ALTe's PHEV F-150 unveiled at Work Truck Show

Putting a bigger battery and a plug-in hybrid powertrain into a pick-up truck isn't exactly a new idea. Of course, sometimes, old ideas are worth keeping around.

At the 2010 National Truck Equipment Association Work Truck Show this week, ALTe LLC, based in Michigan, showed off a Ford F-150 that has a plug-in hybrid powertrain installed. Of course, because everybody's got to make their mark, ALTe calls their system a range-extended electric powertrain (REEP).

File this along with General Motor's extended-range electric vehicle (ER-EV) as a different name without a meaningful distinction. These are all plug-in hybrids.

In any case, the demonstration truck uses a 25 kWh lithium-ion manganese oxide polymer battery pack and 82 kW Remy DC drive motors that provide a 52-mile (84 km) all-electric range. When needed, a 2.0-liter, 4-cylinder normally aspirated gasoline engine generates power for the battery. In this charge-sustaining mode, reportsGreen Car Congress, the truck's fuel economy is about 32 miles per gallon (7.34 l/100 km).

The powertrain offers 295 pound-feet of torque and has a towing capacity of 6,500 lb.

Source : AutoBlogGreen, by Sebastian Blanco, March 12th, 2010

Powertrain hybridization; The evolution of the engine

Having honed the modern engine to the point where it is going to take an enormous change (camless valve activation, for example) to further the economy cause, the next logical step is the hybridization of the powertrain.

There are two main types of hybrid systems. The mild hybrid uses the electric side to supplement the gasoline engine. As such, it cannot drive the vehicle on its own. These systems, such as that in the Mercedes-Benz S400 do have a place in the near term.

However, it is the full-on hybrid that is the future of the breed. The fact it can motivate the vehicle using the gasoline engine, electric motor or a combination of both power sources is the key advantage.

A growing number of hybrids share the same basic syste: the Two-Mode hybrid, a system used by BMW, General Motors and Mercedes-Benz. On paper, this system has the potential to cut fuel consumption by 40% in the city and deliver a 20% to 25% overall city/highway improvement when compared with a similar gasoline-only vehicle.

The keys to the Two-Mode system are a large battery and a complex transmission. The latter not only houses two electric motors, it integrates a four-speed automatic with low-and high-speed electric continuously variable transmission modes. Yes, it is a complex piece of engineering, but that does not affect the manner in which it works or, more importantly, how it drives.

While much of the Two-Mode system is more or less common between the various manufacturers, as each developed its own operating logic, the systems have slightly different slants and driving characteristics. In GM's case, the Silverado and its Two-Mode system rely on a 300-volt battery and a 6.0-litre V8 that uses cylinder deactivation (it shuts down four of the cylinders when loads are low) and something called late intake valve closing (also known as the Miller cycle). This cycle is rarely used in conventional cars and trucks because the fuel efficiency gains (between 10% and 20%) come with a noticeable drop in performance. Here, however, the electric side more than compensates for the shortfall– the Silverado boasts a net system output of 332 horsepower and 367 pound-feet of torque, which gives the 4×4 model a towing capacity of 2,676 kilograms. The fuel economy numbers tell the other side of the story. The Silverado 4×4 with a 5.3L gas-only V8 (315 hp and 338 lb-ft of torque) consumes 14.4 litres per 100 kilometres in the city and 9.5 L/100 km on the highway. The Silverado Hybrid returns 9.8 and 9.1 L/100 km, respectively.

Mercedes' take on the Two-Mode system combines a 288-volt nickel metal hydride battery with the Two-Mode transmission and a 3.5L V6 that delays the closing of the intake valve to improve efficiency. The V6 is rated at 275 hp and 258 lb-ft of torque– throw in the electric side and the ML450's net system output is 335 hp and 381 lb-ft of torque. The design also allows the ML to be driven at speeds of up to 55 km/h on electric power alone.The X6, which is BMW's first use of the Two-Mode system, is the world's most powerful hybrid. It marries the complex transmission to a 4.8L twin-turbo V8 gas engine. The net output is 478 hp and 575 lb-ft of torque– now, that's what you call tire shredding. It also gives the X6 the wherewithal to run to 100 km/h in 5.4 seconds, while returning a claimed average fuel economy of 9.9 L/100 km.

As is obvious, BMW uses the electric power more for performance than outright economy benefits.The advantage of the hybrid has not been lost on Porsche. The Cayenne S Hybrid uses a 3.0L supercharged V6 (borrowed from Audi) and marries it with a full-on hybrid system (very different in nature to the Two-Mode) that can be driven at speeds of up to 60 km/h. Porsche claims an output of 380 hp and 427 lb-ft at just 1,000 rpm. The caveat here is that Porsche adds the electric motor's 47 hp to the engine's 333 hp. As the engine and electric motor do not produce peak power at the same time, the actual output is likely to vary from the published number. Notwithstanding, there's enough power to put the hybrid's performance right up there with the V8-powered Cayenne S but with the fuel economy of a V6 engine. This powertrain will eventually trickle down to the Panamera.

The next step is the plug-in hybrid. Charging the battery overnight increases its electric-only capacity. This combined with larger, more efficient batteries will pave the way to the future.

Any look at the future of the powertrain would not be complete without the Chevrolet Volt. It is not really a hybrid in the strictest sense because the primary power source is the electric motor — the gasoline engine is along for the ride to extend the driving range. When the battery has given its all, the gas engine comes to life and drives a generator, which then powers the electric motor. If the Volt is as successful as it deserves to be, the range-extending hybrid will catch fire in a hurry.

Source : Kelown, March 12th, 2010

LG to build li-ion cell factory in Michigan

LG Chem made it official today. The South Korean manufacturer is moving forward with plans to start production of lithium ion cells in Michigan. LG Chem and its U.S. subsidiary, Compact Power Inc. (CPI), will spend $303 million to build the cell plant in Holland on the west side of Michigan. By 2013, the facility figures to employ over 400 people. Groundbreaking will start this summer with the factory fully operational by 2012.

At full production, the plant will have enough capacity to produce cells for 50,000-200,000 packs depending on the configuration (E-REV vs PHEV). LG Chem already has supply agreements with two major automakers, General Motors and Hyundai-Kia.

Hyundai is using LG Chem cells and battery packs in the Korean market Elantra hybrid along with sister company Kia, which builds the Forte hybrid. Hyundai will be launching the Sonata hybrid in the U.S. market later this year.

General Motors is using LG Chem cells in a pack of its own design for the Chevrolet Volt. It will also use the same cells in packs manufactured by CPI for a plug-in hybrid based on the two-mode system for an as yet unnamed vehicle.

With Volt cell manufacturing moving to Michigan, the majority of the value of the new car will be manufactured within a fairly small geographic area. Along with the $700 million being invested by GM in assembly and systems manufacturing for the Volt in Michigan, this brings the total to over $1 billion. Much of the funding for the plant will come from federal and state incentives including a $151 million grant that CPI received last year as part of the stimulus bill. LG Chem will contribute matching funds to the program.

LG Chem joins A123 Systems and Johnson Controls-Saft (JCS) in manufacturing lithium ion batteries in Michigan. The JCS factory is also in Holland while A123 is setting up shop closer to Detroit in Livonia.

Source : AutoBlogGreen, by Sam Abuelsamid, March 12th, 2010

KB Home to pre-wire homes for electric vehicles

Los Angeles-based home builder KB Home announced it will begin offering an option to pre-wire Built to Order homes to accommodate electric and plug-in hybrid vehicle charging stations to customers nationwide.

“KB Home is building new homes that are relevant to the way home buyers are living -- now and in the future,” said Jeffrey Mezger, president and CEO of KB Home. “This is just one of many innovative and earth-friendly options that homeowners can choose from as part of KB Home’s Built to Order experience. It’s a great feature for home buyers who currently drive electric cars, or for those who want to build their new home to accommodate these cars in the future,” he added.

The company said it is continually surveying the market to better understand what customers are looking for in a home.

Source : Home Channel News, March 9th, 2010

Jaguar Land Rover gets EU clean car loan

Jaguar Land Rover is getting a 340 million pound ($514 million) loan from the European Investment Bank, a lender backed by European Union governments, to help it develop more fuel-efficient cars. The eight-year loan for the British-based car maker announced Tuesday is one of several the EIB is giving European auto producers, who have pleaded for government help as car sales crashed during the recession. Money-losing Jaguar Land Rover has been weighing on its owner, India-based Tata Motors, since it bought it from Ford Motor Co. in June 2008 for $2.3 billion.

Tata Motors stock fell by almost 6 per cent on Tuesday as Daimler announced that it had sold its 5.34 per cent stake in India largest carmaker to the group founders and other investors.

Source : Financial News USA, March 9th, 2010

Boston Power interested in battery vehicle tech

Boston-Power Inc., a Westborough company focused on lithium-ion batteries, said that Robert C. Purcell Jr. has joined its board of directors.Purcell is a former executive with General Motors, and from 1994 to 2002, he led the GM Advanced Technology Vehicles Group.

Boston-Power, which develops batteries for laptop computers, sees opportunities in battery-powered vehicles.

"Working closely with Boston-Power's executive team and fellow board members, Purcell is applying his expertise in battery electric vehicles and plug-in hybrid electric vehicles to help drive the deployment of Boston-Power's batteries throughout the transportation sector," Boston-Power said in a press release.

Source : The Boston Globe, February 22nd, 2010

Storage will be strategic

This surge in hybrid and plug-in automobile usage will result in one thing; storage solutions. Each of these vehicles will require some sort of rechargeable battery. Currently, nickel metal hydride (NiMH) batteries rule the roost, finding their way into the popular Prius. However, many analysts predict that old style NiMH batteries will soon be replaced outright, by lighter, better-charging lithium-ion units. Deutsche Bank estimates that just the automotive market place for these L-ion will reach $10-15 billion in sales through 2010, dwarfing the entire market for L-ion batteries in electronic devices. This echoes the bullish stance from auto makers and the Obama administration, who handed out $2.4 billion in stimulus grants to companies involved in the engineering and design of batteries. Deutsche estimates that advances in L-ion technology could replace NiMH style systems completely by 2020.

Source : Investopedia, by Aaron Levitt

More Green cars to come !

Toyota's recent recall problems aside, the Prius has been a remarkably successful vehicle, highlighting the nations appetite for such cars. The upcoming much-hyped Chevy Volt and its rated 230 miles per gallon is just one of the slated 75 new hybrid electric models expected to make their debuts in the 2011 model year. And that number is growing. Reports from the National Highway Safety Commission estimate that nearly 20% of the United States auto market will be hybrid cars by 2015. Similar findings from J.D. Power and Associates show Europe reaching 50% hybrid saturation in the same time frame.

Source : Investopedia, by Aaron Levitt, February 11th, 2010

Kia Ray Plug-In Hybrid

The latest result of Kia's continued research into hybrid motoring has been revealed at the Chicago Auto Show. The dramatic-looking Ray coupé concept is designed to use a 153bhp 1.4-litre direct injection petrol engine and a 105bhp electric motor, both of which drive the front wheels through a CVT transmission.

With that amount of power available, the Ray should be pretty quick, so Kia's claimed top speed of 109mph is rather disappointing. Not so the fuel economy, though. Kia reckons that the Ray has the potential to run at 202 miles per gallon (1.16l/100km) (admittedly a figure which has not been confirmed by an EU economy test). The reason it can do this is that it's a plug-in hybrid, which means that the battery pack can be charged not only during braking or coasting but also through a mains electricity supply.

Don't expect to be able to buy a Ray from your local Kia dealer. It's more a suggestion of the way things might be in future.

Source : CarKeys.co.uk, February 11th, 2010

NYC to buy 70,000 EVs

A study came out today saying that electric cars–both battery electric and plug-in hybrids–would make up as much as 16% of new car sales inNew York City come 2015. That’s roughly 70,000 vehicles.

But what’s driving these EV sales? Governments are expected to impose higher restrictions on CO2 emissions, for one. Plus, subsidies and tax benefits for EVs are expected to increase.

“The biggest carbon dioxide production concentration is in megacities,” said Stefan Knupfer, who heads McKinsey’s Automotive & Assembly practice in the Americas.

In other large metropolitan areas, like Paris and Shanghai, they expect to see a 9% and 5% increase respectively. These findings were the result of a year long study surveying around 2,000 consumers. The study claims half of the EVs purchased by 2015 will be plug-in hybrids. In Paris, the researchers found that plug-in hybrids would account for 80% of new vehicle sales by 2051.”

The early adopters are relatively happy with a basic charging infrastructure,” said Axel Krieger, a partner in McKinsey’s New York office who led the research. “That means they have the opportunity to charge at home, and to charge at their workplace in their garage.” The report says that a dense public charging infrastructure won’t be needed early on, but it will in the long run. NYC is currently looking to partner with other neighboring cities and vehicle stakeholders to set up a EV joint initiative.

Of course, we’ve already seen companies like California-based Coulomb Technologies expand its network of ChargePoint charging stations.

Source : Gas2.0, by Jerry James Stone, January 12th, 2010