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DIY Plug-In Hybrid Pickup Truck

Hi everyone,

For a while, I've had this as my "back-burner" project. I'm trying to really get going on it now.

It's an Open Source, DIY, Plug-in Diesel/Electric Hybrid Pickup truck. That's really a mouthful, so I'm just calling it the "SuperTruck" project, until I can come up with a better name.

The entire concept is that it is a parallel hybrid, which you can charge from the wall, and it has a diesel engine that can run on diesel, bio-diesel, and possibly veggie oil. Either the engine OR forklift motor will be able to propel the vehicle. (Meaning that it will have a dedicated EV mode.) The driver can manually decide to run it on diesel, electric, or both depending on the driving situation.

The mechanicals are relatively simple. It uses a manual transmission (rather than a CVT or planetary gearing.)

In theory, this will be a project than any advanced grease monkey will be able to duplicate. I'm not much of a car guy, but I have learned quite a bit working on my electric motorcycle, electric car, and experimenting with running my car as a hybrid.

Here's a YouTube playlist of what I've got going so far.



For the latest on this project, please visit the page for it on my blog: http://300mpg.org/projects/supertruck/
I'll definately need help on this project, so please tell all your friends about it!

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54
bennelson (author) says: Jan 31, 2013. 6:28 AM
Anyone have a MANUAL steering box off a Chevy S10 or older Sonoma?
No, seriously, I'm having a hard time finding one. If anyone have one they can donate or sell at reasonable price, I would be very interested (Jan 31, 2013)
54
bennelson (author) says: Jan 23, 2013. 1:06 PM
Here's some related documents on the project - a drivetrain layout and some thoughts on the throttle

http://300mpg.org/wp-content/uploads/2013/01/PowerTrain_rough_Jan212013.png
http://300mpg.org/wp-content/uploads/2013/01/throttle_concept_Jan212014.pdf
26
liquidhandwash in reply to bennelsonJan 23, 2013. 7:11 PM
just a thought on your throttle control, I see what your trying to do, how about you connect both engine and electric motor to the gas pedal and have a three position switch,
diesel, electric, both
just my 2 cents
54
bennelson (author) in reply to liquidhandwashJan 24, 2013. 7:15 AM
The reason why I was thinking the hand throttle for the electric is so that the two systems can be controlled INDEPENDENTLY. For example, if I want to show off and really burn rubber, I might want to CRANK the electric and still want to shift through the gears on the diesel engine so that I get full power from each system.

The EMIS system does use the single accelerator approach, and then pulls data from the ODBII port (which my pre-1996 does NOT have) to a microprocessor, which then creates the throttle signal for the electric motor controller. However, that system is not a full parallel. You always need to have the gas engine running and the electric merely acts as a "boost". My system will be both a complete ICE and EV system in a single hybrid.
26
liquidhandwash in reply to bennelsonJan 24, 2013. 12:37 PM
ok thanks for explaining im not familiar with the EMIS system.
54
bennelson (author) in reply to liquidhandwashJan 24, 2013. 2:26 PM
For more on the EMIS, please see: http://www.go-ev.com/EMIS.html
My plan uses a similar mechanical connection, but will feature a manual transmission, and the ability to TURN OFF the engine and drive on just electric.

It's neat to see the EMIS as a commercial product, because it gives me confidence in my design, just knowing that something else similar is out there and working for people.
2
clay7185 says: Jan 24, 2013. 10:34 AM
Does that engine have a throttle position sensor because if it does they are generally 0-5k resistors so you could just tap into it to run your motor controller and just have a switch as previously mentioned for electric hybrid or diesel. Also as a method to keep your diesel from gelling in the winter if you have a 10 gallon tank add about 1/3 to1/2 a gallon of gasoline it thins it out so it wont gel.
54
bennelson (author) in reply to clay7185Jan 24, 2013. 12:25 PM
A friend of mine converted a Dodge Neon to an AC powered electric car. It had a 0-5Kohm in the throttle body, so we kept that and routed the signal to the motor controller. It worked pretty well.
54
bennelson (author) says: Jan 23, 2013. 1:06 PM
Here's some related documents on the project - a drivetrain layout and some thoughts on the throttle

http://300mpg.org/wp-content/uploads/2013/01/PowerTrain_rough_Jan212013.png
http://300mpg.org/wp-content/uploads/2013/01/throttle_concept_Jan212014.pdf
46
Jayefuu says: Jan 11, 2013. 1:48 AM
Good luck Ben! If anyone can do it, you can, your other projects are great.

As a suggested name, how about "Electruck" or "Electruc", a pun on truck and electric.

James
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