Three Alums Collaborate on Electric Charger New At-Home Device Will Power the Ford Focus Electric
T
hree alumni from the Department of Mechani- cal Engineering are at the heart of a collaborative team that developed a new at-home charger for the Ford Focus Electric, due to hit the streets in
late 2012.
Stephanie Janczak (B.S. 1988) of Ford Motor Company worked with Michael Mattei (B.S. 1987) and Manoj Karwa (B.S. 1989) at Leviton to design the charger and bring it successfully to market. Leviton is a global leader in electrical wiring devices, network and data center connectivity solu- tions, and lighting energy management systems. Starting three years ago, Mattei—Vice President and General Manager for Leviton’s Commercial and Industrial Division—and his team began planning their company’s entrance to the electric vehicle market. Mattei brought in Karwa,
who had worked in the auto industry, as Program Manager. As luck would have it, fellow alum Stephanie Janczak, an Engineering Manager at Ford, was on the core team responsible for the specification and sourcing of Electric Vehicle Infrastructure at Ford. Janczak’s team had created a bid request for just the sort of electrical vehicle charger that Leviton was developing. After Ford selected Leviton’s proposal for its electric
charger, the three MechE grads met weekly throughout 2011 to bring the innovative charger to market.
A PRACTICAL GREEN SOLUTION The new Ford Electric Vehicle Home Charging Station provides up to 32 amps at 240 volts AC (7.7 kW output)— fully charging a Ford Focus Electric’s battery in a little over three hours, more than four times faster than the standard portable charger. The device’s energy-efficient design—the enclosure is made from nearly 60 percent recycled materi- als—features a low-energy standby power design, contrib- uting to a 50 to 80 percent reduced carbon footprint.
The team designed the practical at-home device with the customer’s safety in mind. A ground monitor circuit and built-in communication system verify proper connec- tion before charging can commence. The device’s “Auto Restart” feature enables charging to restart following a minor fault, thereby reducing the chance of being stranded with an undercharged battery. With a weatherproof NEMA Type 4 enclosure, the device is safe for both indoor and outdoor use. “Non-perma- nent” plug-in installation is ideal for indoor applica- tions, while a “hard wired” conversion kit is available for outdoor locations. Since charging is one of the most important com- ponents of owning an elec- tric vehicle, it was a priority for the team to develop an easy, affordable solu- tion, according to Janczak. The charger had to meet stringent automotive qual- ity, product development,
and testing requirements that would allow Focus Electric owners to charge with ease. “This innovative solution will help promote the adoption and expansion of electric vehicles around the world—and it speaks volumes about the Department of Mechanical Engineering that three of its alumni were closely involved in this groundbreaking effort,” says Mattei. While the Ford Focus Electric will not debut until later
this year, the Ford EV Home Charging Station is now avail- able through select Ford dealerships and Best Buy stores to support the upcoming launch. The device retails for $1,499, including standard installation. The at-home charger features an ADA-compliant, sim- ple, one-button user interface. Installation of the device’s wall mount is impermanent, making relocation easy, while the included 18-foot long “wrap-around” charging cable offers maximum convenience. The device is backed by an industry-leading 10-year limited warranty and is certified by UL.•
CARNEGIE MECH
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