{{Infobox automobile |name = Ford Ecostar |type = Experimental vehicle |manufacturer = [[Ford of Europe]] |production = 1992-1993 |body_style = 2-door van |related = [[Ford Escort (Europe)#MkV|Ford Escort Mk V]] |image = Ford Ecostar.jpg |wheelbase = {{cvt|102.6|in}} |length = {{cvt|169.3|in}} |weight = {{cvt|3110|lb}} }} The '''Ford Ecostar''' is an experimental [[electric car|electrically powered]] small [[delivery van]] that was built by the VCC110 Program Team in Dearborn, Michigan. A [[sodium-sulfur battery]] in the floor of the cargo area stored power for a {{convert|75|hp|kW|0}} electric motor under the front hood. The Ecostar introduced the road-and-leaf logo now used on a number of Ford products.
Just over 100 Ecostars were produced, and used in fleet tests between 1992 and 1996 with over {{convert|1000000|miles|km|0}} driven, collectively. The Ecostar averaged {{convert|94|miles|km|0}} on a full charge, and demonstrated {{convert|155|mi|km|0}} range in one test. However, on several occasions the battery burst into flame during use. For this, and several other reasons, Ford lost interest in the sodium-sulfur battery and turned to [[fuel cell]] concepts instead.
The product niche appeared to be a useful one and has led to a number of similar designs. While the 1998 [[Citroën Berlingo électrique]] was almost identical in performance and range, it just replaced the older 1991 [[Citroën C15|C15 électrique]]. Ford is re-entering the market as well, with an electric version of the [[Transit Connect]].
==History== Ford developed the sodium-sulfur battery technology in 1965,<ref name=f>{{cite press release |url=http://media.ford.com/article_display.cfm?article_id=14300 |title=Today in Ford History--Feb. 3 {{!}} Chicago's Comm Ed Joins ford EV Pilot Fleet |publisher=Ford Media |date=February 3, 1992 |archive-url=https://web.archive.org/web/20041121084544/https://media.ford.com/article_display.cfm?article_id=14300 |archive-date=November 21, 2004 |url-status=dead}}</ref> but had not continued to develop it for commercial use. Development was later picked up in Europe.
The experimental Ecostar was introduced to help develop all aspects of electric vehicle design, including engineering, supplier development, and market development. A "prototype-of-the-prototypes" was completed with lead acid batteries in 1992, giving a range of {{cvt|30|mi}}; future planned models would include the new battery technology, providing an estimated range of {{cvt|100|mi}}. Several similar models followed and were lent out for test drives with favorable results.<ref>{{cite magazine |first=Richard |last=Stepler |url=https://books.google.com/books?id=HAMbdaR3IvYC&pg=PA32 |title=Coming: Speedy Electric Delivery |magazine=Popular Science |date=January 1993 |page=32 (sidebar)}}</ref>
A total of 80<ref name=f/> to 105<ref name=h/> "production-prototype" sulfur-powered Ecostars were hand-built starting in 1993, and used in fleet trials with several electric utility clients starting the next year,<ref>{{cite book |first1=Seth |last1=Leitman |first2=Bob |last2=Brant |url=https://archive.org/details/buildyourownelec0000leit |title=Build Your Own Electric Vehicle |publisher=McGraw-Hill |date=2008 |pages=61–62 |isbn=978-0-07-154373-6 |edition=Second |url-access=registration}}</ref> including [[Southern California Edison]], [[Pacific Gas & Electric]], [[Allegheny Power]], [[Commonwealth Edison]], [[Detroit Edison]], and the [[United States Department of Energy]].<ref name=h/> At the time, the cost of the battery was a significant {{USD|46000|1993|round=-3}},<ref name=CD-94/> and the battery had a life of approximately one calendar year.<ref name=congress/> However, the vehicles were hand-built at a cost of $250,000, so the battery cost was not representative of a production version.<ref>{{cite news |first=Anita |last=Lienert |url=http://www.accessmylibrary.com/coms2/summary_0286-9378679_ITM |title=Where's the plug? |work=Management Review |date=1 December 2005}}</ref> The total cost of a 30-month lease was {{USD|100000|1994|round=-3}}.<ref name=CD-94/>
The tests ran for 30 months. During the testing period, there were problems with the system, including two vehicles that burst into flame while charging.<ref name=CD-94/><ref>{{cite news |url=https://www.chicagotribune.com/1994/06/06/ford-unplugs-electric-vans-after-2-fires/ |title=Ford Unplugs Electric Vans After 2 Fires |newspaper=Chicago Tribune |agency=Bloomberg Network News |date=6 June 1994}}</ref> The sulfur in the battery was flammable, a serious safety risk. The root cause of the fires was leaking sulfur, which corroded the connections between the cells. These corroded connections increased the resistance and the resulting heat was sufficient to melt the surrounding cells and cause a chain reaction. The program team was able to introduce a workaround that permitted the trials to conclude, but future Ford electric vehicles over the next five years would have to rely upon the older lead acid battery. ABB introduced a new version of the battery, but was unwilling to guarantee performance beyond one year.<ref name=congress>{{cite report |url=https://rosap.ntl.bts.gov/view/dot/55968 |date=1995 |title=Advanced Automotive Technology |publisher=United States Congress, Office of Technology Assessment |page=104}}</ref>
In late 1997, Ford announced a partnership with [[Daimler-Benz]] and [[Ballard Power Systems]] to introduce car-ready [[fuel cell]]s,<ref>{{cite news |first=Donald |last=Nauss |url=https://www.latimes.com/archives/la-xpm-1997-dec-16-mn-64565-story.html |title=Ford Investing $420 Million for Fuel-Cell-Powered Auto |newspaper=Los Angeles Times |date=16 December 1997}}</ref> and their experiments with the sodium-sulfur batteries ended.
==Description== The Ecostar's chassis was based on the Escort Van produced by Ford's [[Halewood Body & Assembly]] factory outside [[Liverpool]]. This was essentially a European [[Ford Escort (Europe)#MkV|Escort Mk V]] with a raised cargo area forming a 2-door [[panel van]]. Fully equipped, it weighed {{convert|3100|lbs|kg|0}}.<ref name=h/>
A significant portion of that weight was its {{convert|780|lb|kg|0|adj=on}} [[sodium-sulfur battery]], which stored 37 kWh.<ref name=h/> Using the Federal Urban Driving Schedule, this gave the Ecostar a range of {{convert|100|miles|km|0}}.<ref name=h/> The sodium-sulfur technology was invented by Ford in the 1960s,<ref name=c/> but the battery for the Ecostar was built by [[ABB Group]] in [[Heidelberg, Germany]].<ref name=h/> The battery operates at a nominal 331 V. In the Ecostar's sodium-sulfur battery, there are 480 individual cells, each contained in an aluminum can {{cvt|1.5|in}} in diameter and {{cvt|18|in}} long.<ref name=CD-94/> In order for the battery to work, it had to be maintained at a temperature of {{convert|600|F|C|0}}, which keeps the sulfur molten.<ref name=c>{{cite web |first=Ron |last=Cogan |url=http://www.greencar.com/articles/ford-ecostar-ev.php |title=Ford Ecostar EV |website=Green Car |date=1 October 2007 }}</ref>
To avoid heat loss, and to insulate the cabin from its heat, the battery was stored inside a double-walled stainless steel [[vacuum flask]]. This allowed it to maintain its temperature overnight and during cold weather, when traditional batteries are less responsive.<ref name=c/> Approximately 200 W are required to maintain the battery at operating temperature.<ref name=CD-94/> The battery container was mounted below the floor pan of the cargo area, which gave the vehicle a low center of gravity that give it well-liked handling.<ref name=c/> One complaint, however, was the lack of [[power steering]].<ref name=c106/>
The battery supplied power to a three-phase alternating current electric traction motor located under the hood in the area normally used for the gasoline engine. The motor delivered only {{cvt|75|hp}}, low for a vehicle of this size, but up to {{cvt|143|lbft}} of [[torque]], typical of a much more powerful gasoline engine. This was better torque than the Ford Escort GT, for instance, whose 1.8 litre four-cylinder engine delivered {{cvt|127|hp}} but only {{cvt|114|lbft}}.<ref name=c106>{{cite magazine |first=Don |last=Chaikin |url=https://books.google.com/books?id=L2UEAAAAMBAJ&pg=PA106 |title=Ford Electric Van |magazine=Popular Mechanics |date=March 1996 |pages=106–107}}</ref>
One drawback of the sodium-sulfur battery is its relatively slow discharge rates, which limited the amount of power that could be drawn from the battery during acceleration.<ref name=c/> Drivers described it as "sedate", while Ford estimated its 0-{{cvt|60|mph}} acceleration at about 16.5 seconds.<ref name=h/> Instrumented testing showed this acceleration time to be 18<ref name=c106/> to 25 seconds.<ref name=CD-94>{{cite news |url=https://www.caranddriver.com/reviews/a36174141/1994-ford-ecostar-ev-cargo-van-drive/ |title=Tested: 1994 Ford Ecostar Cargo Van Makes a Case for EVs |author=Smith, Kevin |date=September 1994 |work=Car and Driver |access-date=17 January 2023}}</ref> While slow by car standards, this is similar to other small European delivery vans of the era, like the [[Volkswagen Transporter (T4)|Volkswagen Eurovan]].<ref name=h>{{cite web |url=https://greencarjournal.com/from-the-archives/ford-ecostars-on-the-highway/ |title=Ford Ecostars take to the Highway |website=Green Car |date=December 1993 |archive-url=https://web.archive.org/web/20090623063830/http://www.greencar.com/articles/fords-hot-ecostar-electric-car.php |archive-date=June 23, 2009 |url-status=live}}</ref>
While cruising the motor used only 8 kW to maintain speed,<ref name=j>{{cite book |first=Ronald |last=Jurgen |url=https://books.google.com/books?id=MpSNZCOSy6MC&pg=SA33-PA21 |title=Automotive Electronics Handbook |page=33.21 |publisher=McGraw-Hill, Inc. |edition=Second |location=New York, New York |date=1999 |isbn=978-0-07-034453-2}}</ref> about {{convert|8|kW|hp|0|disp=out}}. This speaks to the motor-to-wheel efficiency of the electric drivetrain, as well as the 50 psi low-drag tires.<ref name=c106/> However, the long quoted ranges referred only to driving, not accessory systems. These added considerably to the load; the electric heater burned 5 kW, and the [[air conditioner]] 6 kW.<ref name=j/> In real-world driving, using either would significantly impact range.
==See also== * Ford introduced the [[Transit Connect Electric]] vehicle, similar to the Ecostar, in 2010. * Ford also made [[Ford Ranger EV|an electric version]] of the [[Ford Ranger]] pickup truck in both 1995 and 1998 and sold or leased almost 2000 of these vehicles.
==References== {{reflist}}
===Further reading=== {{refbegin}} * GH Cole, [http://www.osti.gov/bridge/servlets/purl/125358-qjvs4Z/webviewable/125358.pdf "Dynamometer Testing of the Ford Ecostar ElectricVehicle #41"], INEL HEV Laboratory, 1995 {{refend}}
[[Category:Electric vehicles]] [[Category:Ford of Europe vehicles|Ecostar]]