How a Hybrid Car Works: Ford 2nd Generation Hybrid System

[@viniciusnoyoutube]

Your knowledge about cars is stunning. Even the electronic parts you know very well. I bet most of the engineers that made that project couldn't explain every single part and interaction as you did.

[@paulvandal4444]

Shocking demonstration of electrical knowledge. Thank you sir!👍

[@saturn9706]

I see what you did there

[@speedkar99]

Shocking ⚡indeed

[@BenMcghie]

This is an excellent illustration of why a computer chip shortage will affect car delivery times! Great video. I'm always shocked how large HV capacitors get. Crazy.

[@speedkar99]

Agreed, but I think that's behind us now. A gasoline shortage would cripple the car industry just as badly.

[@michaelbezoski3096]

Another fine video brought to you by "Speedkar99". Thank you. Surprises me all those electronic parts with stand the environment. Finally saw a video on a Mazda plant building cars from casting to machining. Transmission building & how they use rotary engine for the gas engine portion. I swear I could hear your voice except no voice. Low music & written explanation. Being an I/E Journeyman I can truly appreciate the PLC programming that goes into making those robotic welders & other automated equipment function. PM's & calibrations, wow. Lots of visual & hands on QC goes on still. Amazing

[@speedkar99]

It sure takes alot more than just what I dissect here that goes into making these work. Machine work, design, programming, manufacturing, logistics! Amazing

[@berniefranks4876]

Your videos are so informative. Thank you!

[@speedkar99]

Glad you could learn something. Thanks

[@hybridsolutiondiagnostics]

B E A U T I F U L video demonstration 😁👍 great job and great explanation

[@speedkar99]

Glad you enjoyed it!

[@MichaelMossmanNZ]

Thank you @speedkar99 for the informative video. BTW: love the purple pointing stick =)

[@speedkar99]

You are welcome. The teach-brush lives on!

[@1uch1n11]

Merry Christmas buddy!

[@Z7d3nR4]

2:51 You wonder what is underneath there. Did we finally find something you did not know?

[@dehypnotizerz]

Great content, as usual. You've just shown me something really scary. What I've just seen is $$$ repairs. I wonder what tolerances they used. Usually, in automotive, we're using elements, like caps, with operational limits between -50 - 105°C and I wonder what's the upper temperature limit this assembly reaches. The higher the temperature, the shorter the longevity of the elements. Usually, the lifespan of elements like capacitors is up to 5 years. As for semiconductors - it depends heavily on the temperature. And now I wonder: what happens after these 5 years. Capacitors simply can't last longer. What's the cost of the unit you've just disassembled. Power electronics never last long because of the very nature of semiconductors: they lose their properties in functions both of time and operational temperature. The question is what tolerances they used. What's also common in automotive is gradually shrinking these tolerances to absolute minimums. Each iteration will last shorter. Add to this the cost of wearing motors - isolating enamel has also a short lifespan, also heavily dependent on heat - and we have a disaster. And eco-ignorants will keep saying that "EVs have very few moving parts" - so what, if they heavily rely on complex electronics! Imagine now: one, cold solder joint... This thing vibrates because it's a moving vehicle! That's just terrifying. It's not "green"/"eco" whatsoever. And what about recycling all that crap? There's no single facility recycling this and there's not even one company recycling Li-Ion batteries. Mind boggles.

[@speedkar99]

Agreed there are different failure points on these than a typical turbo engine. However with its own dedicated cooling circuit, hybrid cars have proven to outlast their turbocharged counter parts. Toyota had made a good example of this with the Prius. I just wish ford made this inverter and the transmission more servicable than just replacing the whole unit.

[@BCdgz]

We are waiting for the reassembly video 😂

[@speedkar99]

Play the buddy in reverse

[@BCdgz]

@speedkar99 I mean tearing apart engines and other components isn't a big deal. Almost anybody can do that. Reassembly is a big deal ....

[@Jean-Sylvain-v5t]

@@BCdgz Taking apart an engine may be easy for many, but understanding how the engine works and explaining it is another thing. Same for an autopsy.

[@KPKCCK]

Good video. Can anyone tell please @7:37, what is the purpose of that white color "big resistor"? Thanks.

[@ComplicatedStuff]

To discharge the capacitor after the system shuts down. Its a safety feature, so to not shock anyone working on the system as they will asume there is no voltage.

[@speedkar99]

I explained in the video, for capacitor discharge

[@KPKCCK]

@@ComplicatedStuff Thanks for your kind clarification. Appreciate!

[@mattkroening7964]

I remember the first ford escape hybrid becoming one of the most reliable vehicles you could buy from that time period. Knowing how ford usually likes to build their cars, I consider that to be entirely by accident

[@arthurmario5996]

no, they just licensed it all from japan.

[@TotodrivesspdTanker]

Thank you.

[@7null]

what could possibly go wrong with such a simple car.

[@speedkar99]

Well It's more reliable than the turbo variant of the Fusion!

[@zxggwrt]

I’ve had spirited discussions about whether when it says 3 phase does that mean the motors are AC. We concluded they are in fact three pole DC motors. With a speed controller. A three phase AC motor is a specific thing and if you want to control its speed that is another matter. You mostly find that in industrial speed controllers. What do you think?

[@YourFriendlyHoodVampire]

They call it DC, but in principle it is an AC motor. A DC supply imitating three phase by switching on and off. They call the motor "brushless DC" But I think that's more for engineers to feel smart about minute differences. A BLDC and an AC motor will both have three windings (in three phase; we aren't going to esoterics in this comment like six and nine phase) The motors are technically referred to as "BLDC AC motors" or "ECM's" electronic commutation motor" A "speed controller" regulates voltage, for the most part.

[@zxggwrt]

@ Yes! Brushless DC was what we settled on and I’m not an engineer but my brother and the men I was discussing this with were. Thanks for the breakdown 💯

[@YourFriendlyHoodVampire]

@@zxggwrt my point is, it's the same thing.

[@AKAtheA]

@@YourFriendlyHoodVampire there's a distinct difference...brushless DC is made for trapezoidal waveform, synchronous AC a sine. Trying to run on the wrong type results in (much) lower efficiency + will probably make the controller...unhappy...

[@YourFriendlyHoodVampire]

@ you're over thinking this; A winding is a winding. A "trapezoidal wave form" has no bearing on efficiency. In fact, a trapezoidal waveform is AC, so what now? BLDC controllers are PWM and output AC.... If you want efficiency then you focus more on bearing quality, Permanent magnet quality, etc. Add more pole pairs, blablablabla No matter what, switching from DC to AC will make efficiency pointless; You will always lose efficiency from that process.

[@KPKCCK]

Can anyone tell please what type of "smoothing capacitors" are thet? Thanks.

[@Scottie5809]

AC compressor tear down, please.

[@speedkar99]

Sure

[@Thegonagle]

This hybrid controller is so similar to Toyota. Both are very robust looking for electronics. Both are very obviously designed with a priority on reliability and longevity. I hope the Fusion hybrid transmission is next. It will be interesting to see how Ford build theirs compared to Toyota.

[@YourFriendlyHoodVampire]

I don't think you understand what you're looking at. It certainly isn't made for longevity.

[@ComplicatedStuff]

I wonder how much Toyota influence is packed into this Ford Inverter. At least it is made in Japan. The details will dictate if they are just as reliable on the long term.

[@YourFriendlyHoodVampire]

@@ComplicatedStuff they probably traded favors. Scratch my back i scratch yours. Cant imagine what ford has to offer, seeing as they make garbage

[@Andy-rk9mu]

awesome

[@speedkar99]

Thanks

[@timbober1]

Yeah I want to see the engine transmission tear down.

[@speedkar99]

The engine teardown was last week's video. Check it out.

[@timbober1]

@ had my hip replaced last week and missed it or maybe I forgot. I will definitely check it out. I appreciate your channel

[@pcranger1]

Very interesting.

[@nengyang1895]

I still so surprise that they are using thermal paste that can dry out and lead to failure. You would think that for the price of these vehicles they aren't using some kind of phase change material instead.

[@speedkar99]

I didn't think they expected it to last that long! Fyi Toyota uses a similar thermal paste

[@ComplicatedStuff]

It doesn’t dry out in such a system as the temperature range is not that high (water cooled). It is not a computer CPU for tinkerers. Phase change material has a different purpose. Thermal paste only fills up voids between to metals. It’s actual conductivity is quite bad (but much better than voids).

[@YourFriendlyHoodVampire]

Can you slap the lid of the ECU more so I can understand that thats the ecu? *slaps hand on keyboard* thanks

[@speedkar99]

🤣

[@ComplicatedStuff]

Interesting stuff and well explained, but you are also falling for the stepped wave pattern someone at the marketing department for digital audio invented a long time ago. In reality this stepped waveform doesnt exist, instead the waveform is a PWM signal (full on/full off).The PWM frequency causes the typical whine EV and hybrids make (some louder than others).

[@kclefthanded427]

I thought it was a big fancy toaster with computer chips

[@speedkar99]

Well it can be a toaster if you put your hand across that capacitor

[@Aleks_Mechanics]

Notification Squad!🔥🔥🔥

[@WilliamHollinger2019]

Look at those Cooper imagine scrapers doing after your hybrids system over catalytic converters.

[@msylvain59]

Getting to the bare copper pieces requires a lot of time consuming and tedious disassembly tho, unless you have a big shredder to break the boxes to bits, not sure it is worth the work needed.

[@the-one-and-only-mkultra]

Backyard got too cold?

[@speedkar99]

Yeah! Will be inside for the winter. Got a propane heater.

[@carmast3r]

IGBT 🌈 hybrid wow love me some electronics. I think that was solid epoxy at 8:18, super hard to open lol

[@happy543210]

How it works?......poorly!

[@Thegonagle]

Nah, I owned one for a few years. It works great. Fewer moving parts (see the Prius transmission teardown; Ford’s is conceptually identical). No alternator, no starter, and no drive belts (water pump, AC, and power steering are electric). Never a single issue with the drivetrain or electronics, good performance with 188 HP, and averaged 40 MPG even though I get on the gas like a meathead most of the time (the “secret” to good MPG in a hybrid is not tempering your acceleration, it’s refining your braking technique).

[@3isr3g3n]

Our Forester Hybrid has a worse mileage than our old Outback which was a regular car

[@Meatpipeify]

Ford’s hybrid systems are actually very good. They’re almost identical to Toyotas.

[@dustinswatsons9150]

​@@Thegonagle so you prefer Ford

[@JDMSwervo2001]

It’s actually very similar to Toyotas

[@jimmytimmy3680]

Can you be my mechaninc?

[@speedkar99]

I'm not a mechanic. I'm an engineer. I don't fix stuff. I break stuff like in my videos. 😁

[@jimmytimmy3680]

@speedkar99 close enough. 😆

[@joskd8491]

I can't imagin that Ford designed and thinked it over all by themselves. I think they had to pay Toyota to think for them.

[@speedkar99]

Past ford designs were literally licensed from Toyota. This generation was Ford designed with the main difference being the parallel hybrid setup you'll see in transmission teardown next week !

[@rods6405]

Its not really efficient you have to cool the electronics with water thats a loss of energy plus the motor also needs cooling same same or double same!

[@olspanner]

Bulk $$$$$$$$$ - Life span?????????? Use your brothers gloves!