Electric Cars Revived: Behold the Plug-In Hybrid
By Ron Cogan
Photography by Don Kerkhof/Imagewerks Studio
There is a growing and vocal movement across the country to commercialize plug-in hybrid vehicles, or PHEVs. The reason is simple enough: With these vehicles' extended electric-only driving range of typically 20 to 50 miles, daily driving costs are measured in pennies rather than dollars, just the same as with battery electric cars. Those with limited commutes or around-town driving needs that fall within a PHEV's all-electric range may never visit a gas station again. Even those with more extensive daily driving requirements may find that the combination of electric and gasoline hybrid power used results in more than 100 mpg average fuel economy.
With its potential for zero-emission motoring and fuel cost savings, the value of a PHEV is without question. That said, there is a rather hefty cost to acquiring these capabilities. Today, it requires over $10,000—sometimes substantially more so—to modify a hybrid like a Toyota Prius into a PHEV. That's quite a financial stretch considering a hybrid already presents buyers with a sizeable incremental cost over conventional models, typically measured in the thousands of dollars.
Another important consideration is that such a conversion could place a new car warranty in jeopardy if it creates problems with the factory powertrain, electronics, or battery system. That's less an issue with fleets that spend substantial sums to gain experience with early advanced technologies and vehicles, and have maintenance staff to deal with issues if they arise. It is a greater concern with individuals dependent on their new car warranty.
Today's high PHEV costs could become a thing of the past once major automakers offer plug-in hybrids at the showroom. Automakers like GM and Ford point to the battery as the real challenge, since the power required for extended all-electric operation requires much more on-board energy than a standard gasoline-electric hybrid's nickel-metal-hydride (NiMH) batteries can typically provide. Thus, commercially viable, mass-production PHEVs will happen once the battery challenge is overcome. The same really holds true for electric cars in general.
In the meantime, there are plenty of serious contenders aiming to come up with the ideal battery to power both plug-in hybrids and electric cars. One of those is A123Systems, a leading supplier of high-power, nanophosphate lithium-ion batteries for automotive applications. This battery technology is being incorporated in A123Systems subsidiary Hymotion's Battery Range Extender Modules (BREMs), which are being used by electric utilities, state government entities, and private companies to create PHEVs for demonstration today. The rationale is that by building a groundswell of support for PHEVs and actually getting units on the road and into production, costs will come down, a market will build, and automakers will be encouraged to focus on PHEVs in a big way. While it could be some time before cost and mass market challenges are overcome, the process has clearly caught the attention of automakers and prompted them to devote substantial resources to exploring PHEVs today.
Wisconsin Public Power Inc. (WPPI), a nonprofit power company serving 48 municipal owned utilities in Wisconsin, Upper Michigan, and Iowa, recently converted a pair of Toyota Prius hybrids into PHEVs using Hymotion's L5 Lithium Polymer conversion pack. WPPI already offers incentives for its member utilities to purchase hybrids and neighborhood electric vehicles, and has expanded its program to include incentives for converting hybrids into PHEVs. Its conversions were done at a contract price of $12,500 each, with Hymotion providing both hard parts and labor.
The update from conventional hybrid to super-efficient PHEV took just over two hours for Hymotion's technicians to complete...an amazing feat. Cost is the next challenge, and plenty of people are waiting breathlessly for that breakthrough to occur.
PHOTOS
Prius wiring is adapted to accept plug-in technology.
Access hole for plug receptacle is drilled in bumper.
Plastic receptacle for grounded plug is installed.
Spare tire is removed to make room for battery pack.
The new lithium polymer battery is lifted in place.
Battery pack cables are connected...then done!
The Hymotion kit creates electric cars in disguise.
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