Ford Ecostar
Encyclopedia
The Ford Ecostar was an experimental electric car
in the form of a small delivery van. A sodium-sulfur battery
in the floor of the cargo area stored power for a 75 hp electric motor under the front hood. The Ecostar introduced the road-and-leaf logo now used on a number of Ford products.
Just over 100 Ecostars were produced, and used in fleet tests between 1992 and 1996 with over 1000000 miles driven. The Ecostar averaged 94 miles on a full charge, and demonstrated 155 miles miles range in one test. However, on several occasions the battery burst into flame during recharging. For this, and several other reasons, Ford lost interest in the sodium-sulfur battery and turned to fuel cell
concepts instead.
The product niche appeared to be a useful one and has led to a number of similar designs. The Citroën Berlingo électrique
was almost identical in looks, performance and range. Ford is re-entering the market as well, with an electric version of the Transit Connect.
The Ecostar was introduced as a purely experimental effort, to help develop all aspects of electric vehicle design from engineering to supplier development to market development. A "prototype-of-the-prototypes" was completed with lead acid batteries in 1992, and introduced with the comment that future models would include the new battery technology. Several similar models followed and were lent out for test drives with favorable results.
A total of 80 to 105 "production-prototype" sulfur-powered Ecostars were hand-built starting in 1993, and used in fleet trials with a number of customers starting the next year. At the time, the cost of the battery was a significant $46,000. However, the vehicles were hand-built at a cost of $250,000, so the battery cost was not representative of a production version.
The tests ran for 30 months. Throughout the tests there were problems with the system, including two vehicles that burst into flame while charging. The sulfur in the battery was flammable, a serious safety risk. ABB introduced a new version of the battery, but was unwilling to guarantee performance beyond one year.
In late 1997, Ford announced a partnership with Daimler-Benz
and Ballard Power Systems
to introduced car-ready fuel cell
s, and their experiments with the sodium-sulfur batteries ended.
factory outside Liverpool
. This was essentially a European Escort Mk V with a raised cargo area forming a 2-door panel van
. Fully equipped, it weighed 3100 lbs.
A significant portion of that weight was its 780 pounds (354 kg) sodium-sulfur battery
, which stored 37 kWh. Using the Federal Urban Driving Schedule, this gave the Ecostar a range of 100 miles. The sodium-sulfur technology was invented by Ford in the 1960s, but the battery for the Ecostar was built by ABB Group in Heidelberg, Germany. In order for the battery to work, it had to be maintained at a temperature of 600 °F (316 °C), which keeps the sulfur molten.
To avoid heat loss, and to insulate the cabin from its heat, the battery was stored inside a double-walled stainless steel vacuum bottle. This allowed it to stay warm overnight, and keep its temperature constant even during cold weather, when traditional batteries are less responsive. The container was mounted below the floor plan of the cargo area, which gave the vehicle a low center of gravity that give it well-liked handling. One complaint, however, was the lack of power steering
.
The battery powered a three-phase electric motor located under the hood in the area normally used for the gasoline engine. The motor delivered only 75 hp, low for a vehicle of this size, but up to 143 foot-pounds of torque
, numbers typical of a much more powerful gasoline engine. This was better torque than the Ford Escort GT, for instance, whose 1.8 litre four-cylinder engine delivered 127 hp but only 114 ft-lb.
One drawback of the sodium-sulfur battery is its relatively slow discharge rates, which limited the amount of power that could be drawn from the battery during acceleration. Drivers described it as "sedate", while Ford estimated its 0-60 mph (0-100 km/h) acceleration at about 16.5 seconds. While slow by car standards, this is similar to other small European delivery vans of the era, like the Volkswagen Eurovan.
While cruising the motor used only 8 kW to maintain speed, about 6 hp. This speaks to the motor-to-wheel efficiency of the electric drivetrain, as well as the 50 psi low-drag tires. However, the long quoted ranges referred only to driving, not accessory systems. These added considerably to the load; the electric heater burned 5 kW, and the air conditioner 6 kW. In real-world driving, using either would significantly impact range.
Electric car
An electric car is an automobile which is propelled by electric motor, using electrical energy stored in batteries or another energy storage device. Electric cars were popular in the late-19th century and early 20th century, until advances in internal combustion engine technology and mass...
in the form of a small delivery van. A sodium-sulfur battery
Sodium-sulfur battery
A sodium–sulfur battery or liquid metal battery is a type of molten metal battery constructed from sodium and sulfur . This type of battery has a high energy density, high efficiency of charge/discharge and long cycle life, and is fabricated from inexpensive materials...
in the floor of the cargo area stored power for a 75 hp electric motor under the front hood. The Ecostar introduced the road-and-leaf logo now used on a number of Ford products.
Just over 100 Ecostars were produced, and used in fleet tests between 1992 and 1996 with over 1000000 miles driven. The Ecostar averaged 94 miles on a full charge, and demonstrated 155 miles miles range in one test. However, on several occasions the battery burst into flame during recharging. For this, and several other reasons, Ford lost interest in the sodium-sulfur battery and turned to fuel cell
Fuel cell
A fuel cell is a device that converts the chemical energy from a fuel into electricity through a chemical reaction with oxygen or another oxidizing agent. Hydrogen is the most common fuel, but hydrocarbons such as natural gas and alcohols like methanol are sometimes used...
concepts instead.
The product niche appeared to be a useful one and has led to a number of similar designs. The Citroën Berlingo électrique
Citroën Berlingo Electrique
The Citroën Berlingo électrique is a battery-powered version of the Berlingo range of vans. It has a 162 V Saft NiCd battery , a 28 kW Leroy Somer electric motor and has a maximum speed of 95 km/h , with a maximum range of in typical driving...
was almost identical in looks, performance and range. Ford is re-entering the market as well, with an electric version of the Transit Connect.
History
Ford developed the sodium-sulfur battery technology in 1965, but had not developed it commercially. Development was later picked up in Europe.The Ecostar was introduced as a purely experimental effort, to help develop all aspects of electric vehicle design from engineering to supplier development to market development. A "prototype-of-the-prototypes" was completed with lead acid batteries in 1992, and introduced with the comment that future models would include the new battery technology. Several similar models followed and were lent out for test drives with favorable results.
A total of 80 to 105 "production-prototype" sulfur-powered Ecostars were hand-built starting in 1993, and used in fleet trials with a number of customers starting the next year. At the time, the cost of the battery was a significant $46,000. However, the vehicles were hand-built at a cost of $250,000, so the battery cost was not representative of a production version.
The tests ran for 30 months. Throughout the tests there were problems with the system, including two vehicles that burst into flame while charging. The sulfur in the battery was flammable, a serious safety risk. ABB introduced a new version of the battery, but was unwilling to guarantee performance beyond one year.
In late 1997, Ford announced a partnership with Daimler-Benz
Daimler-Benz
Daimler-Benz AG was a German manufacturer of automobiles, motor vehicles, and internal combustion engines; founded in 1926. An Agreement of Mutual Interest - which was valid until year 2000 - was signed on 1 May 1924 between Karl Benz's Benz & Cie., and Daimler Motoren Gesellschaft, which had...
and Ballard Power Systems
Ballard Power Systems
Ballard Power Systems , located in Burnaby, British Columbia -- a suburb of Vancouver -- is a company that designs, develops, and manufactures zero emission proton-exchange-membrane fuel cells. This company has made a bus that uses only hydrogen fuel cells. These fuel cells combine hydrogen and...
to introduced car-ready fuel cell
Fuel cell
A fuel cell is a device that converts the chemical energy from a fuel into electricity through a chemical reaction with oxygen or another oxidizing agent. Hydrogen is the most common fuel, but hydrocarbons such as natural gas and alcohols like methanol are sometimes used...
s, and their experiments with the sodium-sulfur batteries ended.
Description
The Ecostar's chassis was based on the Escort Van produced by Ford's Halewood Body & AssemblyHalewood Body & Assembly
Halewood Body & Assembly is a Jaguar Land Rover production facility based in Halewood, Merseyside, England.Halewood was originally opened by the Ford Motor Company on 2 October 1963 to build the then small-saloon sized Ford Anglia...
factory outside Liverpool
Liverpool
Liverpool is a city and metropolitan borough of Merseyside, England, along the eastern side of the Mersey Estuary. It was founded as a borough in 1207 and was granted city status in 1880...
. This was essentially a European Escort Mk V with a raised cargo area forming a 2-door panel van
Panel van
A panel van is a form of solid van, smaller than a lorry or truck, without rear side windows...
. Fully equipped, it weighed 3100 lbs.
A significant portion of that weight was its 780 pounds (354 kg) sodium-sulfur battery
Sodium-sulfur battery
A sodium–sulfur battery or liquid metal battery is a type of molten metal battery constructed from sodium and sulfur . This type of battery has a high energy density, high efficiency of charge/discharge and long cycle life, and is fabricated from inexpensive materials...
, which stored 37 kWh. Using the Federal Urban Driving Schedule, this gave the Ecostar a range of 100 miles. The sodium-sulfur technology was invented by Ford in the 1960s, but the battery for the Ecostar was built by ABB Group in Heidelberg, Germany. In order for the battery to work, it had to be maintained at a temperature of 600 °F (316 °C), which keeps the sulfur molten.
To avoid heat loss, and to insulate the cabin from its heat, the battery was stored inside a double-walled stainless steel vacuum bottle. This allowed it to stay warm overnight, and keep its temperature constant even during cold weather, when traditional batteries are less responsive. The container was mounted below the floor plan of the cargo area, which gave the vehicle a low center of gravity that give it well-liked handling. One complaint, however, was the lack of power steering
Power steering
Power steering helps drivers steer vehicles by augmenting steering effort of the steering wheel.Hydraulic or electric actuators add controlled energy to the steering mechanism, so the driver needs to provide only modest effort regardless of conditions. Power steering helps considerably when a...
.
The battery powered a three-phase electric motor located under the hood in the area normally used for the gasoline engine. The motor delivered only 75 hp, low for a vehicle of this size, but up to 143 foot-pounds of torque
Torque
Torque, moment or moment of force , is the tendency of a force to rotate an object about an axis, fulcrum, or pivot. Just as a force is a push or a pull, a torque can be thought of as a twist....
, numbers typical of a much more powerful gasoline engine. This was better torque than the Ford Escort GT, for instance, whose 1.8 litre four-cylinder engine delivered 127 hp but only 114 ft-lb.
One drawback of the sodium-sulfur battery is its relatively slow discharge rates, which limited the amount of power that could be drawn from the battery during acceleration. Drivers described it as "sedate", while Ford estimated its 0-60 mph (0-100 km/h) acceleration at about 16.5 seconds. While slow by car standards, this is similar to other small European delivery vans of the era, like the Volkswagen Eurovan.
While cruising the motor used only 8 kW to maintain speed, about 6 hp. This speaks to the motor-to-wheel efficiency of the electric drivetrain, as well as the 50 psi low-drag tires. However, the long quoted ranges referred only to driving, not accessory systems. These added considerably to the load; the electric heater burned 5 kW, and the air conditioner 6 kW. In real-world driving, using either would significantly impact range.
See also
- Ford introduced the Transit Connect Electric vehicle, similar to the Ecostar, in 2010
- Ford also made an electric version of the Ford RangerFord RangerThe Ford Ranger is a pickup truck produced by the Ford Motor Company. The "Ranger" name had previously been used for a premium styling package on the F-Series full-sized pickup trucks since 1965. The name was moved to this line of North American compact trucks for the 1983 model year.In North...
pickup truck
Further reading
- GH Cole, "Dynamometer Testing of the Ford Ecostar ElectricVehicle #41", INEL HEV Laboratory, 1995