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 HOW IT WORKS excellent fuel economy, performance and shift 8 1
“must have” for some motorists and it’s easy Ford’s state-of-the art PowerShift transmission is quality. PowerShift works without interrupting the
to understand the attraction. They’re simple to a six-speed gearbox which has more in common power flow and, compared to conventional autos
use, they really come into their own in stop-start with a manual than an auto. Like a manual it has it achieves fuel consumption and CO2 emissions 7
traffic conditions, and of course they’re virtually layshafts and input shafts but Powershift actually savings of between 4 to 12 percent, depending 2
impossible to stall! consists of two transmissions working in parallel, on the application.
But that ease of operation comes at a cost. each with its own automatic wet clutch. “Initially the wet clutch PowerShift was devel-
Traditional autos have torque-convertors and In practice the system selects the next gear oped for the 2.0-litre Duratorq Focus and C-MAX
planetary gear systems which sap engine power in advance so when it does change up or down, but it also works exceptionally well in the new 3
and produce more emissions than equivalent there’s no delay and most importantly, the high power petrol S-MAX and Galaxy ‘EcoBoost’
“stick shifts”. What’s needed then is an auto- changes are seamless, even at full power. models.  The system is very flexible and can be 6
matic manual, or perhaps a manual automatic? Because there are no torque converters or easily calibrated to suit various applications and
Ford customers have been benefiting from planetary gear sets, there’s very little mechanical it has been tested in extreme ambient tempera- 4
such a system for two years. The company’s drag compared to conventional autos. tures to ensure robustness, reliability and
5
six-speed wet-clutch PowerShift transmission Ford transmission expert Johann Kirchhoffer performance.
technology made its debut in the 2.0-litre explains: “PowerShift combines the attributes “The wet clutches in particular have been
Duratorq diesel Focus and C-MAX in 2008 and of a manual transmission with the comfortable designed to withstand tremendous abuse and
is now available on new S-MAX, Galaxy and new automatic upshift/downshift control of a can handle torque loads of up to 450 Nm.” PowerShift gearbox
Mondeo, and will also feature in new C-MAX, conventional auto. It’s highly efficient and 1. Hydraulically Controlled Shift Mechanism 2. Gear Position Sensor
new Grand C-MAX and next generation Focus. thanks to the double clutch system offers 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

2 Ford Technology Newsbrief 10-2010

PowerShift

Introducing Johann Kirchhoffer…

Johann Kirchhoffer, or Hennes as he is known to
PowerShift transmission
friends and colleagues, joined Ford in 1980 and has
delivers fuel consumption spent his whole career developing manual and
savings of up to 12 percent automatic transmission systems for the company.
compared with traditional
automatics. These days he’s based at Ford’s advanced engineering
and research facility in Merkenich, Germany, where he

ON THE ROAD “At the same time the shifts are very fast and to deliver 60 new or significantly upgraded focuses on maximizing the quality and reliability of
Operating Ford’s PowerShift transmission crisp and give the customer a sporty driving engines and transmissions around the world Ford transmission systems.
couldn’t be simpler. Just like a conventional experience, especially while driving in manual by 2013. “It can be very demanding work but it is very satisfying too,
automatic transmission, there’s a standard mode. The driver gets immediate and jerk free “We are committed to achieving class-leading especially when we as a team achieve our targets,” says
automatic gear lever in the centre console response after an acceleration pedal tip in. gains in fuel economy and CO2 reductions Kirchhoffer. “Creating technology which benefits our
offering P, R, N and D settings. It delivers outstanding driving smoothness through world-class engineering and a laser-like customers is rewarding. I like every aspect of my work,
When D (Drive) setting is selected, the gear performance with a minimum of clutch slip focus on high efficiency powertrains,” explains perhaps with the exception of micro management, which
lever can also be moved to its right into manual during the entire speed range. As a result, Kirchhoffer. “Ford knows car buyers around the is not part of Ford’s philosophy.”
mode. Driver’s can then change up or down by overtaking is safer compared with a traditional world are focused on cost of ownership, and the
During his longer career with Ford, Kirchhoffer has
nudging the gear level forwards or backwards. automatic transmission.” introduction of the PowerShift transmission is
seen many technologies evolve but the one that really
Unlike some traditional autoboxes which have one step towards our goal of being a global
impresses him is ESP, electronic stability program.
a tendency to creep forwards when stationary, DEVELOPMENT leader for fuel economy.”
“Any technology that helps save lives is good and ESP is
PowerShift has a built-in ‘neutral idle control’ Ford’s 6-speed wet clutch PowerShift transmis- Ford’s wet-clutch PowerShift transmission is
particularly effective at doing just that,” he says.
which helps keep the vehicle still with the gear sion took four years to develop and is the result currently available on the company’s mid-size
lever in the D position when the brakes are of a joint venture between Ford of Europe and and larger vehicles. GETRAG Transmission is Kirchhoffer currently drives a Ford S-MAX equipped with
applied. GETRAG FORD Transmission. The technology developing a dry-clutch PowerShift system PowerShift transmission which he rates as one the best
“The first impression you get when you try was driven by a desire to reduce fuel consump- specifically for lighter vehicles with lower torque Fords he has ever driven. There’s another, rarer car he
PowerShift for the first time is just how good tion for automatic transmission customers while outputs. covets too. “If I could have any car it would be a Mustang
the gear-change is,” adds Kirchhoffer. “Both up also improving their driving experience. Convertible 5.0-litre from the 1990 and 1995 model year.
and downshifts are seamless and certainly equal PowerShift is just one of many exciting new I’d really like one of those!”
to or better than traditional torque converter powertrain technologies Ford is bringing to
automatic transmissions. market. Two years ago the company pledged

3 Ford Technology Newsbrief 10-2010