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Build Your Own Hybrid-Electric Car?
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?"
It may not be too prevalent in electric motors, but there's a demon that lives in power transmissions, especially where shafts are involved. It's called tortional vibration. It's a close relative to harmonic vibration of the type that tears poorly designed bridges down in heavy winds. Automotive companies are able to tweak a design until all or most of the tortional vibration is ironed out, then they mass produce. Building a one-off unit, you'll have to resolve these issues, as they may crop up, on your own.
BTM
That was the turning point of my life--I went from negative zero to positive zero.
Remove the main pulley on the engine, and replace it with a special toothed one for this rig. Remove the alternator. Hell, remove the starter while you're at it. Put the special bracket on the engine. Mount the Integrated Starter Generator (the term has been around long before this product was announced) on the bracket. Use the toothed belt to connect the ISG to the main pulley. Mount the electronics box and connect it to the whole thing. Congratulations: you now have what's known as a light hybrid vehicle. The ISG can provide regenerative braking and off-the-line torque. Technically, you can kill the engine while you're sitting at the light, and the ISG has enough horsepower to spin the engine to operating speed (roll-starting it, essentially) and get you started off the line.
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.
... by the Dew of Mountains the thoughts acquire speed, the hands acquire shakes, the shakes become a warning
The toyata prius has a very special system that deals with this, as this page shows. Especially with hybrid SUV's 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.
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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!