Ford Fiesta Hybrid Concept Car Announced September 2004

Aachen, 21 September, 2004 Engineers from Ford's Aachen Research Centre in Germany have developed a micro hybrid Ford Fiesta capable of improving fuel economy by a minimum of five per cent. In heavy traffic with frequent stops this figure could rise to as much as 15 per cent, saving the owner up to ¬150 a year in fuel costs at today's prices, and also lowering exhaust emissions by a similar amount.

Although it is currently a research project, the Fiesta micro hybrid potentially could be in production by 2006. Ford's partner in the development of the system is Valeo, the supplier for electrical car systems from France.

Stop/start and regenerative braking technology

At the heart of the Fiesta micro hybrid's powertrain is a standard Duratec 1.4 litre 80 PS petrol engine coupled to a Durashift 5-speed manual transmission. However, on this prototype start-stop technology, a regenerative braking function and advanced battery management are fitted.

In stop-start driving conditions, such as heavy traffic or at traffic lights, the engine of the micro hybrid Fiesta switches off whenever the car is brought to a halt. An integrated system of sensors enables the engine instantly to start again when the driver instinctively performs one first of a number of actions that signal the intent to drive off.

The process is almost imperceptible, and occurs when the brake pedal is released or when the accelerator or clutch pedal is operated. The intelligent control strategy also ensures that the system does not operate during parking manoeuvres.

While stationary, all the car's electrical systems operate normally using stored electrical energy delivered by the regenerative braking function.

The Ford Fiesta micro hybrid concept is fitted with technology that allows part of the braking energy to be converted into electricity and stored in the battery in the engine compartment. To make this happen, the starter-generator as provided by Valeo applies bigger load forces during engine deceleration.

Under these conditions, the Fiesta decelerates with engine braking forces that are more typical for a diesel engine despite the prototype having a conventional petrol powertrain.

Effectively this electricity, generated during deceleration phases is for free, requiring no fuel-expending power from the engine to operate the generator and thus charge the battery. The regenerative braking system even works on motorways when the driver lifts off the throttle pedal to slow down gently.

Belt-driven Integrated Starter Generator

The technology that delivers these fuel-saving functions is known as a Belt-driven Integrated Starter Generator (B-ISG).This system operates as a generator and a starter combined in one unit that is not very much larger than a standard alternator.

The engine compartment of the micro hybrid Fiesta looks little different from that of the standard car even the battery looks the same, although it features all-new adaptive glass mats technology that is tolerant of high charging cycles.

The Ford Fiesta micro hybrid concept has all the functionality and features of the highly-praised standard Fiesta, including excellent driving dynamics. No bodywork modifications are required and the stop/start system is automatically disabled when the engine is warming up or when the air conditioning system is operating under a heavy load.

Reduced emissions

The advanced hardware and Ford-developed software mean that the car is actually 'cleaner' in terms of emissions than the latest Euro IV standard even with all the stopping and starting.

"We worked very hard to ensure that drivers didn't have to change their driving habits when behind the wheel of this micro hybrid concept Ford Fiesta and that everything was straightforward to use and easy to understand," said Don Kees, technical leader on the project.

"So far, the feedback from those who have driven the car has been hugely encouraging. Almost everyone mentioned that the system is really fun to operate," he added.

Editors' notes: Ford defines the three main types of hybrid vehicles thus:

Micro hybrids feature stop/start functionality with no electric propulsion support. Other features include efficient generator, regenerative braking, comfort stop/start.

Mild hybrids can have all of the above plus limited electrification of propulsion, typically 5-12 kW and less than 1kWh storage capacity.

Full hybrids feature a high electrification of propulsion, typically more than 20 kW and more than 1kWh storage capacity. They have a power assist feature, usually in association with a smaller internal combustion engine than the base vehicle and limited zero emission (electric only) operation using its own on-board electric motor.

SOURCE: Ford

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