EVLN(e-Ka's new "dedicated soft lithium ion" water-cooled batt)

[Bruce EVangel Parmenter <brucedp@yahoo.com>]

EVLN(e-Ka's new "dedicated soft lithium ion" water-cooled batt)
[The Internet Electric Vehicle List News. For Public EV informational
 purposes. Contact publication for reprint rights.]
 --- {EVangel}
Ford's prototype electric Ka.(Brief Article)(Statistical Data
Included) Jean L. Broge 07/01/2000 Automotive Engineering
International 28 Copyright 2000 Information Access Company. All rights
reserved.  COPYRIGHT 2000 Society of Automotive Engineers, Inc. (SAE
International)

Ford Motor Co. has developed a prototype electric small car, the e-Ka.
Based on Ford's Ka production car, it is powered by a new generation
of lithium ion batteries.  claims to be the first manufacturer to
produce an electric vehicle using this type of battery propulsion,
which the company says has the performance of a gasoline-fueled car
and a range of 150 km (93 mi). The e-Ka was developed at Ford's
Research Center in Aachen to demonstrate the capabilities of new
"dedicated soft lithium ion" water-cooled battery technology.

The lithium ion battery pack is approximately 70% lighter than an
equivalent pack using conventional lead acid technology. The result is
that the e-Ka can accelerate from 0-100 km/ h (0-62 mph) in 12.7 s and
0-50 km/h (0-31 mph) in 3.9 s, with a maximum speed of 130 km/h (81
mph). If the vehicle is maintained at a constant speed of 80 km/h (50
mph) it could travel more than 200 km (124 mi) before needing a
recharge.

A particular advantage of lithium ion battery technology is its
tolerance to high electric current when recharging. Unlike other
battery systems, lithium ion packs are immune to the so-called "memory
effect," retaining full charging capacity regardless of usage.
Featuring an onboard recharger, the e-Ka can be fully charged in just
six hours.

The e-Ka battery pack consists of a total of 180 cells divided into
three separate battery "troughs." One trough is located in the engine
compartment, the other two directly behind and in front of the rear
axle. The entire bundle of lithium ion batteries have a combined mass
of 280 kg (617 lb), which is 70% less than that of normal lead-acid
battery packs. The battery troughs are divided into modules that each
contain six lithium ion cells. An onboard battery-management system
(BMS) constantly monitors the modules both during operation and while
they are being recharged. Data concerning cell voltage, battery charge
status, and the operating temperature of the battery module are passed
through an onboard communications network to the e-Ka's central
control unit, called the Vehicle System Controller (VSC). The VSC
ensures optimum operation of the battery charger, the battery itself,
and the electric motor.

The flow of electricity from the battery unit is automatically shut
off if the system is turned off or if sensors detect a crash. There
are independent coolant systems: one for the drive system consisting
of electric engine, transmission, and differential, and the other for
the lithium ion battery pack. The three battery troughs in the system
are completely sealed.

Ford engineers equipped the vehicle with electric power assisted
steering (EPAS), which uses sensors to register torque as well as
steering wheel position. This data are continually conveyed to an
electronic module, which controls the precise amount of electrically
powered assistance required. The advantages of the EPAS system
compared to conventional hydraulic power steering systems include
compact construction, reduced weight, and environmental benefits. The
e-Ka is also equipped with an electric brake booster and ABS.

The use of a composite material called Hylite, which consists of two
aluminum sheets sandwiching a layer of polypropylene, contribute to a
mass reduction of 5.5 kg (12.1 lb) in the roof and 5.3 kg (11.7 lb) in
the hood. Hylite is up to 65% lighter than aluminum or steel of
comparable stiffness. Aluminum was used for the rear axle, wheels, and
brakes to provide another 35 kg (77 lb) mass reduction. The car is
also equipped with low rolling resistance tires to maximize the
vehicle's range.

The lithium ion battery in the e-Ka has a power density of 126 W
[multiplied by] h/kg and a high-energy capacity for its volume, 197 W
[multiplied by] h/L. In practice, this allows for more energy charging
capacity without an increase in volume or mass. Other advantages of
the lithium ion battery system are longevity, cycle consistency, and
temperature stability.
 ...
 http://www.sae.org/automag/
Automotive Engineering International (SAE)
 ---
Bruce {EVangel} Parmenter  BruceDP@iname.com
         ____        % Use Renewable Energy to charge your EV %
      __/o|__\~        EVangel: messenger bringing good news
=)---'@ -----@'      'Electric cruis'n the Santa Clara Valley'
132V S-10 Blazer EV          http://eaaev.org/brucedp
Electric Vehicle List Editor      http://crest.org/ev-list-archive/


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