using the standard 120V “convenience cord” that comes with the vehicle takes about 12 hours, compared with 20 hours for the Leaf.

The Focus' 240V wall-mounted charge station will be sold and installed separately by electronics-retailer Best Buy and its Geek Squad subsidiary.

Although other electrified vehicles, such as the Leaf and Chevrolet Volt, also are available with a charging station, Ford's version is unique in that it comes in two parts — a mounting bracket and charging component.

The design drops the installation rate by some 30%, compared with the competition, and allows the station to be relocated should the owner move, Marakby says. “The only cost is to run a wire to the outside of the wall and plug it in. Other chargers with boxes have a more elaborate installation.”

Ford says the Focus EV will have a top speed of 84 mph (135 km/h), near that of the Leaf, which achieves 90 mph (145 km/h).

Derrick Kuzak, Ford's North American product chief, says the 84-mph top speed is a good fit for EV buyers, who are more concerned with environmental issues than driving fast.

The auto maker is less clear on the Focus EV's range, noting only that it will be “competitive” with other battery-electric vehicles. However, Marakby says the reason for not naming a specific range is because it's a moving target.

Range also can change depending on how often and effectively the regenerative brakes are used. Both hybrid and EV brakes capture kinetic energy otherwise lost during slowing or stopping. The captured electricity is funneled back into the battery and is capable of extending the range.

“We've (demonstrated) that customers can recoup about 8 miles (13 km) of range because of regenerative brakes, and that's normal,” Marakby says, noting optimizing the braking procedure can recharge the battery by up to 25%.

To assist drivers in how best to utilize regenerative brakes, Ford has developed an onboard tutoring system that helps drivers learn smooth deceleration generates more electricity than abrupt stops.

To help manage the Focus EV's systems, the auto maker plans to offer the “MyFord Mobile” app free of charge for the first five years of ownership.

The app, compatible with the iPhone, Blackberry and Android-based smartphones, provides users with a vast array of vehicle information, including battery state of charge, range, distance to a charge point and expected range surplus.