Michigan Assembly will be home to the all-new global Ford Focus, which has started production and goes on sale early next year. The Focus Electric zero-emission battery electric vehicle goes into production late next year followed by production of a new hybrid and a plug-in hybrid in 2012.

“We’ve modernized just about every square foot of this facility to establish a new standard for a high-tech, green, flexible and efficient auto factory,” said Jim Tetreault, Ford vice president of North America Manufacturing. “The transformation of Michigan Assembly Plant stands as a symbol for the transformation of Ford.”

On the outside, a new 500-kilowatt solar panel system will be installed to help generate renewal energy for production of Ford’s all-new Focus and Focus Electric cars. Ten new electric vehicle charging stations on the property will be used to recharge the electric trucks that transport parts between adjacent facilities.

Inside, new cars making the three-mile trip down the assembly line must pass dozens of rigorous quality inspections. A new three-wet paint booth utilizes 66 paint robots with seven axis of movement to precisely apply paint to the cars. In the body shop, 500 new robots capable of 4,000 welds per vehicle add to the plant’s flexibility. And a new internal communications system flashes updates and information to the plant’s 3,200 employees via 163 monitor screens distributed throughout the plant.

Flexible: Trends move fast
Bright, modern and green – like the car it is building – the refurbished Michigan Assembly Plant is the company’s new benchmark for flexible manufacturing. At 1.2 million square feet – about the size of 22 football fields – the plant becomes Ford’s most flexible, high-volume and modern manufacturing facility in its global operations.  Ford will continue to evolve its manufacturing flexibility as the company’s facilities are rapidly being transformed into more nimble, flexible, and technologically advanced operations.

The changes at the plant will allow the company to run multiple models down the same production line without requiring considerable downtime for changeover of tooling. Two different models of the Focus can be adjusted between builds without restrictions.

“If the last few years have taught us anything, it is that customer wants and needs can change quickly – much more quickly than we have been equipped to efficiently respond to in the past,” said Tetreault. “At Michigan Assembly, we will achieve a level of flexibility we don’t have in any other plant around the world, which will allow us to meet shifting consumer preferences in real time.”

Renewable: Power from the sun
Michigan Assembly also will boast Michigan’s largest solar power generation system and several electric vehicle charging stations for greener, more sustainable manufacturing when installation is completed next year.

Ford is teaming with Detroit Edison and Xtreme Power to install the 500-kilowatt solar photovoltaic panel system. The system will be integrated with a 750-kilowatt energy storage facility that can store 2 million watt-hours of energy using batteries – enough to power 100 average Michigan homes for a year. A secondary, smaller solar energy system will be added at a later date to power lighting systems at Michigan Assembly. The combined systems are expected to result in projected energy cost savings of about $160,000 per year.

Quality: At every turn
To ensure best-in-class quality for the all-new Focus, vehicles on the line will endure rigorous examinations. Workers will perform hundreds of comprehensive quality tests and checks to ensure every bolt, seam and joint has been thoroughly inspected before continuing down the line.

“We are leveraging our people, processes and products to consistently build cars that will surpass the competition,” said Tetreault. “This plant embodies everything we as a company strive to become – modern, efficient, flexible, global and sustainable.”

Contributing to Focus’ best-in-class quality and Michigan Assembly’s transformation:

• Virtual manufacturing technology to improve ergonomics for easier, safer work
• Redesigned water soak testing booth to ensure zero water entry for long-term durability
• Highly efficient and environmentally friendly painting process
• Best-in-class squeak and rattle track that shakes and rolls vehicles for noises
• New energy-efficient illumination lighting for better vehicle inspections
• Moving platforms with real-time height adjustments for better operator ergonomics
• Vision-guided automation for better installation, fit-and-finish of doors, decks and hoods
• New robotic paint spray booths for more consistent and environmentally friendly application
• Electric tools capable of precisely measuring torque and the number of rotations required to secure bolts, screws and other attachments

Adding to the physical transformation of the plant, Ford and the United Auto Workers have developed a framework to establish a strong, progressive culture that encourages joint problem solving and continuous improvement of the production process.

“This plant is an inspirational example of how a modern manufacturing facility should look and work,” said Tetreault. “It’s bright, high-tech and efficient, while also being environmentally and ergonomically friendly.”

Source: Ford Press Release

The all-electric commercial vans, built on the Ford Transit Connect vehicle body, equipped with Azure Dynamics’ patented Force Drive^™ battery electric powertrain, and assembled by AM General at its facility in Livonia, Mich., are reaching the market 13 months after the collaboration to develop the zero-emission vehicle was first announced.

To date, all initial units have designated customers. Azure Dynamics’ LEAD customer program includes seven companies that are taking delivery of their first units in 2010, with the remainder of their orders to be filled in 2011. Customers that have been previously announced include AT&T, Southern California Edison, Xcel Energy, Johnson Controls Inc., New York Power Authority, Canada Post and Toronto Atmospheric Fund EV300. Additional LEAD customers will be identified by the end of the year.

Ford first announced the collaboration in October 2009, with an agreement for Azure Dynamics to upfit the Transit Connect van with Azure’s Force Drive battery electric drivetrain technology including Johnson Controls-Saft’s advanced lithium-ion battery, and a commitment to deliver the initial vehicles by the end of 2010 to the North American market. Initial production began in the fourth quarter of 2010 with full production of the Transit Connect Electric slated to ramp up in April 2011.

“Supplier collaboration is important on all Ford product programs, but it was especially key in this effort, which went from contract signing to vehicle production in 13 months,” said Sherif Marakby, Ford director, Electrification Programs and Engineering. “A strong teamwork environment established by Azure and Ford was critical to delivering this vehicle.”

“The Transit Connect Electric program is a great representation of our product development approach,” said Scott Harrison, CEO, Azure Dynamics. “We have been able to focus on integration of our Force Drive powertrain solution and benefit from Ford’s expertise in building ground-up global vehicle platforms. Meanwhile, capital costs are kept in check by contracting AM General for labor and assembly services – an area where the company excels. Transit Connect Electric is a revolutionary technology and achieving our aggressive time line is a testament to the professionalism and spirit of cooperation among all the project partners.”

The Michigan Economic Development Corporation provided incentive funding for Azure Dynamics to encourage selection of a Michigan-based partner for final assembly. Azure chose AM General LLC, to produce the Transit Connect Electric in its facility in Livonia, Mich.

AM General, a long-established contract vehicle assembler and services provider, is responsible for final upfit of the Transit Connect Electric.  

Transit Connect Electric is the first product in Ford’s accelerated electrified vehicle plan, and will be followed by the Focus Electric passenger car in 2011, along with a plug-in hybrid electric and two next-generation lithium-ion battery-powered hybrid vehicles in 2012.

Ultra-Low Carbon Vehicle Demonstrator program

In addition to delivery of units to LEAD customers in North America, the Transit Connect Electric commercial van is headed to the United Kingdom, where 14 of the vehicles will take part in the government’s Ultra-Low Carbon Vehicle Demonstrator program. The program, supported by Scottish and Southern Energy, utilizes a fleet of zero-emissions vehicles for the energy company, with designated drivers to test vehicle and infrastructure technology.

The consortium of Ford, Scottish and Southern Energy and the University of Strathclyde will provide Transit Connect Electric vehicles and a charging infrastructure in and around the London suburb of Hillingdon during 2010 and 2011.

Ford and Azure Dynamics already have announced they will collaborate to produce the Transit Connect Electric for the European market with first units to be delivered in 2011.

Designed with fleet users in mind

The all-electric, zero-emissions Transit Connect Electric has a driving range of up to 80 miles per full charge and is ideal for fleet owners who have well-defined routes of predictable distances and a central location for daily recharging. Delivery fleet and utility vehicle operators have begun to show a preference for smaller, more efficient vehicles, which creates an ideal time for Transit Connect Electric to come to market.  

“The Transit Connect provides a unique choice for the fleet owner who wants the convenience of a utility vehicle,” Marakby said. “The electric version takes that one step further, delivering a dependable, zero-tailpipe-emission vehicle that requires no petroleum.”

Owners will have the option of recharging Transit Connect Electric with either a standard 120-volt outlet, or preferably a 240-volt charge station, typically installed at the user’s base of operations for optimal recharging in six to eight hours. A transportable cord that works with both types of outlets will be available for convenient recharging at either voltage.

The vehicle’s charge port is located above the passenger-side rear wheel well. The onboard liquid-cooled 28-kilowatt-hour lithium-ion battery pack is charged by connecting the charge port to a power outlet. Inside the vehicle, an onboard charger converts AC power from the electric grid to DC power to charge the battery pack.

Transit Connect Electric is expected to offer lower cost of operation, because charging with electricity is generally less expensive than fueling with gasoline.

When the vehicle is operating, battery power is provided to the drive motor through the electric powertrain’s motor controller. The motor controller uses throttle input from the driver to convert DC power supplied by the battery into three precisely timed signals used to drive the motor. The onboard DC/DC converter allows the vehicle’s main battery pack to charge the onboard 12-volt battery, which powers the vehicle’s various accessories, such as headlights, power steering and coolant pumps.

In Transit Connect Electric, the battery pack has been efficiently integrated without compromising interior passenger room and cargo space. The Johnson Controls-Saft battery pack is expected to last the life of the vehicle.

First in Ford’s overall electrified vehicle strategy

The electrification strategy builds on Ford’s vision for bringing affordable technology to millions. It takes advantage of rapid advancements in electrified vehicle technology – particularly lithium-ion batteries – while leveraging the scale of global vehicle platforms to bring the cost of new technology down.

About Ford Motor Company

Ford Motor Company, a global automotive industry leader based in Dearborn, Mich., manufactures or distributes automobiles across six continents. With about 163,000 employees and about 70 plants worldwide, the company’s automotive brands include Ford, Lincoln and Mercury, production of which has been announced by the company to be ending in the fourth quarter of 2010. The company provides financial services through Ford Motor Credit Company. For more information regarding Ford’s products, please visit www.ford.com .

About Azure Dynamics

Azure Dynamics Corporation (TS X : AZD) (O T C: AZDDF) is a world leader in the development and production of hybrid electric and electric components and powertrain systems for commercial vehicles. Azure is str at egically targeting the commercial delivery vehicle and shuttle bus markets and is currently working intern at ionally with various partners and customers. The Company is committed to providing customers and partners with innov at ive, cost-efficient, and environmentally-friendly energy management solutions. For more inform at ion please visit www.azuredynamics.com .

About AM General

AM General designs, engineers, manufactures, supplies and supports specialized vehicles for commercial and military customers. The AM General business units also include two wholly-owned subsidiaries, General Engine Products, a diesel engine manufacturer, and General Transmission Products, an automatic transmission manufacturer. As creator and manufacturer of the famous HMMWV (HUMVEE ®) and HUMMER ® H1 andH2 vehicles, AM General has more than six decades of experience meeting the changing needs of the defense and automotive industries supported by approximately 2,500 employees at major facilities in Ind., Mich., and Ohio and a strong supplier base that stretches across 43 states. More information can be found at www.amgeneral.com .

SOURCE Ford Motor Company

The 2012 Focus, on sale early next year in North America and Europe, uses these cottons from recycled clothing in areas such as carpet backing and sound-absorption materials for interior quietness. Using environmentally friendly materials, including recycled clothing, is one part of Ford’s overall green strategy.

“Ford is continually looking for greener alternatives,” said Carrie Majeske, product sustainability manager. “One of our key goals is to use more recycled or renewable materials without compromising performance or durability. Recycled content is a way to divert waste from landfills and reduce the impact of mining virgin material.”

Ford’s “reduce, reuse and recycle” commitment is part of the company’s broader global sustainability strategy to reduce its environmental footprint while at the same time accelerating the development of advanced, fuel-efficient vehicle technologies around the world.

Over the past several years, Ford has concentrated on increasing the use of non-metal recycled and bio-based materials, including soy foam seat cushions, recycled resins for underbody systems, recycled yarns on seat covers and natural-fiber plastic for interior components.

Creative, eco-friendly solutions

Ford vehicles continue to become more eco-friendly through the creative use of renewable and recycled materials. For instance, one of the clothing materials used in the next-generation Focus is post-consumer cotton that comes from recycled blue jeans.

“The good news is these jeans didn’t end up in a landfill, nor did we use the water, fertilizer and land to grow virgin cotton,” Majeske said. “It’s an alternative that our customers can appreciate, it’s cost effective, and it’s better for our planet. These are the kinds of sustainable solutions we are looking for in all our vehicles.”

The amount of post-consumer cotton from blue jeans used in a vehicle comes out to roughly two pairs of average-sized American jeans, based on pounds of cotton used per yard of denim and the yards of denim used to make a pair of jeans.

“Great fuel economy is our first priority for reducing the vehicle’s impact on the environment,” said Majeske. “As we deliver that, we also seek to use materials inside a vehicle that reduce the environmental impact as well. The use of recycled clothing is one step, but what else are people discarding that could be used in our vehicles?  Ford is determined to find out.”

The new Focus is the result of a global product development program bringing together Ford’s best engineers and designers from around the world. The high-tech, fuel-efficient Focus will be manufactured in Ford plants in Asia, Europe and North America.

About Ford Motor Company
Ford Motor Company (NYSE: F), a global automotive industry leader based in Dearborn, Mich., manufactures or distributes automobiles across six continents. With about 163,000 employees and about 70 plants worldwide, the company’s automotive brands include Ford, Lincoln and Mercury, production of which has been announced by the company to be ending in the fourth quarter of 2010. The company provides financial services through Ford Motor Credit Company. For more information regarding Ford’s products, please visit www.ford.com .

SOURCE Ford Motor Company

The two companies are teaming up to implement the Microsoft Hohm™ energy management application for Ford’s electric vehicles. Ford is the first automaker announcing the use of Hohm, starting with the Focus Electric next year. Hohm will help owners determine when and how to most efficiently and affordably recharge battery electric (BEV) and plug-in hybrid (PHEV) vehicles. It also should help utility companies manage the added demands of electric vehicles on the electric grid.

“Ford and Microsoft both share a strong commitment to contributing to a better world. Today, we begin the next major step in our working together and leading the way for energy efficiency and environmental sustainability,” said Alan Mulally, Ford Motor Company president and CEO. “For Ford, this is a needed step in the development of the infrastructure that will make electric vehicles viable.”

Both companies agree that effective management of the energy ecosystem is critical for electric vehicles to be successful and for consumer interest to grow. In a recent Accenture survey, 42 percent of consumers said they are likely to buy a hybrid or electric vehicle in the next two years.

Increasing numbers of electric vehicles, however, will have a significant impact on energy demand. That is because the addition of an electric vehicle to a household could effectively double home energy consumption while the vehicle is charging.

Ford and Microsoft agree that making energy management easy and affordable for consumers will be key to the success of electric vehicles in the marketplace as well as in creating a positive environmental impact.

“Electric vehicles will play an important role in the global effort to improve energy efficiency and address the issues of climate change and sustainability,” said Steve Ballmer, Microsoft CEO. “But as the market for electric vehicles expands, it will have a significant impact on home energy consumption and demand across the nation’s energy grid. With Microsoft Hohm, Ford and Microsoft will deliver a solution that will make it easier for car owners to make smart decisions about the most affordable and efficient ways to recharge electric vehicles, while giving utilities better tools for managing the expected changes in energy demand.”

Introducing Hohm to Ford’s electric vehicles supports Ford’s aggressive global electrification plan, which will put five new electrified vehicles on the road in North America and Europe by 2013. In North America, they include the Transit Connect Electric later this year, Focus Electric in 2011, a plug-in hybrid electric vehicle and two next-generation hybrids in 2012.

America’s largest domestic hybrid seller, Ford Motor Company today has four hybrids on the road and another coming this year. They include the Ford Fusion Hybrid, Ford Escape Hybrid, Mercury Milan Hybrid and Mercury Mariner Hybrid. Also coming this fall is the Lincoln MKZ Hybrid, which is expected to be the most fuel-efficient luxury sedan in America.

Life with electrified vehicles – with full battery electric (BEV) and plug-in hybrid (PHEV) vehicles needing to be recharged daily – will require consumers to change how they think about personal transportation and energy use.

Hohm, an Internet-based service, is designed to help customers avoid unnecessary expense by providing insight into their energy usage patterns and suggesting recommendations to increase conservation. With Ford electric vehicles, Hohm also will help drivers to determine the best time to charge their vehicle. Smart recharging habits will help utility companies understand and better manage the increased demands placed upon the electric grid because of electrified vehicles.

Ford and Microsoft’s participation in the Hohm program builds on the success of their decade-long partnership to provide customers with superior in-car experiences. The Ford SYNC® communications and infotainment system, built on the Windows Embedded Automotive platform, has been installed on more than 2 million Ford, Lincoln and Mercury vehicles since its launch in 2007, helping drivers connect and voice-control their mobile devices while driving.

Microsoft Hohm is available today for free to all U.S. residential energy consumers and has multiple partnerships with utilities and other stakeholders already in place. Ford is the first automaker to join in collaboration with Hohm.

Ford and Microsoft also plan to continue to work with utility partners and municipalities to help further develop the energy ecosystem. Ford’s work includes collaboration with a dozen North American energy companies to road-test a fleet of 21 Ford Escape plug-in hybrid vehicles. The research has accumulated more than 160,000 miles of real-world data, which provided important groundwork for the new Hohm application.

“Rechargeable vehicles represent a new frontier. Their commercialization will take broad-based collaboration and systems solutions,” said Mulally. “Working together, Ford and Microsoft will provide the systems solutions to help facilitate this exciting future.”

Specifically, Ford will launch two zero-emission full battery-electric vehicles including the Transit Connect Electric light commercial vehicle in 2011 followed by the Ford Focus Electric in 2012. Three other vehicles – two next-generation petrol hybrid-electric vehicles and a plug-in hybrid – will be introduced in 2013. Ford’s global electrification strategy will deliver a suite of electrified vehicles to a variety of markets and build on the company’s overall vision of offering the widest possible range of technology solutions – instead of a single vehicle or technology – to improve fuel economy and lower CO2 emissions for customers around the world.

“We recognise that one technology does not work for all our customers,” said Derrick Kuzak, Ford’s group vice president of Global Product Development. “Our electrification strategy and plans include hybrids, plug-in hybrids and battery electric vehicles to best meet our global customers’ needs. Leveraging our global platforms is also central to this strategy and allows us to build on our strong product line-up in the most customer-driven, affordable way.”

As Ford’s global product vision accelerates to ensure that all the company’s vehicles competing in global segments become common in Europe, North America and Asia, the resulting efficiencies will allow a global portfolio of environmentally friendly transportation solutions to be developed based around hybrid electric, plug-in hybrid electric and all-electric vehicles.

“Our goal is to provide consumers with access to significant fuel economy improvements and reduced CO2 emissions to meet their functional needs and without compromising their driving experience,” said John Fleming, Chairman and CEO, Ford of Europe.

“There is increasing interest among a number of customers in Europe for electrified vehicles and we are responding by stepping up our efforts to bring these models to the marketplace alongside our latest-generation, fuel-efficient petrol and diesel powered models,” Fleming added. “This is further evidence of how the ONE Ford global product vision is transforming our business. European consumers will not have to wait too long before they can choose from a range of electrified alternatives from Ford.”

Zero-Emission

The first models to be launched in Europe will be zero-emission, full-electric versions of two significant models in Ford’s global product portfolio.

The Focus Electric will be based on Ford’s next-generation Focus model and is one of at least ten vehicles that will be developed from the company’s new global C-car platform. Focus Electric will be introduced in the US and Canada in 2011, followed by Europe in 2012.

The Ford Transit Connect Electric is a zero-emission, pure electric-powered version of the award-winning Transit Connect light commercial vehicle and goes on sale in North America later this year. Ford is aiming to make the Transit Connect Electric available for European customers from 2011.

Future Hybrids

While Ford has considerable experience in the North American market with full petrol-hybrid vehicles, the company also is planning to expand its presence in Europe with two all-new, next-generation hybrid passenger cars based on global platforms following in 2013.

In addition, European customers will be able to opt for a plug-in hybrid model, also coming in 2013. “Thanks to the global economies of scale afforded to us by our ONE Ford initiative, I am delighted we are able to make the commitment now to deliver these models to customers in Europe, particularly as the demand for hybrid vehicles grows,” added John Fleming.

Further details of Ford’s hybrid and plug-in hybrid models will be revealed closer to launch.

Prototype Trials in Europe

Ford’s Product Development team is participating in two specific European trial initiatives to demonstrate the technology in real world driving conditions, and generate feedback to help develop further the Focus Electric and the Transit Connect Electric for market acceptance in Europe.

In the UK, a consortium of Ford, Scottish and Southern Energy (SSE) and Strathclyde University is preparing later this year to run a fleet of zero emissions prototype Ford Focus Battery Electric Vehicle prototypes, based around the current Focus model sold in Europe and using elements of the technology under development for the new Focus Electric. The vehicles will be used for evaluation by both SSE and a number of fleet and private customers based in Hillingdon, Middlesex from mid-2010.

This new UK-based BEV demonstration fleet is being created partly with public funding from the UK Government’s Technology Strategy Board (TSB), which promotes innovative industry-led projects that reduce CO2. The BEV research programme aims to test the technology’s suitability and to gain greater insight into customer charging behaviour.

In Germany, Ford has recently announced its participation in the colognE-mobil project. This initiative will research the impact of electric vehicles on urban air quality, traffic safety and the electricity supply infrastructure. Scientists will then scale up the results to examine the true benefits an electric future could deliver for German cities.

Ford is one of four partners in the colognE-mobil project and will provide an early fleet of next-generation Focus Electric vehicles in late 2011.

The other partners are utility company RheinEnergie AG, the City of Cologne and the University of Duisburg-Essen. The colognE-mobil project is partly funded by the German Government and coordinated by the federal state of North Rhine-Westphalia.

“These initiatives are a revolution for both the utility and automotive industries,” Fleming said. “Collaborating across sectors is essential to ensure customer focused products that provide the right value along with the readiness of the infrastructure. We need to work and learn together and Ford is very pleased to be a part of these important trials.”

Meanwhile, Ford reported on February 26 that it was spending $155 million at its Cleveland operations to build a new fuel-efficient V-6 engine for the 2011 Mustang. Ford’s investment at the Cleveland Engine Plant is supported by DOE’s Advanced Technology Manufacturing Incentives Program. The new Mustang engine is one of nine new or upgraded engines or transmissions for Ford, Lincoln, and Mercury vehicles to be released in the 2011 model year. The latest investment brings Ford’s total investment in powertrain engineering and facility upgrades in North America to $1.8 billion for the 2011 vehicle launches alone, with more to come. This year’s revamped engines and transmissions are part of a five-year effort, which began in 2008, to overhaul all of Ford’s powertrains. One of its most advanced new engines will be a new normally aspirated 2.0-liter direct-fuel-injection engine, the first of its kind for a North American Ford vehicle, which will be deployed in the 2012 Ford Focus. See the Ford press releases on the engine investment and the 2012 Ford Focus.

Chrysler is also revamping its powertrain lineup, implementing new technology that will contribute to an overall fuel-efficiency improvement of more than 25% by 2014. As a result of its new alliance with Fiat, the company’s five-year business plan has added a powertrain offensive, including a progressive vehicle electrification strategy. The overhaul will include adopting Fiat technology such as Multiair, Fiat’s patented electro-hydraulic variable valve actuation technology. Fiat will also add its direct-injection, turbocharging, and six-speed transmission systems to Chrysler’s portfolio. Four-cylinder engine options are being expanded at Chrysler with the introduction of Fiat’s 1.4-liter and 2.4-liter four-cylinder engines, both featuring Multiair. As part of its five-year plan, the Chrysler Group is currently developing a hybrid version of its Ram 1500 pickup for 2010. The company also continues its plan with the DOE to build a small test fleet of plug-in hybrid Ram 1500s and minivans.

Source:EERE

Currently, the transportation sector accounts for 28% of total U.S. energy use. As these vehicle technologies are adopted broadly across the country, they could save more than 100 million gallons of gasoline and diesel per day, and reduce carbon emissions from on-road vehicles by 20% by 2030.

Vice President Biden said;

“By investing Recovery dollars in next generation fuel efficient trucks here at home, we’re not only creating new job opportunities now, but helping lay a new foundation to keep American auto manufacturers competitive in the 21st century global marketplace. Through strategic public-private investments like these, the Recovery Act is helping lay the groundwork for an expansion of our clean energy economy.”

“Improving the efficiency of our vehicles is critical to reducing America’s dependence on foreign oil and addressing climate change,” said Secretary Chu. “Today’s awards will help demonstrate the potential benefits for long-haul trucks and passenger vehicles and will play an important role in building a more sustainable transportation system for the country.”

Three projects will focus on cost-effective measures to improve the efficiency of Class 8 long-haul freight trucks by 50%. These projects will receive more than $115 million in funding to develop and demonstrate systems-level fuel efficiency technologies by 2015, including improved aerodynamics, reducing engine idling technologies, waste heat recovery to increase engine efficiency, advanced combustion techniques, and powertrain hybridization.

The remaining six projects totaling more than $71 million will support efforts to increase the fuel economy for passenger vehicle engines and powertrain systems. The goal is to develop engine technologies that will improve the fuel economy of passenger vehicles by 25-40% by 2015 using an engine-only approach.

The following projects have been selected for awards under two topic areas:

One of the advanced and fuel-efficient North American powertrains is the 2012 Ford Focus’ all-new normally aspirated 2.0-liter direct fuel injection engine, the first of its kind in a Ford vehicle in North America.

“Ford is delivering on our commitment to lower emissions, improve fuel economy and deliver the highest quality powertrains in the industry,” said Barb Samardzich, Ford vice president, Powertrain Engineering. “We are making this happen with one of the most ambitious powertrain upgrades ever undertaken by Ford. By the end of 2010, nearly all of Ford’s North American engines will have been upgraded or replaced since 2008.”

North American launches

In 2010, Ford will launch new engines and transmissions in Fiesta, Mustang, Super Duty and F-150. These new powertrains are expected to propel each vehicle to best-in-segment in fuel economy.

Fiesta’s Ti-VCT 1.6-liter engine and PowerShift dual clutch transmission will deliver an estimated 40 mpg on the highway, topping both Honda Fit and Toyota Yaris.

Mustang’s new Ti-VCT 305-horsepower, 3.7-liter V-6 delivers the class-leading performance and fuel economy Mustang buyers expect. The 2011 Mustang V-6 with six-speed automatic will deliver at least 30 mpg on the highway. No other V-6 powered sports coupe in the world delivers this level of performance and fuel economy, regardless of price.

Mustang GT gets a new 5.0-liter V-8 that cranks out a 412 total horsepower and 390 ft.-lb. of torque yet delivers at least 25 mpg on the highway – better than any competitor.

Both versions of the Mustang get all new fuel-saving manual and automatic six-speed transmissions.

Spring also marks the arrival of an all-new Ford-designed-and-built Super Duty diesel truck engine. The 6.7-liter Power Stroke® V-8 turbocharged diesel powerhouse is expected to lead the class in fuel economy towing, hauling, horsepower and torque.

With its advanced emissions systems, the new 6.7-liter diesel engine also will run cleaner than the outgoing model. The 2011 Super Duty also gets a new 6.2-liter gasoline engine.

Ford engineers continue to reduce engine and transmission weight. For example, the new Super Duty diesel and transmission together are185 pounds lighter than the outgoing powertrain.

With its novel features such as a “live drive” Power Take Off (PTO) and rugged TorqShift six-speed automatic transmission, Super Duty will remain the most capable workhorse in the segment.

Ford: Driving powertrain innovations into the market

By 2013, Ford plans to offer EcoBoost engines on 90 percent of its product lineup with annual volume of vehicles with EcoBoost at 1.3 million globally.

Toward the end of the year, a new 2.0-liter Ti-VCT four-cylinder for the next-generation Focus will mark the first introduction of a normally aspirated direct injection engine to the powertrain lineup. The all new engine will launch on the 2012 Focus in North America.

Ford credits its recent gains in fuel economy in part to its introduction of the Ford Escape and Mercury Mariner hybrids and numerous incremental aerodynamic, mechanical, energy management and weight-saving improvements across its vehicle lineup. Going forward, it expects the 2009 introduction of the Ford Fusion and Mercury Milan hybrids and its fuel-efficient EcoBoost engines to further improve its fleet-wide fuel economy.

Dramatic fuel efficiency improvement is evident throughout Ford’s vehicle lineup – from cars and crossovers to sport utilities and trucks. Depending on powertrain specifications, the 2010 Fusion, Fusion Hybrid, Escape Hybrid, Taurus SHO, Flex, F-Series and Transit Connect offer best-in-class or unsurpassed fuel economy. The same can be said of the 2010 Lincoln MKS and MKT and Navigator, Mercury Milan Hybrid and Mariner Hybrid.

Ford expects to see its overall fuel economy continue to rise in 2010 with the introduction of the 2011 Ford Fiesta and redesigned 2011 Ford Focus – both high-mileage small cars.

Sue Cischke, group vice president, Sustainability, Environment and Safety Engineering said;

“2009 has been a breakthrough year for Ford, leading with the launch of EcoBoost and the introduction of new products that will result in further improvement in 2010.  Our commitment to delivering affordable, fuel-efficient vehicles for millions has never been stronger or better demonstrated.”

Not only is the improved fuel efficiency good for customers’ wallets, it benefits the environment as well. As a result of the boost, Ford lowered its tailpipe CO2 emissions more than any other automaker with a fleet-wide average of 434 grams per mile – 37 grams lower than its 2007 total and 25 grams lower than 2008.

A powerful difference maker

The fuel efficiency of the 2010 Ford Fusion improved 21 percent over the 2009 model, jumping from 28 mpg to 34 mpg in highway driving, and leap-frogging the competition. Powertrain improvements were a big difference maker. Fusion and other new models benefit from the introduction of Ford’s new six-speed transmission, which offers a wider gear span than four-speed transmissions.

The six-speed allowed Ford’s engineers the flexibility to tune the powertrain for greater responsiveness in low gears and better fuel economy in the taller gears. The new double-overdrive gearbox is designed to contribute up to 4 percent fuel economy improvement. Ford has committed that almost 100 percent of its transmissions will be advanced six-speed gearboxes by 2013.

Ford’s EcoBoost

This year, Ford introduced its new line of powerful, fuel-efficient EcoBoost engines, available in the Ford Taurus, Ford Flex, Lincoln MKS and Lincoln MKT. Recently honored with a Popular Mechanics’ Breakthrough Award, EcoBoost uses gasoline turbocharged direct-injection technology for up to 20 percent better fuel economy, 15 percent fewer CO2 emissions and superior driving performance versus larger-displacement engines.

On average, nearly one in five buyers of the Taurus, Flex, Lincoln MKS and MKT have opted for EcoBoost since the engine lineup’s introduction in August. By 2013, Ford will offer EcoBoost engines in 90 percent of its product lineup with annual volume of vehicles with EcoBoost at 1.3 million globally.

Barb Samardzich, vice president, Ford Global Powertrain Engineering said;

“We are committed to delivering new products with the best fuel economy in every segment in which we compete – driven in large part by substantial advancements in powertrain technology. We are focusing on sustainable technology solutions that can be used not for hundreds or thousands of cars, but for millions of cars, because that is how Ford truly will make a difference.”

It’s all about incremental improvements

The fact that the 2010 Ford Taurus and 2009 Ford F-150 are up to 12 and 17 percent respectively better on fuel economy than their 2004 predecessors isn’t due to one “silver bullet” solution but a host of vehicle enhancements, including aerodynamic refinements, weight efficiency and mechanical improvements.

Nancy Gioia, Ford director of Global Electrification added;

“Next-generation hybrids, plug-in hybrids and pure battery-powered vehicles are the logical next steps in our pursuit of greater fuel economy and sustainability. A growing number of consumers want that kind of choice, and we want to be in a position to deliver it to them across multiple vehicle categories.”

The collaboration with Azure Dynamics for the Transit Connect BEV will build on the existing business relationship between Ford and Azure as well as their shared experience with battery supplier, Johnson Controls-Saft.

Nancy Gioia, Ford director of Global Electrification had this to say;

“We recognize an increasing interest in electrified vehicles and have an aggressive strategy to bring these vehicles to the marketplace. Our work with Azure to create a pure electric battery Transit Connect vehicle will allow us to offer our commercial customers an additional option for environmentally friendly transportation.”

The Transit Connect BEV will be built on Ford’s global commercial vehicle platform as part of the company’s One Ford global product vision. It is the first of four electrified vehicles from Ford that will become available over the next three years in the U.S. and Canada including:

•Battery electric Transit Connect van in 2010

•Battery electric Ford Focus passenger car in 2011

•Next generation hybrid vehicle in 2012

•Plug-In hybrid vehicle in 2012

Collaboration builds on existing business relationship

Azure Dynamics develops hybrid electric and electric drive technology for shuttle buses and commercial trucks, such as the Balance™ Hybrid Electric, which is built on the Ford E-450 cutaway and strip chassis for the medium duty commercial vehicle segment.

“The opportunity to work with Ford on the Transit Connect BEV is a breakthrough advancement for us at Azure and for the light commercial vehicle market,” said Scott Harrison, Azure Dynamics CEO. “For Azure, it’s an important evolution of our existing relationship with Ford. From an industry standpoint, we are seeing delivery fleet and utility vehicle operators move to smaller, more fuel efficient vehicles. The Transit Connect BEV will come to market at an ideal time to meet this growing trend.”

Oak Park, Mich.-based Azure Dynamics will integrate its proprietary Force Drive™ battery electric drive train into the Transit Connect BEV, which will have a targeted range of 80 miles minimum on a full charge and zero tailpipe emissions. Force Drive™ components have previously been deployed in more than 40 vehicle integrations and have more than 25 million miles of on-the-road experience. The Transit Connect BEV will offer fleet owners the opportunity to eliminate the use of gasoline and help to lower operating costs. The vehicle will be badged with both the Ford Blue Oval and Azure’s Force Drive logo.

Azure Dynamics has selected Johnson Controls-Saft as the supplier for lithium-ion battery cells and battery packs for the Transit Connect BEV. Azure Dynamics and Ford both currently utilize Johnson Controls-Saft battery technology for other products. The Transit Connect BEV will use the same proven cell technology that is currently deployed in the Ford Escape plug-in hybrid fleet that is on the road today. In addition, Azure had previously announced it would use Johnson Controls-Saft lithium-ion batteries for its E- 450 Balance Hybrid Electric beginning in the second half of 2010. The shared supplier business relationship is expected to provide additional synergy between Ford and Azure in the Transit Connect BEV project.

Transit Connect commercial platform ideal choice for battery electric power

The Ford Transit Connect already is a proven global success. Ford introduced the gasoline-engine Transit Connect to North America this year. With a unique combination of car-like driving dynamics, cargo capacity, accessibility and low purchase and operation costs, it is an ideal choice for electrification. Commercial users often travel predictable, short-range routes with frequent stop and go driving in urban and suburban environments. For customers seeking sustainable mobility solutions, the Transit Connect Battery Electric Vehicle with Azure Force Drive™ will provide a zero emissions option.

The Transit Connect was designed, engineered and manufactured on a dedicated global commercial vehicle platform to beat tough commercial vehicle durability standards. The final manufacturing location for the Transit Connect BEV has not yet been determined.