News - 2006 Archive

Expanding HEV Universe

A capsule of trends and developments that point to the future of hybrid and electric propulsion

• December
• November
• October
• August-September
• July
• June
• April-May
• February-March

December

HEV Pioneer Perishes Tragically in Plane Crash

David W. Hermance, Executive Engineer of Advanced Technology Vehicles at Toyota Motor Corp.'s North American headquarters, was killed November 25 while piloting a small aircraft off of the California coast. Mr. Hermance apparently lost control of the plane, which crashed into the Pacific Ocean. Often credited as being the "American father of the Prius," Mr. Hermance had been with the Toyota Technical Center since 1991 and had had responsibility for reconfiguration and recalibration of the original Prius engine and drivetrain designs for compatibility with the North American market.

Road Show for Hydraulic Hybrid Concept

The medium-duty truck configured as a hydraulic parallel hybrid utility vehicle by DaimlerChrysler subsidiary Freightliner LLC and Eaton Corp. is now on a proof-of-concept tour. Specific plans for full-scale manufacture of this vehicle have not been announced.

Fuel Cell Hybrid Buses Target of New Battery Development

In support of hybrid fuel cell bus development now underway at General Electric, Ballard Power Systems and lithium battery manufacturer A123Systems are providing cutting edge components under the aegis of the National Fuel Cell Bus Program directed by the U.S. Federal Transit Administration. A123Systems' contribution is a lithium-based (M1) power boost cell that can deliver over twice the power density of present high-power Li-ion units at about one-third the weight to discharge at 1500 watts and twice the remaining life at 100% degree of discharge. The M1's power density also reportedly beats that of NiMH by a factor of four and of NiCd by a factor of five.

Honda Insight Officially Sunsets — First Production Hybrid

Honda Motor Corp. has officially announced it is discontinuing production of the Insight, a two-seater that was the first road-legal production hybrid car and whose innovative design and aerodynamics enabled it to achieve in-use gasoline fuel efficiency as high as 3.35 liters/100 km. Honda is now focused on applying its integrated motor assist (IMA) hybrid technology to its popular Civic and Accord models.

Diesel Emission Control Costs Brighten Prospects for Hybrids to Compete on Price

What has long been viewed as a competitive penalty for diesel hybrids in the truck market — excess (tare) weight of battery packs and other components — could dwindle as a factor under the 2007 and later emission standards for U.S. trucks, as it has been estimated that after-treatment and other new equipment required to be installed on most diesel-burning models could increase unit cost by as much as $10,000 and mass by over 100 kg, resulting in increases in duty cycle fuel consumption. Hybrid conversions of some class 8 trucks are already achieving fuel savings greater than 5 percent against comparable conventional diesels fully equipped to meet the 2007 emission standards.

November

Toyota Begins Manufacturing HEVs in U.S.

The Georgetown, Kentucky manufacturing facility of the Toyota Corporation has rolled the first Toyota hybrids manufactured in North America off of its assembly line. The Kentucky plant is targeted to produce 48,000 Camry hybrids each year, about 10 percent of its total production capacity of 500,000 units. The changeover represents a US $10 million investment in retooling by Toyota.

GM/Saturn Announces "Dual-Mode" HEV Availability Beginning 2008

Saturn General Manager Jill Lajdziak has announced that the MY2008 Saturn VUE, while continuing to offer its hybrid option based on GM's "belt alternator starter" system, also will be the launch platform for the first front-wheel-drive version of an advanced "two-mode" hybrid system designed to deliver even more fuel economy. This two-mode hybrid can be configured as a plug-in hybrid, and is thus officially the first step in GM's commitment to complete development on and market a Saturn VUE plug-in hybrid production vehicle that will use an advanced battery (possibly Lithium-Ion). GM is now working with a number of battery companies to perfect the necessary technology. GM expects the front-wheel-drive, two-mode VUE hybrid to improve overall fuel economy by 45 percent over today’s model, based on current EPA labeling.

Citroen (France) and TM4 (Canada) Join Forces in Producing New Hybrid Concept Vehicle

PSA Peugeot Citroën Group has renewed a long-standing relationship with TM4 of Canada in the development of a 4-wheel motor-assist system concept that could be the platform for a variety of diesel hybrid applications. Its all electric range is limited (only about 3 km at 30 kph), but its primary function will be to supply clean boost in synergy with power demand in frequent acceleration/deceleration modes ("saw-toothing") that should significantly reduce transient emissions.

Momentum of Support Growing in U.S. for Plug-in Hybrids (PHEVs)

AutoNation, Inc., the USA's largest-volume automotive retailer, has joined the Plug-In Partners campaign in calling for manufacturers to put PHEV development on the fast track. The company's participation in the campaign is considered significant because of its proven knowledge of what U.S. car buyers are demanding and willing to buy. Almost 60 U.S. cities currently participate as Plug-in Partners. President Bush has already weighed in with a strong endorsement of PHEVs at an October Renewable Fuels meeting in St. Louis, and recent promising developments in academic and corporate R & D have shown that substantial increases in all-electric range and power for these vehicles are in view.

HEV Component Supply Industry Expanding, Increasing Technological Sophistication

Major improvements have recently been announced in components for HEVs that are designed to increase power whilst reducing the size of control and power management systems. These include a power module from Infineon Technologies (a relative newcomer in hybrid components supply) that is only half the size and weight of current installed control systems but increases efficiency up to 20 percent, thanks in part to reduced cooling requirements. Infineon expects these modules to be installed in production hybrids within two years. Other high-tech suppliers such as Renesas Technology America, Inc., and International Rectifier have introduced, respectively, a 32-bit microcontroller specialized for HEV motors, and a significant upgrade to its hi-reliability hybrid motor control module that enables sensor-free digital control of permanent magnet motors.

2005-6 Hybrid SUV Sales Top 100,000 Worldwide

The following available (approximate) worldwide sales figures for HEV SUVs through October 2006 show that total sales for this configuration have eclipsed the 100,000 mark:
Ford Escape: 39,000
Mercury Mariner: 4,200
Toyota Highlander: 46,500
Lexus RX 400h: 39,000

October

Achievement Awards to be Presented at EVS-22

At a ceremony in Yokohama (Japan) on 25 October, the International Energy Agency Hybrid and Electric Vehicle Implementing Agreement (IA-HEV) will present its 2006 Clean Vehicle Awards recognizing three categories of achievement: to manufacturers, or outstanding worldwide sales figures for hybrid models; to a nation or institutional entity in recognition of outstanding promotion of electric vehicles; and to an individual, the "Personal Award" that honors his or her long-standing commitment to promoting clean vehicles. This year's winners are:

1. HONDA (Japan) achieving sales of more than 135,000 hybrid models worldwide
   LEXUS Division (Japan) for achieving sales of more than 50,000 hybrid models worldwide
   FORD (USA) achieving sales of more than 30,000 hybrid models worldwide.
2. THE PEOPLE'S REPUBLIC OF CHINA for outstanding promotion of electric vehicles.
3. HANS THOLSTRUP (Australia) for decades of commitment to enable progress in electric vehicles by establishing the World Solar Challenge solarmobile race.

Concept Hydraulic Hybrid Anticipates Medium-duty Truck Market

A joint venture by Freightliner LLC (a DaimlerChrysler Company) and Eaton Corporation has come to fruition in the roll-out of a proof-of-concept diesel hybrid utility truck targeting the market for medium-duty trucks that require large amounts of power while working on a job site. The parallel hybrid system with regenerative braking has been integrated into a 33,000-lb. gross vehicle weigh chassis featuring a 230-hp (172-kW) engine and 44-kW (59-hp) electric motor that enable peak power of 216 kW when paired; this arrangement is in turn linked to hydraulics in the electric power takeoff system whereby the engine would be off most of the time at a job site while batteries power the hydraulics, engaging only when the batteries need to be recharged. Thus, it will not be necessary to run the truck's diesel engine at idle for ancillary power constantly at the job site, with a resulting significant reduction in fuel use, idle time, noise, and brake wear (thanks to the regenerative system). Freightliner is looking next to apply this concept in beverage transport trucks, school buses, and pick up/delivery vehicles in the medium-duty (= 33,000 lb.) class.

Minnesota Pursues Plug-in Hybrids

Legislation introduced in the state of Minnesota would require the state to begin purchasing plug-in hybrid vehicles (PHEV) for the state fleet, and stipulates purchase inducements for small and large private fleets, whenever such vehicles become commercially available. A secondary objective of the bill is to provide financial incentives for Ford Motor Company (the IA-HEV 2006 Clean Vehicles Awardee for corporate achievement in manufacturing) to produced flexible-fuel PHEVs at its St. Paul plant. In New York State, early introduction of PHEVs is already being promoted and assisted by a $3 million dollar fund too finance successful competitively-submitted proposals for developing, demonstrating, and commercializing innovative transportation products, systems, and services.

GEM Platform for Hydrogen PEM Fuel Cell Drive

The Energy Research Centre of the Netherlands (ECN) has mounted its in-house-developed proton electrolyte membrane (PEM) fuel cell propulsion system onto the two-seater GEM car platform for low-speed operations. GEM has already captured important EV market share in both Europe and the U.S., but heretofore all available units on the GEM platform have been exclusively battery-powered. This "HydroGEM" carries a 76-liter, 3,000 psi hydrogen storage tank mounted behind the rear wheels; coupled with the 5-kW fuel cell and the original 6.5-kWh battery pack, it can handle payloads of up to 400 kg or achieve an operating range of 200 km.

2006 U.S. Hybrid Sales Outpacing 2005 Record

As of August, U.S. hybrid vehicle sales had already surpassed 160,000 units in 2006 and clearly seemed poised to beat the 2005 sales record of 205,000. Toyota continues to lead the 2006 competition among marques with over 70,000 Priuses, 23,000 Highlanders, 17,000 Camry hybrids and 14,000 Lexus 400h sold, while Honda boasts sales of 22,000 Civic hybrids and 4,000 Accords. Ford has sold over 9,000 of its Escape/Mercury Mariner hybrids.

August-September

Pennsylvania’s Hybrid Purchase Incentive Back in Play

Governor Edward Rendell of Pennsylvania has announced that the consumer rebate of US$500 per hybrid electric vehicle (HEV) purchased and registered in Pennsylvania will again been made available thanks to reauthorization in the 2006-07 General Fund budget of US$3 million in alternative energy initiative funding. Only the “cleanest” HEVs with full (not mild or idle-off-only) hybrid technology will be eligible, and request forms with appropriate documentation must be submitted within six months of purchase. Pennsylvania has adopted an objective of making 25% of its government-operated fleet HEVs by 2011.

Lithium-Ion Propulsion Battery Development Takes Another Step Forward

Johnson Controls and Saft have won a joint 24-month 50% cost-sharing contract from the U.S. Advanced Battery Consortium (USABC) to develop advanced lithium-ion batteries for HEV propulsion. This contract combines the talents and expertise of two organizations that have already undertaken llithium-ion technology development under prior USABC contracts. The new consortium, Johnson Controls-Saft Advanced Power Solutions, will supply cell modules for abusive testing in a variety of environments, seeking to meet FreedomCAR USABC battery performance requirements. The existence of the partners’ facilities in both the United States and Europe is viewed as a plus for the contract.

ZAP Orders 500 EVs from China, Commences Long-Term Partnership

ZAP, a California manufacturer of street-legal electric three-wheelers, has placed an order with Shandong Jindalu Vehicle Co. Ltd. of China (PRC) for more than 500 units of the new Xebra four-seater “city car.” The lead-acid-powered 110-V chargeable Xebra can achieve 40 mph (64 km/h) and has a range of 40 miles (64 km). Shandong Jindalu has indicated that as part of ZAP’s exclusive 10-year distribution U.S. contract it provides the capacity to produce up to 1,000 of these units per month. This car will be the first production electric vehicle (EV) made in China that is designed specifically for U.S. roads.

Enova Continues to Figure Prominently in HEV Component Supply

Enova Systems of California, a prominent supplier of hybrid drive and power management systems, has entered into several new contracts serving different sectors of the HEV market. Continuing a professional relationship established during the Th!nk EV era, Ford Motor Company has ordered Enova’s advanced high-voltage energy converters for a projected fuel cell HEV. Enova will also be providing its 90-kW electric drive system to 10 electric sport utility trucks manufactured by Phoenix Motorcars of Ojai, California, and will integrate its 80-kW hybrid drive system with nnickel-metal hydride batteries into 13 service vans of a major North American fleet operator.

GHG Crackdown Coming in Europe? Hybrids Could Help!

The European Union’s executive has taken the position that European and Asian auto makers must do more to meet voluntary targets to reduce carbon dioxide (CO2) emissions from new cars or face possible legislative action. The European Commission said the reduction in average CO2 emissions from 1995-2004 new cars in the 15 “old” EU member states was not on track to meet the 25% cut targeted by 2008/09. Commission spokesman Gregor Kreuzhuber reiterated that the Commission would consider imposition of binding legislative targets if necessary.

July

Toyota One Step Forward on Hybrids, Ford One Step Back

The president of Toyota Motor Corp. has announced that the company will persevere in the ambitious pursuit of making hybrids available across its full line of light-duty vehicles within the next decade.  This comes in the wake of the announcement by Ford Motor Co. (CEO William Clay Ford Jr.) that Ford will de-emphasize future hybrid development for the U.S. light-duty market in favor of flex-fuel (E85-capable) vehicles.  Ford still plans to produce a limited line of hybrid cars (rather than trucks or SUVs), but will not meet its earlier-announced target of building 250,000 gasoline-electric hybrids by 2010.

British Auto Show to Introduce Two New EVs; Brazilian EV Model Coming to United States

The British International Motor Show in August will see the launch of two new battery electric cars: the Smart Ev (from the manufacturers of the SmartCar) and the NICE (“No Internal Combustion Engine”) city vehicle.  The Smart EV has a 30-kW output and can reach 115 km/hr, with a driving range of just under 120 km.  Yet another new EV will be introduced to the U.S. market later this year by ZAP cars of California, which will import the Brazilian Obvio! Microsport model.  This 2- to 3-seater car is projected to have a range of 350 to 400 km on a five-hour battery charge and, having 150-kW peak power, achieve up to 190 km/hr with an acceleration rate of 0 to 100 km/hr in 4.5 seconds.

Payoff of Taking the Plunge on Heavy Hybrids

Recent market research has identified numerous instances of favorable return on investment for hybridized heavy commercial vehicles, given that sales volumes have now yielded an economical price point.  These economic considerations have overcome much of the risk aversion by commercial fleet buyers that normally attends the introduction of a new technology or fuel, which is an interesting point in that three distinct hybrid configurations (parallel electric, series electric, and hydraulic) are available in the heavy vehicle market, and each seems to fit well in particular niches.

Announced and Projected HEV Introductions through 2008

June

New Corporate Incentives for Hybrids

The approximately 21,000 qualifying employees of the Bank of America Corporation (BOA) who reside within 90 miles of Boston, Los Angeles, and Charlotte, North Carolina, will now receive US$3,000 cash from the corporation if they purchase a hybrid car, comparable to the federal tax credit. This makes BOA the most dispersed and one of the largest U.S. employers to offer such an incentive (Google offers its Mountain View, California, employees $5,000 cash for purchase or $2,500 for lease of any low-emission vehicle EPA-rated at 45 mpg or higher). BOA is considering extension of this benefit to all 202,000 of its employees.

Biofuel/Hybrid Synergy Seen Emerging from New Renewable Fuels Emphasis

Alexander Muller, Assistant Director-General (Sustainability) for the United Nation’s Food and Agriculture Organisation, sees biofuels providing a full 25% of the world’s energy needs by about 2025 and use of these fuels in hybrid engine technologies, both mobile and stationary, representing a significant component of that contribution.

Electric Vehicle Orders on the Rise in the United States

The ZAP Corporation, manufacturers of the XEBRA city electric vehicle (40-mph peak speed, 40-mile range), has reported a backlog of US$500,000 in orders, thanks primarily to gasoline prices in the US$2.50–$3.00 range. ZAP is seeking to move abreast of DaimlerChrysler’s GEMCar division in establishing a U.S. dealer network.

Lithium-Ion Explosion Hazard Mitigated

Prototypes of lithium-ion battery cells for electric and hybrid vehicle application have been subject to safety hazards related to the propensity of the negative electrode to explode if cells are overcharged or reach extreme temperatures. A company called Altair Nanotechnologies has announced development of a nanostructured material, called nano lithium titanium oxide, that can replace the graphite in negative electrodes and thereby improve safety and performance. Throughout a temperature range of -50–75°C, the new batteries performed successfully in bench tests with no unsafe characteristics, in normal conditions could be charged in as little as 1 minute, and lasted through more than 9,000-deep discharge cycles. They also provided safe operation in hot-cell tests up to 240°C, more than 100°C above the expected explosion point of graphite electrode cells.

April-May

Hybrid Demand Exhausts Pennsylvania's Purchase Incentive Rebate Reserve

The Department of Environmental Protection of the Commonwealth of Pennsylvania (U.S.) has announced that US$1.3 million of the $1.5 million allocated by state legislation for rebates on the purchase of hybrid vehicles in the 2005-2006 fiscal year has been awarded, and the fund is expected to run out by May. However, an additional US$1 million for the 2006-2007 fiscal year will become available to car buyers in the commonwealth beginning July 1, and hybrid purchasers who bought a qualifying vehicle within the previous six months would still be eligible for a rebate from the new funds.

Prototype Hybrid Buses to be Tested in Chinese Cities

Eaton Corporation and Beiqo Foton AUV Bus Company of China have joined forces to test prototype hybrid buses with Eaton's parallel hybrid power system in Beijing and Shanghai later this year. These buses could be deployed in large numbers for the 2008 Beijing Olympics and the 2010 Shanghai World Expo. The buses will couple automatic transmission, an advanced motor/generator, a high-power battery pack, and Eaton's system controller with a Cummins 5.9L Euro III-conformal diesel engine. In the export market, China's Wu Zhou Long Motors group is already producing hybrid, compressed natural gas, and propane buses for sale in the United States, Mexico, and India.

Capacitor Manufacturing Expansion Anticipates More Hybrid Vehicle Demand

In an effort to, in part, meet automakers' cost and customization demands, Maxwell Technologies, Inc., is one of several manufacturers of ultracapacitors to ramp up introduction of product, promising more than 30 new configurations through the end of this year. Cell sizes will range from 140 to 3,000 farads, with the higher-capacitance (>500°F) cells designed to an operating voltage of 2.7V, thus enabling reduction in the number of cells required per application. About 39% of Maxwell's business in 2006 is expected to come from hybrid transit bus producers, but increased opportunities in fork-lifts and auxiliary power applications for highway vehicles loom on the horizon..

Biofuel-Electric Hybrids: More Promise than Fuel Cells?

Electric hybrids powered with biofuels such ethanol and biodiesel in place of petroleum are widely touted in Europe as a path to future greenhouse gas reduction more promising than fuel cell vehicles, for which the hydrogen (energy carrier) may still be produced from fossil fuels. Also, the mass production of hydrogen-fueled vehicles now appears to become feasible much farther in the future than originally thought, and certainly farther than the hybrids being produced now. However, there may be an environmental challenge to be overcome when a (predominantly) renewable fuel such as E85 is married to electric propulsion, as shown in recent engine tests at Ford Motor Company: when a hybrid in operating in electric mode, the vacuum-based evaporative emission control system does not function— possibly because, unlike with all-gasoline vapor, the system does not detect emissions. Although E85 is a relatively low-volatility fuel, this feature could still create difficulties for compliance with very stringent evaporative emission regulations unless the operating principles of the evaporative control system are revised.

ZAP to Challenge GemCar in LSV Urban EV Market

Daimler-Chrysler's support of its GEM electric four-wheeler subsidiary, has figured prominently in the high visibility of that federally certified low-speed vehicle at auto shows and other venues in both the United States and Europe, and the company has enjoyed healthy sales of its cargo-haul and four-passenger versions in France, Switzerland, and Italy as well as the United States Sun Belt. However, California's ZAP, manufacturer of street-legal electric three-wheelers, hopes to compete with the GemCar in its prime markets in rolling out the new Xebra four-seater "car." The lead-acid–powered Xebra can achieve 40 mph (64 km/h) and has a range of 40 miles (64 km).

Plug-In Hybrid Electric Vehicles Figure Prominently in Bush Energy Message

In addition to endorsing, in a general sense, alternative fuels such as ethanol as a pathway to easing the U.S. "addiction to oil," President G.W. Bush in an April address specifically pointed to the promise of emerging plug-in hybrid vehicle technology as a potential major player in the quest to decrease America's petroleum reliance. It was likely the very first exposure of most Americans to news and information about PHEVs.

February-March

New State Government Incentive for Hybrids

The state of New York is the latest to permit single-occupant hybrid vehicles rated by the U.S. Environmental Protection Agency (EPA) at 45 miles per gallon or better to use designated high-occupancy vehicle (HOV) lanes on controlled-access roads such as freeways and tollways. Currently, the only New York highway with an HOV lane is the Long Island Expressway (Interstate 495). California, Arizona, Florida, Georgia, and Virginia also allow hybrids carrying only the driver to use HOV lanes on expressways.

Bullish Forecast for U.S. Hybrids

The Fredonia Group, a market research firm in Cleveland, Ohio, has projected that U.S. sales of full and mild hybrid vehicles could approach 10% of the total market share for 2014 model year vehicles, with average annual sales growth rate for mild hybrids exceeding 125% between 2009 and 2014, a rate that would actually surpass full-hybrid sales share during that period. In the same time frame, fuel cell vehicles are expected to make very modest inroads in the fleet, whilst growth in diesel (compression ignition) units for light-duty application will be very robust.

Tougher U.S. Truck Emission Rules Could Accelerate Diesel Hybrid Commercialization

With finalization of the U.S. timetable for EPA regulations that reduce exhaust particle and NOx emissions from diesel trucks, manufacturers now confront having to make their offerings for the 2007 model year (and beyond), which go on sale later this year, compliant with stringent new standards. These standards incorporate by assumption the 2006 mandate for the introduction of low-sulfur fuel that reduces the sulfur content of highway-legal diesel from 500 parts per million (ppm) to 15 ppm. The Bush Administration strongly supported implementation of these truck-focused emission rules, introduced in 1997 by the Clinton Administration following a settlement between the Department of Justice and the major truck engine manufacturers. Many experts concur that, with regulations now going forward as originally scheduled, the door has been opened wide to exploitation of diesel hybrid technology for trucks somewhat earlier than had heretofore been anticipated.

Prominent Chinese Firm Moves Decisively to LIthium-Ion Batteries for HEV Propulsion

BAK Battery Co., Ltd. (Shenzen, China), was founded in 2001 as an American public high-tech foreign-funded enterprise, mainly specializing in the research and development, production, and sale of lithium-ion (Li-ion) battery cells. The company has recently signed an agreement with A123 Systems, which licenses battery fabrication nanotechnology from the Massachusetts Institute of Technology, for exclusive manufacture on a mass production basis of A123's lithium-ion products that could include hybrid vehicle propulsion packs.

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