Zurc said:
I mentioned the idea of an extra battery in an earlier post under 3 suggestions to ford.
No battery in the trunk. Put it down under like tesla did. And yes ford kinda came up a bit short on range.
They should have used an engineering rule of thumb and doubled what they think is the average commute and gone with the resulting range. It would have made the car a bit more useful.
Zurc
A longer range, especially if it could be 150 miles, would almost definitely be everybody’s prime improvement recommendation for the FFE. But what seems to be missing in many of these posts, not just Zurc's which I have chosen as a starting point, is an acceptance of the fundamental limitations imposed on the FFE by its sharing a glider common to the Focus ICE. Safety considerations require that the batteries are located within the protected part of the chassis without any infringement into the crumple zones front or rear. So chances are that Ford have already put in pretty much the largest battery pack (by volume) that the glider can accept. And given the fundamental chassis design there is little if any opportunity to put additional battery volume and hence capacity under the floor of the FFE. One could consider “stacking” a second battery pack above the one already located in the hatchback but that would have adverse effects on vehicle dynamics resulting in compromised steering and braking behaviour and substantially compromising anti-rollover safety. Remember one of the reasons we love the FFE is it handling which is very similar to the Focus ICE. After considering the lack of available volume to add more battery packs or the compromises that stacking a second battery in the hatchback would impose significantly increasing the energy density of the current battery packs becomes pretty much the only opportunity to improve the vehicle range.
The cost of increasing the range by utilizing either more battery packs or higher energy density batteries will be significant. If we assume that the cost of the battery pack is 30% of the car’s production cost (and that is probably a conservative estimate) doubling the effective range – which is what we are really saying we want if we go from a nominal 80 mile range to a nominal 150 mile range through increasing the number of battery packs (cells), then the battery costs will for all intents and purposes double. Based on a retail cost of $32K then we could reasonably expect a 150 mile range FFE to cost approximately $41.6K. Are we really willing to pay an extra $9.6K for that range cushion which will be rarely utilized by 95% of prospective FFE owners.
We don’t really know how “stressed” or “energy optimized” the FFE battery packs are compared to a Tesla for instance. If the energy density is similar to that of the Tesla then then there is little opportunity to improve energy density as Tesla is generally considered to have the highest energy density cells in the industry. If however the FFE batteries are of a significantly lower energy density then there is a potential for increasing the FFE’s range through that venue but such an improvement would most probably follow a polynomial or exponential cost curve rather than the linear relationship of simply utilizing more battery cells. Such development costs could render the costs so high as to be prohibitive both to Ford in the production of such an FFE variant and to prospective consumers when purchasing the car. “There is no free meal” especially in a BEV. More range costs substantially more money up front as well as well as higher energy costs when that increased range is utilized in a BEV, one of the big differences (disadvantages) between BEVs and ICEs. (A bigger gas tank has much less significant cost impact on an ICE.)
We also have to realize that Ford would have done these studies and options analyses when the FFE was developed. In the end the battery capacity and consequent range rendered the FFE with a range competitive to the then extant competition of the Nissan LEAF and Mitsubishi MiEV at a price point where Ford thought it would be sufficiently successful to market and help the company meet overall fleet fuel economy regulations (compliance vehicle). I suspect that any range increase for the FFE would be cost prohibitive compared to its current competition. Now, if the Mercedes Benz B-Class electric proves to a commercial success starting at approx. $41,5K then, if technically feasible based on battery pack energy densities, cell numbers and form factors, Ford may be enticed to offer a longer range variant of the FFE. We can only hope!
Thanks and Cheers
Carl