Chuck Gray: Taking on New Challenges, Advancing Technologies as Ford Charges Up a Growing Electrified Vehicle Lineup

Chuck Gray, chief engineer, Global Core Engineering, Hybrid and Electric Vehicles

• Who: Chuck Gray, chief engineer, Global Core Engineering, Hybrid and Electric Vehicles
• Role: Oversees development of Ford’s hybrid, plug-in hybrid and electric powertrains
• Did you know? Owns seven motorcycles – likes to go riding off- and on-road

Chuck Gray has never been one to back down from a challenge. As a teen, his father offered him a deal: Fix the ’68 Firebird his sister had wrecked, and the work would earn him his own car. It wasn’t an easy task; Gray scoured local junkyards for parts.

“It was a lot of work,” he recalled, laughing. “But getting a car of your own is a great motivator, especially as a teenager.”

He earned his first car – a ’73 Plymouth Duster. Today, Gray is still taking on challenges. As Ford chief engineer, Global Core Engineering, Hybrid and Electric Vehicles, he leads an engineering team that designs and develops the high-voltage batteries, motors and electrical systems of Ford electrified powertrains.

A Detroit native, Gray graduated with a bachelor of science in mechanical engineering from GMI/Kettering and with a master of science in mechanical engineering from the University of Michigan-Dearborn. He has been at Ford for nearly 20 years, only recently moving from traditional gasoline powertrains to electrified vehicles.

“We at Ford are at the forefront of a revolution for the auto industry as we lead the transition to electrified vehicles,” Gray said. “Electric vehicles aren’t new, of course – they dominated the roadways in 1910. But Henry Ford made the gas-powered car affordable and fast. Today’s technology is what’s so remarkable.”

Ford’s current hybrid electric vehicles use a high-voltage nickel-metal-hydride battery. A gasoline engine and a regenerative braking system charge the battery automatically during operation. Ford’s longstanding research in hybrid technology has laid the groundwork for taking the next step in battery durability – moving to lighter, more powerful lithium-ion batteries.

It’s a change that makes sense, said Gray. But change always brings challenges.

“Lithium-ion is known primarily for consumer electronics,” he said. “But we’re taking this technology and we’re adapting it for automobiles – and that’s an incredibly high-demand application.”

But for Gray, the competition is part of the motivation of his job. “I want to make sure our products are the best,” he said. “We need to stay ahead of the game.”

And, he’ll have no shortage of opportunities to apply this competitive spirit as Ford plans to roll out five new electrified vehicles in North America by 2012 and in Europe by 2013.

Of course, no one works all the time. Away from the office, Gray usually can be found outdoors, on a boat or a motorcycle. If he’s riding, he’s probably with his family up north or in the Great Smoky Mountains.

“The roads in the Smokies are absolutely incredible,” he said. “They’re so smooth. It’s like water-skiing on pavement. With those curves, they’re just an absolute pleasure to ride.”

Personal Insights and Fun Facts

• Chuck recently inherited a 1926 Model T. “I’m not really sure what I’m going to do with it, but it’s such a great car. How can you turn down a Model T?”
• Since ninth grade, Chuck knew he wanted to be a mechanic; engineering seemed an even better career
• In his dream garage, Chuck would have an original Shelby A/C Cobra
• Chuck owns seven motorcycles