Build Your Own Hybrid-Electric Car? 328
BlueJay465 writes "On almost every news outlet, everyone is talking about the price of oil, both foreign and domestic. This sent me to do some research on what it would take to keep the investment in my current vehicle, while getting the added benefits of hybrid-electric technology at the lowest price. One company, Sigma Automotive, has already jumped on that bandwagon, and will soon be offering a kit for your car engine that will boost performance and increase fuel-economy by adding all the extra electronics, hardware and capacity (avail. Q3-Q4 2004). My question is, how much would it cost to really 'Do It Yourself' using off-the-shelf parts?"
Seems legit to me (Score:5, Informative)
I read through their site, and while I am vaguely skeptical of things like the lifespan of the Super Capacitor Battery Pack and I2R losses system wide the basic theory is sound.
It seems like the product right now is targetted at people who want an extra 35 b.h.p. "off the line". And if you do a lot of stop-and-go driving, that could help a lot.
In my gut, I think a fully electrical transmission would provide better systemic efficiency, but that would be nowhere near a bolt-on system. (I base that on: the specific consumption of any I.C. engine is lowest when it is near it's peak output. Any system that is predicated on running the engine at variable speed (i.e. using a traditional mechanical transmission) is going to, by necessity, run the engine most of the time away from it's peak efficiency. I would be willing to hear the argument that the gain of running the engine at peak efficiency would be offset by the losses in the motor-generator pair. (If so, why has it been the standard technology in railway traction for over fifty years?)
Re:Seems legit to me (Score:3, Interesting)
Some data points, that could point either way: Toyota claims to be getting 40% efficiency from the Prius gas engine, which if true is dramatically superior to conventional designs and is a big enough win to make up for a lot of motor-generator-charge-discharge lo
Re:Seems legit to me (Score:2)
Ahhh, I had not considered that. You must be right.
I figured that was what the MAP sensor was for ... during periods of
low MAP (High vacuum) you must want
Re:Seems legit to me (Score:3, Interesting)
The 48 volts could be because, well, the duty of the electric motor is nowhere near what it would be in a true hybrid. So a balance of cost, efficiency, safety and power was likely found at 48 volts.
(Just guessing, though)
=Smidge=
Re:Seems legit to me (Score:2)
They would probably work better than a retrofit hybrid system like the one linked to, since the controls for regenerative braking would be better. (For example, causing the transmission to downshift, increasing engine and generator RPM.)
The suggestion of triggering on MAP is a good one though, although there are probably cases where the driver would want to
Re:Seems legit to me (Score:2, Funny)
Hey, this is Slashdot! You're not allowed to be civil!
Regenerative breaking... (Score:5, Informative)
Remember that any DC motor can work equally well as a generator. In regenerative braking, the motor becomes a generator providing mechanical resistance to slow the vehicle and the energy produced is fed to the energy storage device, either batteries or super capacitor where it can later be recovered and used over.
Actually this is fairly common practice in certain types of traction (cabled) elevators where the motion of the elevator car, say, up in the case of an empty cab with counter-weights heavier than the cab, actually pushes power back into the 3 phase power lines. There are no big resistors needed to consume the energy produced when the drive motor becomes a generator. This is efficient in terms of energy consumption.
Mechanical brakes on elevators are normally set only after the cab is electrically stopped and held at floor level.
"Do the Right Thing. It will gratify some people and astound the rest." - Mark Twain
Braking.... Oh, the humanity, Oh, the misspelling. (Score:2)
"Do the Right Thing. It will gratify some people and astound the rest." - Mark Twain
Re:Regenerative breaking... (Score:3, Informative)
Actually no. in regenerative braking, the motor that is attached to the wheels no longer provides power, and reverse energizes the coils, the spinning wheels then have to overcome the engine, basically running in reverse, done right this creates a net gain
Re:Regenerative breaking... (Score:3, Informative)
Try appling voltage to your alternator and see if it spins As is, it will turn a bit and lock into position when fed electricity, take out the diode recitfi
Re:Regenerative breaking... (Score:3, Informative)
Your generator doesn't need to be the size of your drive motor, thats the whole idea. You only need a generator that would meet the continuous power requirements for your vehicle. The batteries are there to supply lots of power for accelerations, and to put power on regen.
For your motor, keap in mind the speed it runs and what kind of r
Re:Seems legit to me (Score:2)
Overall, while the concept sounds OK, the devil is in the details, and I have my doubts the energy savings would be worth the $$$ and effort.
Railroad locomotives (Score:3, Informative)
Re:Seems legit to me - railroads (Score:4, Informative)
The reason for having electric drive is simple once you realize the previous facts. First, there's simply a direct shaft from the engine to the alternator or generator (Trains can be both AC and DC). That means no gears at all, and no clutch or torque converter. The wires from our generator can run to the drive motors in any manner that they wish. Finally, they connect to the wheels directly, with no gearing. Note that the speed that the engine is turning is completely independent of the speed of the wheels. This allows improved efficiency, and it lets you have any torque at zero velocity. Furthermore, note that we also have maximum torque starting out, and trains really need it when someone decides to save money by putting fewer engines on a larger consist. Even though it suffers from all the inefficiency of the two conversions, it can always run at the engine's sweet spot. However, the fuel efficiency isn't as big of a problem as it seems. Once a train is rolling, they need very little power to keep it going. The fuel that is used in the engines is also not the kind of stuff that you would put in your car, or your tractor for that matter. It's like high-sulfur 30 weight, and it costs less than any other petroleum product short of road tar.
Re:Seems legit to me (Score:2, Informative)
Re:Seems legit to me (Score:2)
Good points, thanks for mostly agreeing with my gut :)
Although I disagree that it would have to necessarily add to unsprung weight -- think Jaguar inboard disc brakes ... now replace "brakes" with high efficiency PM pancake motors. Use last few decades improvements in materials science to solve problem of broken half-axles.
Of course that leaves unanswered the question, Well, now where do we put the brakes? Bah -- braking is for wusses. I'm in a hurry!
Well, they could easily be integrated with th
Re:Seems legit to me (Score:2)
Because electric motors have maxium torque at minimum velocity.
I.e. it's much easier to get going from a dead start, a major problem for trains, but not such a big deal for cars.
-- less is better.
Re:Seems legit to me (Score:4, Informative)
I could hazard some guesses about why we don't currently see electrical transmissions in cars:
Weight: It seems to me that a motor/generator pair would probably weigh more than a mechanical transmission, which is just a few gears and/or hollow turbines. This isn't an issue on a locomotive, where heavier is better for creating traction (IIRC, some of the biggest steam locomotives weighed as much as a 747).
Power: A lot of people are used to having 300hp on tap. That's almost 1/4 of a megawatt. You'd need to have some serious power control circuits to handle that much juice. A locomotive is powerful, but pulling a train is really more about torque than raw horsepower. Electric drives do have excellent torque capabilities (and it's just about the only technology besides steam pistons with enough torque to start a freight train), but people in cars want neck-snapping acceleration. That would require a lot of copper and power controls.
CVT: Continuously variable mechanical transmissions have already been on the market for a few years. I would imagine that they can keep the engine running at a fairly constant rate. I think that they are somewhat more efficient than standard transmissions, but not by a huge factor. What makes hybrids special is that the engine produces almost constant power, not just speed, because it uses the batteries for power storage when it is generating a surplus. This allows for much more efficient operation than just a CVT. It's interesting that some of the hybrids use a mechanical transmission in addition to the electrical boost. I gather that that's because the mechanical drive was more cost-effective for transmitting that portion of the total power.
Re:Seems legit to me (Score:3, Interesting)
ultracapacitors, FFVs and regen braking (Score:3, Informative)
Here [evworld.com] is an interesting related interview. Also check out the specs for these ultracapacitors [maxwell.com]. The key benefit of capacitors over batteries is in deep discharge, near instantaneous bursts of current. It takes the load off your bulk storage supply, allowing them to operate more efficiently.
I still can't buy a hybrid flexible fuel vehicle, so I can shift my usage over to a more renewable source [ethanol.org]. This system opens up some options though. I like!
Aside: The regenerative braking aspect of all hybrids is
ultracaps are US$25 in small quantities (Score:2)
Re:ultracapacitors, FFVs and regen braking (Score:2)
Yeah, you'll be literally drunk with power!
Re:Screw Hybrid electric, go hybrid hydrogen (Score:2)
To an insight owner (O/T) (Score:2)
First, do you have the automatic or the manual? I'm looking at a manual..
second, what kind of mileage are you ACTUALLY getting? I've heard too many people say that it isn't near what it's rated.
And finally.. how does it really do power wise? I figure it'd be hard pressed to suck more than my current car, but do you ever find hills that you can't climb at the same speed everyone else is going? I drive about 70 on the highways (I
Just a guess (Score:2, Informative)
Cheers,
Erick
Re:Just a guess (Score:5, Informative)
Not bad ... in their own site they suggest MSRP should be +/- 2800.
Re:Just a guess (Score:3, Interesting)
Re:Just a guess (Score:2)
Re:Just a guess (Score:3, Interesting)
Re:Just a guess (Score:2, Interesting)
This is a website for geeks. I personally would rather drive at 40mpg and pay 3000 to the engineers and company that designed a hybrid engine than drive at 35mpg and pay 1000 to the billionaire aristocrat oil tycoons.
Wouldn't you?
Seems like - (Score:4, Interesting)
$2800 MSRP (according to the FAQ) seems like a hell of a lot to me, considering the fact that it is not a true hybrid conversion, but rather, a bolt-on part.
But really, how many people will spend that much for what seems to be a little gain in performance? Maybe the tax break helps?
-thewldisntenuff
Re:Seems like - (Score:2)
Re:Seems like - (Score:3, Insightful)
Re:Seems like - (Score:2)
Devil in the system (Score:5, Interesting)
BTM
Re:Devil in the system (Score:2)
Re:Devil in the system (Score:5, Informative)
Since the engine output is pulsed (a pulse happens with every power stroke) there is a ready supply of driving or excitation vibration which is just waiting to find the resonant frequency of the whole system.
And since the pulse frequency varies with the engine speed, you have a full range of driving frequencies to work with.
If the resonant frequency of the engine/gimler-belt/alternator system is outside the driving frequencies caused by the engine, everything is fine.
If not, the forces in the belt can become "Large"
:)
Re:Devil in the system (Score:3, Informative)
BTW I used to tune the TV dampers on cars.
Re:Devil in the system (Score:3, Interesting)
So someone should mod you up and me down.
;)
Re:Devil in the system (Score:3, Funny)
Re:Devil in the system (Score:3, Interesting)
Avoid oil (almost) entirely (Score:3, Interesting)
Re:Avoid oil (almost) entirely (Score:2)
Re:Avoid oil (almost) entirely (Score:3, Funny)
Re:Avoid oil (almost) entirely (Score:2)
If everyone hit up the restaurants for used oil, then I doubt it would remain free for long and it certaintly would not be unlimited!
=Smidge=
Re:Avoid oil (almost) entirely (Score:2)
I want a grease car (Score:3, Interesting)
We could grow almost all the oil we need, certainly enough to make a huge dent in imports, on a couple hundred square miles of the Senora Desert. I know it's ecologically sensitive but I think for oil independence the scorpions, mice and other critters can just deal with it.
Why aren't we doing this now? Guess it couldn't be because we have an oil family with connections to the Saudi Royal family in office? Or big oil comp
Transmission woes. (Score:5, Informative)
The toyata prius has a very special system that deals with this, as this page [howstuffworks.com] shows. Especially with hybrid SUV's [fordvehicles.com] coming out soon, building your own hybrid seems like it would be way too much work.
Also keep in mind, that right now making a hybrid car (for a major automanufacturer) costs several thousand dollars more than making an equivalent conventional car mostly because they don't have enough mass production on the hybrid parts, and they are making thousands and thousands of cars. Buying the parts individually, the price would be outragous.
Re:Transmission woes. (Score:2)
The efficiency is very, very poor, due to losses in pumping the oil around.
On a front end loader, efficiency is not really a major customer need, though.
Re:Transmission woes. (Score:2)
Other types of kits? (Score:4, Interesting)
Unfortunately, though I've heard some debate on this regarding current events, the state of California does not allow hybrid cars in the HOV lanes w/o a second passenger. This seems funny, since my Toyota Prius gets ~50 MPG, meaning its consuming less than half that - and often closer to a third - of most large SUVs. One person using gas in a 50 mpg vehicle still means less consumption than 2 using a 15-20, and the whole point of the HOV lane was to promote conservation.
Re:Other types of kits? (Score:3, Funny)
Close. It was to promote conversation.
Re:Other types of kits? (Score:2, Interesting)
Re:Other types of kits? (Score:2, Interesting)
Actually, no, that's not the point of the HOV lane. The point of the HOV lane is to reduce traffic congestion by providing an incentive to reduce the number of vehicles on the road. Lower pollution is a significant bonus, which they felt was valuable enough to grant exceptions for alt-fuel vehicles
Re:Other types of kits? (Score:2)
Re:Other types of kits? (Score:2)
Okay, but where do you think the line should be drawn?
First of all, I doubt you are getting 50MPG in the real world, and even if you are, I'm getting 40+MPG with my normal 4-cyl small car. Should everyone with a small car be allowed to drive in the HOV lanes? Takes away the whole point, doesn't it?
Personally, I happen to dislike the idea of HOV lanes in the first place.
Re:Other types of kits? (Score:2)
Supposedly there is legislation in the works to rescind that,
Don't try this on your leased car. (Score:5, Funny)
Re:Don't try this on your leased car. (Score:2)
http://media.ebaumsworld.com/index.php?e=snowtow.w mv [ebaumsworld.com]
ive got a hybrid (Score:2, Informative)
$8,000 (Score:2, Interesting)
You use a pickup truck because the allows you to fill the bed with batteries (1 layer deep) and then build a nice looking cover for it and still use the bed of the truck.
It is all electric, not hybrid.
The cost is $8,000, not including the vehicle.
What I really want to know is if hybrids built using Toyota's hybrid engine, which is a FULL hybrid (meaning it can operate on elect
How about brew-your-own alternative fuel? (Score:5, Interesting)
Now the state govt. has stepped in and want him to pay state fuel tax on the fuel what he makes and uses himself....
If he were making it and selling it to others, I could see their point...but jeez!
Re:How about brew-your-own alternative fuel? (Score:2)
Re:How about brew-your-own alternative fuel? (Score:2)
Re:How about brew-your-own alternative fuel? (Score:3, Informative)
Re:How about brew-your-own alternative fuel? (Score:3, Insightful)
Isn't that the same argument the established telecos are using to "encourage" state governments to tax VOIP?
illegal for NHRA racing (Score:3, Informative)
This is not really new (Score:3, Funny)
Popular Mechanics (Score:3, Funny)
jeff
Isn't this how Diesel got a bad rap? (Score:2)
Didn't the US auto industry try this with Diesel back in the seventies and learn this lesson for us? Are we doomed to repeat that mistake too?
Re:Isn't this how Diesel got a bad rap? (Score:3, Informative)
The block and crank and bearings were not strong enough for the much higher forces in a diesel engine, and the Olds diesel had poor reliability.
People who bought a Mercedes diesel did fine, but the money they spent on the car was never recovered in fuel savings.
People who bought a diesel volksvagen rabbit did fine too, but that car had poor acceleration, I've drive
Pretty foolish (Score:5, Insightful)
IMHO, if you are truly economically sensitive to gas prices, I suggest that you buy a '94 or '95 Toyota Tercel/Corolla, Ford Escort or Honda Civic. You'll easily get 35-45mpg with these cars and spend a grand total of $3-5k for the whole vehicle.
If you want to make a statement about "saving" the environment, move closer to work.
dammit (Score:2)
byoHC.com
=(
e.
you guys see the compressed air car? (Score:2)
(ok it's closer to a tractor or golf cart but still novel idea)
I hear if you get 5 friends to sign up at the article's site you get a free hybrid electric car =)
e.
I don't think so (Score:2)
Not that I'm that much of a stickler for grammar or anything, but, yeah, I'm going to trust these guys.
Can it be as simple as replacing your alternator with a belt-driven motor and battery pack? (How big is that battery pack, by-the-way, compared to "real" hybrids?
Sorry to rain on your parade, but... (Score:3, Interesting)
If you want to really save money and do something cool, go for an all-electric car. With lithium battery chemistries, the range is good [acpropulsion.com]. There are plenty of companies that offer help in retrofitting old ICE cars to be electric. The big problem here is that automotive-scale lithium batteries are not in mass-production yet so they are very expensive. The battery pack on a lithium-powered electric could cost in the tens of thousands. This is not because the materials that make up a lithium battery are inherently expensive; they just aren't mass-produced in large enough sizes and quantities yet.
As a further advantage, all-electric cars have much less maintenance. Hybrid cars should have more maintenance than regular ICE cars because hybrids have everything a regular ICE car has, plus all the electric stuff, plus a complicated way to interface the two of them.
Maybe if you do almost all stop-and-go city driving, hybrids have some advantage, but I think they are just a boondoggle [slashdot.org]. If you don't want to buy gas, then go 100% electric, but don't think that bolting on a bunch of electric parts to your current ICE is going to do much more than have you pay a hefty up-front fee to save a trickle of gas over the next decade.
Guaranteed easiest way to make your car hybrid (Score:4, Funny)
2. Move remainder of car off the driveway.
3. Attach a Toyota Prius or Civic Hybrid to the gas cap.
Seriously, it seems like it would be very difficult and expensive to make this work, and even if you did somehow succeed, most states would require you to get the car smogged or otherwise inspected, which could prove difficult after such extensive modifications. If you want an inexpensive hybrid, I suggest a 2001 or 2002 model Prius. They're cheap because everyone wants the 2004 model.
Telecommute already! (Score:2)
Made of Unobtainium -- (Score:2)
The electric motor/generator part is listed as becoming available in the fall/winter of 2004. This makes it vaporware, as far as I'm concerned.
Now give me a hand while I try to keep my tinfoil hat on while installing this little fan under my carburetor that will supermix the gas, giving me 25 per cent more power....
We converted one, and built a few. (Score:3, Informative)
A look at the converted Geo is here [utulsa.edu]. It was retitled the "Paradyne."
A much cooler looking HEV, though, is the Proxima [utulsa.edu], which was built ground-up. I was on the team that built and designed the car. The design and material cost for this car, being built from ground up (I kid you not. I remember nights out there with a heat gun, hot glue, and pipe making the frame and shaping the body) is way out there.
I don't remember the costs of the conversion for the Metro, since I wasn't involved, but someone interested in the numbers could certainly write and ask. Contact information is on our webpage, or you could IM me, and I could ask next time I am around the HMW.
We need more Open-Source Automotive (Score:2)
You can't diagnose a car without closed-source software, specific to the brand. You can't get parts from just anybody.
Build cars like we build PC's and they'll be cheaper to repair, more efficient,
Oh please (Score:2, Informative)
Here's better way to improve fuel mileage.... (Score:4, Informative)
Thanks to the phasing in of low-sulfur gasoline (petrol) and diesel fuel here in the USA starting in 2005, we can apply the latest in fuel-delivery systems and exhaust emission controls to improve fuel efficiency AND reduce harmful exhaust emissions.
In the case of gasoline engines, the switch to direct fuel injection (where fuel is directly injected into the combustion chamber) could improve fuel efficiency in the range of 15 to 20 percent!
In the case of diesel engines, the arrival of low-sulfur diesel fuel means we can use common-rail direct fuel injection for very precise fuel delivery and also use the latest in diesel engine catalytic converters that will remove diesel exhaust particulates in addition to dramatically reducing other harmful exhaust gases. By switching minivans, SUV's and light trucks to these new cleaner diesel engines it means these class of vehicles can get 35-50 percent improvements in fuel efficiency compared to the current gasoline engines being used.
Re:Here's better way to improve fuel mileage.... (Score:3, Interesting)
The problem with this idea is that a gas turbine runs at a ce
Re:News outlets (Score:2)
Re:News outlets (Score:2)
Re:News outlets (Score:2)
Ice Cream.. electric cars.. Chewbacca lives on Endor!
Re:News outlets (Score:4, Insightful)
Re:News outlets (Score:2)
How about this, the US economy requires less $ per $ of GDP. We are actually using less energy now (relativly speaking) then we were after the last gulf war.
One of the real reas
correction... (Score:2)
sorry, that should be "less energy per $ of GDP."
Re:News outlets (Score:3, Insightful)
i wouldn't drive one if i didn't need it to get up my fucken driveway in the winter.
Re:News outlets (Score:2)
administration in stealth mode.
And its not you to judge how many cylinders I have in my car as being bad or good..
Re:News outlets (Score:2)
- the US economy and GDP isn't nearly as dependent on oil as it was in the 1970s. MPG is up, more people use mass transit,
Re:BUILD? (Score:5, Interesting)
Ford has been playing with a prototype system similar to this. They got about 15% improvement in fuel economy. Considering the increased costs involved, they decided it wasn't worth it. Not for a measly 3-4 MPG on an Escape. For an Excursion, you're talking 1-2 more MPG.
Don't get me wrong; this helps. Just not as much as you might hope. It's a good step in the right direction, in an attempt to help reduce the fuel consumption of existing vehicles. And, as they mention, since there are NO internal modifications to the engine, it's a bolt-on accessory which your typical shade-tree mechanic could probably install on a Saturday.
Re:BUILD? (Score:3, Interesting)
For an Excursion, you're talking 1-2 more MPG.
Don't count on that. Much of the fuel costs on a big vehicle like an Excursion are spent in starting it from a dead stop. I own a diesel Excursion, and it can get 22 mpg (usually more like 18.5) on the highway, but get into stop and go, and it plummets to 13.5. The gas ones are much worse.
Ford has a prototype transmission for the "SuperDuty" chassis (F-[250,350,450,550], and Excursion) that uses pressurized nitrogen to effect regenerative braking, and use
Re:BUILD? (Score:3, Informative)
Re:BUILD? (Score:2, Informative)
According to Autotrader.com, I am supposed to get around 25 MPG with my 4-cyl 1994 Honda Accord, however I general
Re:35 bhp through a rubber belt (Score:2)
Thats more than 35 Hp
I agree... (Score:3, Informative)
Especially since the main advantage of electric motors is low-speed torque (good for rice rockets, not nearly as much improvement for monster V8s) - While an electric motor can make a HUGE difference at the very low end, that is also where traction is a large problem, nullifying much of the motor's advantage.
Re:"decreases your 0-60 time by a min of 3 seconds (Score:2, Informative)
for example:
2004 Lamborghini Gallardo 1/4 mile time is 12.40 seconds
1999 Honda Civic Si 1/4 mile time is 15.70
Imagine, with just this one device installed on a totally stock Honda, you can bring it into the same league as a Lamborghini...