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In this paper we present three main principles for commercially viable hybrid-electric vehicles: 1) using ICEs only near maximum thermodynamic efficiency, 2) using a high voltage electric power subsystem for reduced losses, 3) using only existing automobile materials and processes for low cost. One implementation of these principles is presented in a popular American SUV using our Hyperdrive hybrid-electric powertrain. We will show that driving performance can be enhanced while towing capacity, climbing capacity, and top speed can be preserved without compromise. Fuel economy can be improved by over 50% and regulated emissions can be reduced to near background level. All components of the system are analyzed and it is shown that a 300 V based electric subsystem is materially inferior to the 800 V system in fuel economy, driving performance and cost. In discussing components, we substantiate the case for using a lead-acid battery system.

Recent availability of high-voltage power semiconductors has allowed implementation of a unique, highly efficient, Hybrid-Electric powertrain, the Hyperdrive. It uses an innovative method of control for the internal combustion engine (ICE). Comparative analysis of an application of the Hyperdrive to a popular American SUV is presented, including performance, fuel economy, emissions and costs. In summary, the Hyperdrive, which provides near-thermodynamic-limit fuel efficiency over a wide range of vehicle sizes covering almost all the automotive market, has the potential to succeed conventional powertrains. Vehicle design freedom is considerably enhanced, performance is improved and safety is not compromised. Substantial socio-economic effects are presented.