Even as we get closer to new mass-produced PHEVs, those converting vehicles continue work that shows future possibilities and has a strong impact on important decision-makers. Who would have ever expected to see a PHEV Hummer? Who'd have guessed the leading state government air quality regulatory agency would find a way to accommodate conversions? Who'd have predicted independent engineers would invent a way to get a Prius driving all-electrically at 70 MPH? For this and other conversion stories, read on...
CALCARS' BROAD PERSPECTIVE ON CONVERSIONS
Since we announced our first conversion of a Prius (and before that as we spotlighted Dr. Andy Frank's conversions of multiple vehicles), we've always seen their value as primarily strategic, helping to build awareness and support for mass-produced plug-in cars. But as our understanding has grown that new plug-ins won't contribute significantly to overall petroleum use for 10-15 years, we're now emphasizing the potential of the companies building businesses around conversions to go beyond new hybrids.
The small aftermarket companies offer previews of a giant new industry to convert millions of internal combustion engine (ICE) vehicles to plug in. We're working to make the case for broad government and corporate support of that approach as a second path to achieving all the benefits of electrifying transportation. For these retrofits, our goal is tested, validated, warranted designs, ideally done in partnership with carmakers. In April CalCars released an eight-page White Paper on the subject. Now we have a new 21-slide presentation, downloadable at http://www.calcars.org/calcars-beyond-new-plug-ins.pdf that includes slides on some of the small ICE-conversion companies that we hope will emerge as players in this far larger opportunity.
HUMMER: THE ULTIMATE COUNTER-INTUITIVE CONVERSION
When we said, "the bigger the vehicle the more the benefit in switching to electricity," we weren't thinking of Hummers, which may go down as one of the follies of the first decade of this century. Yet now Raser Technologies has taken an H3 (the smallest Hummer) and turned it into a series PHEV with a 40-mile all-electric range. The most significant aspect of this vehicle may be that GM cooperated with Raser and integrator FEV, making available design information that helped them in the conversion and an efficient EcoTec engine for range extension. We hope this is a preview of automakers recognizing that conversions can provide them and their dealers with a revenue stream for cars they've already sold!
PRIUS CONVERSIONS NOW WITH LARGE NICKEL-METAL HYDRIDE BATTERIES
We (and those who've driven Toyota RAV4-EVs for over 100,000 miles) have long felt that NiMH's day was not over: like advanced lead-acid solutions, this proven technology still has life (as well as proven safety and durability records). Now Plug-In Conversions Corp. (PICC). of Poway, CA, which recently received an investment from large international battery maker Gold Peak, has a solution that replaces the original Prius battery. Its $12,500 conversion may be the design with the longest EV range. PICC has tested its system at Argonne National Labs with positive results including SULEV-level emissions, and intends to fully crash-test and validate its designs
SPEED BREAKTHROUGH ON PRIUS CONVERSIONS
Several aftermarket converters have found ways to circumvent the Prius limitation that starts the engine above 34 MPH, raising that number above 50MPH. In "forced stealth" mode. the car has to be turned off and restarted to go at higher speeds—hardly simple or practical — and there are potential emissions complications. Now Chicago's Ewert Energy Systems has announced a proprietary electronic solution that enables some converted Priuses to drive up to 70 MPH all-electrically, and in general consistently exceed 100MPG at highways speeds during the battery's range. (The company was co-founded by Chris Ewert, team member for CalCars' second Maker Faire conversion in 2007 and key member of the CalCars-co-sponsored Open SourcElectric Auto Association PHEV Discussion Group.) Ewert has an exclusive distribution agreement with PICC (above), in part because its replacement battery can provide more energy to the system than do add-on-battery conversions.
For more on plug-in hybrid electric conversions, visit calcars.org.
