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Auto Tech: 2010 Ford Fusion Hybrid powertrain

May 20, 2009

Depending on the hybrid computer programming, the electric motor can be designed to just compensate for the lower gas engine torque, or it can be programmed to provide much more torque than possible with just a gas engine. The Honda Accord Hybrid was designed more with power in mind. Most other hybrids are programmed for a balance of economy and power and the Fusion is no exception.

2010 Ford Fusion Hybrid. Click image to enlarge

The electric motors For the Fusion Hybrid are located inside their E-CVT transaxle. Two electric motors/generators are meshed together through a planetary gearset. By varying the speed and direction of the two motors, a continuously variable gear ratio can be obtained from the planetary gearset, which is a big benefit in performance and economy. When the gasoline engine is operating in conjunction with the electric motors, the engine can be operated at the best r.p.m. for economy instead of having to operate over a wider rpm range.

Another feature of the E-CVT is that both motor/generator units can be used for regenerative braking. With a 94 per cent efficiency capability, controlled by a brake simulator module, the transaxle is able to recapture most of the energy used to accelerate the car whenever it is slowing down.

One big feature of the Fusion Hybrid is its ability to operate on electric power alone up to 75 km/h. When you press the start button, the powertrain computer takes a look at battery state of charge and interior temperature demands. If heat is required in the passenger compartment or the battery is low on charge, the gas engine will start. Otherwise, the gas engine remains off. An electric air conditioning compressor can provide cool air and the car can pull away from a stop on electric power alone. Even if the car runs out of gas, you can still drive as long as there is a charge in the battery.

One advantage of hybrids over pure electric vehicles is that the battery pack can be smaller. The Fusion battery pack is 14 per cent smaller than the Escape Hybrid but produces 20 per cent more power. You don’t have a long range on electric power alone, but driven carefully it is possible to drive the Fusion Hybrid a long way on a tank of gas. Ford trained some test drivers in economy driving methods and took the Fusion out for a trip. Over 2,300 kilometres later, it ran out of gas. I am sure most drivers wouldn’t match that on a single tank of gas, but it does show that driven carefully, hybrids can produce exceptional mileage.

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