Converted car not running on empty

The VPT Energy System enhanced Toyota Prius for Breakell Inc. gets nearly 140 mpg by combining multiple technologies. (10/04/2008)

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By Duncan Adams
981-3324 - Raonoke Times

Stan Breakell motors by gas stations, smiles and keeps rolling.

His converted 2006 Toyota Prius totes components not found in the hybrid's factory models. Added features include an electric plug-in cord in the trunk and a supplemental battery array in the spare tire well.

A performance log maintained by Breakell shows that his "plug-in hybrid electric vehicle" averages about 137 miles per gallon in around-town driving.

But won't charging the Prius' add-on batteries increase demand on the power grid and, ironically, create the potential for even more coal-fired power plants?

Breakell plugs in the vehicle after 8 p.m. when demand for power is lower. He has signed up for a time-of-day rate plan with Appalachian Power that should offer access to a lower, off-peak rate. He estimates he will be able to charge the vehicle overnight, providing a range of 12 to 15 miles of all-electric operation, for about 18 cents.

The Prius has been altered and doesn't even know it, Breakell said.

"This non-invasive modification essentially adds a much larger battery in the spare tire well and a computer controller that monitors the Prius' electrical system," he said. "It will connect and disconnect the add-on battery as needed, up to the point where the add-on battery is depleted and needs to be recharged."

All the Prius' normal systems "operate exactly the same," he said. The car will switch to gasoline power beyond a certain speed, with sudden acceleration or when the battery is depleted. The conversion allows the car to travel farther in all-electric mode.

Ultimately, even though others have converted hybrids into plug-in vehicles, Breakell's altered Prius could serve as one production prototype for an emerging industry, said Glenn Skutt, president of Blacksburg-based VPT Energy Systems.

Breakell's car was the guinea pig for research and development conducted by VPT Energy Systems, a spinoff of VPT, a power electronics firm that sells power supplies for the military/aerospace and space markets.

Skutt and Jack Lesko, vice president of the spinoff, plan to join Breakell at a press conference today in Roanoke to introduce the converted Prius.

In an e-mail, Skutt said the company first connected with Breakell through a listserv focused on PHEV conversions and related conversations soon followed.

"We are working with Stan so that someday he will be able to integrate products we are developing for vehicles and buildings into his business as he pushes the envelope of [Leadership in Energy and Environmental Design] and sustainable building technologies," Skutt said.

Breakell, 55, is president of general contractor Breakell Inc. of Roanoke. His company renovated the State and City Building downtown, the city's first LEED certified building.

He has emerged as one of the region's leaders, as advocate and contractor, in supporting "green," or environmentally friendly, building and business practices.

His company's fleet includes six Prius hybrids and he offers employees a $1,000 bonus if they purchase for personal use a hybrid vehicle promising at least 42 mpg.

Monday's press conference will offer "a demonstration of what the technology is and a view of what the future looks like," he said.

The public is invited.

Skutt said he believes the converted Prius is unique.

"Technically, I think it is one of the cleanest conversions I have seen that is very close to a produce-able product," he said.

Breakell said the conversion's technologies have been based on work by CalCars, a nonprofit group based in Palo Alto, Calif., promoting plug-in hybrids.

In an e-mail, Felix Kramer, CalCars' founder, complimented VPT Energy Systems and Breakell's efforts.

"VPT [Energy Systems] and Breakell are pioneering," Kramer wrote.

"When people see that both can be cleaner and cheaper to operate using today's technology and no new infrastructure, they start saying, 'Why can't we do more of this?'"

What's in it for VPT Energy Systems?

At some point, the company might take a stab at a business that sells conversions.

"It is not necessarily our immediate goal, but we are very interested in seeing this technology develop and are very much trying to understand the market for conversions in this area," Skutt said.

Breakell's commitment to green causes takes him away frequently from his business.

Certainly, Breakell Inc. reaps positive and free publicity when some of those efforts receive news coverage. But does his absence from the helm also hurt the business?

Breakell said no.

"I think it's the future. If you are not thinking about reshaping your business in the world of carbon caps and trades, then good luck to you. This is one of those times of great opportunity."

For more information about VPT Energy Systems, go to: www.vpt-es.com/about.php. For more information about CalCars, go to: www.calcars.org.

http://www.roanoke.com/news/roanoke/wb/178563

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