What is the most energy efficient way to stay warm? As the cost of heating our homes rises, this is a question on many people’s minds. Ford engineers undertook to answer the same question as part of a project to improve the autonomy of electric vehicles.

In terms of electric vehicle heating, warm air can be channeled into the cabin using the air conditioning (A/C) system. Alternatively, the surfaces can be heated. These can be surfaces that passengers come into direct contact with or panels that radiate heat to the driver and passengers.

In both cases, battery power is required. However, the engineers discovered that with the heated surfaces the energy consumption for heating the cabin could be reduced by 13% compared to a conventional air conditioning system – and this could extend the electric range by 5% on a typical charge. This is a difference capable of adding hundreds of additional kilometers of range per year.

“We all know that if we open the doors or windows when it’s cold outside, the temperature inside the vehicle drops. This is strongly observed in delivery vans, as drivers make frequent deliveries and the heat generated through the air conditioning is lost more quickly, while the heated surfaces remain warm” said Markus Espig, systems engineer, Propulsion Systems Engineering, European Research & Innovation Center of Ford. “Reducing energy consumption not only improves range, but also reduces costs and helps us travel more sustainably.”

The research was carried out in the framework of the Connected Electric Vehicle Optimized for Life, Value, Efficiency and Range (CEVOLVER) program of the European Commission, which lasted from October 2018 to October 2022. The project was designed to inform the way in which the new electric vehicles and help create software updates for EVs already on the road. The results from the heat management tests feed into the development of future Ford vehicles.

By 2026, Ford plans to sell 600,000 EVs annually in Europe, supporting its global target of annual production of 2,000,000-plus EVs over the same period.

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How the test worked

Engineers fitted an all-electric Ford E-Transit with heated armrests, floor mats, door panels, sun visors and a panel under the steering wheel. The test included deliveries of parcels and special goods, with the driver covering a distance of 350 kilometers in one working day on roads in and around Cologne, Germany. The tests were carried out in both winter and summer, on dry and wet roads, as well as in heavy rain and wind, reflecting Ford’s unrivaled experience of the needs of van buyers.

The research also showed that changes in weather, traffic and road conditions can affect range. Integrating this data into the range computer would help predict it more accurately in real time. For commercial vehicles, this aggregated driving data could be used as “fleet range prediction”, to estimate energy requirements for a particular route.

Technologies tested by Ford engineers that could provide significant improvements in energy and time savings include:
• One heat exchanger which takes the heat given off by the electric drive unit and uses it to heat the cabin and/or the battery pack
• One battery cooling system which allows efficient cooling and conditioning of the battery pack
• The Eco-routing in combination with current state of charge calculates the optimal route, including charging stops, to make the most of the vehicle’s range.
• Smart fast charging pre-cools or pre-heats the battery before the next fast charging session
• Function Powertrain conditioning keeps the electric drive unit components at a temperature for optimal energy consumption.

The CEVOLVER research is a continuation of Ford’s tests on how energy consumption can be reduced in electric cars, such as by using interior lighting that creates a cooler or warmer feeling in the cabin. Advanced energy-saving technology to be used in future Ford electric vehicles includes a steam-injection heat pump featured in the all-electric Ford E-Transit Custom.

In addition to developing future technologies to increase range, Ford already offers a number of useful features to maximize the efficiency of its current electric vehicles. For example, the Mustang Mach-E and E Transit offer Scheduled Pre-Conditioning to remotely optimize cabin and battery temperatures while still charging before departure. The vehicle will assess the weather conditions to decide how much energy is needed to create a comfortable temperature in the cabin before the departure time set by the owner. Ford estimates that a half-loaded E-Transit at an outside temperature of 0°C will retain 75% of its range if pre-conditioning is applied, compared to 66% otherwise. For increased range Ford electric vehicles also offer selectable driving profiles to reduce energy demands, as well as the ability to recuperate energy during braking