Is there a revolutionary cooling design in the Ford Mach-E? This episode starts off with Sandy bringing up this very topic, saying that they have found something unique inside this design.
Sandy hands over the reins to Ben as he explains what is found in each battery bay, focusing on the cooling plates and their unique design using a dimpled design pathway for the coolant to flow, similar to the “Plinko Board” from “The Price Is Right” causing the coolant to move in random directions around different areas of the plates and creates a turbulent flow that more effectively transfers heat. All of the coolant is supplied through well designed cooling lines that are attached through quick connects.
Ben also points out that it is actually the battery modules that fix the cooling plates down using the studs that protrude through the cooling plates, which is a great double use of a fastener.
Sandy and Ben then move over to look at the battery modules and cells themselves and where we get a chance to see that the Ford Mach-E and Chevy Bolt batteries are identical which makes sense as they are both supplied by LG. However, Ford made some interested improvements on the rest of the modules, using collector plates that are copper that have been nickel plated with the ends of the battery tabs welded to the plates, but more importantly, Ford chose a smart ribbon cable design for the circuitry to manage the battery cells which prevents breakage during installation and ultimately a cost savings.
From there Ben goes over a great design choice on the Ford Mach-E where Ford has placed bent aluminum strips that aligns up witht the thermal interface compound allowing them to use less compound, saving money, and helping to speed heat transfer. Ben also talks about the foam pads in between the cells which allows for expansion as the cells age.
Finally, Sandy talks about our future “best-of-best” battery tray design that we are coming up with. To catch what he says, watch the full episode below:
Cory Steuben, President of Munro & Associates, and Ben Lindamood, Account Director and lead on the Ford Mach-E teardown, take our viewers on a tour of their findings of the thermal system of the Ford Mach-E.
Cory first points out that the compressor motor needs quite a bit of power to effectively compress the refrigerant R1234YF gas and that is why in an electric vehicle it requires a high voltage line running to it. From there the refrigerant moves through the hoses into the condenser that then cools the compressed gas by having outside air run through its fins and piping from the grills opening up if the car is moving or the fan if the car is stationary. This process condenses the high pressure, high-temperature gas and dissipates the heat allowing the gas to form into a liquid.
From the condenser, the refrigerant flows through another line and into the chiller which has two functions: 1) the heat exchanger portion cools the ethylene glycol run in a loop that cools the batteries and other electric and vehicle systems and 2) leads up to the thermal expansion valve and then into the evaporator at the front of your dashboard which opens up the volume of the line and allows the compressed liquid refrigerant to revert back to a gas which drops the temperature significantly thus giving you airconditioning.
For heating of the electronics, battery, and cabin, the Ford Mach-E uses a traditional heater core which is a heat exchanger that derives its heat from a PTC (positive temperature coefficient) electric heater.
From here, Cory reviews the HVAC cooling and heating system in a Model Y, which instead uses a heat pump system that effective eliminates the need for a heater core or PTC heater. But to find out it’s advantages, you will have to click on the link below:
In this episode of Munro Live, Sandy takes a step back and has Cory Steuben and Ben Lindamood take the audience through a detailed comparison of the Tesla Model Y Thermal System components and the corresponding components on the Ford Mach-E
As Cory points out, the location of the components is very important when it comes to efficiency and cost. Many of the components of the Tesla Model are grouped fairly tightly giving it a smaller footprint in the vehicle. When Ben dumps out all of the hoses for the Mach-E and compares them to the Tesla Model Y, it is overwhelming! There is 35 different hoses on the Mach-E which is a very large number comparatively to what it found on Tesla Model Y (10) or even some of the other EVs we have looked at.
The team goes on to compare the pumps, valves bottles, chillers, eletronics and more. Don’t miss this episode if you are enthusiastic about understanding the thermal systems of these vehicles.
In this episode of Munro Live, Sandy and Ben explore the Instrument Panel of the Ford Mach-E and point out all of their interesting findings.
Sandy starts off by pointing out the massive magnesium casting for the structure of the instrument panel, explaining that it is his favorite choice of material because the casting will perform excellent in a crash situation and has the benefit of being one of the most sound-absorbing materials, helping to reduce NVH.
Ben goes on to point out the molded-in features in the casting that help with the alignment and positioning of components that are added to it. Ben also likes the mounting features that the magnesium casting has. Ben goes on to point out that the vehicle has a column mounted power stearing motor which is an interesting choice, because while it might have been more efficient to mount the motor on the rack, it would have been more expensive and might have intruded in the space created for the frunk.
Ben and Sandy move on to the features they like and don’t like on the interior of the IP, covering the steering wheel and its ability to be easily adjusted, the vents, infotainment system, glove box, HVAC system and more. But then they move into the cavity area behind the IP and they pick up on some interesting hidden features that are probably meant for an ADAS unit in the future.
In this episode of Munro Live, Sandy and Munro’s president Cory Steuben go through the suspension and high voltage wiring of the Ford Mach-E.
Cory, who is an expert in suspensions at Munro, gives us a walkthrough of all of his findings on this Vehicles suspension, giving the rear link suspension an A, but not and A+ for a cost and performance perspective, only for the fact that one of the links is not straight, which means you can’t choose the most efficient cost manufacturing method due to the fact that the bend in the one link requires the operator to have to weld the piece again in order to maintain structural integrity to compensate for the extra loads being exerted on that piece.
From rear to front suspension and the HV wiring surounding it, this is quite an information packed video. So if you are an engineering student looking to get a great insight into how suspension “should” be made as well as some deep insight into the HV wiring and design choices that Ford made on this vehicle, you NEED to watch this whole episode through.
In this episode of Munro Live, Sandy, Mark Ellis, and Victor Trevino open the Mach-E battery box up and take us on a tour of its insides.
The show starts off with a comparison of the size of the ID.4 vs the Mach-E battery box and then goes into design choices made by each company.
But the real meat of the video begins when Mark starts to explain what he finds with the batteries and the management system itself. From two different sized batteries, to a high wire count for the battery management system, there are some interesting finds within the box.
But to learn more, you will have to watch the video by clicking below:
In this episode of Munro Live, Ben takes what is left of the Mach-E (before removing the battery box), and has a fun quick ride around in the parking lot of Munro & Associates.
Returning to Sandy’s comments in an earlier episode about how he was surprised NOT to find a frunk in the VW ID.4 when doing a review of the vehicle, Sandy has been asked to justify this reaction, and what he finds, will intrigue our viewers: SPACE, tons of SPACE under and behind the instrument panel. This usually fought-over area is quite underutilized and unfilled, meaning that if the product design engineering teams would have decided to utilize this space and move/design some of the systems found under the hood to behind the IP, they would have had room.
Sandy will take the viewer on a comparison tour of the Mach-E vs. the ID.4 focusing on design choices that each of the respective product design engineering teams made and how things could have been different. The episode ends with Sandy also comparing the hatch designs of these two vehicles to the Tesla and lastly, wishing our viewers an (albeit belated) Happy Independence Day, and for our Canadian viewers, a happy Dominion (Canada Day).
In this episode of Munro Live, Sandy and Ben have a look at the electric battery setup in the Mustang Mach-E. The episode begins with Sandy and Ben looking at the underbelly of the vehicle after the battery tray has been removed. The battery tray is bolted in place under the vehicle into a rocker panel that combines together to create a structural member. This is a good design choice for the vehicle.
Going forward to the front of the car, Ben explains why the battery box also fits into an extruded aluminum piece that is also attached to a hollow cast aluminum piece behind the front craddle in order to create a crush zone, protecting the battery in a front collision.
Sandy and ben then go on to explain the connectors going to the battery and what they are for and finally they talk about the structural aspects of the battery box itself.
From there Sandy and Ben go through a chart comparing different electric vehicles batteries ranges, capacity and weights. Sandy puts out a special plea to help Audi with some of their designs that we think could be improved… for a cost of course, but to understand why, you will have to watch the video by clicking below:
Sandy Does a Walkthrough of How Seat Works in the Mach-E
Sandy takes us on a walkthrough of what you can expect to find in a seat, in particular, one of the Mach-E seats.
From hog rings to the controls of a 6-way seat with 2 lumbar controls (or an 8-way seat if you are Ford), the viewer will learn the basics of what is inside a seat, how seats are assembled, and the controls and structures.
In this episode of the Mach-E teardown, Sandy and Ben first examine the air-intake for the HVAC and the battery management cooling system. Sandy discusses the design choices that the Ford team made and why are good, allowing the Mach-E to make space to have a frunk.
Sandy goes on to talk about the front facia of the car and design choices he likes that were made such as the snap fits for attaching the facia onto the vehicle frame. Sandy is particularly impressed with the snap fits found on the headlamps that help also to locate and align their position.
The topic then shifts to how Sandy and Ben feel about the design choices made on the body to withstand the SORB test (Small Overlap Rigid Barrier), where the car is run at a speed of 40 Mph towards a barrier that is at a 25% offset of the front side of the vehicle to simulate a collision with a roadside barrier. There are many design choices that Sandy is happy with that add safety and perform well.
Then Sandy and Ben move on to the side of front fender area where the discuss some re-design choices that Ford could make to save both money and weight to the vehicle, but to hear about those, you have to watch the video: