gas mileage

Sitting in a Connecticut warehouse, the very first Poulsen Hybrid looks like a standard Honda Civic with immobilizer boots attached to its rear wheels. It is, one would have to say, not the most visually elegant of solutions to the pressing problem of using electric power to extend the range of the internal-combustion automobile. But it's also both practical and affordable.

Ulrik Poulsen and his converted Honda Civic.

Ulrik Poulsen is a mechanical engineer and Danish immigrant whose Shelton, Connecticut-based Bridgeport Magnetics Group makes a range of transformers, power supplies, magnetic cores, audio cables and other products. One new product for Con Edison is an isolation transformer designed to prevent people from getting electric shocks from defective streetlights. But Poulsen is branching out with a bolt-on kit that, he says, can transform ordinary cars into a form of plug-in hybrid. And he's entered his invention as a contestant in the Progressive Auto X Prize, which carries a $10 million purse.

The concept is relatively simple: Two of the company's seven-horsepower (five kilowatt) disc-shaped DC electric motors are bolted onto the rear wheels of the host car, connected by cables to a controller, battery charger and 4.5-kilowatt-hour lithium-ion battery pack in the trunk. The system, adding approximately 200 pounds to the car and taking up 20 percent of trunk space, acts as range extender. The motors do not drive the car, but kick in to provide a power boost between 15 and 60 miles per hour. Regenerative braking helps keep the batteries charged.

There are several companies converting Priuses and other hybrids to plug-in status, but Poulsen may be the only contender starting with ordinary gasoline cars. For $10,000, for instance, HyMotion will turn your ordinary Prius into a 100-mpg plug-in with a five-kilowatt-hour battery pack.

Poulsen installation is not a do-it-yourself operation, but an authorized dealer can accomplish it in as little as four hours. If the system works as advertised, a 30-mile-per-gallon car will be raised to 55 mpg.

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President-elect Barack Obama went into the Motor City's lion's den last year, speaking before a sold-out audience convened by the Detroit Economic Club. He told the assembled business and political leaders not what they wanted to hear, but what they needed to hear.

"'For years," he said, "while foreign competitors were investing in more fuel-efficient technology for their vehicles, American automakers were spending their time investing in bigger, faster cars....Here in Detroit, three giants of American industry are hemorrhaging jobs and profits as foreign competitors answer the rising global demand for fuel-efficient cars....The need to drastically change our energy policy is no longer a debatable proposition. It is not a question of whether, but how; not a question of if, but when. For the sake of our security, our economy, our jobs and our planet, the age of oil must end in our time."

Obama then described a plan to subsidize 10 percent of the Big Three's retiree health care costs (as much as $7 billion) if the companies would invest half of that savings in fuel-efficiency research. His alternative idea was $3 billion over 10 years to remake auto plants for a new generation of clean cars.

Obama wants a million plug-in hybrids on the road by 2015, a plan that could be derailed by insufficient lithium-ion battery capacity by then. He has a 10-year, $150 billion renewable energy plan.

Felix Kramer of CalCars.org, an early and consistent voice for plug-in hybrids, thinks the Obama plan is achievable. "Scaling up to produce a million plug-in vehicles in six years is far less challenging than what auto industry achieved after Pearl Harbor, switching in a year from cars and trucks to tanks and planes," he said. "And supplying batteries for those vehicles is attainable, especially since we have good enough technology to get started now."

Kramer also likes Obama's plan to have half of all new federal new car purchases by 2012 all-electric or plug-in. "That firm commitment to purchase 30,000 or more vehicles annually will be welcome to carmakers gearing up to produce plug-ins. It won't be hard to deliver," he said.

All well and good. But none of the proposals Obama has put on the table so far, by themselves, will turn around the increasingly dire situation for American automakers, which have indeed let foreign companies take the lead in fuel efficiency. The automakers need immediate and concentrated help, and they need clear direction. It's hard to see how a GM/Chrysler merger--bringing together two companies with SUV-heavy product lines--is a clear answer.

It's a cliche to say that Obama has a lot on his plate. But he can't defer action on the auto industry for long. He clearly understands the issues, and the imperatives of a quick turnaround. The Senator from Illinois is proving adept at getting his transition team in place. Let's hope that putting the ailing automakers on a green path is a day one priority.

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Wouldn't it be great if you could buy a device on the Internet for, I don't know, $200, bolt it onto your car and enjoy an instant reduction in emissions and an increase in fuel economy?

Claims like that are as old as the hills. We've all heard about the 100-miles-per-gallon carburetor that "they" don't want you to have, and the scientist whose invention was mysteriously suppressed just as he was about to bring incredibly cheap people's power to the world (think Nikola Tesla).

The Blade: Looks good, doesn't it?

It's inevitable that when fuel prices zoomed up, these devices would see a revival. (Yes, I know gas has come down, but is anyone really happy with $3 a gallon?)

Free lunches are hard to come by, however. Popular Mechanics tested a bunch of "fuel savers" back in 2005 and concluded that absolutely none of them worked. One even started a fire. These devices use miracle magnets, vortex generators, ionizers and water injection. But the only thing they reduced, PM said, was the cash in your wallet.

And this brings us to the latest device, The Blade, which bolts on to the exhaust pipe. It's kind of cool looking in a retro way. Remember those chrome exhaust tips people put on their cars to create a fake hot rod? I've only seen pictures on the website, and I have no idea if the Brazil-sourced Blade actually works. But, given the history, I think caution might be in order.

Don't worry, though, because actress Laura Dern says it works. "Having a Blade on my hybrid car allows me to continue driving with the satisfaction that I am lowering my carbon footprint and burning less fuel," she says.

The Blade is definitely more credible than most. The company paid for independent testing by the respected Automotive Testing and Development Services (ATDS) in Canada. On a 2004 Honda Civic, the Blade allegedly achieved a 57 percent reduction in hydrocarbons, 14 percent in carbon monoxide, 34 percent in nitrogen oxides and six percent in carbon dioxide (the main global warming gas). And on the highway, the numbers show it achieving a five percent fuel economy improvement.

ATDS Vice President Lin Farmer, who conducted the tests, said the Blade "seemed to be doing something on the positive side." He pointed out, however, that the 2004 Civic is a very low-emission car (the numbers for emissions of hydrocarbons, for instance, ranged from 0.0010 without the Blade, to 0.0004 with it).

"It's possible that some of the large improvements in gases are due to test-to-test variability and the fact that we were working with such small numbers," Farmer said. He added, however, that the Blade "performed better than other devices we tested." And the fuel economy numbers impressed him.

William J. O'Brien founded parent company Sabertec in 2005, after he came across the Blade on a visit to Brazil in his role as a venture capitalist. He's a great talker, and I can't pretend to understand everything he said. Luckily, there's a You Tube video that lets you judge for yourself. Here's some of what he said to me when I asked him how a device bolted on to the tailpipe can increase fuel economy. It's unfortunately somewhat paraphrased, because he talks fast:

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You might think that all the emphasis on clean and green cars in recent years -- and all the talk about people finally giving up their SUVs -- would have an effect on overall fuel economy. And you'd be right!

A new Environmental Protection Agency report concludes that the average "light duty" vehicle (cars and light trucks) got 20.8 miles per gallon in model year 2008. That's a small but heartening increase over the 20.6 mpg they got in 2007.

SUVs are going begging.

What's more, the EPA says that its study of sales data shows that subcompacts, compacts and midsized cars are the only classes meeting projections. Big gas-guzzling SUVs and pickups are down as much as 25 percent. And -- can this be the United States of America? -- the four-cylinder engine has gained ground over the six and V-8.

The EPA thinks its projections are too conservative, and that the actual increase in mileage is even more.

For those of us who had reluctantly concluded that SUVs were part of America's "sacred way of life," this is very good news. One wishes the improvements were bigger, but this is an incremental shift. The last time we saw it was from 1975 (after the Arab oil embargo) through the early 1980s. Remember Ronald Reagan removing the solar panels from the White House? That was also around the time that gas prices plummeted, and the country went to sleep on fuel economy.

The EPA actually seems passionate about reducing our fossil fuel intake even further. "Fuel economy is directly related to energy security," it says, "because light-duty vehicles account for approximately 40 percent of all U.S. oil consumption, and much of this oil is imported."

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The original Honda Insight, which broke the fuel economy barrier with 70 miles per gallon on the highway, certainly made a splash when it appeared on American roads back in 1999.

Although the Insight was the first hybrid for sale in the U.S., beating out the Toyota Prius, its one-liter engine, limited seating, relatively rough ride and bare-bones accommodations kept it a niche vehicle. The aluminum-bodied car was super-light, less than 2,000 pounds, but the weight advantage also made is susceptible to crosswinds. I remember driving one over a bridge and fighting the wheel to keep it in line. I liked it, though.

Honda's Insight concept car: a Prius fighter.

But now the Honda Insight is back as an approximately $18,000 five-passenger hatchback Prius fighter, and it's much better looking this time (sharing styling with the company's sleek FCX Clarity hydrogen fuel-cell car). The platform is all new for Honda, with the battery pack and controller safely tucked away below the cargo area. As with the earlier Insight and Civic Hybrid, the new generation of the Integrated Motor Assist (IMA) system runs mainly on the gas engine and uses the electric motor as a booster.

Honda has huge ambitions for new Insight sales, anticipating a not-impossible 100,000 a year in North America (half of the worldwide sales). This carmaker has some clean car bragging rights. It introduced the first low-emission gasoline vehicles, the first hybrid on the U.S. market and the world's first EPA-certified hydrogen fuel-cell vehicle.

Honda spokesman Chris Naughton says the new Insight will be at the Paris Auto Show, which starts October 4, though there's no guarantee more information will be forthcoming even then. "There's not much information out there, and much of what's being said is speculation," Naughton says. "Though it could be considered sound speculation if you report that the IMA system will have an evolutionary design."

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General Motors has some real clunkers for which it waves a green flag. Take the new $71,685 Cadillac Escalade Hybrid, which goes on sale this month. It costs $3,600 more than a standard Escalade, and achieves fuel economy of...20 mpg in town and 21 on the highway. Sure, the conventional Escalade is much worse at 12 and 15 mpg, but even as an innovative dual-mode hybrid, the Sierra Club is not going to be celebrating its release.

The all-new Cruze: 40 mpg?

GM should see waving flags in its sales numbers. The Escalade, for instance, was down more than 40 percent from July 2007 to July 2008. Nobody wants big SUVs.

But GM has some models that do deserve attention, such as the Cobalt Xtra Fuel Economy (XFE). For 2009, that one gets a very impressive 37 highway mpg (one mpg more than in 2008), a feat it achieves via variable valve timing, a new and taller final drive and trick tires with low rolling resistance.

The Cobalt is kind of plain-jane, but it's got bragging rights. When it was introduced last year, the XFE was six percent of Cobalt sales; now it's 15 percent. Through July, the 2008 Cobalt was a whopping 29 percent of total Chevrolet sales. The Cobalt line is only around through the 2010 model year, however, and will be replaced by the all-new Cruze (which rides on GM's compact Delta platform).

Initial reports have said the Cruze, built in Lordstown, Ohio and around the world, will get more than 40 mpg, but there's also news that the car will be larger than the Cobalt -- a danger sign.

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I don't really understand General Motors. The company is totally on the ropes, reporting a three-month loss of $15.5 billion in early August, with North American sales down 20 percent. Some 74,000 workers could lose their jobs in a new round of buyouts and early retirements. And more factories making big SUVs and trucks will close.

The Tahoe XFE: only modest fuel-efficiency gains.

We're still waiting for competitive small cars that would get people excited about going into a GM showroom. Meanwhile, the company's strategy is...to make minuscule improvements to its big Silverados, Sierras, Tahoes and Yukons and paint them PR green.

The new Xtra Fuel Economy (XFE) models (all with two-wheel-drive and the 5.3-liter V-8 engine), deliver a five percent improvement in highway mileage and seven percent in city driving! Wow! A combination of weight loss, aerodynamics and mechanical improvements gets them to 15 city and 21 highway! Standard big boys are at 14/20, so if you do much highway driving you'll hardly notice an improvement.

The same basic problem exists with GM's big hybrids. The '06 Chevy Silverado Hybrid, for instance, delivers 16/19 mpg. Not exactly impressive, and again hardly better than the standard (and cheaper) truck. For '09, GM will put its sophisticated dual-mode hybrid system in the Silverado, for a claimed 25 percent overall fuel economy improvement. But it's still a gas guzzler.

Guess what? GM trotted out its $50,000 dual-mode Yukon and Tahoe hybrids (21 city/22 highway, comparable to a standard four-cylinder Toyota Camry), and sales have been, well, slow. Instead of the projected 10,000 to 15,000 per year, GM has been selling more like 500 a month.

Here's the problem: They're too big! People don't want big cars and trucks anymore! GM argues that it can have more impact on the environment by improving the performance of the big vehicles that "people want to buy" than it can making small, fuel-efficient cars. But that argument is threadbare today.

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Stranded in the Minneapolis airport as hailstones the size of quarters pounded the tarmac, I turned to the local Star Tribune. Responding to an article entitled "Is This the End of the SUV?" a letter writer noted that 76 percent of Americans still drive to work alone, mostly in huge, off-road vehicles.

It's the way of things, the writer added: "When supply and demand go through their natural fall and gas seems cheap again, people will buy big cars."

Today's oil troubles are unlikely to fade away like the 1970s Arab oil embargo.

The letter writer has history on his side, but I think he -- and the many Americans who agree with him -- are wrong this time. The Arab oil embargo and the gas lines it engendered did indeed give small cars a great ride for a few years in the 1970s. (At the height of the crisis, by the way, gas was selling for $1.20 a gallon, and oil was $11 a barrel.) When that artificial shortage ended, the big cars were soon back in the showrooms, followed soon after by the first popular SUVs.

But that's unlikely to happen again. The fundamentals are entirely different now. Americans are finally driving less. Demand will likely drop in 2008, a milestone we haven't seen in 17 years. At the same time, more than half the new car registrations are for passenger vehicles, not trucks. The death of the SUV is upon us.

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