Design and Development of the 2002 Penn State University Parallel Hybrid Electric Explorer, the Wattmuncher

The 2002 Pennsylvania State University FutureTruck Team has converted a stock 2002 Ford Explorer sport utility vehicle into a post-transmission, pre-transfer case parallel hybrid electric vehicle, dubbed the Wattmuncher. The stock 4.0L, V-6 spark ignition engine was replaced with a more efficient 2.5L direct-injection, common-rail, turbocharged diesel engine that meets Euro 3 emission standards. A diesel particulate filter was implemented for additional emission reductions. ADVISOR simulation results predict 23.5 mpg city and 31.9 mpg highway fuel economy while maintaining stock acceleration and towing capacity. The vehicle was designed for manufacturability, and a complete cost analysis for mass production results in an expected $4,050 added cost for this hybridized Explorer.