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`Electric Automobile
`
`Hybrid Electric Vehicles
`
`Ernest Henry Wakefield, Ph.D.
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`Page 1 of 26
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`FORD EXHIBIT 1019
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`INTERNATIONAL ®
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` Library of Congress Cataloging—in-Publication Data
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`Wakefield, Ernest Henry, 1915—
`History of the electric automobile : hybrid electric vehicles / Ernest Henry
`Wakefield.
`p. cm.
`Includes bibliographical references and index.
`ISBN 0—7680—0125—0
`1. Automobiles, Electric——History. 2. Hybrid Electric Cars——History. I. Title.
`TL220.W343 1988
`629.22'93——DC21
`
`98—3420CIP
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`Vehicles pictured on cover (clockwise from upper left): Esoro H301 Family hybrid electric car; General Motors
`1987 Sunraycer; American fuel cell bus; Woods’ dual-powered 14~hp coupe of 1917.
`
`Copyright © 1998 Ernest H. Wakefield
`
`ISBN 0—7680—0125—0
`
`All rights reserved. Printed in the United States of America.
`
`Permission to photocopy for internal or personal use, or the internal or personal use of specific clients, is
`granted by SAE for libraries and other users registered with the Copyright Clearance Center (CCC), provided
`that the base fee of $.50 per page is paid directly to CCC, 222 Rosewood Dr, Danvers, MA 01923. Special
`requests should be addressed to the SAE Publications Group. 0—7680—0125—0/98 $.50.
`.
`;
`
`Society of Automotive Engineers
`400 Commonwealth Drive
`Warrendale, PA 15096—0001 USA.
`Phone: (724) 776—4841
`Fax: (724) 776—5760
`Email: publications @ sae.org
`Page 2 of 26
`http://www.sae.org
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`FORD EXHIBIT 1019
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`
`Other SAE books of interest on this topic:
`
`Alternative Cars in the 21St Century
`Robert Q. Riley
`(Order No. R—139)
`
`Building the E-motive Industry
`Essays and Conversations About Strategies for Creating an Electric Vehicle Industry
`S cott A. Cronk
`
`(Order No. R—148)
`
`Electric Vehicles
`Driving Towards Commercialization
`Edited by Ron Sims and Bradford Bates
`(Order No. PT—S8)
`
`For information on these or other related books, contact:
`2'- ficiety‘of Automotive Engineers Inc.
`400 Commonwealth Drive
`Warrendale, PA 15096-0001U.S.A.
`Page 3 of 26
`Phone: (724) 7764970
`Fax: (724) 7760796
`E—mail: publications @ sae.o'rg
`
`FORD EXHIBIT 1019
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`
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`Table of Contents
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`Foreword ............................................................................................................................. XV
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`Preface ............................................................................................................................... xvii
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`Acknowledgments ............................................................................................................ xix
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`Chapter 1 Background for the Hybrid Electric Horseless Carriage ...................... 1
`Establishing the Principles of Electricity .......................................................... 1
`Development of the Bicycle and the Tricycle .................................................. 3
`Tires and Batteries ........................................................................................... 4
`The Lead—Acid Battery and the First Electric Cars ........................................ 6
`Generation and Distribution of Electricity ........................................................ 7
`Early Transportation Problems ......................................................................... 9
`The Modern Approach .................................................................................. 13
`Notes .............................................................................................................. 13
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`References ..................................................................................................... 14
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`Chapter 2
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`The History of the Petro-Electric Vehicle .............................................. 17
`Competition for Nascent Power Systems ...................................................... 18
`The First Petro—Electric Vehicle .................................................................... 19
`The Belgian and the French Petro—Electric Cars ........................................... 21
`Other European Hybrid Electric Vehicles ...................................................... 23
`The Lohner—Porsche Hybrid Electric Vehicle ................................................ 24
`The Auto—Mixte Petro—Electric Car .............................................................. 25
`
`The Mercedes—Mixte Petro—Electric Car ...................................................... 27
`The Krieger Petro—Electric Car ..................................................................... 27
`Early American Petro—Electric Vehicles ........................................................ 27
`The Baker and the Woods Petro—Electric Vehicles ....................................... 29
`The Jeffery Petro—Electric Automobile .......................................................... 32
`Notes .............................................................................................................. 32
`Page 4 of 26
`FORD EXHIBIT 1019
`References ..................................................................................................... 33
`1
`5‘
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`History ofthe Electric Automobile: Hybrid Electric Vehicles
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`Recent Petro- and Natural Gas-Electric Car Systems .......................... 35
`The Minicars Petro—Electric Drive Train ....................................................... 36
`Wouk’s Petro—Electric Automobile ................................................................ 36
`The Linear Alpha Petro~Electric Van ............................................................ 39
`The General Motors Petro—Electric Vehicle ................................................. 40
`Trailer Petro—Electric Automobiles ............................................................... 42
`The McKee Engineering Company Range Extender ................................... 43
`Aronson’s Petro—Electric Silver Volt ............................................................ 45
`The Brobeck Petro—Electric Automobile ...................................................... 46
`Briggs & Strratton—Marathon Petro—Electric Automobile ............................. 48
`The General Electric/US. Department of Energy
`Petro—Electric Automobile .......................................................................... 49
`The Mclnnis Petro—Electric Car ................................................................... 52
`The 1993 Ford Hybrid Electric Vehicle (HEV) Challenge ........................... 52
`The University ofIllinois Entry ..................................................................... 55
`The Natural Gas—Electric Multi—Powered Automobile ................................. 60
`Note l—Additional Comments ..................................................................... 61
`Note 2——A Petro—Electric Bus ..................................................................... 64
`Note 3———The Briggs & Stratton Hybrid Electric Vehicle ............................. 65
`References .................................................................................................... 67
`
`Modern International Petro—Electric Automobiles .............................. 69
`British Petro—Electric Automobiles ............................................................... 69
`Canadian Petro—Electric Automobiles ........................................................... 70
`French Petro—Electric Vehicles ..................................................................... 72
`German Petro—Electric Automobiles ............................................................. 72
`A Robert Bosch Hybrid Electric Automobile ............................................... 72
`The Volkswagen—Electricité Neuchateloise S.A. System ............................. 74
`Opel Twin Petro—Assist Automobile ............................................................. 76
`European Ford Petro—Electn'c Car ................................................................ 78
`The Volkswagen Petro—Electric CaI——The Chico ....................................... 80
`Japanese Petro—Electric Vehicles .................................................................. 81
`Swedish Petro—Electric Automobiles ............................................................ 81
`Petra-Electric Cars of the Former Soviet Union .......................................... 85
`A Swiss Petro—Electric Motorcar ................................................................. 85
`Note l——Miss Purity Participants ................................................................ 88
`Note 2-‘The Otto Engine-............................................................................ 88
`References .................................................................................................... 90
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`Chapter 4
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`Chapter 3
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`Chapter 5 :age 5 of 26
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`Experiments with Non-Petro-Electric Vehicles ..................................... 93
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`Carli’s Electric—Spring Tricycle ...................................................................... 94
`Battery-Battery Automobiles ...........................
`........................................... 97
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`Table of Contents
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`Fuel Cell—B attery Powered Automobiles ....................................................... 98
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`The Family of Fuel Cells .............................................................................. 102
`Aluminum-Air Fuel Cell with Lead—Acid Battery Van ................................ 104
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`Noncontact Inductively Charged Moving Vehicles ...................................... 107
`Summary ...................................................................................................... 110
`Note l—The General Motors Fuel Cell—Battery Powered Van .................. 110
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`Note 2—The Canadian Hydrogen-Fueled Bus ............................................ 111
`Note 3—Mirai I ......................................................................................... 114
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`Note 4—The Chrysler Fuel Cell Powered Vehicle ...................................... 114
`References ................................................................................................... 116
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`The Flywheel-Electric Vehicle ................................................................ 119
`Flywheel—Institut fur Kraftfahrwesen ....................................................... 121
`Flywheel Work at Other Sites ...................................................................... 123
`The AIResearch Manufacturing Company Flywheel—Electric Vehicle ....... 125
`American Flywheel Systems ....................................................................... 128
`Continuing Work on Flywheels for Transportation ....................................... 129
`Summary Articles on Flywheel Energy Storage .......................................... 134
`Note 1—Another Flywheel System ............................................................. 135
`Note 2—Gyroscopic Effects ....................................................................... 135
`Note 3—The Parry People Mover .............................................................. 137
`Note 4—Flywheel Energy Storage in Japan ................................................ 139
`References ................................................................................................... 139
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`Chapter 6
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`Chapter 7
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`Gas Turbine-Electric Motorcars ............................................................ 141
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`History of the Gas Turbine ........................................................................... 141
`Chrysler and Volvo Motorcars ..................................................................... 142
`The Chrysler Turbine—Flywheel Car—The Patriot ..................................... 143
`The Volvo Gas Turbine Electric Car ............................................................ 144
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`The Rosen Motors Turbine~Flywheel Power Train for Automobiles ........... 150
`Note l—The Whittle Jet Engine .................................................................. 152
`Note 2—Chrysler Gas Turbine Cars ........................................................... 152
`References ................................................................................................... 153
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`Chapter 8
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`The Origin, Operation, and Applications of the Stirling Engine ....... 155
`Robert Stirling .............................................................................................. 155
`Subsequent Development of the Stirling Engine .......................................... 157
`Eighty Years Later ....................................................................................... 158
`Sterling Thermal Motors’ Solar Power Conversion ..................................... 164
`General Motors Stir-Lec I .,.......................................................................... 167
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`Stephenson’s Conclusions on Hybrid Electric Vehicles ............................... 168
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`FORD EXHIBIT 1019
`Notes ............................................................................................................ 170
`References ................................................................ a ................................... 172
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`History of the Electric Automobile: Hybrid Electric Vehicles
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`Chapter 9
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`Chapter 10
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`On the Road to an Emissionless Automobile ...................................... 175
`Competing with Gasoline-Powered Cars ..................................................... 175
`Opening the Window for Emissionless Cars ................................................ 177
`The Influence of Hans Tholstrup ................................................................. 179
`Robert Stempel Becomes Chairman and CEO of General Motors ............. 181
`Notes ............................................................................................................ 182
`References ................................................................................................... 182
`
`Photovoltaic Cells and Their Status ...................................................... 185
`History of the Photovoltaic Cell ................................................................... 186
`Gallium—Arsenide Solar Cells ....................................................................... 190
`Note l——More on Gallium—Arsenide Solar Cells ......................................... 190
`Note 2mEconomic Considerations .............................................................. 191
`Note 3—-Solar Cells in Boats ....................................................................... 191
`Note 4—The Wave Theory of Light ........................................................... 191
`References ................................................................................................... 192
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`Chapter 11
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`Sun Areas of the World and the Atmosphere ....................................... 195
`Geographic Considerations in Solar—Electric Vehicle Design ....................... 195
`Solar—Assist and Solar—Dominant Motorcars ............................................... 200
`Notes ............................................................................................................ 202
`References ................................................................................................... 202
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`Chapter 12
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`History of Solar-Electric Vehicles .......................................................... 203
`Background .................................................................................................. 203
`Freeman’s British Solar—Electric Vehicle ..................................................... 205
`The General Motors Sunraycer .................................................................. 210
`The MIT Solarmobile Solectria IV.............................................................. 211
`Ford Motor Company of Australia Sunchaser ............................................ 213
`Electrical and Mechanical Features of a Solarmobile .................................. 214
`American Solar—Assist Electric Motorcars .................................................. 217
`1996 Solar—Battery Ford Festiva, Designed for Saminco Inc. .................... 218
`Japenese Solar—Assist Automobiles ............................................................. 218
`References ................................................................................................... 220
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`Chapter 13
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`The Trans-Australian World Solar Challenge Race—1987 ............... 223
`Background .................................................................................................. 223
`The Race Begins ......................................................................................... 227
`Entries and Results of the 1987 Australian World Solar
`Challenge Race .......................................................................................... 235
`Comments from Winning Team Members ................................................... 237
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`FORD EXHIBIT 1019
`Performance of Cars ................................................................................... 238
`Other Vehicles ................................................
`.......................................... 246
`References ................................................................................................... 249
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`Table of Contents
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`Chapter 14 American Tour de Sol—1992 ................................................................... 251
`Background .................................................................................................. 251
`The American Tour de Sol Race ................................................................ 254
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`Vehicle Range Increases with Time ............................................................ 262
`References ................................................................................................... 269
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`Chapter 15 Solar Race Car Design: The Late Twentieth Century ....................... 271
`Changes in Design Standards ...................................................................... 271
`Australian World Solar Challenge Race—1993 ........................................... 276
`The Honda Dream ....................................................................................... 278
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`Ingenieurschule Biel Spirit ofBiel III ......................................................... 281
`The Motor—Wheel of the Swiss Spirit of Biel III ........................................ 282
`A Commercial Market for Solar—Powered Cars ......................................... 287
`
`Starting a Solarrnobile Business—Traits of the Entrepreneur ..................... 289
`The Sports Solarrnobile ................................................................................ 290
`Influence of Sunraycer, Spirit of Biel III, and Dream
`on DesignToday ............... 291
`References ..... L ............................................................................................. 294
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`Chapter 16 Final Thoughts and Coda ......................................................................... 297
`The Race for an Emissionless Vehicle ......................................................... 297
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`Reviewing the Past to Better Understand the Future .................................. 300
`Conclusion .................................................................................................... 302
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`References ................................................................................................... 304
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`Appendix A The Hughes Inductive Charger System ............................................... 305
`How Magne—Charge Works ........................................................................ 308
`Electrical Performance ................................................................................ 310
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`Availability and Price ................................................................................... 310
`References ................................................................................................... 312
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`Appendix B Ultracapacitors for Electric Automobiles ............................................. 313
`References ................................................................................................... 316
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`Index .................................................................................................................................. 317
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`About the Author ............................................................................................................. 331
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`Page 8 of 26
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`FORD EXHIBIT 1019
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`CHAPTER 2
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`The History of the
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`Petro—Electric Vehicle
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`For more than four generations, experimenters have assembled electric vehicles bearing a
`supplemental energy source for the enhancement of range. Historically, this extra energy has
`been supplied by springs, flywheels, fuel cells, petroleum or natural gas-powered engines, and,
`most recently, solar cells.
`In a recent study, the US. Department of Energy identified 81
`worldwide attempts in which one or two hybrid electric vehicles were made to yield extra
`range.1 Therefore, we may conclude that range limitation has long been identified. T0 over-
`come this deficiency, two common approaches have been exploited: 1) to develop batteries
`with greater specific energy, and 2) to proceed with the hybrid principle.
`
`The questions of batteries are discussed in Chapters 10 and 11 of History of the Electric
`Automobile: Battery—Only Powered Cars2 and will receive little treatment here. Figure 2.1
`illustrates two types of hybrid electric vehicles. The drawing to the left is a series type of
`hybrid electric vehicle. It contains an engine—generator, batteries, and an electric motor, the
`torque from which drives the wheels. Energy from the fuel is continually being transformed
`and stored as chemical energy and potential electric energy in the batteries. In contrast, with
`the parallel hybrid electric system, the petro—engine may uniquely drive the wheels, or together
`or separately the electric motor supplies torque to the wheels.
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` i Page 9 of 26
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`In general for both series and parallel hybrid electric vehicles, the supplemental energy source
`may be any of the five sources cited above. Years ago, I discussed the most recent, solar
`assist.3 Because series and parallel systems both have possible economic niches, if indeed
`Page 9 of 26
`FORD EXHIBIT 1019
`hybrid electric vehicles are ever Viable, both series and parallel types may be found in service.4
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`ENGINE
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`GENERATOR '
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`POWER CONDITIONER
`MOTOR
`CONTROL
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`TRANSMISSION
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` FUEL TANK
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`ONE-WAY CLUTCH
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`FUEL TANK
`ENGINE
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`MOTOR
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`CONTROL
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`TRANSMISSION
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`BATTERY PACK
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`BATTERY PACK
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`SERIES
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`PARALLEL
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`Figure 2.]. In a series hybrid electric car (left), the engine drives a generator charging
`a battery. In a parallel system (right), the engine may directly couple the wheels.
`(Briggs & Stratton, 14 August 1995)
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`Competition for Nascent Power Systems
`
`Only four years after Trouvé’s original electric vehicle, described in Chapter 1, the initial
`gasoline—powered vehicle was tested in 1885. While 55 years would elapse from the operation
`of Thomas Davenport’s electric motor shown in Ref. 2, the first to perform useful work,5
`until Trouve’s electric tricycle, the time span from N.A. Otto’s four—cycle internal combustion
`engine of 1867 and a vehicle so powered was only 18 years.
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`From 1890 until 1905, a period of approximately 15 years, electric vehicles, internal combus—
`tion powered automobiles, and steam cars were highly competitive in America. On the other
`hand, in Europe, internal combustion cars were preferred from the beginning for many rea—
`sons: 1) the well—built Roman roads linking cities already existed in many parts of western
`Page 10 of 26
`FORD EXHIBIT 1019
`Europe and thus range was important; 2) military—inspired highways were well maintained; 3) in
`contrast, roads linking American cities were largely unimproved and, with long periods of
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`The History of the Petra-Electric Vehicle
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`engines; 5) Edison, Tesla, and Westinghouse gave later—evolving America a leadership in elec—
`tric power, while Europe was more oriented to earlier developed steam power; 6) with a range
`sufficient for the small American cities of that time, the electric vehicle could flourish; and
`7) possibly, too, with less regulation always present in a frontier—inspired society, entrepreneur—
`ship could more readily prosper.
`
`Although an all electric vehicle could potentially displace only a small percentage of a petroleum—
`fueled personal vehicle market, it is presently perceived as occupying a restricted niche. On
`the other hand, the hybrid electric automobile is less subject to range limitation. With as little as
`20% of the petroleum fuel of an internal combustion automobile, a hybrid electric vehicle may
`be discerned as viable.6 The market is expected to make its own judgment. As the philoso-
`pher George Santayana wrote7:
`
`“Those who know not the past are condemned to repeat it.”
`
`Therefore, what does history relate about the petro—electric drive system, two sample vehicles
`of which were ordered by the US. Department of Energy under the 1976 Electric Vehicle
`Act, and the many petro-electric cars for which a purchase order was issued by the City of
`Los Angeles in 1992?
`
`The gasoline—electric car, currently referred to as the petro—electric vehicle, initially was an
`attempt to combine the high efficiency of the electric drive train with the remarkable energy
`storage of petroleum fuels. Presently, electric cars have a drive train efficiency of 90%,
`whereas a similar figure for the internal combustion automobile is probably 15%——a factor of
`nearly six in favor of electricity. As for fuel of both systems, the lead—acid battery in its storage
`of electric energy requires 1 kg (2.2 lb) for 125 Btu.a On the other hand, 1 kg (2.2 lb) of
`gasoline provides 45,300 Btu—a factor of 360 in favor of gasoline. When relative drive—train
`efficiencies are considered, there remains an enhancement factor of 70 to 80 in favor of
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`gasoline. That large number almost shouts the reason why internal combustion cars will be
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`here for many years. However, muting the above statement, and particularly in the last
`decade of the twentieth century, is the growing air pollution of urban areas largely as a result
`of the ubiquitous internal combustion vehicle. The petro—electric vehicle, the thought goes,
`could be petro-powered in country operation and electrically powered in urban regions, with
`the parallel type, hybrid electric automobile. If of series construction, the vehicle might have a
`low—polluting, constant—speed internal combustion engine driving a small generator that is con—
`tinually replenishing the battery. Power from the battery would supply the electric motor.
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`The First Petro—Electric Vehicle
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`Almost surely. the first petro—electric car was built by Justus B. Entz, chief engineer of the Electric
`Page 11 of 26
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`Storage Battery Company of Philadelphia. The date was 4 May 1897, as the chalkboard
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`History of the Electric Automobile: Hybrid Electric Vehicles
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`drawing in the Pope Manufacturing Company indicates in Figure 2.2. His concept was not the
`simple approach ofthe early European designers of an internal Combustion engine powering a
`generator which in turn charged a battery that drove the motor—a series type. As Hiram
`Percy Maxim, who early designed and built both electric and gasoline—powered automobiles,
`describes this vehicle:8
`
`Entz proposed a generator with a revolving field as well as a revolving armature. This
`(assembly) was made to act as a clutch. When the armature of this generator was short—
`circuited, its armature and revolving field became electrically locked together, and the
`engine drove the carriage through this locked clutch on what corresponds to high gear.
`When a grade was encountered, or for any other reason more driving torque was required,
`Entz eased off the short circuiting more or less, which permitted the clutch to slip. This
`slipping generated a current, and this current was fed to the BleCtriC motor, which was
`thereby enabled to help out the direct drive from the engine.
`After this explanation, Maxim, as did many modern designers, wondered why all this electric
`gear was required when a simple ‘gear box’ (the transmission) could obviate the above and
`yield the drive system of a modern electric car.
`In 1898, all was ready for testing the new car. Maxim, Entz, and a mechanic drove ‘slug—
`gishly,’ the former relates, from the Pope factory to Capitol Street in Hartford, Connecticut.
`While on the street, Maxim left the vehicle for some reason and his foot caught on a Wire to the
`ammeter. This breaking of the electrical circuit caused an electric arc to pierce the copper
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`FORD EXHIBIT 1019
`Page 12 of 26
`(Ref. 8, copyright 1937
`Figure 2.2. Entz’s blackboard masterpiece offhe petro—electric car.
`by Harper & Brothers; copyright renewed J964 by PercylMaxim Lee; reprinted by
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`The History of the Petra-Electric Vehicle
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`gasoline tank, and a stream of gasoline was ignited, burning the vehicle with the 7 gallons
`(26 liters) of contained gasoline. The Pope Manufacturing Company made no more petro—
`electric vehicles. However, Entz’s idea did not die, according to Maxim. The concept even—
`tually became the Owen Magnetic Car.
`
`The Belgian and the French Petro—Electrie Cars
`
`To implement the claimed advantages of the hybrid electric systems previously cited, both the
`Pieper establishment in Liege, Belgium, and the Vendovelli & Priestly Electric Carriage Com—
`pany of France announced petro—electric vehicles at the Paris Salon of 1899.9 In the Pieper
`vehicle, a small, air—cooled gasoline engine was forward and coupled to an electric motor
`powered by lead—acid batteries.10 (See Figure 2.3.) Initially, the gasoline engine was started
`by the electric motor (probably among the first electric starters). When the vehicle was
`standing or coasting, the engine charged the battery. In contrast, when a hill was encountered
`requiring power greater than the air—cooled engine could provide, as the carriage slowed,
`additional electrical power flowed to the motor from the battery which provided supplemen—
`tary torque to the rear wheels.
`In these early days, if the engine failed, and at this time all
`internal combustion engines were ‘cranky’ (a term used at the time), the reliable electric motor
`could be the power source to bring home the carriage!
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`Page 13 of 26
`Figure 2.3. The Pieper Stanhope.
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`(Ref. 9)
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`FORD EXHIBIT 1019
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`History ofthe Electric Automobile: Hybrid Electric Vehicles
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`The Pieper vehicle was of the parallel configuration. In contrast, the Vendovelli & Priestly
`carriage was of the series type and was three-wheeled. The two rear—wheels were each
`powered by a separate electric motor, the batteries being carried beneath the carriage to
`yield a range of 40 miles (64 km). For longer trips, a portable 308—lb (MO—kg) engine—
`generator was added, consisting of a 3/4—hp De Dion—Bouton engine coupled to a generator
`capable of supplying continuously 10 amps at 110 volts (1.1 kW of power) to the battery.
`The engine/generator, the article stated, was also capable of supplying power sufficient to
`illuminate 15 lO—candle (130—lumens) lamps, a phrasing used by the US. Army in purchase
`of its first electric vehicle in 1898 from the Woods Electric Vehicle Company of Chicago, as
`cited in Ref. 2.
`
`Particularly unique to the Vendovelli hansom, however, was the steering mechanism. Steering
`was effected by utilizing the reversibility of the differential gears. By acting on the latter, one
`wheel revolved faster than the other, and the vehicle would turn with a short radius; indeed, the
`hansom can be made to pivot on itself by an action associated with the steering wheel before
`the driver. For braking the hansom, placing the controller in the ofi‘ position also applies a
`friction—brake to a cast—iron pulley on the motor shaft. Figure 2.4 illustrates this French han—
`som. Figure 2.5 sketches the steering details.
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`Page 14 of 26
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`Figure 2.4. The Vendovelli & Priestley hansom.
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`FORD EXHIBIT 1019
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`
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`The History of the Petra-Electric Vehicle
`
`
`
`”hummus....
`
`Figure 2.5. Method of steering through the velocity of a variable wheel.
`(Scientific American Supplement. Ref. 1])
`
`Other European Hybrid Electric Vehicles
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`Because of the frequent impassability of American roads and the confinement of electric
`vehicles to the small cities of that time, all electrics had a better environment in which to thrive.
`
`This was not true in Europe where, for m