Design of an Electric Powertrain for a Ford F150 Crew Cab Truck Utilizing a Lithium Battery Pack and an Interior PM Synchronous Machine Drive

The design of an electric drive system for a Ford truck is presented. The electric drive system is designed to have similar performance to the stock truck, a 2002 model year Ford F150, with a 4.2L 150kW (peak) gasoline-powered engine. The power capabilities of lithium batteries from two manufacturers have been measured to aid in designing a battery pack that can supply sufficient voltage, power and range. A prototype interior permanent magnet (IPM) synchronous machine has been designed that can produce the desired output power with the chosen battery pack and a commercial motor controller. Dynamometer test results are provided for the machine that demonstrates a close match to the predicted performance. Additionally, the other vehicle system components that must be electrified as well as the custom data acquisition and battery management systems are described.