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Car Forum / Driving, Maintenance, Tuning / Maintenance and Repair / January 2007

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Hybrid cars a safe buy?

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John S. - 09 Jan 2007 18:40 GMT
Honestly though - the EPA mileage estimates of all cars tend to be
higher what most people experience in the real world.  It's unfair
to single out hybrids for unrealistic published fuel economy.

JS>  The scale of error is very different.  We are talking about erring
on the high side 15 to 20 mpg for the hybrids.  For gasoline/diesel
cars the variance might be +- 3 or 4 mpg.

At least in California, a hybrid's battery pack is considered part
of the emissions system.  In California, all emissions parts are
required to be warranted for 10-years or 150,000 miles.  The cost
of rechargeable batteries are going down, and I'd expect that the
price of replacement battery packs will be extremely reasonable if
they need to be replaced after the warranty period.  Honda has an
8-year factory warranty on their hybrid batteries, which may be
higher in some states.

JS>  Having an extended emissions warranty would be some help.  The
high initial price really isn't offset by the net cost savings though.

<http://automobiles.honda.com/models/model_overview.asp?ModelName=Civi...>

Really though - NiMH batteries can last an extremely long time
provided they're not deeply discharged.  I kind of worry about
people who insist on needing a "battery only" mode.  I know the
typical NiMH AAs I use in my camera have a rated life of about
700-1000 recharge cycles before the capacity is reduced to
less than 80% of original capacity.  I've read information that
they can literally last many (dozens to hundreds) times this if
exposed to only shallow discharge periods - like being topped
off by the generator or regenerative braking.

JS>  I've read that 100,000 miles is about the level at which problems
could begin to show up with the batteries and charging system.

But the real question is whether the consumer ends up saving money by
buying one.  With their real world mpg down in the 40's I don't think
there is much invcentive.  If they were able to return average mpg's in
the high 60's as originally advertised then a better case could be
made.

<http://autoelectronics.com/mag/nimh_batteries_charge>

"Cobasys' NiMH batteries are capable of supplying powers of
200 W/kg to greater than 1000 W/kg to a load. They have
demonstrated cycle life of greater than 1000 80% depth of
discharge (DOD) charge discharge cycles. And in HEV
applications, with shallow charge-discharge cycles, they have
achieved 200,000 to 300,000 cycles."

Reply »     Rate this post:  Text for clearing space
y_p_w - 10 Jan 2007 07:04 GMT
> JS>  The scale of error is very different.  We are talking about erring
> on the high side 15 to 20 mpg for the hybrids.  For gasoline/diesel
> cars the variance might be +- 3 or 4 mpg.

I've heard some are averaging 50+ while others aren't.
This may be a case where YMMV, literally.

> JS>  Having an extended emissions warranty would be some help.  The
> high initial price really isn't offset by the net cost savings though.

I really doubt anyone is under the impression that they've
buying a current hybrid because the net fuel savings will
offset the increased cost.  Right now, people are early
adopters, much like I was when I bought my first DVD players
in 1997 for $1100 and $600.

> JS>  I've read that 100,000 miles is about the level at which problems
> could begin to show up with the batteries and charging system.

However - it has been shown that bad cells can be replaced
individually.  If they do fail, I don't think it's all at
once.  I'd think in the future there might be more advanced
monitoring systems and that failing cells could be detected
early and replaced as preventative maintenance.  As it is
now, one failing doesn't seem to mean that the next one
is bound to go bad in a month.

There are real world cases where people have gotten more
mileage out of hybrids (on the original battery) that most
get out of standard cars.  There are plenty of hybrids
that have gone beyond 100K miles, and there hasn't been
a documented case where there's been catostrophic failure
of multiple cells.

> But the real question is whether the consumer ends up saving money by
> buying one.  With their real world mpg down in the 40's I don't think
> there is much invcentive.  If they were able to return average mpg's in
> the high 60's as originally advertised then a better case could be
> made.

Again - nobody is buying current hybrid cars simply because
they think they'll save money overall.  I don't think the
original poster is asking that question.  The real question
is whether or not it's going to be possible to service these
cars in the future, and whether shops will be able to
service them.

I take my car to Art's Automotive (Berkeley, California),
which is a Japanese car specialist.  They will service all
Toyota and Honda hybrids.  They were considering servicing
Ford and other hybrids, but probably can't justify the
cost of subscriptions for all the info services for just
one model.

<http://www.artsautomotive.com/Hybrid.htm>
John S. - 10 Jan 2007 12:30 GMT
> > JS>  The scale of error is very different.  We are talking about erring
> > on the high side 15 to 20 mpg for the hybrids.  For gasoline/diesel
[quoted text clipped - 11 lines]
> adopters, much like I was when I bought my first DVD players
> in 1997 for $1100 and $600.

That is the story I hear.  But if cost savings is not the reason then
why would anyone pay more money for a car that would only deliver the
performance of a lesser priced one.

> > JS>  I've read that 100,000 miles is about the level at which problems
> > could begin to show up with the batteries and charging system.
[quoted text clipped - 26 lines]
> cars in the future, and whether shops will be able to
> service them.

Again, then why would anyone buy one if there is no cost savings and
likely an increased cost in operation..

> I take my car to Art's Automotive (Berkeley, California),
> which is a Japanese car specialist.  They will service all
[quoted text clipped - 4 lines]
>
> <http://www.artsautomotive.com/Hybrid.htm>
Joe Sterling - 13 Jan 2007 17:33 GMT
> Again, then why would anyone buy one if there is no cost savings and
> likely an increased cost in operation..

One would buy one in order to do one's part to protect the environment.

I really suspect that "John S." is a sockpuppet for someone who posts
drivel all over Usenet.

Joe
John S. - 13 Jan 2007 18:03 GMT
> > Again, then why would anyone buy one if there is no cost savings and
> > likely an increased cost in operation..
>
> One would buy one in order to do one's part to protect the environment.

How would one protect the environment by purchasing a hybrid car that
converts energy from one form to another by burning fossil fuel.

They use fuel at real world rates (not EPA ratings) not unlike that of
high mpg standard cars.  And they use a large number of storage
batteries made of noxious materials that will have to be disposed of at
some point.  Where's the net improvement to the environment.
y_p_w - 14 Jan 2007 22:54 GMT
>>>Again, then why would anyone buy one if there is no cost savings and
>>>likely an increased cost in operation..
[quoted text clipped - 3 lines]
> How would one protect the environment by purchasing a hybrid car that
> converts energy from one form to another by burning fossil fuel.

Over the life of the vehicle, I believe there will be fewer
noxious tailpipe emissions from a hybrid than a similarly
sized ICE-only car.  I think the hybrid strategy is creative.
Use an efficient engine that would otherwise be gutless without
the aid of an electric motor.  Operate the engine at times
where it's most efficient (in terms of fuel use and emissions
output).

> They use fuel at real world rates (not EPA ratings) not unlike that of
> high mpg standard cars.  And they use a large number of storage
> batteries made of noxious materials that will have to be disposed of at
> some point.  Where's the net improvement to the environment.

The problem with real high MPG ICE cars is that they are almost
universally gutless and tiny.  Maybe diesels are OK, but diesel
has higher energy content (meaning higher CO2 output per unit
of fuel), limited availability, and low temperature problems.

NiMH batteries aren't super toxic like lead-acid types.  Most
auto companies making hybrids have already started up recycling
infrastructure.  If a battery is at end of life, I'm pretty sure
dealer service departments will take them.

<http://www.toyota.co.jp/en/environment/recycle/battery/index.html>
John S. - 15 Jan 2007 18:05 GMT
> >>>Again, then why would anyone buy one if there is no cost savings and
> >>>likely an increased cost in operation..
[quoted text clipped - 11 lines]
> where it's most efficient (in terms of fuel use and emissions
> output).

The small engined toyota/honda/nissan cars get milage that is not all
that much lower than the real world milage of an electro/hydrocarbon
powered hybrid.  From what i've read there is no cost justification for
buying such a car, especially when replacement of the batteries is
factored in.

> > They use fuel at real world rates (not EPA ratings) not unlike that of
> > high mpg standard cars.  And they use a large number of storage
[quoted text clipped - 7 lines]
>
> NiMH batteries aren't super toxic like lead-acid types.

They aren't ???   Wow that's a unique description....

> Most
> auto companies making hybrids have already started up recycling
> infrastructure.  If a battery is at end of life, I'm pretty sure
> dealer service departments will take them.
>
> <http://www.toyota.co.jp/en/environment/recycle/battery/index.html>
y_p_w - 15 Jan 2007 19:40 GMT
> The small engined toyota/honda/nissan cars get milage that is not all
> that much lower than the real world milage of an electro/hydrocarbon
> powered hybrid.  From what i've read there is no cost justification for
> buying such a car, especially when replacement of the batteries is
> factored in.

Like I said - gutless.

I really don't get it when it comes to the batteries.  There is
evidence that the large majority of the cells in a battery stack
should last the life of the car.  I doubt there's going to be any
mass failure of the cells. It should be more like light bulbs.
There might be a few early failures here and there that would
fall under warranty repair.  Even after that, I don't get the scare
tactic that all batteries are doomed for failure in rapid succession.

I could see a cottage industry of businesses that buy out old batteries
and test/recondition them.  I can buy systems for consumer electronics
batteries that do a similar function.  At that point, I think most
people will be looking to squeeze just a few more years out of the old
heap rather than look for it to last another 150,000 miles.

I think another thing that might be noted is that the majority of the
current hybrid buyers like new cars and probably will be moving on
to the latest technology in ten years.  Some people get attached
to their cars and put more money into their repair than it's worth.
That's the nature of most older vehicles that aren't collector's items.

> > NiMH batteries aren't super toxic like lead-acid types.
>
> They aren't ???   Wow that's a unique description....

Some people have stated that NiMH cells are legal to dispose of in
landfills.  I think that's possible in some jurisdictions, but I
wouldn't advise it.  There is some mild toxicity with NiMH batteries,
but a lead-acid battery is WAY more toxic.  More tailpipe emissions
over the life of a car are also way more toxic.  In any case, the means
to recycle NiMH batteries is fairly common even today.
Pete C. - 15 Jan 2007 21:19 GMT
> > The small engined toyota/honda/nissan cars get milage that is not all
> > that much lower than the real world milage of an electro/hydrocarbon
[quoted text clipped - 7 lines]
> evidence that the large majority of the cells in a battery stack
> should last the life of the car.

Exactly.

What you don't seem to get is the fact that the life of the battery pack
*IS* the life of the car. If the pack lasts 10 years that is the life of
the car. Once the pack fails the whole car has little more than scrap
value.

With the conventional economy car you simply don't have this
catastrophic end of life scenario. The conventional economy car gets
just about the same mileage, costs less and has a longer viable life
span - win, win, win.

You comment of "gutless" is also not really true as anyone who has
driven one of the old Subaru Justy 3 cylinder conventional economy cars
with the ECVT transmission can attest. Those little 50 some odd HP
glorified golf carts would go like a bat out of hell thanks to the ECVT
matching the little engines power output to the drive train needs and
their extremely low weight.

Add in the recently refined variable displacement technology for
conventional engines and you can get the 200 HP kick when you mash the
gas with little MPG penalty when all you need is 20 HP to cruise the
highway.
y_p_w - 15 Jan 2007 21:58 GMT
> > > The small engined toyota/honda/nissan cars get milage that is not all
> > > that much lower than the real world milage of an electro/hydrocarbon
[quoted text clipped - 14 lines]
> the car. Once the pack fails the whole car has little more than scrap
> value.

Like I said - the individual cells can be replaced.  The individual
cells won't die off all at once.  250,000 miles and 15 years shouldn't
be out of the question for the large majority of the packs in a stack.
I would imagine that there will be some mechanics that might
specialize in overhauling hybrid batteries.  NiMH technology has
been around for a while.  Equipment to analyze and recondition
batteries should be available, as exists now for consumer electronics
cells.  I see the sale of reconditioned battery packs like we find
rebuilt engines or starters.  Of aftermarket drop-in modules.

The battery pack isn't a single module.  It's not as simple as the
entire pack being scrapped just because one or two fail.  The hybrid
systems seems to do a fairly simple thing that maximizes the life of
the battery stack.  Just keep it from being completely drained, but
keep it from being completely full where it might be overcharged.
With that type of use, 15-20 years doesn't seem to be out of the
question.

> With the conventional economy car you simply don't have this
> catastrophic end of life scenario. The conventional economy car gets
> just about the same mileage, costs less and has a longer viable life
> span - win, win, win.

Who cares.  This is just an option, and not everyone will try to
get 250,000 miles out of a car.  If someone is really intent on
getting 250,000 miles out of a hybrid, I think it can be done
for less than the price of a complete battery stack.

> Add in the recently refined variable displacement technology for
> conventional engines and you can get the 200 HP kick when you mash the
> gas with little MPG penalty when all you need is 20 HP to cruise the
> highway.

And you're still hauling around that weight and heating up a
full-sized engine block.
Pete C. - 16 Jan 2007 00:07 GMT
> > > > The small engined toyota/honda/nissan cars get milage that is not all
> > > > that much lower than the real world milage of an electro/hydrocarbon
[quoted text clipped - 16 lines]
>
> Like I said - the individual cells can be replaced.

True.

> The individual
> cells won't die off all at once.

True, however the individual cells are all the same age and have seen
the same usage so they will all die within the span of about one year.

> 250,000 miles and 15 years shouldn't
> be out of the question for the large majority of the packs in a stack.

In commercial taxi service perhaps. Not for the typical consumer.

> I would imagine that there will be some mechanics that might
> specialize in overhauling hybrid batteries.

Pretty unlikely given the state of mechanics today. The bulk are nothing
more that parts changer with little understanding of how things actually
work and minimal troubleshooting ability beyond what the decision tree
in the manual tells them to try. The few good mechanics that actually
understand a vehicle are mostly employed by racing teams.

> NiMH technology has
> been around for a while.  Equipment to analyze and recondition
> batteries should be available, as exists now for consumer electronics
> cells.

It exists, but it isn't cost effective in most cases. Spending $100 on a
charger / conditioner that will get you an extra six months of life from
a $10 battery just doesn't make economic sense. Applied to hybrid
battery packs it still doesn't make much sense due to the minimal life
extension it might provide.

> I see the sale of reconditioned battery packs like we find
> rebuilt engines or starters.  Of aftermarket drop-in modules.

Take a look at the most comparable battery market, one that has been
around many years - electric forklift batteries. They don't generally
get reconditioned, they get recycled since the effort of reconditioning
them does not provide enough extra life to be worthwhile and the
unpredictability of that extra life and the inconvenience and down time
it causes costs more money than the potential savings.

> The battery pack isn't a single module. It's not as simple as the
> entire pack being scrapped just because one or two fail.

Not relevant. The battery in my forklift is composed of 12 individual
cells in a big steel case (whole thing weighs 1,571#). You simply don't
replace an individual cell, when one fails the others aren't far behind.

> The hybrid
> systems seems to do a fairly simple thing that maximizes the life of
> the battery stack.  Just keep it from being completely drained, but
> keep it from being completely full where it might be overcharged.
> With that type of use, 15-20 years doesn't seem to be out of the
> question.

It might not seem out of the question, but it vastly exceeds the service
life of pretty much any Ni-MH pack in use today in other applications. I
know I have quality Ni-MH packs on tools that are approaching 10 years
old and they are showing signs of impending failure such as reduced
capacity.

> > With the conventional economy car you simply don't have this
> > catastrophic end of life scenario. The conventional economy car gets
[quoted text clipped - 5 lines]
> getting 250,000 miles out of a hybrid, I think it can be done
> for less than the price of a complete battery stack.

Correct, it can be accomplished by driving at least 25,000 miles a year
so you reach that mileage mark before the battery pack fails since it's
service life relates more to age than use. That way your service costs
will be tires, brakes, wheel bearings and oil changes, all far less
expensive than a battery pack.

No comment on the Subaru Justy? It was a 3 cylinder 50 some odd HP
conventional IC economy car that had plenty of pep, proving your gutless
claim false.

> > Add in the recently refined variable displacement technology for
> > conventional engines and you can get the 200 HP kick when you mash the
[quoted text clipped - 3 lines]
> And you're still hauling around that weight and heating up a
> full-sized engine block.

The heating part is utterly irrelevant since unless you do all your
driving in the arctic the radiator is busily dissipating heat constantly
after the first few minutes of operation. Having more thermal mass to
heat does nothing more than add one or two minutes to the warm-up. As to
weight, that is minimal for a car engine and is less weight than the
battery pack the hybrid hauls around.
y_p_w - 16 Jan 2007 03:18 GMT
> > The individual
> > cells won't die off all at once.
>
> True, however the individual cells are all the same age and have seen
> the same usage so they will all die within the span of about one year.

I really don't see that happening.  I would expect that a few might
fail here and there; more like a increasing distribution rather than
a cliff.  Possibly one might go next month or three years down the
line.  It's not like a bad apple where the one failing one alerts all
the others that they need to execute some massive die-off.

I think of it more like an older house that's been well taken care of.
I live in a 50+ year old house with some of the original wiring.  Some
hardware has worn down with age and needs to be replaced, but the
house as a whole hasn't fallen apart.  When older components fail, they
can be repaired as needed.  We don't walk into the house expecting
that all the original doors are going to start failing in short order
if just one needs to be repaired or replaced.

> > 250,000 miles and 15 years shouldn't
> > be out of the question for the large majority of the packs in a stack.
>
> In commercial taxi service perhaps. Not for the typical consumer.

The biggest enemy of NiMH battery life are excessive heat,
overcharging, and deep-discharge cycles.  The latter two are handled
by the system design.  The stacks are fan cooled.  Most of the tools
I've worked with use simple dumb chargers, and I'd expect that
the batteries would show the signs of overcharging and or deep
discharge use after 10 years.

> > I would imagine that there will be some mechanics that might
> > specialize in overhauling hybrid batteries.
[quoted text clipped - 4 lines]
> in the manual tells them to try. The few good mechanics that actually
> understand a vehicle are mostly employed by racing teams.

I'd expect to see semi-automated equipment.  Break down the old
battery and insert several cells into the analyzer.  Analyzer gives a
report and the cells are marked and/or graded.  It might not even be
all that different than the equipment that the manufacturer uses to
test new batteries.

> > NiMH technology has
> > been around for a while.  Equipment to analyze and recondition
[quoted text clipped - 6 lines]
> battery packs it still doesn't make much sense due to the minimal life
> extension it might provide.

I only bring a "conditioner" as an example of the technology out there.
What I had in mind was an analyzer to detect which cells are likely
to have a long, useful life and to discard (i.e. recycle) the cells
that might fail.

> > I see the sale of reconditioned battery packs like we find
> > rebuilt engines or starters.  Of aftermarket drop-in modules.
[quoted text clipped - 12 lines]
> cells in a big steel case (whole thing weighs 1,571#). You simply don't
> replace an individual cell, when one fails the others aren't far behind.

Typically lead-acid batteries that aren't fan-cooled during the charge
and discharge cycles, right?  I expect the failure characteristics of
a fan cooled NiMH battery (that's kept well between fully charged and
fully depleted) to very different.

> > The hybrid
> > systems seems to do a fairly simple thing that maximizes the life of
[quoted text clipped - 8 lines]
> old and they are showing signs of impending failure such as reduced
> capacity.

Again - how many applications are designed to keep a NiMH battery
from being deep-discharged AND fully-charged?  While being fan
cooled.  That environment is far more conducive to longer life than
a tool battery pack.

Now I don't expect that every last battery pack in every car is going
to be perfectly reliable over the course of 15 years and 250,000 miles.
That's unrealistic for any car part.  I do believe that these hybrid
systems are set up to maximize rechargeable battery life better than
almost any other use to date.  I wouldn't expect that amount of
monitoring/cooling would be worth it for typical consumer electronics
where I could get another set for less than $10.

> > > With the conventional economy car you simply don't have this
> > > catastrophic end of life scenario. The conventional economy car gets
[quoted text clipped - 11 lines]
> will be tires, brakes, wheel bearings and oil changes, all far less
> expensive than a battery pack.

No room for other parts failures?  I had a coolant hose go at 110K
miles.  The radiator tank cracked at 130K miles.  There were also
other little things that probably needed servicing.  It was stolen,
recovered, and declared a total loss.  I got a great settlement that
was more than I could have sold it for.

> No comment on the Subaru Justy? It was a 3 cylinder 50 some odd HP
> conventional IC economy car that had plenty of pep, proving your gutless
> claim false.

I remember the Justy.  That sucker was tiny.

> > And you're still hauling around that weight and heating up a
> > full-sized engine block.
[quoted text clipped - 5 lines]
> weight, that is minimal for a car engine and is less weight than the
> battery pack the hybrid hauls around.

I thought the typical weight difference between a V8 and an I4 is about
200-250 lbs.  A battery pack is about 100-120 lbs.  The battery can be
placed anywhere you can find it, while a V8 would require more volume
under the hood.
Pete C. - 16 Jan 2007 07:23 GMT
> > > The individual
> > > cells won't die off all at once.
[quoted text clipped - 15 lines]
> that all the original doors are going to start failing in short order
> if just one needs to be repaired or replaced.

It's a predictable electro-chemical thing, no analogy whatsoever to home
electrical.

> > > 250,000 miles and 15 years shouldn't
> > > be out of the question for the large majority of the packs in a stack.
[quoted text clipped - 7 lines]
> the batteries would show the signs of overcharging and or deep
> discharge use after 10 years.

If they have dumb chargers you're using cheap tools. The quality tools
have smart microprocessor controlled fast chargers and the battery packs
have built in temperature sensors. Some battery packs have built in
intelligence as well with flash memory to track the packs history.

> > > I would imagine that there will be some mechanics that might
> > > specialize in overhauling hybrid batteries.
[quoted text clipped - 10 lines]
> all that different than the equipment that the manufacturer uses to
> test new batteries.

You can analyze and grade all you want, but you're still going to have a
90%+ reject rate because all the cells will be about equally worn out in
almost every case.

> > > NiMH technology has
> > > been around for a while.  Equipment to analyze and recondition
[quoted text clipped - 11 lines]
> to have a long, useful life and to discard (i.e. recycle) the cells
> that might fail.

Look at some of the battery management chips from Microchip and Dallas
Semi. The intelligence is intended to be built right into the pack.
Helps maximize the life expectancy of a pack, but either way, all the
cells will be near death at about the same time.

> > > I see the sale of reconditioned battery packs like we find
> > > rebuilt engines or starters.  Of aftermarket drop-in modules.
[quoted text clipped - 17 lines]
> a fan cooled NiMH battery (that's kept well between fully charged and
> fully depleted) to very different.

Yes, big honkin' lead-acid, but not relevant to the point about not
replacing individual cells in the pack.

> > > The hybrid
> > > systems seems to do a fairly simple thing that maximizes the life of
[quoted text clipped - 13 lines]
> cooled.  That environment is far more conducive to longer life than
> a tool battery pack.

Quality tools have smart chargers and the battery packs have internal
temperature sensors. Indeed my packs and chargers are all indoors in a
relatively controlled environment, not bouncing around in a car in the
Texas heat.

> Now I don't expect that every last battery pack in every car is going
> to be perfectly reliable over the course of 15 years and 250,000 miles.
[quoted text clipped - 3 lines]
> monitoring/cooling would be worth it for typical consumer electronics
> where I could get another set for less than $10.

The Ni-MH packs for quality tools are typically around $70.

> > > > With the conventional economy car you simply don't have this
> > > > catastrophic end of life scenario. The conventional economy car gets
[quoted text clipped - 15 lines]
> miles.  The radiator tank cracked at 130K miles.  There were also
> other little things that probably needed servicing.

Those are simple, inexpensive failures and the hybrid is equally subject
to them (a pure EV wouldn't be).

>  It was stolen,
> recovered, and declared a total loss.  I got a great settlement that
> was more than I could have sold it for.

I don't think a stolen vehicle has much relevance to this discussion.

> > No comment on the Subaru Justy? It was a 3 cylinder 50 some odd HP
> > conventional IC economy car that had plenty of pep, proving your gutless
> > claim false.
>
> I remember the Justy.  That sucker was tiny.

Tiny yes, but inexpensive, peppy (chirp tires at will) and pretty
reliable. Rather comparable to the mini cooper, but without the hype or
price tag.

> > > And you're still hauling around that weight and heating up a
> > > full-sized engine block.
[quoted text clipped - 8 lines]
> I thought the typical weight difference between a V8 and an I4 is about
> 200-250 lbs.

Perhaps comparing an aluminum I4 to a cast iron big block V8. There is a
great variety of V8 engines out there covering a huge weight range and
huge displacement range. There are also very nice aluminum V6s that are
more appropriate in a car.

An aluminum V6 with variable displacement is probably not more than 50#
heavier than the engine and electric motor in a hybrid.

> A battery pack is about 100-120 lbs.  The battery can be
> placed anywhere you can find it, while a V8 would require more volume
> under the hood.

The battery pack may be 120#, but the framework required to hold it and
give it some protection in an accident adds a lot more weight. Again, an
aluminum V6 is more applicable to a car than a cast iron V8 which
belongs in a truck.
y_p_w - 16 Jan 2007 22:34 GMT
> > The biggest enemy of NiMH battery life are excessive heat,
> > overcharging, and deep-discharge cycles.  The latter two are handled
[quoted text clipped - 7 lines]
> have built in temperature sensors. Some battery packs have built in
> intelligence as well with flash memory to track the packs history.

Still - typically no fan cooling which is rare in most applications.
Most people have different expectations for rechargeable batteries.
Charge the battery to full capacity and try to get as much use out
of a single charge is the most typical pattern.

> > I'd expect to see semi-automated equipment.  Break down the old
> > battery and insert several cells into the analyzer.  Analyzer gives a
[quoted text clipped - 5 lines]
> 90%+ reject rate because all the cells will be about equally worn out in
> almost every case.

Depends on the expectation.  Much like there are reconditioned
batteries for low/medium-duty forklifts, I'd expect that there might
be different grades of used batteries for people looking to get the
last 3-5 years out of a hybrid car.  The usage pattern is also way
different with only a shallow discharge.  I would retire a set of
camera batteries if they were down to maybe 50% of original capacity.
For a hybrid car battery that stays between a small window of charge/
discharge, that might still be acceptable.  The meaning of "failure" is
considerably different.  The way the batteries are used leads me to
believe that the large majority should be adequate for the intended
duty after 15 years and 250K miles.  Those that aren't can be
replaced with known good cells matching the condition of the
original ones.

> > > > NiMH technology has
> > > > been around for a while.  Equipment to analyze and recondition
[quoted text clipped - 16 lines]
> Helps maximize the life expectancy of a pack, but either way, all the
> cells will be near death at about the same time.

Again - a much different usage than the fully charged then discharged
pattern that's typical with most consumer/industrial electronics cells.

> > Again - how many applications are designed to keep a NiMH battery
> > from being deep-discharged AND fully-charged?  While being fan
[quoted text clipped - 5 lines]
> relatively controlled environment, not bouncing around in a car in the
> Texas heat.

You forgot the part about the battery cooling fan.

> > Now I don't expect that every last battery pack in every car is going
> > to be perfectly reliable over the course of 15 years and 250,000 miles.
[quoted text clipped - 5 lines]
>
> The Ni-MH packs for quality tools are typically around $70.

Just an example.  The 7.2V NiMH battery pack for a Canon 1D-MkII
is about $150.  However - I think most people can understand what I
was getting at.  The expense of replacing a single battery pack for
a camera is considerably less than an entire stack for a hybrid car.
I still contend that the average owner isn't going to need that full
replacement down the line.  Those who do will likely have options
other than a complete, brand-new stack that will get it in working
condition for several years.

The Honda Insight battery is rather interesting.  I know the car is
rather small, but still an interesting battery design.  Essentially 120
D-cells selected specifically because it was a standard size with the
likelihood of multiple sources down the line.

> Perhaps comparing an aluminum I4 to a cast iron big block V8. There is a
> great variety of V8 engines out there covering a huge weight range and
> huge displacement range. There are also very nice aluminum V6s that are
> more appropriate in a car.

I was comparing an aluminum block I4 (typically around 200 lbs) to
an aluminum block V8 (400-450 lbs).

> An aluminum V6 with variable displacement is probably not more than 50#
> heavier than the engine and electric motor in a hybrid.

So far I haven't heard of any.  I thought it was mostly used in the
large V8s in GM SUVs.  I thought that Cadillac's early attempts were
massively unreliable.
Steve - 15 Jan 2007 23:27 GMT
> What you don't seem to get is the fact that the life of the battery pack
> *IS* the life of the car. If the pack lasts 10 years that is the life of
[quoted text clipped - 3 lines]
> With the conventional economy car you simply don't have this
> catastrophic end of life scenario.

Well, you actually DO. Most economy cars are pretty much Bic razors with
wheels. Reliable as hell for the first 100k miles, then not worth fixing
when the typical Asian car "massive organ failure" starts happening
somewhere in the mid-100k miles range. Sure, there are isolated cases of
Civics and Tercels going 200k or more, but the vast majority get turned
to beer cans long before then. Not true of larger/higher end cars.
Seriously, when was the last time YOU saw a Civic (or similar car) more
than 5 years old on the road? I see a 10-year-old Neon in the office
parking lot every day, but man does it ever stick out, because that's
the only time I ever see a tiny car that old!

If someone would ever bother to produce an economy car with the
ruggedness and longevity of a high-end car, there probably would be a
market for it. But right now, "economy car" is so closely correlated
with "minimal intial purchase price" that they simply aren't built to last.
Pete C. - 16 Jan 2007 00:10 GMT
> > What you don't seem to get is the fact that the life of the battery pack
> > *IS* the life of the car. If the pack lasts 10 years that is the life of
[quoted text clipped - 19 lines]
> market for it. But right now, "economy car" is so closely correlated
> with "minimal intial purchase price" that they simply aren't built to last.

If you rely on a dealer for service and install new parts, sure the
uneconomical point could be in the 100k mile range. If you have a decent
independent mechanic or do the work yourself, and use salvage parts from
the junk yard / recycler that uneconomical to maintain point will be a
lot further out.
 
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