Think Again: Crafting a Plug-In Hybrid Is Far More Complex Than You Imagined

It’s significantly more challenging compared to building an efficient electric vehicle. Therefore, if you believe plug-in hybrid vehicles offer a simple solution, reconsider your stance.

Just make plug-in hybrids It's clear. Straightforward, even. It's the solution. By reading numerous forums, social media posts, and comments, you will likely come across this realization. The automotive industry appears convinced. From Ram to Chevy to Nissan, everyone is jumping on board with this trend.

The major challenge lies in developing a plug-in hybrid vehicle. It’s more complex than producing an excellent electric car. Those believing they can easily create a top-notch PHEV are mistaken.

The problem lies in simplicity versus complexity. If your aim was to design a car, you wouldn’t end up with anything as intricately complex as one needing a gas engine, electric motors, a sizable battery for independent operation, a charging mechanism, a gearbox, along with all the sophisticated software and adjustments needed to seamlessly integrate these components.

It’s not surprising that many end up having more of a crunchy peanut butter texture.

Just ask Consumer Reports The typical Plug-in Hybrid Electric Vehicle (PHEV) experienced 70% more issues compared to regular vehicles. standard gasoline vehicle in its most recent reliability survey That’s a poorer performance compared to electric vehicles, which still experience 42% more problems overall than gasoline-powered ones. However, this represents an impressive enhancement from last year when plug-in hybrids reported having 146% more issues than both conventional gas and hybrid models.

While the BMW X5, Kia Sportage, and Lexus NX PHEVs exhibit average reliability, their conventional counterparts are more dependable, Consumer Reports said. For more proof, check out the Mazda CX-90 that I'm behind the wheel of this week It’s an elegantly crafted SUV from a brand known for consistent dependability. However, this model is entirely new for the 2024 year.

According to the report, the Mazda CX-90 PHEV stands out as the least dependable three-row SUV due to problems related to the hybrid battery, electric components, and climate control systems. The publication also noted that it isn’t unexpected for this model, which features an exclusive engine, plug-in hybrid system, and rear-wheel-drive configuration, to be entirely engineered anew.

A contributing factor to this problem is that new products often exhibit lower reliability compared to well-established designs, which is a common observation that also sheds light on numerous electric vehicle concerns. However, plug-in hybrid electric vehicles compound this issue further due to their increased complexity.

Now, Mazda has resolved numerous problems with the CX-90 through updates and service bulletins. And the model I'm operating seems much more refined compared to initial feedback on earlier versions. Still, this instance provides valuable insight.

It's extremely challenging to nail this technology on your initial attempt. Unlike extended-range electric vehicles (EREVs) , PHEVs do not have enough all-electric oomph to fully disconnect their engines from the wheels. Doing so streamlines design, as you don't have to worry about blending two dissonant power sources, or figuring out the handover between them. ( EREVs face their own set of challenges, as Kevin Williams details in his comprehensive explanation about the Ram 1500 Ramcharger’s battery. )

PHEVs do have to blend their powertrains and braking systems, like a conventional hybrid. Unlike a hybrid, though, PHEVs need enough power to run for significant mileage with the engine off, and need onboard chargers to convert external AC energy into the DC power a battery needs.

This implies that you require all the intricate components of an electric vehicle along with all the complex parts of an internal combustion engine. Enhancement occurs solely through adding elements. Therefore, although an EV might become easier to manufacture after overcoming initial challenges, plug-in hybrid electric vehicles will consistently remain more difficult to construct and integrate compared to conventional gasoline-powered automobiles.

This helps explain that while hybrids have achieved near cost parity with traditional gas-only engines, PHEVs remain far more expensive. This CX-90 I'm driving starts around $12,000 higher than the gas version, and only $7,500 of that can be offset via tax credits, and only if you lease it.

This is not unusual. In July, the typical PHEV had a price tag of slightly less than $63,000. according to Business Insider . That's over $14,000 higher than the average transaction price of a new vehicle overall that month, $48,401 per Kelley Blue Book That's anticipated. What might astonish you is that it was approximately $4,400 more than the mean selling price for a fully electric vehicle during the same period.

This stems from their complexity. Plug-in hybrid electric vehicles (PHEVs) are more difficult to manufacture and come with lower overall reliability, which increases costs for warranties as well. Additionally, they present significant challenges when it comes to calibration and adjustment.

PHEVs need to manage the shift between the consistent, linear power delivery of their electric motors and the less predictable torque output of their internal combustion engines. This transition should occur almost instantly, regardless of speed, as drivers continuously modulate the gas pedal.

They need to swiftly cut off power to the internal combustion engine to conserve fuel and rapidly restart it once the torque requirement surpasses what the electric motors can provide. Additionally, they have to maintain the engine within its optimal performance zone without allowing it to run steadily at an annoying constant speed, as this is not well-received by consumers. This presents quite a challenge.

Many companies have figured out how to handle it. Plug-in hybrids I've sampled from Toyota and the Hyundai Motor Group, which includes Kia, are great. The Chevy Volt It was delightful. The BMW system particularly stood out during my test drive of the X5 PHEV. Some had initial difficulties but managed to find solutions. Early versions from Volvo were clunky and frustrating, yet their recent advancements have improved significantly. Initially, Mazda’s CX-90 and CX-70 faced challenges as well; however, they now operate much more smoothly.

However, many have not yet bridged this gap. Stellantis produces numerous plug-in hybrid electric vehicles (PHEVs), with varying levels of performance; some models run smoothly, whereas others do not. A number of these vehicles face reliability problems. Although General Motors excelled with the first generation of the Volt, the subsequent model, introduced ten years later, has shown signs of being outdated. GM recently announced last year that it was reinvesting in PHEVs. We'll find out if the expertise needed to create quality products endures through that period.

Audi has also achieved some success, but Volkswagen's push toward PHEVs The effectiveness remains unverified. Subaru’s plug-in hybrid Crosstrek also failed, featuring an underwhelming electric power system that frequently needed assistance from the gasoline engine.

The upcoming hybrid variants of Subaru’s Forester and Crosstrek will be standard hybrids lacking a plug-in option. Although Ford’s Plug-In Hybrid Electric Vehicles (PHEVs) might offer superior performance, it's difficult to definitively state this. Despite the significant number of Escape Hybrids, Mavericks, and F-150 Hybrids that the company has sold, its PHEV offerings haven’t fared as well in the market.

The Escape Plug-in Hybrid performed reasonably well, whereas the C-MAX PHEV was primarily introduced as a compliance vehicle. Although the brand heavily promoted the plug-in hybrid variants of the Ford Explorer and Lincoln Aviator upon their release, these models were eventually phased out without much fanfare. issues with their quality (which did not exclusively affect the hybrid versions) .

This does not imply that PHEVs are an inferior solution or destined for failure.

Given my limited Level 1 slow charging capabilities at home and the fact that I take more than the average number of road trips, a Plug-in Hybrid Electric Vehicle (PHEV) could be ideal for me.

Even so, I observe numerous individuals behaving as though these represent an effortless fix. Let me clarify this misconception once and for all. They do serve as solutions; indeed, essential ones that will be required. However, if your aim is to develop an outstanding Plug-in Hybrid Electric Vehicle (PHEV), it demands far greater effort compared to crafting a top-notch Battery Electric Vehicle (EV).

Those who place large bets on them without waiting for the issues to be resolved will face a lengthy and difficult journey.

Contact the author: Mack.Hogan@insideevs.com .

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