Global automotive supplier Johnson Controls says it has reduced a micro-hybrid battery pack from the size of a car trunk to the size of a shoebox, representing a significant breakthrough for a technology whose presence in the U.S. auto market is expected to grow significantly by end of the decade.
The newer, more advanced forms of micro-hybrid technology — in conjunction with smaller, cheaper battery packs — could help automakers achieve better CAFE ratings.
Don't confuse micro-hybrids with tiny cars like General Motors Co.'s Chevrolet Spark or Toyota Motor Corp.'s Scion iQ. Micro-hybrid vehicles, currently a mostly European trend, are most often associated with start-stop technology — the engine stops running when a vehicle is stopped, and restarts when the accelerator is pressed. That technology can be combined with regenerative braking, which allows a vehicle to recoup energy normally lost during the braking process, for even greater fuel savings.
Micro-hybrids are seen by many in the industry as a more affordable alternative to full hybrids, which have a much larger lithium-ion or nickel-metal-hydride battery pack.
The Johnson Controls system consists of a 48-volt lithium-ion battery pack and an advanced low-voltage lead-acid battery that supports higher power loads and regenerative braking features.
The allure of a micro-hybrid system is that it can be implemented in large gas or diesel-powered vehicles — SUVs and trucks — at a lower cost. Those costs, because of the shrunken Johnson Controls battery pack, will be hundreds of dollars instead of thousands for full hybrids. That micro-hybrid system could be a part of automakers' U.S. lineups by the end of the decade, during the first wave of CAFE requirements, which call for each automaker's fleetwide average fuel economy to equal 54.5 miles per gallon by 2025.
The smaller lithium-ion battery costs less, but has a lifespan of about four years, compared to 10 years for a full hybrid or a plug-in or full electric vehicle. It will be as simple — though likely not as inexpensive — as replacing a traditional 12-volt battery in an average vehicle.
A micro-hybrid system with an advanced, lead-acid 12-volt battery that allows for start-stop technology and the lithium-ion battery will improve fuel efficiency about 15 percent when compared to a standard internal combustion engine. For a vehicle that averages 20 miles per gallon, that would mean an improvement of up to 23 mpg, or a fuel savings of approximately $1,800 based on gas that costs $3.61 per gallon and driving habits of about 15,000 miles annually over a five-year period.
That's better than the 8 percent improvement of a start-stop system — on vehicles such as the Chevrolet Malibu and Ford Fusion — but less than that of a full hybrid, which can improve fuel efficiency by as much as 20 percent.
Though the price of hybrids has decreased the past few years, it is difficult to pinpoint the true cost of hybridization because costs vary depending on the powertrain and how many battery cells are included in each battery pack.
Micro-hybridization could be a complementary technology to the burgeoning turbocharger market, and automakers could realize even greater fuel-efficiency gains that could get them closer to meeting CAFE standards.
Global sales projections for micro-hybrids vary, with a few estimating upward of 40 million annual sales by the end of the decade. The two regions where micro-hybrids will sell the most are Europe — which accounts for most of the 5 million current global sales — and China, the world's fastest-growing auto market.
A123 Systems Inc. says it will launch a micro-hybrid project for a major German automaker which it did not identify. A123 Systems, which this year had most of its assets purchased by a Chinese firm, recently said it will shift its primary focus to micro-hybrid technology.
One of the major challenges that will face advanced forms of micro-hybridization is the idea that consumers will have to swap their vehicle's lithium-ion battery every four years. Batteries on other electric vehicles have an expected lifespan of about a decade.
Another pressing issue is the hybrid name, which appeals to some but not all consumers. It's for that reason that some automakers, like Ford Motor Co., currently choose to strictly stick with start-stop technology on its fuel-powered vehicles. Ford says the start-stop system can save 3 to 4 percent for the typical driver at an added cost of about $300.
from The Truth About Cars http://www.thetruthaboutcars.com
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