Comment by gcanyon

14 hours ago

One thing that always puzzled me was how the gas engines in hybrids were so efficient. Technology Connections has a great video explainer: https://www.youtube.com/watch?v=KnUFH5GX_fI

tl;dw: constant RPM and a weird stroke geometry where the power stroke is longer than the other strokes to extract more energy from the expanding gasses.

wow this seems like a great video and a channel overall. Following it.

I'm surprised there isn't more effort to create hybrids in reverse--an electric car with optional gas generator. The gas generator could run at constant speed, never changing RMP, while the battery handles constant changes in acceleration. The idea is not mine. I've heard about it in China

  • TFA is exactly that...

    I think it's also because EREVs need a performant generator that isn't much different from the drive motor. So you'll have a full ICE+EV drivetrain on top of an EV as its battery for it to work, which is not ideal.

    Compared to that, other hybrid systems like the motor-clutch combo packs that sit between the ICE and gearbox, as well as the fixed gear Toyota systems, can have motors that are weaker, lighter, and cheaper than the ICE, while being able to be additive to the ICE power output. That makes more efficient use of steel and copper than full serial setups.

    BMW i3 had such EREV option, but it apparently used a cheap OEM bike engine(not like a BMW Motorrad engine) and also could not overcome power draw of the EV drive motor. So it literally just extended the range, not allowing it to run indefinitely at highway speeds with just refueling. Nissan e-POWER system is powerful enough to do that, but then the readers of comment will have to back to the line 3.

    • I've done some long trips with my i3. The key is to turn the engine on when the battery reaches 75%. The battery then absorbed the large power draws when accelerating or going up big hills. The engine does vary in RPM depending on my power draw, and by the end of my trip, the battery is usually not significantly lower, maybe around 60%. I usually turn off the engine when I'm almost at my destination so I can use the remaining battery energy.

    • People claim the EREV i3 won't do extended highway but I did Boston MA to Wichita KS in one shot in my 2014 with a hurt battery using Hold State Of Charge mode starting at a 75% battery charge and using a 7 gallon fuel cell in the frunk with a transfer pump to allow longer stretches between refueling. It worked a treat. I have since removed the additional fuel system once I got to Wichita and now it is my daily commuter and goes 2000+ miles between fillups.

    • Yeah. I'd love a decent plug-in EREV in the US. The 2027 Rogue appears to NOT have a plug-in option at the moment.

      I can't fathom buying an EV and still only getting 40 MPG and needing to buy gas. Ninety percent of my trips are < 40 miles round trip and could be handled by a modest 15kWh battery. For that last ten percent, I'd happily use some gas to not have to worry about charging on the route.

      Mazda had (has?) some cool EREVs using rotary engines as the power plant. Though sadly without plans to bring them to the US.

  • There’s a lot of good replies here but I’ll add mine too:

    The simples reason is this. What you’re describing is having a gas motor spin a thing (the generator) -> charge battery -> discharge battery -> spin a thing (the wheels) to make car go. Each of those steps has efficiency losses.

    That’s why most hybrids are parallel hybrids, where both the gas engine and the battery+motors can spin the wheels more or less directly, even at the same time.

    you still basically get the engine spinning at a more constant rpm, and the battery kicks in for acceleration (and charges on deceleration), and now highway cruising doesn’t have any lossy conversion steps, while acceleration and braking uses the advantages of the electric drive chain.

  • That is exactly what ePOWER is, that configuration is called a series hybrid and is more commonly seen in heavy industry like diesel trains or trucks in the mines (for better or worse).

    More recently effort is also going into series hybrids for public road haulers, which I personally think is a great application for it since you can potentially put a lot of the equipment into a hot-swappable dolly.

    I drove a Nissan Note (Nismo esition) with ePower and it could happily spin the wheels when taking off, not something you normally get out of a tiny economy hatchback. I think it has 140kw electric drivetrain? 140kw is pretty sporty when delivered instantly.

  • What you are referring to is usually referred to as an EREV (Extended Range Electrical Vehicle). The reason legacy manufacturers market their less efficient plugin hybrid and non plugin hybrids (100% of the power comes from petrol) instead is because that's what they have and want to milk for as long as possible. In terms of drive train these are more complex to manufacture and more costly to maintain than an EREV. EREVs typically have slightly larger batteries than a typical PHEV as well. Typical electrical ranges are at least 80-100 miles or more in some cases. Usually the cars are available as without the range extender as well. This is less common for PHEVs and hybrids. Though of course some legacy manufacturers are still trying to push compromise cars. Like Nissan in this case.

    Nissan has been really struggling for the last few years, this new hybrid engine doesn't look like it will turn things around for them to me.

    EREVs are an idea that is not new and also relevant in shipping and aviation. Many modern large ships (oil tankers, cruise ships, etc.) are already EREVs effectively: an electrical motor drives the propeller and a generator powers the motor.

    And there are are a few plane designs that are using small batteries + generators to power flight. It makes a lot of sense: electrical motors are a lot simpler, lighter and cheaper to maintain. Engine maintenance is very costly in aviation. And so is fuel. The recently announced X1 is a good example of a plane that does this. There are a few other manufacturers working on this as well. Early days but the potentially large fuel savings probably ensure this is going to happen one way or another.

    • EREVs aren't magic. They make sense for some applications but less efficient than mechanically coupling the engine to the wheels. If the user is going to run mostly on fossil fuels due to trip distance or lack of available battery chargers then a parallel hybrid design like the standard Toyota Prius model is generally a better design.

    • > In terms of drive train these are more complex to manufacture and more costly to maintain than an EREV

      They really aren't, an EREV needs two electric motors and fixed gears connecting to the engine and wheels. Toyota-style hybrids (also Ford, Chrysler, Subaru, Mazda) need... two electric motors and fixed gears connecting to the engine and wheels. Everything else is quite similar, though the hybrid will obviously have much smaller and cheaper batteries, onboard chargers, battery temperature management systems, etc.

  • Range extender EVs made a lot more sense a decade a go when batteries were much more expensive, and fast chargers were not yet ubiquitous. Then range extenders were more affordable than EVs and could go to places EVs couldn't.

    Now these EREVs are mostly luxury niche of big cars (where extra space taken by two power trains doesn't matter) for people who don't want to spend 20 minutes at rapid chargers on that yearly long trip they do. Or for people who live in some global warming ignoring backwater[1] that hasn't built out rapid charger yet.

    [1] even China has ubiquitous fast charging network now

    • We just drove from the UK to Portugal (via ferry). They were in the electric car and anxious about the next charger almost entire time.

      The only thing worse than the staple "all chargers except one broken, wait time 1h+", was the ghost charging station existing only on the map - they drove there only to see the empty field instead.

      Needless to say we barely made it in time for the ferry (their refueling was about 3 hours total in the UK alone), and sadly won't make me getting EV as the main car anytime soon.

      Second, small town car for errands, maybe, but that means having no comfort or equipment I'd like to have in the "main" car (and half of it is safety).

      Also - note you seem to suggest the mythical ubiquity of the fast chargers is the solution to the range, but they're also so expensive to use that any savings from the local driving and charging at home (if someone is lucky enough to own a house with garage or off-street parking) is immediately burned on the first longer trip.

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    • China is the first country I would expect to have ubiquitous fast charging. They are years ahead of the west in the EV rollout. Also high speed rail, robotics, high tech manufacturing in general is kind of their jam now.

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    • In America we don’t have enough chargers for roadtrips.

      The capacity issue is specially evident on long weekends or sundays when everyone needs to use the same few chargers.

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  • Just a note: the Technology Connections video above goes over why this doesn't work well for cars (but does for train locomotives).

  • Not for cars, but Edison Motors in Canada seems to be going this route right now for their heavy duty trucks and heavy-duty pickup truck conversions.

    Disclosure: I have a small investment in them.

    • I really love what Edison are doing, I have no skin in the game I just think it's a great business ethos.

      Feom a fictional perspective I also dig the rugged blend of electric industrial equipment and utilitarian design. Like a mad-max solar punk, rather than a utopian one.

      I picture them pulling up to a makeshift solar outpost en-route, in the middle of the wasteland desert, covered in red dust, the thick sheet metal scarred from raiders...

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  • That's pretty much how the Chevy Volt worked. It was an incredibly good system in that car and GM did their usual thing and killed it

  • It seems to me you’re talking about a range extender, which lots of Chinese EV makers use. Many do buy them but sometimes you get the worst of both worlds: weighty like an EV and the heat, vibration, exhaust of a petro car. For most people the extended range is only needed very occasionally but you have to carry the ICE system the whole time.

    • Depending on the compromises you're willing to make, a small gas engine that doesn't run very often isn't a lot of excess weight, and it's not going to make heat, vibration, and exhaust except when it's running ... which could be 30 minutes a month (to keep it healthy) plus whenever you actually need the extended range.

      Since it's just for range extension, you could maybe stuff the engine in the rear, so you don't have to pipe exhaust under the whole car. Although then you probably want to pipe coolant to a radiator in the front and have to protect that piping... but at least it's only coolant hot and not exhaust hot. The engine noise would be away from the driver at least.

      You said you didn't want the heat of a gas car, but you might choose to run it a little bit more in the cold to help warm the interior on cold days (especially at startup).

      Potentially, but not really likely, you could try to make it modular-ish... attach it when you need it, leave it in your garage otherwise. But I think it's going to be too heavy ... I have a 7200 W portable generator which is roughly half of what an EV uses at cruising speeds, and it takes two people to lift it. Automotive engineers do amazing things, but I don't think they're getting twice the power and less weight and easier to move...

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  • The original/first BMW i3 (2013) was like this, full battery electric (with an admittedly small battery 80-160 miles range depending on model), with an "range extender" engine.

  • Personally I'm a big fan of the EREV (which only drives an alternator, rather than a PHEV which drives the wheels directly) due to the simpler mechanical design - however I'm not sure if it's a personal preference. I feel even a fairly small 30kw (40hp?) would make a huge difference to the utility of the vehicle, while still being small and economical.

  • The above comment’s video explains why.

    You lose energy converting the the gas power to electrical power to mechanical power. Constant RPM doesn’t matter as much as you think.

  • There were several of them: the first and second generations of Chevy Volt, Fisker Karma, BMW i3, and a couple of Chinese brands.

    They're less efficient than parallel hybrids at high speeds (on a freeway). And you also need a fairly sizeable engine to keep up with the consumption at freeway speed, so at this point you might as well just throw in a planetary gearbox.

    • The Chevy Volt (and it's predecessor the GM 2-mode hybrid, and the Allison power-split hybrid) was a work of art. It is fundamentally a planetary gearbox, with 2 motor-generators.

      In ICE mode, under 35 MPH, it worked as a series hybrid. Above 35, the engine mechanically connected to the wheels. One motor-gen extracted power and fed it to the other, acting as a CVT in parallel. This provided the ratio changes needed for the small engine.

      It was way too complicated and expensive the two times they tried it (2008, then the Volt). It was successful and lives on to this day in its original application: city buses.

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  • bmw I3s were this type of hybrid as far as I remember.

    the ICE extender was an option.

    • And the range extender was underpowered. Drive up a hill on a freeway at 70 mph and the battery would deplete and the car would slow down to 25 mph which was the fastest the range extender could make it go up a gentle incline.

      It's dangerous to do 25 mph on a freeway... There are some roads I'm too scared to drive my i3 on now.

      If you pulled over to let it recharge, it wouldn't do so, since the range extender refuses to run at full throttle when the car isn't moving fast (perhaps no cooling fan??)

    • Yup, my friends had one and loved it despite the... unique styling.

      They live in the Puget Sound area, and both work at the same place. It worked out to where they could do their commute, and ordinary errands entirely on battery, and only needed the range extender if they were going into downtown Seattle or on a road trip or such.

  • Theoretically couldn't you take an electric car and put an off-the-shelf generator in your frunk and wire it up to charge the battery as you drive?

    • My PHEV won't 'start' while plugged in. You'd need to bypass the usual charger mechanisms, and then the computer seems likely to get mad...

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    • >>and put an off-the-shelf generator

      Even my really underpowered PHEV has a 65kW electric motor. No "off the shelf generator" can generate 65kW, in fact it would be a huge unit that could.

      We could of course say - well, it doesn't need to match peak usage, it just has to charge the battery faster than it depletes - you still probably need around 20kW for steady motorway driving, and that's a pretty hefty generator.

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  • You mean like a BMW i3 with a range extender? Little two-cylinder petrol that just spins a genny.

    They work, they're not terribly efficient in terms of converting fuel to distance travelled, and really batteries are getting so good these days there's little point any more.

  • The concept is called range extenders, and the video does explain why it’s one of those false great ideas and every production vehicle has failed: EVs with range extenders are at best bad EVs and at worst terrible hybrids.

  • Aka EREV, thats becoming majority of “PHEVs” now.

Yes, gas engines have very bad efficiency. The best way to run them is with constant torque and RPM, that is, charging a battery

And yes the Atkinson cycle helps

  • Yes, but it doesn't mean the overall system is better because of losses during the power conversion. It's usually better to have the engine driving the wheels directly which is possible with a continuously-variable transmission (CVT).