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Recharge Wrap-up: Ford 1.0L EcoBoost a hit in Europe; Build a tiny inverter, win $1 million

In Europe, Ford's 1.0-liter EcoBoost engine is the best-selling turbocharged gasoline engine. The three-cylinder motor powers 20 percent of new Fords sold in Europe. Earlier this year, it won its third International Engine of the Year award, and between January and June, it was sold in about 120,000 cars. So far this year, 38 percent of Fords sold in the Netherlands, 35 percent in Denmark and 32 percent in Switzerland have been powered by the 1.0-liter EcoBoost. The engine's turbocharger spins at 248,000 rpm, and provides 24 psi of pressure. The engine produces up to 138 horsepower, depending on the version. Read more in the press release below. When lithium-ion battery packs are retired from the road, remanufacturing, repurposing, and recycling are worthwhile options, according to a study by Mineta Transportation Institute. The study included a cost-benefit analysis of those three options, and found remanufacturing to be the best route. To get the most out of them, batteries should be tested and have their damaged cells replaced then put back to use. Repurposing is the second best option, using the remaining available charge for something besides cars. Recycling on its own isn't profitable, but it could make economic sense with "increased technological breakthroughs." Learn more at Recycling International or download the report here. A smaller inverter for EVs can win you $1 million. The Little Box Challenge is an open competition to build a power inverter with a density of at least 50 watts per cubic inch. Google and the Institute of Electrical and Electronics Engineers (IEEE) are offering the hefty prize to the team that builds the inverter with the highest power density within an enclosed volume of 40 cubic inches. Teams must register by September 30. Read more at Green Car Congress or learn more at the Little Box Challenge website.

Ford Green Zone works magic with GPS to make your drive smarter, cleaner

For the most part, plug-in hybrids rely on the power stored in the battery until that charge is depleted. Unless the switch can be changed manually, it's only then that the cars fire up the internal combustion engine and begin using the fossil fuels on board. This is ideal, of course, when one's drive isn't long enough that the car needs to start sipping gasoline at all. On longer commutes, when it's certain that the route is longer than the car's all-electric range, this isn't necessarily the most efficient use of energy. Ford's Green Zone system is designed to save some of that juice for the parts of the drive that require slower speeds. Ford is working on a smart system, based on Nokia mapping technology, that uses GPS data to use both the electricity and conventional fuel more efficiently. Since battery power is less efficient at highway speeds, Ford's Green Zone system is designed to save some of that juice for the parts of the drive that require slower speeds, rather than just using up all the electrons right at the beginning of the drive. Using a website or the in-car navigation system, the driver can pinpoint the parts of the route, highlighted in green, where using battery power would be more effective, and set the car to automatically switch to electricity for those sections. Depending on the route, the car could automatically switch back and forth between the two power sources multiple times, particularly if the drive is a mix between city and highway driving. Of course, Green Zone will be go beyond that. The program is being developed to take traffic and road grade into account, details that allow the car to be make even smarter choices to improve efficiency. Ford even hopes to have Green Zone learn driver habits, and respond accordingly depending on who is driving the car. The system could control other features as well, such as anticipating corners and shifting the headlights to better illuminate the road ahead. Green Zone could also potentially use information from vehicle-to-vehicle networking to control functions in the car. The Green Zone system still has a few years before it will be ready to be put into production vehicles, but Ford is confident it will make its way onto the road eventually. As with other innovations that improve efficiency and make our vehicles smarter, we can expect to see similar technology from other manufacturers, until it becomes a regular part of driving in the future.

Ford recalls 90,736 vehicles due to engine valve issue

Ford will recall 90,736 vehicles as engine intake valves in the vehicles may break while driving, the National Highway Traffic Safety Administration (NHTSA) said on Saturday. The recall impacts certain 2021-2022 Bronco, F-150, Edge, Explorer, Lincoln Nautilus, and Lincoln Aviator vehicles equipped with either a 2.7L or 3.0L Nano EcoBoost engine, the NHTSA said. According to documents posted by NHTSA and sourced from the automaker, "The engine intake valves may break while driving, which can result in engine failure and a loss of drive power." Following an investigation that started in January, 2022, Ford found 22 instances where "the engine intake valves fractured and fell into the combustion chamber of the engine causing catastrophic engine damage." The automaker's analysis continues: "Ford identified that the potential root cause of the failures was engine intake valve failure due to valves that exceeded the designed specification for hardness, were brittle, and more likely to fracture. Ford determined that this was due to the supplier’s grinding processes and the sensitivity of the intake valve material to grinding processes that were not within control specifications. The intake valve material was changed for vehicles produced after October 31, 2021." Fixing the problem will require replacement of the entire engine. "Dealers will inspect each vehicle to determine its cumulative number of engine cycles. For vehicles that do not meet the engine cycle threshold, dealers will accumulate high revolutions per minute (rpm) engine cycles per a service procedure. Engines will be replaced on vehicles that do not pass the engine cycle accumulation," Ford says.