00:01Untertitelung des ZDF für funk, 2017
00:30Untertitelung des ZDF für funk, 2017
01:30Wir wussten, dass wir noch mehr Tacks auf die Batterie machen können.
01:32Wir wussten, dass wir besser auf eine Sache über alles tun können.
01:36Efficiency.
01:37Und wir haben das mit allen Englern auf dem Projekt gearbeitet.
01:40Mit dem wir bezeichnen, Bounties.
01:43Bounties sind die Numerical Metrics, die wir assignen zu den Faktoren,
01:46wie Vehikel Mass und Aerodynamik Drag.
01:49Faktoren, die direkt zu Efficiency sind,
01:52und daher die Range und die Kosten für die Batterie.
01:55In einem Low-Cost Vehikel,
01:56kann es sichern, um die Kosten zu reduzieren.
02:01Aber wenn wir die Leistung von der Leistung von der Batterie machen können,
02:05dann können wir entscheiden, ob die Batterie einfache,
02:07wenn es die Batterie einfache ist,
02:09macht uns mehr Geld, als die Batterie einfache.
02:12Bounties guide unsere Englern zu machen.
02:15Die Aufgabe ist es zu reduzieren,
02:17die Energie Energie zu reduzieren,
02:18als eine Systeme,
02:20nicht nur eine Optimierung von einer Partie.
02:22Es beginnt mit der all-neue Eintracht Elektrik.
02:25Let me pass it over to Salim to talk about aerodynamics and parasitic friction.
02:33Aerodynamics is a crucial part of an electric vehicle's performance.
02:37Because every bit of inefficiency caused by drag robs you of range.
02:42At higher speeds, drag becomes even more significant.
02:45If you go twice as fast, the air holds you back four times as much.
02:49And you need eight times more power to keep going that speed.
02:52Our designers and engineers across all disciplines worked hand-in-hand with our own team of ex-Formula 1 aerodynamicists.
03:01To make the truck not only look great, but perform even better.
03:06Together, we obsessed over our bounty targets.
03:10Just like in racing, where everyone is united and shaving milliseconds off lap times.
03:14The bounties keep us focused on chasing physics.
03:17When we finally achieved our target, we reset it to continue challenging ourselves and go even further.
03:24One small improvement, let's say a millimeter change in the roof height, equates to $1.30 savings of battery costs.
03:31And as a result, the aerodynamic efficiency of our truck is more than 15% better than any other pickup
03:38truck on the market today.
03:39And will ultimately result in longer range and lower costs for our customers.
03:44If we go underneath the vehicle, you can see how we streamlined the underbody to manage the air.
03:50Starting at the front, we made the bolt holes shallower and carefully directed air around the tire and suspension.
03:57We also painstakingly designed underneath the car to steer the front tire wakes directly onto the rear tires.
04:03Hiding them from the high-speed flow and ultimately reducing drag.
04:07Changes like this can contribute to an estimated 4.5 more miles of range for the customer.
04:13Moving to the back of the car, we positioned the drive units as low as possible.
04:17To reduce the angle of the half-shafts, making them last longer and minimizing wasted energy caused by friction in
04:23the joints.
04:25We then sculpted the motor case to allow the air we carefully managed at the front to pass under the
04:30vehicle uninterrupted to reduce the size of the wake.
04:34Here, the roof was sculpted to carefully shed the high-speed air on top in a teardrop shape over the
04:39bed, creating a virtual surface for the air to completely skip over it.
04:44To the air, it's no longer a truck.
04:46We also applied the same mindset to the side mirrors.
04:50Instead of separate motors for glass adjustment and another motor for folding, we've merged those functions into a single actuator.
04:57The entire body of the mirror now moves.
05:00The mirror body size is now more than 20% smaller than a conventional mirror, which reduces mass, saves on
05:06costs, and unlocks a more aerodynamic shape, resulting in 1.5 miles more range for the vehicle.
05:12We also needed to reduce mechanical friction, so the team obsessed over every single bearing, seal, and joint inside the
05:20vehicle.
05:20We treated the drive unit oil management system just like a race car.
05:24Our control software, which can be updated and improved over the air, adjusts the speed of the electric oil pump
05:29so it runs at the lowest speed possible to cool the motors and lubricate the gears,
05:34while carefully designed jets and baffles reduce windage inside the gear case.
05:37And to make sure we aren't letting any energy go to waste, we enhanced the design of our regenerative brake
05:43system,
05:44which, like all electric vehicles, captures the kinetic energy, converting it into usable electric power for the high-voltage battery.
05:52Our new design will save us around $100 in battery costs.
05:55The result of all this work?
05:57If the same battery was married to the aerodynamics of the most aerodynamically efficient mid-sized gas truck in the
06:03U.S.,
06:03we believe our new electric truck would have nearly 50 miles, or 15% more driving range, and a 30
06:09% improvement at highway speeds.
06:11That's what happens when every curve, every surface, every detail has been obsessed over, over and over again, and works
06:20together as a system.
06:21Now let me turn it over to Vlad to talk about the vehicle structure.
06:30Vlad is another one of our greatest efficiency robbers.
06:33Our engineering team had a philosophy.
06:36The best part is no part.
06:38If the part is necessary, then it must serve multiple purposes.
06:42It's not easy to find those opportunities.
06:45That is why we need a close collaboration of a small, nimble team.
06:49So first, we focus on reducing one of our biggest contributors to the vehicle weight, body structure.
06:56To do this, Ford is using large, aluminum unicastings for the first time.
07:03These unicastings make the structure significantly lighter,
07:08delivering more than 27% advantage in casting weight over our competitors.
07:13They also serve as a structural element of the mixed-metal body structure architecture.
07:19which is the backbone for both vehicle and assembly process.
07:25To put a final point on it, by comparison to the Maverick,
07:28has 146 structural parts in the front and the rear structure.
07:33The mid-size electric pickup truck will have two parts.
07:38Using unicastings enables 25% fewer fasteners than typical program.
07:43With reduction in parts comes reduction in joints, ceiling,
07:47their four robots in the factory giving us immeasurable gains in product quality and the throughput.
07:53Let me hand it over to Alan to talk about the battery.
08:12Now let's take a look at another big contributor to weight, the battery.
08:17Our holistic focus led the team to select a low-cost chemistry called lithium-iron phosphate, or LFP.
08:25With no nickel or cobalt, our battery cell contains lower-cost ingredients over other battery chemistries.
08:32Next, we focused on the packing of the battery cells.
08:36Think of it like a puzzle.
08:39We're trying to fit the most battery material possible inside the pack.
08:43Our prismatic LFP form factor enables an incredibly efficient cell-to-structure architecture.
08:50This architecture essentially turns the battery into an integral part of the truck's skeleton.
08:55The battery pack also uses a multi-layer, single-piece, flexible circuit board.
09:01This board integrates low-voltage, high-voltage, and thermal-sensing connections, reducing hundreds of bus bars and wires into a
09:09single part.
09:10We can measure voltage and temperature, and connect each cell using this hyper-efficient module.
09:16Overall, the cell-to-structure architecture reduces non-cell cost.
09:21It also works together with a super-compact, in-house-designed power electronics inside the battery pack.
09:27This eliminates extra connectors, enclosures, mass, and overall volume.
09:33Instead of carrying the cells, this new architecture couples the cells directly to the structure.
09:39This makes the cabin quieter, and the structure more capable of excellent, dynamic performance.
09:46It's also a key enabler in delivering our new universal production system.
09:51Which means, our family of electric vehicles will be super fun to drive.
09:55A non-negotiable here at Ford.
09:57And let's not forget, we're using proven, long-lasting battery cell technology that ships in millions of vehicles today.
10:05We then married this battery technology with Ford's new innovative approach to make these cells into a pack.
10:11We'll be making the battery cells right here in the United States, at Blue Oval Battery Park, in Marshall, Michigan.
10:18Now let me turn it over to Lucas, to share more about our electric vehicle architecture.
10:26Okay, this is where we get a little more technical, but stay with me here.
10:31Vlad already told you about our philosophy, and you see it come to life in our approach to the vehicle's
10:36electrical architecture, too.
10:37I joined the team two years ago when Ford acquired automotive power.
10:41At Amp, we specialize in pushing the limits of energy management, and we've brought that expertise here to optimize hardware
10:48and software for faster charging and smarter battery performance.
10:52With this platform, we're moving to a zonal architecture, where we're integrating multiple vehicle functions into a small number of
10:58modules.
10:59Conventional vehicles are built with over 30 scattered electronic control units, or ECUs, which are the brains of the vehicle.
11:08In the past, they were individually housed and sourced from various suppliers.
11:13This results in a tangled web of connectors and wiring, adding complexity and weight and cost to both manufacturing and
11:20assembly.
11:21Our platform combined those into five main modules, drastically reducing cost and complexity of the wire harness.
11:28We're also moving from a 12-volt system to a 48-volt system, which allows us to reduce the copper
11:34thickness of the harness.
11:35In fact, these changes helped us make the mid-size electric truck's wire harness 4,000 feet shorter and 22
11:42pounds lighter than one of our first-gen electric vehicles.
11:45We did not stop this consolidation effort on the zonal modules, but carry the same philosophy to the power electronic
11:52components, which are the muscles of an electric vehicle.
11:56For example, the DC-to-DC converter, which converts the 400 volts battery power to 48 volts, now shares a
12:04board and components with the AC-to-DC charger.
12:06This single module also manages power distribution, battery management, and provides AC power back to your home during an outage.
12:14Grouping these together allowed us to consolidate common parts, such as sensors and auxiliary supplies, reducing the number of components
12:21and printed circuit boards.
12:23This results in a surprisingly small and serviceable unit.
12:27Despite all its capabilities, it's elegant in its simplicity, and we call it the E-Box.
12:33Lastly, I want to talk a bit about some of the diagnostics we intend to run on the battery packs.
12:39We're leveraging machine learning to create a predictive model for the battery pack, which will track and adapt its usage
12:45based on both historical data and real-world conditions.
12:49This will, for example, allow us to adjust charging rates to help prevent degradation of the battery over time.
12:56Let me turn it back to Alan.
13:01So that's how the team is collaborating to develop the platform.
13:04We're using a true systems engineering approach across design, product development, software engineering, supply chain, and manufacturing to completely rethink
13:14vehicle production.
13:16Every decision centers on how much we can reduce the size of the battery.
13:20How can we give more to the customer so they get better value?
13:23For our industry to truly unlock the transformative potential of electric vehicles, the strategic integration is foundational to achieve cost
13:31parity with gas vehicles.
13:33Gas cars have been optimized over the last hundred years, but there are still countless ideas for reducing the cost
13:40and increasing the capabilities of electric vehicles.
13:43The technology, engineering, creativity, and innovation are already happening.
13:50We need to scale these advancements and deliver them to dryways across America and around the world.
13:56We can't wait to share more as we continue on our path to deliver our universal EV platform and a
14:02family of compelling and fun-to-drive affordable electric vehicles.
14:07Thanks for coming along for the ride.
14:09We can't wait to get you behind the wheel.
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