Ford UEV platform achieves optimal performance with smaller battery packs
Ford has designed its UEV platform to achieve optimal system performance while using smaller battery sizes. The automaker is changing its electric vehicle development approach by implementing fundamental design simplification instead of continuing to expand battery capabilities. The new Universal Electric Vehicle (UEV) platform from Ford enables the company to achieve longer electric vehicle range through its battery weight reduction and efficiency improvements.
Ford's skunkworks team created a "bounty" culture to control costs for their future mid size electric truck development. The system assigns specific monetary and range values to every millimeter and gram added to the vehicle. The system based method requires engineers from different fields to work toward shared objectives.
- Unified Goals Aerodynamics and interior teams no longer negotiate in isolation; they analyze how design changes impact battery costs.
- Real world Impact For example, adding 1mm to the roof height translates to $1.30 in additional battery costs or a loss of 0.055 miles in range.
Through the optimization of components, the redesign of mirror bodies achieved a 20% size reduction, which resulted in decreased weight and an increase of 1.5 miles to the vehicle's driving range. After Ford bought Auto Motive Power (AMP), the company started making their high voltage power electronics and software design work at their own facilities. The company developed its first 48 volt low voltage system because the new system architecture simplified vehicle design.
Ford has completed multiple technical achievements for its UEV platform by combining internal development of hardware and software components.
The wire harness of the mid size electric truck has been reduced by 4,000 feet, which results in a weight decrease of 22 pounds when compared to the earlier models. The platform reduces the need for over 30 Electronic Control Units (ECUs) scattered throughout the system by introducing five central control modules. The operation of in house bi directional charging and power conversion software provides an efficient energy transfer solution that effectively reduces energy loss during voltage conversion activities from high to low.
The ultimate objective of the UEV platform is to produce a family of electric vehicles that compete on price with gasoline powered counterparts. The EcoBoost engines in the F 150 received turbocharging as a performance upgrade to let the engine achieve higher power outputs from its smaller engine sizes. Ford expects that this integrated platform will enable large scale affordable battery production while delivering high performance for their smaller and lighter battery packs.
The current development of the mid size electric truck marks the first use of this platform, which aims to extend battery life while reducing costs for the battery and total vehicle ownership.
