Magna Spearheading Ford's Battery EV Program

In 2007, in a bid to diversify, Magna International Inc. executives set out to expand the Canadian supplier's expertise in pure-electric vehicles.

After securing partners versed in electric drivetrains, Magna began looking at how best to demonstrate its technology, Chief Engineer Dick DeVogelaere says.

“The plan was to put it in a vehicle, but we had to decide what the best vehicle was,” he tells Ward's, noting a domestic car was sought because its parts would be readily available.

“We decided on the (Ford) Focus, because it has less mass than some other domestic products. From past experience, we knew Ford (Motor Co.) would be a good partner.”

Magna approached Ford about the project, and officials said to “keep them posted” on its progress, DeVogelaere says.

Magna converted the Focus into a battery-electric vehicle, dubbed BEV, which convinced Ford to sign on as a partner.

As part of the deal, Ford agreed to assist Magna in packaging the electric components and conducting validation testing. The auto maker also supplied Magna with resources it needed from its extensive hybrid-electric vehicle program.

The BEV's electric-traction motor, transmission, motor controller, energy storage system and battery charger all were developed by a team of 30 engineers at Magna's facility in Troy, MI.

Assisting with the program is Magna-subsidiary BluWav Systems LLC of Rochester Hills, MI. Acquired by Magna in October,, BluWav boasts considerable experience in electric and battery technology.

Neither Ford nor Magna will disclose the battery supplier for the program. However, DeVogelaere says it will be a lithium-ion battery utilizing a prismatic cell, rather than cylindrical, for packaging reasons.

There are two test mules on the road, with plans to add a third to the fleet by the end of the January and three more by March 1. A second-generation BEV will be included by the summer's end.