One of Ford Motor Co.’s most significant launches—especially from a technical perspective with an impact on future mobility—is coming next month to U.S. market customers. The company’s first from-scratch long-range electric vehicle, the 2021 Mustang Mach-E, represents the company’s best attempt at a class-leading effort in the vehicle electrification space.

The company just announced U.S. EPA (Environmental Protection Agency) certification and range labeling processes for several variants of the Mach-E. It met all its targeted EPA-estimated range ratings, an important step in validating the car for range-anxious consumers.

The premium extended-range rear-wheel-drive model meets its targeted range of 300 mi (482 km), while the extended-range all-wheel-drive version can go 270 mi (434 km). The standard-range rear-wheel-drive version can go 230 mi (370 km), and the standard-range all-wheel-drive model clocks in at 211 mi (339 km).

“This validation by the EPA comes at a perfect time as the Mustang Mach-E is gearing up to take on the open road,” said Darren Palmer, Global Director, Battery Electric Vehicles, Ford Motor Co.

The California Route 1 has a targeted range of 300 mi, which will be confirmed once EPA officials complete its test. Trim levels are Select, Premium, First Edition, California Route 1, and GT.

 

Mustang design on an EV platform

Developed in a century-old brick building a few blocks away from Henry Ford’s first factory in Detroit, the Mach-E is the first production vehicle to be tuned by Ford’s Performance team using its racing simulator in North Carolina.

The company’s first long-range electric vehicle was not originally going to be a Mustang. However, after Jim Hackett took over as the company’s President and CEO in May 2017, and created a dedicated electric vehicle group called Ford Team Edison, the focus shifted gears to create what would be the Mach-E.

In a somewhat unusual bit of program transparency, Ford identified many of the top leaders and product developers instrumental in making the Mach-E a reality:

The Mach-E’s new architecture, like most others for recently launched EVs, places the heavy batteries in the underbody for a low center of gravity and maximized interior space—for the five passengers and cargo in the new Ford. Designers tried to make the electric crossover instantly recognizable as a Mustang, so included signature elements such as a long hood, rear haunches, and tri-bar headlights and taillamps.

“Thanks to advances in battery technology, the Mustang Mach-E is the kind of car that gets people excited about driving, with a sporty, beautiful silhouette that delivers an incredible shape rarely seen in SUVs,” said Ron Heiser, Chief Program Engineer.

Clever design and engineering delivers surprising rear-seat roominess and cargo space. The rear cargo area fits 29 ft³ (821 L) with rear seats in place or 59.6 ft³ (1687 L) with the seats down. A drainable front trunk provides a 4.8 ft³ (135 L) volume that can, for instance, be packed with ice to keep food and beverages refrigerated for a tailgate or beach trip.

The available panoramic fixed-glass roof has a special coating with UV protection that helps the interior stay cooler in the summer and warmer in the winter. Its overall solar transmission performance is said to be better than all Tesla models, which must include the primary Model Y competition.

Like the Tesla competition before it, the Mach-E also has phone-as-a-key technology, which makes its debut in the Ford lineup. Bluetooth detects a customer’s smartphone as they approach, unlocking the car and allowing driving without getting cell phones out of pockets or using key fobs. A backup code can be entered on the center touchscreen to start and drive the vehicle if a phone loses charge or is not present.

 

Intelligent range and charging

The Mach-E’s lithium-ion battery pack for standard-range models has 75.7 kW·h from 288 cells and in extended range 98.8 kW·h from 376 cells. The packs are housed in a water-proof case surrounded by crash-absorption protection and are liquid cooled to optimize performance and charging in extreme weather.

To accommodate the 80% of EV owners that charge at home, Ford offers a connected charging station that can add an estimated range of 32 mi (51 km) per charging hour on a 240-V outlet for the extended-range and rear-wheel-drive configuration. A mobile charger included with the vehicle can add an estimated range of 22 mi (35 km) per charging hour on a 240-V outlet. With the peak charging rate of 150 kW, the extended-range RWD version can add an average of 47 mi (75 km) of range in about 10 min with a DC fast-charging station.

The Mach-E comes equipped with an intelligent feature to help more accurately predict how much range drivers have left, becoming more precise over time. It calculates range based on past driver behavior and forecasted weather conditions, taking advantage of the cloud to predict how much energy will be used in future driving. Crowdsourced data from other connected Ford electric vehicles who choose to share information on the road can improve estimates considerably.

The Mach-E can track how much energy is used in different circumstances, including varying speed, terrain, and climate conditions. It uses fleet averages across all Mach-Es to improve range estimates—even for routes and conditions a customer has never driven before. If it does run out of charge, Ford Roadside Assistance will tow customers free of charge within 35 mi (56 km) to their home, the nearest public charger, or an EV-certified Ford dealership.

Ford will upgrade Intelligent Range through over-the-air updates to deliver more accurate prediction capabilities for connected Mach-Es. A future update will allow a vehicle to take more advantage of cloud-connected capabilities, enabling it to factor in real-time traffic conditions, road slope, the terrain and elevation of a given route, and even the temperature at a final destination.

“Changes in driver behavior and the environment can impact range, which is the reason other electric vehicles often experience significant range adjustments,” said Mark Poll, Ford’s EV Charging User Experience Manager. “Ford is tapping the power of the cloud to make estimates even more accurate – reducing the need for surprise charging stops and helping reduce customers’ range anxiety.”

In advance of the arrival of the Mach-E—and other 2021 models including the Porsche Taycan and Lucid Air, last week Electrify America announced that its network now offers an innovative payment technology called Plug&Charge on all chargers across the U.S. It allows EV owners to begin a charge without reaching for their wallet, smartphone, or bank card.

After online registration, drivers can automatically pay for charging by just plugging in their EV. The charger communicates with the vehicle to identify, authenticate, authorize, and bill the customer’s registered account for the charging session. Electrify America says it is the first company to offer this service to multiple automakers. It also says it offers the fastest technology available to provide charging speeds of up to 150 and 350 kW.

“We are investing in customer-focused technologies like Plug&Charge to make the charging experience easier than filling up at a gas pump,” said Cliff Fietzek, Senior Director of Technology at Electrify America.

The feature is enabled by advanced vehicle-to-grid communication technology that uses encrypted security measures. It follows the ISO 15118 standard and it enables simplified charging functionality for the most prevalent EV charging connector type—the Combined Charging System (CCS).

 

Upgraded output

In conjunction with U.S. order banks opening in June, Ford confirmed performance specs better than initially announced in November 2019.

The extended-range all-wheel-drive Mach-E will deliver 258 kW and 428 lb·ft (580 N·m), with a targeted 0-60 mph (0-97 km/h) time in the mid-5-s range. The extended-range rear-wheel-drive models will produce 216 kW and 317 lb·ft (429 N·m); standard-range all-wheel-drive models will pump out 198 kW and 428 lb·ft; and the standard-range rear-wheel-drive models will output 198 kW and 317 lb·ft.

“We remain dedicated to delivering on the promise of the Mustang name,” said Heiser. “These better-than-estimated performance figures show that our team is squeezing every last bit of performance out of this vehicle so that it not only delivers Mustang style but Mustang soul as well.”

However, it’s the GT and the GT Performance Edition, coming in the Spring of 2021, that are creating the most excitement. The latter’s permanent-magnet dual-motor electric all-wheel drive puts out 342 kW and 612 lb·ft (829 N·m), for 0-60 mph acceleration in the mid 3 s range, though the targeted range is estimated at least 235 mi from a 98.8-kWh battery. The top model gets Magneride suspension, a unique “carbonized” grille, and 20-in forged aluminum wheels.

BorgWarner is supplying the Mach-E’s Integrated Drive Module (iDM), which comes with a BorgWarner thermal-management system and gearbox integrated with a motor and power electronics from other suppliers.

“Our knowledge of system integration, paired with our gearing proficiency, allows us to design iDMs that are easy to assemble and operate as quietly as possible, which is even more important in electrified vehicles,” said Dr. Stefan Demmerle, President and General Manager, BorgWarner PowerDrive Systems.

The company was able to capitalize on its experience with scalable and modular approaches to iDMs to deliver this customized drive module that met Ford’s stringent requirements. Unlike BorgWarner’s other eGearDrive units, the iDM does not use parallel axis gearing, instead featuring a concentric design with outputs on the same axis as the electric motor, resulting in a more compact package. The gearbox is capable of handling 4278 N·m (3155 lb·ft) of axle torque and input speeds up to 13,800 rpm. Beyond its versatile architecture, the iDM is said to deliver impressive efficiency and noise, vibration, and harshness characteristics.

The iDM powers the Mach-E’s rear-wheel-drive and all-wheel-drive configurations. On the all-wheel-drive GT version, BorgWarner also supplies the secondary drive unit to power the front wheels.

 

Sync 4 debut

Making its debut in the Mach-E is the next-generation Sync communications and entertainment system. Sync 4 presents a more modern interface that uses machine learning to quickly adapt to user preferences and gets better over time thanks to advanced over-the-air updates.

It is powers a user-interface system with outputs to driver instrument and center infotainment screens and Bang & Olufsen speakers neatly integrated across the instrument panel, floating above the air vents like a sound bar.

Inrix, Inc. parking and fuel services will be available globally in all new Sync 4 connected vehicles with navigation, starting with the Mach-E and the more conventional Bronco and F-150. Real-time connectivity ensures drivers have the latest available traffic, incident, parking, charging, and fuel information. Sync 4 also combines conversational voice recognition with Internet search so drivers and passengers always have access to the latest information.

“These services are no longer just a selling point but a requirement; real-time information like traffic, parking and fuel play a critical role in the entire driving experience,” said Bryan Mistele, President and CEO of Inrix.

Inrix launched the industry’s first dynamic off-street parking service in 2013, followed by the first integrated on-street parking solution in June 2015. Sync 4 will provide users with routes to the closest street and garage spot, including rates, restrictions, and real-time occupancy.

The Inrix Parking offers access to the world’s most comprehensive and accurate parking database in 150 countries. To enable its service, the company collects billions of anonymous data points every day from sources including connected vehicles, cities, DOTs, road weather conditions, journalistic incidents, social media, parking, mobile, and other IoT devices.

 

OTA updates

The Mach-E will get over-the-air updates, with improvements going well beyond Sync updates. Nearly all of the vehicle’s computer modules can be updated wirelessly, meaning Ford can provide performance enhancements and entirely new features after customer take delivery of their vehicles. Many will be completed in under 2 min, and some virtually invisible to customers, enabled by a cloud-connected platform that keeps current software running until a new version is ready to go.

“Our clever over-the-air updates also minimize downtime through incredibly fast activation and ensure your Mustang Mach-E is always getting better, even when you’re asleep,” said John Vangelov, who was Connected Services Manager, Ford Motor Co., but now is a senior consultant with Amazon Web Services.

Ford expects to deliver its first updates within six months after the first Mach-Es reach customers. Owners will receive notifications detailing software updates when they are available, which can then be applied using either Wi-Fi or cellular connections, depending on the update.

Mach-E is just the start when it comes to this technology. In 2020, Ford will begin equipping most redesigned vehicles in the U.S. with advanced over-the-air update capability.

 

Hands-free driver assist for 2021

Coming first to the Mach-E and the 2021 F-150 pickup is the optional Ford Co-Pilot360 technology. The advanced driver assistance system (ADAS) allows for hands-free driving on prequalified sections of divided highways the company calls Hands-Free Zones that make up over 100,000 mi (160,000 km) of North American roads. The Active Drive Assist, based on advanced computing of camera and radar sensing technologies, is expected to add more zones in the future.

Ford is promoting the technology’s more mainstream adoption by making it standard or a relatively affordable option for certain F-150 and Mustang Mach-E, with expected first year sales of 100,000 vehicles with the technology hardware. It will become available in the third quarter of 2021 via an over-the-air update, demonstrating Ford’s new “bumper-to-bumper” OTA capability.

“As breakthroughs in new technology allow us to help reduce the stress of long highway drives, it’s important to make sure these capabilities can be enjoyed by the largest spread of people possible,” said Hau Thai-Tang, Chief Product Platform and Operations Officer, Ford Motor Co. “Active Drive Assist can help improve the driving experience while ensuring people remain aware and fully in control, all for a price unmatched by our competitors.”

When Active Drive Assist is not equipped as standard, the company says it will be priced competitively. For the Mach-E, it will come standard on CA Route 1, Premium, and First Edition variants. It’s an available package on the Select trim for $3200 as part of the larger Comfort and Technology package, which includes features such as a 360-degree camera, heated front seats, and heated steering wheel. The hardware enabling Active Drive Assist—including forward-facing camera and radar sensors—will be available through the Ford Co-Pilot360 Active 2.0 Prep Package.

The Active Drive Assist builds upon available intelligent adaptive cruise control with stop-and-go lane centering and speed sign recognition. A driver-facing camera will track eye gaze and head position to ensure drivers are paying attention to the road while in hands-free and hands-on lane-centering mode, which works on any road with lane lines. Drivers will be notified by visual prompts on their instrument cluster when they need to return their attention to the road or resume control of the vehicle.

 

Check out how Ford is promoting electric Mustang performance:

Racing improves the electric Mustang breed