Ford, Samsung shack up to bring regen braking to non-hybrid models [w/video]

Mon, 09 Jun 2014

Ford must be desperate to get itself ready for the beach this summer because it is really trying to get into shape. Shortly after unveiling the Lightweight Concept that cut the weight of a Fusion down to that of a Fiesta, it's now the rest of the line's turn for improvement. The company is wrapping up a 10-year research project aimed at developing next-gen automotive batteries to improve efficiency.

Ford claims that 70 percent of its lineup will have stop/start tech by 2017. The key to this massive proliferation is its new dual-battery system that combines a lithium-ion battery with a lead-acid one and regenerative braking. The setup works by harvesting braking energy and converting it to electricity. When the vehicle stops, the engine shuts off, but the Li-ion battery has enough juice to keep the accessories running. The engine starts up again as drivers take their foot off the brake. The layout would mean less wasted gas while idling. It's already available on Ford hybrids and is somewhat similar to the i-Eloop capacitor-based system from Mazda.

The bigger challenge is tuning the regenerative braking right. While hybrid drivers may be a little more adventurous, when it comes to getting a hang of regen braking, conventional buyers might not be so open-minded. The systems have a tendency to be a little grabby at first and then taper off at very low speeds. Ford needs to make sure it's just right to avoid turning off buyers.

The other big breakthrough from the research is the possibility of replacing lead-acid batteries entirely with a Li-ion unit. Ford thinks it could save about 12 pounds over a standard battery, while being physically smaller. Scroll down to watch a video of Ford and Samsung showing off their new battery tech and to read the full release about it.

FORD AND SAMSUNG RESEARCH NEXT-GENERATION BATTERY TECHNOLOGY

Dual-battery system research combines lithium-ion with lead-acid batteries enabling regenerative braking and greater fuel savings

Ford and Samsung SDI research new ultra-lightweight lithium-ion battery concept that could one day render traditional lead-acid batteries obsolete

Leveraging innovation in consumer electronics batteries may lead to reductions in size and weight of automotive batteries, as well as increased efficiencies and capability

Ford Motor Company and Samsung SDI, an affiliate of Samsung Group, today announced research on different levels of hybrid technology that could one day be produced in high volume on non-hybrid vehicles for greater fuel savings.

The result of a 10-year research effort, the dual-battery system combines a lithium-ion battery with a 12-volt lead-acid battery that could enable regenerative braking technology in non-hybrid vehicles for greater fuel savings.

"We are currently expanding our Auto Start-Stop technology across 70 percent of our lineup, and this dual-battery system has the potential to bring even more levels of hybridization to our vehicles for greater energy savings across the board," said Ted Miller, senior manager, Energy Storage Strategy and Research, Ford Motor Company. "Although still in research, this type of battery could provide a near-term solution for greater reduction of carbon dioxide."

Currently available on Ford's hybrid vehicles, regenerative braking enables the battery to capture up to 95 percent of the electrical energy normally lost during the braking process for reuse. The system works in conjunction with Ford's Auto Start-Stop, which seamlessly turns off the engine when a vehicle stops to save fuel. An advanced battery then powers vehicle accessories and systems in place of the engine until the driver begins to release the brake pedal, which restarts the engine.

Light-weighting battery technology
Ford and Samsung SDI also are researching a longer-term ultra-lightweight lithium-ion battery that could one day render traditional lead-acid batteries obsolete. The research advances lithium-ion battery technology currently available on Ford's electrified vehicles.

"Lithium-ion batteries are typically used in consumer electronics because they are lighter and more energy-dense than other types of batteries, which also make them ideal for the vehicle," said Mike O'Sullivan, vice president, Automotive Battery Systems for Samsung SDI North America. "Battery technology is advancing rapidly and lithium-ion could one day completely replace traditional 12-volt lead-acid batteries, providing better fuel efficiency for drivers."

Ford, Samsung Research Next-Generation Battery Technology
Lithium-ion batteries currently used in Ford's electrified vehicles are 25 percent to 30 percent smaller than previous hybrid batteries made of nickel-metal-hydride, and offer approximately three times the power per cell.

The ultra-lightweight battery concept offers a weight reduction of up to 40 percent, or 12 pounds. Combining the battery with other weight reduction solutions, such as the Ford Lightweight Concept vehicle, could lead to additional savings in size and weight of the overall vehicle, as well as increased efficiencies and performance.

Ford's battery legacy
Ford has supported battery research for 100 years, dating back to Henry Ford and Thomas Edison's work on electric vehicles employing nickel-iron batteries as a replacement for lead-acid batteries.

Last year, the company invested $135 million in design, engineering and production of key battery components, and doubled its battery testing capabilities. Ford accelerated its battery durability testing, with test batteries now accumulating the equivalent of 150,000 miles of use and 10 years' life in roughly 10 months in a laboratory setting.

Ford has directly supported several energy storage companies in California in their technology development through the United States Advanced Battery Consortium. Further, Ford supports energy storage research at Lawrence Berkeley National Laboratory, University of California, Berkeley, and Stanford. The company has provided significant support to, and been closely involved with, advanced energy storage technology development in California for several decades, with some technologies applicable for other uses, including grid-scale energy storage.

By Chris Bruce