Ford

Technology
Newsbrief
10-2010
PowerShift Transmission
Smart Regenerative Charging
Ford in WRC

POWERSHIFT TRANSMISSION

Shifting
expectations…
In the market for a new car but
not sure whether to buy a manual
or an automatic? Ford offers a
gearbox that combines the very
best attributes of both systems
with none of the disadvantages.
In fact, it’s the ultimate in user-
friendly transmission technology…
PowerShift
Automatic gearboxes are an absolute
“must have” for some motorists and it’s easy
to understand the attraction. They’re simple to
use, they really come into their own in stop-start
traffic conditions, and of course they’re virtually
impossible to stall!
But that ease of operation comes at a cost.
Traditional autos have torque-convertors and
planetary gear systems which sap engine power
and produce more emissions than equivalent
“stick shifts”. What’s needed then is an auto-
matic manual, or perhaps a manual automatic?
Ford customers have been benefiting from
such a system for two years. The company’s
six-speed wet-clutch PowerShift transmission
technology made its debut in the 2.0-litre
Duratorq diesel Focus and C-MAX in 2008 and
is now available on new S-MAX, Galaxy and new
Mondeo, and will also feature in new C-MAX,
new Grand C-MAX and next generation Focus.
2 Ford Technology Newsbrief 10-2010
HOW IT WORKS
Ford’s state-of-the art PowerShift transmission is
a six-speed gearbox which has more in common
with a manual than an auto. Like a manual it has
layshafts and input shafts but Powershift actually
consists of two transmissions working in parallel,
each with its own automatic wet clutch.
In practice the system selects the next gear
in advance so when it does change up or down,
there’s no delay and most importantly, the
changes are seamless, even at full power.
Because there are no torque converters or
planetary gear sets, there’s very little mechanical
drag compared to conventional autos.
Ford transmission expert Johann Kirchhoffer
explains: “PowerShift combines the attributes
of a manual transmission with the comfortable
automatic upshift/downshift control of a
conventional auto. It’s highly efficient and
thanks to the double clutch system offers
excellent fuel economy, performance and shift 8 1
quality. PowerShift works without interrupting the
power flow and, compared to conventional autos
it achieves fuel consumption and CO2 emissions 7
savings of between 4 to 12 percent, depending 2
on the application.
“Initially the wet clutch PowerShift was devel-
oped for the 2.0-litre Duratorq Focus and C-MAX
but it also works exceptionally well in the new 3
high power petrol S-MAX and Galaxy ‘EcoBoost’
models.  The system is very flexible and can be 6
easily calibrated to suit various applications and
it has been tested in extreme ambient tempera- 4
tures to ensure robustness, reliability and
5
performance.
“The wet clutches in particular have been
designed to withstand tremendous abuse and
can handle torque loads of up to 450 Nm.” PowerShift gearbox
1. Hydraulically Controlled Shift Mechanism 2. Gear Position Sensor
3. High Pressure Oil Filter 4. Mechatronic Unit 5. Outer Input Shaft
(2nd, 4th & 6th Gears) 6. Inner Input Shaft (1st, 3rd, 5th & Reverse
Gears) 7. Oil Pump 8. Twin Wet Clutches
PowerShift
PowerShift transmission
delivers fuel consumption
savings of up to 12 percent
compared with traditional
automatics.
ON THE ROAD
Operating Ford’s PowerShift transmission
couldn’t be simpler. Just like a conventional
automatic transmission, there’s a standard
automatic gear lever in the centre console
offering P, R, N and D settings.
When D (Drive) setting is selected, the gear
lever can also be moved to its right into manual
mode. Driver’s can then change up or down by
nudging the gear level forwards or backwards.
Unlike some traditional autoboxes which have
a tendency to creep forwards when stationary,
PowerShift has a built-in ‘neutral idle control’
which helps keep the vehicle still with the gear
lever in the D position when the brakes are
applied.
“The first impression you get when you try
PowerShift for the first time is just how good
the gear-change is,” adds Kirchhoffer. “Both up
and downshifts are seamless and certainly equal
to or better than traditional torque converter
automatic transmissions.
3 Ford Technology Newsbrief 10-2010
“At the same time the shifts are very fast and
crisp and give the customer a sporty driving
experience, especially while driving in manual
mode. The driver gets immediate and jerk free
response after an acceleration pedal tip in.
It delivers outstanding driving smoothness
performance with a minimum of clutch slip
during the entire speed range. As a result,
overtaking is safer compared with a traditional
automatic transmission.”
DEVELOPMENT
Ford’s 6-speed wet clutch PowerShift transmis-
sion took four years to develop and is the result
of a joint venture between Ford of Europe and
GETRAG FORD Transmission. The technology
was driven by a desire to reduce fuel consump-
tion for automatic transmission customers while
also improving their driving experience.
PowerShift is just one of many exciting new
powertrain technologies Ford is bringing to
market. Two years ago the company pledged
to deliver 60 new or significantly upgraded
engines and transmissions around the world
by 2013.
“We are committed to achieving class-leading
gains in fuel economy and CO2 reductions
through world-class engineering and a laser-like
focus on high efficiency powertrains,” explains
Kirchhoffer. “Ford knows car buyers around the
world are focused on cost of ownership, and the
introduction of the PowerShift transmission is
one step towards our goal of being a global
leader for fuel economy.”
Ford’s wet-clutch PowerShift transmission is
currently available on the company’s mid-size
and larger vehicles. GETRAG Transmission is
developing a dry-clutch PowerShift system
specifically for lighter vehicles with lower torque
outputs.
Introducing Johann Kirchhoffer…
Johann Kirchhoffer, or Hennes as he is known to
friends and colleagues, joined Ford in 1980 and has
spent his whole career developing manual and
automatic transmission systems for the company.
These days he’s based at Ford’s advanced engineering
and research facility in Merkenich, Germany, where he
focuses on maximizing the quality and reliability of
Ford transmission systems.
“It can be very demanding work but it is very satisfying too,
especially when we as a team achieve our targets,” says
Kirchhoffer. “Creating technology which benefits our
customers is rewarding. I like every aspect of my work,
perhaps with the exception of micro management, which
is not part of Ford’s philosophy.”
During his longer career with Ford, Kirchhoffer has
seen many technologies evolve but the one that really
impresses him is ESP, electronic stability program.
“Any technology that helps save lives is good and ESP is
particularly effective at doing just that,” he says.
Kirchhoffer currently drives a Ford S-MAX equipped with
PowerShift transmission which he rates as one the best
Fords he has ever driven. There’s another, rarer car he
covets too. “If I could have any car it would be a Mustang
Convertible 5.0-litre from the 1990 and 1995 model year.
I’d really like one of those!”