JeffKeryk

From the Mach-E forum...
Apparently every unit built up to 5/22/22 will be subject to a recall around the high voltage battery "contacters" welding themselves either open or shut.
All deliveries are halted. They don't know if it will be a hardware fix or software fix. Maybe both?
"Wait 'till the big boys get in..."

LeX2K

That's a critical flaw either the contacts open and you have zero power or they weld shut which means the HV battery has no more fused protection.

AMIRZA786

Well that's not good for the Mach-e. Good for the Ioniq 5 though

LeX2K

I suppose this helps Hyundai in the sense they can probably raise prices doesn't help them produce more cars. Consumers get the shaft, again.

AMIRZA786

Yeah I know. Hopefully it's an easy fix. I just read on MSN that it will be an OTA software update, but I don't see how a software update will fix an overheating contact, unless it's a software bug causing the issue

LeX2K

Software limit on power output would "fix" the problem.

Reading the recall again...
Uh, Ford. Why would you code it this way, waiting for the next drive cycle? This means if the fuse welds closed and you happen to crash the HV battery will stay live no matter what. How do engineers let stuff like this get into production?

Och

iTrader: (3)

Ford is screwed. Bronco engines are bad, now this.

AMIRZA786

Quality control. Trying to get cars out to customers as quickly as possible they must of rushed the process a bit. At least it's a software fix

Striker223

2nd part is my thoughts on this exactly, why is there a situation it's allowed to be driven with this?

LeX2K

Probably because they don't want the headline, "Ford says stop driving your Mach-E until a fix is available".

Margate330

High volts/amp switchgear is bulky and sometimes heavy so I'm sure it's a engineering design nightmare to keep it light and compact.

We don't see this problem a lot on industrial machines because it is usually way overbuilt just for this reason.
The machines don't roll on wheels so no real constraints unless an machine builder oem goes cheap on the copper and switchgear.

Looks like they are making revisions on stuff.

Striker223

But you really really should not. If it did fuse it will need to be replaced in that particular car and if it hasn't done so yet wouldn't it be wise to not risk it?

It is close to running a house without breakers.....probably would be fine but...

JeffKeryk

I believe Ford already limits full power to 5 seconds, due to overheat issues.

Striker223

Uh.....what? Then what does it drop to?

LeX2K

Good question. From what I've read the bus bars in the battery pack are puny they can't sustain what the batteries themselves can put out. I wonder who makes that main fuse its only job is to blow when needed not weld closed that's the worst failure possible for such a device.