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BlueDotTom
Explorer
May 24, 2023

Thoughts on a plug-in hybrid conversion

Hello!
I am the founder of a Seattle-based startup. We are developing a family of universal retrofit kits that convert existing vehicles into plug-in hybrids. Our first product will be for pickup trucks, and I am hoping to get some thoughts from this and other RV communities on what features may be desirable, what the major concerns would be, etc. My thinking is that for people who use their trucks for daily driving but also frequent towing, our product could be very attractive, especially because it can be used as a generator.

In a nutshell, the kits add an electric propulsion system good for 30-45 miles of range without removing the engine. The battery pack and power electronics get mounted in the bed like a small bed toolbox. We remove a section of the tubular part of the driveshaft and install a “coaxial drive unit” that has an electric motor stack, a planetary transmission, and a multi-mode clutch that can shift-on-the-fly. The clutch allows EV operation while disconnecting the engine/tranny, engine operation while disconnecting the electric motors, and generator mode which uses the engine to spin the electric motors without turning the wheels. A linkage that connects to the axle tubes provides reaction torque. We’ve prototyped a simplified version of the system and tested in on real roads.

Because the systems are universal, we can mass-produce them, have them installed by third-parties, and hit a much lower price point than other conversions (approximately $7k-10K covering the range from midsize to ¾ ton). I’d love to get the group’s thoughts and gage the level of interest.

23 Replies

  • What's the total weight of the system? A lot of 1/2 ton trucks only have 1000-1500lb of payload. Most trucks run out of payload before they run out of tow rating.

    Would they system be able to feed ICE and EV power simultaneously? A towing mode where the electric motor kicks in on uphill grades and regenerates on downgrades would be nice. That would improve MPG, keep the ICE from potentially overheating and act as an engine brake. Combined with even the smallest engine option, it should be quite capable.

    Of course, I think cost is likely the deal breaker. Most won't want to risk the warranty on a new truck and dumping $7-10k into a 5-10yr old truck is harder to justify. If buying new, better to just buy an OEM drivetrain and not have to worry about it.

    Obviously, easier to implement via a toolbox in the bed but I would want it underneath, so the bed is still available.

    With the manufacturers pursing various powertrain options, at best I see it as a short term business plan.
  • Thanks for the feedback. The return on investment depends a lot on local fuel price and an individual's use case. Someone in my neck of the woods driving like an average American would break even in 3.3 years and would save about $15k over the life of the product.
  • JMO, but even at the present price of fuel, I can buy a lot of it for $7,000-$10,000. JMO of course.