Design Article
Retrofit kit said to transform cars into hybrids
R Colin Johnson
6/30/2009 8:22 PM EDT
PORTLAND, Ore. A former IBM electrical engineer has designed a retrofit kit that he claims can transform existing automobiles into hybrids by placing an electric motor inside each wheel, thereby doubling gas mileage.
Charles Perry, a former IBM product development researcher, recently received first prize for his invention at a green energy competition at the Tennessee Technology Development Corp. The patent pending Plug-in Hybrid Retrofit Kit will be developed into a commercial product by Palmer Labs LLC (Reston, Va.).
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| The hybrid retrofit kit is installed in the space between the brake mechanism and the hub |
"What makes our approach different is we don't need to modify anything in existing vehicles to turn them into a hybrid," said Perry. "We install the motor in the space between the brake mechanism and the hub without any other modifications."
According to Perry, 80 percent of U.S. drivers make daily trips of less than 30 miles at 40 miles per hour or slower, all of which could be powered by his 10-15 horsepower electric motors to save as much as 120 million gallons of fuel per day in the U.S. alone, he claimed. The motors would be powered by extra batteries installed in the automobile's trunk.
To develop the retrofit kit into a commercial product, Perry has partnered with the Tennessee Technological University (Cookeville), which will will build a working prototype within a year with about $100,000 in existing funding. The next step will be to retrofit the kit on 30 state-owned vehicles for testing. If all goes as planned, Perry estimates that within three years the final kits will be manufactured by Palmer Labs in a new Tennessee facility that would employ about 2000 workers.
Perry said the kit will cost between $3,000 to $5,000.




AlexKovnat
7/7/2009 8:45 AM EDT
What Mr. Perry is advocating is very similar to the arrangement used by Diesel-electric railroad locomotives for something like 70 years now. For a locomotive you need all wheels to be driven, so 100% of the loco's weight becomes effective as an agent in enabling traction. Also, you want axles to be mechanically independent, as compelling any two or more axles to rotate at exactly the same speed invites stress problems.
But with a motor vehicle, I don't favor the Diesel locomotive configuration of engine -->generator --> traction motors. I would rather have something like the Toyota Prius configuration, which is more efficient.
For pickup trucks or other heavy vehicles, my choice is the following: Mechanical drive to the rear wheels, with a motor-generator on the driveline between engine and transmission. Then, I'd put wheel hub motors in the front wheels not only so much for extra traction, but for better regenerative braking because the front wheels do most of the braking when you slow down and stop.
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BobGroh
7/7/2009 12:53 PM EDT
From my understanding of electric cars (including hybrids), the motor is only a small part of the overall system. The controllers, inverters, battery packs and the software are all a huge part of a solution. The software is (again according to some sources) the most critical and the most difficult. To compound the problem of this particular solution, the addition of motors to the wheels will greatly increase the overall weight of the wheel assemblies and will probably have adverse effects on the suspension, handling and tire wear which will all have to be handled.
Don't want to seem negative here but this is an idea which has been done before and needs a lot of work to even see if it is feasible. An interesting engineering project for sure! But hardly only one year away from much of anything.
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hypergolic
7/7/2009 2:05 PM EDT
Ideas like this are good seeds for more developments in the right direction.
For those interested in a full solution of suspension/electric drive see:
http://servicesv2.webmichelin.com/frontnews/servlet/GetElement?elementCode=54609
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jscott27
7/9/2009 9:31 AM EDT
The people desiging and giving out awards for things like this have no clue. What makes a Hybrid vehicle more efficient is NOT that it has electric motors. What makes hybrids more efficient is their ability to recapture power when braking or going down steep hills along with the ability to easily shutdown the motor when stopped. It is the coordination of these systems that makes a hybrid what it is.
This system would create a vehicle that just switches energy consumption from gas to electricity. Why is that such a great idea?
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kenwe
7/14/2009 12:39 PM EDT
@jscott27 "This system would create a vehicle that just switches energy consumption from gas to electricity. Why is that such a great idea?"
My understanding is that even using this system as a plug-in only (wall charger) could provide clean air and energy efficiency benefits since electric drive is more efficient at low speeds compared to an internal combustion engine, regardless of how the electricity is created and delivered to the grid.
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pcsalex
7/15/2009 8:47 AM EDT
let it seee
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pcsalex
7/15/2009 8:48 AM EDT
let it see
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jscott27
7/15/2009 1:00 PM EDT
Guest, the point is that you need to have integration of systems (brake, battery, powertrain) in order to do truly effective re-generation. For instance, in a Hybrid Escape the brake pedal doesn't immediately engage the brake calipers; the engine control coordinates regen with the motor, brake and battery controllers.
kenwe, whether it would provide cleaner air or efficiency would depend on several factors (like what was the electricity produced with?). Also, without pretty large batteries, you aren't going to go far on electricity alone, and it is going to get even worse when you add in the battery weight. A Hybrid Escape can only go a few (5?) miles on its battery alone; running the battery down more than that will greatly reduce it's life expectancy.
In the end, you are talking about having someone attempt to install a high-powered electric system into their car. That system has to be capable of at least 20kW to be even remotely useful. Even @ 100A this would require 200V.
Hybrid autos have about 4-6 micros controlling the hybrid portion of the car, and I don't have much faith in one person putting that much complexity together on their own.
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daleinaz
7/15/2009 4:58 PM EDT
Interesting. I assume this operates in conjunction with the existing gas engine, so that A/C and power brakes/steering/etc also work. I'd love more details.
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Samual Warn
3/14/2011 6:09 AM EDT
I think this is the new kind of system which will create a vehicle that conversts gas to electric power. its a awesome plan, just go on implementing thanks for sharing with us.
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