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Ford Expands Customer Choice – Lowers Manufacturing Cost

original post at Clean Fleet Report

The new Ford Fusion gives car owners unprecedented choice in powertrains and fuel economy. The Ford Fusion can be offered with an efficient EcoBoost engine or as a hybrid with better mileage than any midsized sedan or as a plug-in hybrid that allows many trips to use zero gasoline.

Classic styling, smooth driving, and excellent fuel economy come together in this new five-passenger midsized sedan. Market research revealed that 2 out of 3 U.S. shoppers, before buying, consider a midsized sedan, SUV, or liftback. One out of three buy a midsized sedan, according to Ford. The stakes are high. Safety and reliability perceptions are always a factor.

Ford saw Toyota Camry and Honda Accord sales decline starting when oil prices went over $100 per barrel, accelerate during the Great Recession, and take another hit during Japan’s earthquake and Thailand mudslide disasters. A shift from sedans to liftbacks and SUVs, both with more cargo flexibility, has been another factor. Fuel economy and car lifetime operating costs are important to many buyers.

The new Fusion Hybrid offers a breakthrough 47 miles per gallon (mpg) city and 44-mpg highway. The overall 46-mpg is 4 mpg better than the new Toyota Camry Hybrid. The Fusion has a plug-in hybrid option, the Camry currently does not, but Clean Fleet Report predicts that one will be announced this year. Long term, Ford threatens to leapfrog Toyota’s hybrid leadership with a broad offering of pure battery-electric cars, plug-in hybrids, and hybrids. Unlike Toyota, all 2013 Ford hybrids will use lithium batteries while Toyota primarily stays with nickel metal hydride batteries.

Ford is now in a race with the Renault-Nissan Alliance to be first to sell 100,000 cars in one year with lithium batteries and electric motors. Either or both will achieve this in 2013. In the process they are driving down the cost of lithium batteries, electric motors, and advanced power electronics, making hybrid and electric cars more affordable.

2013 Ford Fusion Energi Plug-in Hybrid

Arriving this fall, Fusion Energi is anticipated to deliver more than 100 MPGe, a mile per gallon equivalency metric for electrified vehicles. This is 8 MPGe more than the Chevrolet Volt and 13 MPGe more than the projected efficiency of the Toyota Prius plug-in hybrid model. Many Volt owners tell me that in real world driving their first 40 miles are electric mode before the gasoline engine engages.

The Fusion Energi is expected to deliver 20 to 30 miles in electric mode, provided the driver stays below 62 miles per hour. The average American drives 4 trips daily with 40-miles per total. City streets and stop-go freeway are much of that driving. The Energi will support Level One and Level Two charging. Go fast, or use most of the lithium battery storage and the Energi drives like a hybrid with its electric motor and 2 liter, 4-cylinder Atkinson cycle engine working together. An electronically controlled continuously variable transmission (eCVT) helps fuel economy.

We will learn more about electric range, motor and battery specs as Ford starts sales in Fall 2012. Sales will start shortly after sales of the Ford Focus Electric and the Ford C-Max Plug-in Hybrid crossover. Ford is expected to make battery packs but use different cell chemistry for pure-electrics, plug-in hybrids and hybrids. Compact Power, a subsidiary of LG Chem, will supply the lithium-ion tri-metal cells and packs for the 2013 Ford Focus Electric.

2013 Ford Fusion Hybrid

Ford Fusion Hybrid interior 37k Ford Fusion Hybrid and Plug in Hybrid for Best Sedan MPGThe Fusion Hybrid – 2010 North American Car of the Year – continues to innovate with new lithium-ion batteries that save 50 percent battery weight, 30 percent size, and generate more power than previous nickel-metal hydride batteries, while raising maximum speed under electric-only power from 47 mph to 62 mph. Even with a smaller battery-pack, however, the Hybrid and Energi only offer 12 cubic-feet of trunk space. The non-hybrid fusion is over 15 and the back seat can be lowered for much more cargo.

Fusion Hybrid also features an all-new 2.0-liter Atkinson-cycle four-cylinder gasoline engine, significantly downsized from the previous 2.5-liter unit while maintaining performance standards. This innovative powertrain is anticipated to deliver best-in-class fuel economy of 47 mpg in city driving and 44 mpg on the highway.

Fusion Hybrid fuel economy stands to outperform the 2012 Toyota Camry Hybrid by 4 mpg city and 5 mpg highway and the 2011 Hyundai Sonata Hybrid by 12 mpg and 4 mpg, respectively. The Fusion Hybrid is one of the top 10 hybrid cars.

2012 Fusion Achieves 32 MPG and Optional AWD

Fusion brings the broadest selection of fuel-efficient powertrains in the midsize car segment. It offers hybrid and plug-in hybrid alternatives, a pair of EcoBoost™ four-cylinder engines, a normally aspirated four-cylinder engine, an automatic start stop system to shut off the engine at stationary idle, front-wheel drive and all-wheel drive (AWD) applications, and a choice between automatic and manually shifted six-speed transmissions.

The 1.6-liter EcoBoost outperforms many larger 6-cylinder engines with non-hybrid fuel efficiency of 26 mpg in the city and 37 mpg on the highway, 32 mpg combined. The 2.0-liter EcoBoost engine – paired with a paddle-shifted six-speed SelectShift Automatic™ transmission, available 19-inch wheels and tires, and all-wheel drive with the ability to send additional torque to the rear – is the Fusion performance option.

Safety Technology and Telematics

The all-new Fusion offers an unprecedented portfolio of driver assistance and convenience technologies based on sensors, cameras and radar that enable the car to see and respond. Fusion can help drivers maintain proper lane position, adjust vehicle speed to changing traffic conditions, identify suitable parking spaces and help park, even aiding drivers backing out of parking space where visibility is obstructed.

Ford Motor has taken customer choice to a new level by reinventing the popular midsized sedan with powertrain options including efficient EcoBoost engine or 46 mpg hybrid drive system or plug-in hybrid drive system. The Lincoln MKZ adds to customer choice with a premium hybrid with the same powertain as the Fusion Hybrid. With customer choice Ford also maximizes utilization of the same manufacturing line with most parts common to all versions. With its growing offering of electrified vehicles and volume manufacturing, Ford is lowering the cost of lithium battery packs, electric motors, and electric powertrains.