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Toyota R&D shows off free piston engine linear generator for future EVs

We often hear how an electric vehicle powertrain architecture allows vehicle designers much more freedom than a traditional ICE powertrain does. With differently shaped battery modules and small electric motors, there are lots of way to put the pieces together. With today's plug-in hybrid technology, engineers still need to put a decent-sized ICE somewhere, but new technology from Toyota could free up the gas-electric vehicle designers of the future. Presented at the recent SAE World Congress in Detroit, the idea from Toyota Central R&D Labs Inc. and involves what is called a Free Piston Engine Linear Generator (FPEG). Think of it as a sort of one-cylinder, two-stroke mini-engine that can work either as a generator (thank to magnets and a linear coil) or to directly drive a vehicle. The current prototype is a 10-kW unit that Toyota say would provide enough power to get a B- or C-segment electric vehicle up to highway speeds (75 miles per hour) when paired up to offer 20 kW. Pairing the FPEGs is also important to minimize vibrations. One system tested by Toyota had a 42 percent thermal efficiency, but the engineers are working to improve the overall efficiency even further. You can watch an animated video of the piston in action here (click on "Outline") and see the SAE papers here and here. More technical details are available at Green Car Congress. News Source: Toyota Labs via Green Car CongressTip: Thanks, Joe V. Green Misc. Auto Shows Toyota Technology Emerging Technologies Electric generator

Is 120 miles just about perfect for EV range?

When it comes to battery-electric vehicles, our friend Brad Berman over at Plug In Cars says 40 miles makes all the difference in the world. That's the approximate difference in single-charge range between the battery-electric version of the Toyota RAV4 and the Nissan Leaf. It's also the difference between the appearance or disappearance of range anxiety. The 50-percent battery increase has zapped any lingering range anxiety, Berman writes. The RAV4 EV possesses a 40-kilowatt-hour pack, compared to the 24-kWh pack in the Leaf. After factoring in differences in size, weight and other issues, that means the compact SUV gets about 120 miles on a single charge in realistic driving conditions, compared to about 80 miles in the Leaf. "The 50 percent increase in battery size from Leaf to RAV has zapped any lingering range anxiety," Berman writes. His observations further feed the notion that drivers need substantial backup juice in order to feel comfortable driving EVs. Late last year, the Union of Concerned Scientists (UCS), along with the Consumers Union estimated that about 42 percent of US households could drive plug-in vehicles with "little or no change" in their driving habits, and that almost 70 percent of US commuters drive fewer than 60 miles per weekday. That would imply that a substantial swath of the country should be comfortable using a car like the Leaf as their daily driver - with first-quarter Leaf sales jumping 46 percent from a year before, more Americans certainly are. Still, the implication here is that EV sales will continue to be on the margins until an automaker steps up battery capabilities to 120 or so miles while keeping the price in the $30,000 range. Think that's a reasonable goal to shoot for?

Toyota teams with FirstElement Fuel on 19 hydrogen stations in California

Cross Toyota with a former General Motors and Hyundai executive and you might just get some real momentum when it comes to hydrogen refueling station deployment. Toyota and FirstElement Fuel Inc., which is headed by ex-GM and Hyundai executive Joel Ewanick, are working together on a project designed to complement California's agreement to spend about $200 million building 100 stations in the state. And while Toyota didn't put out any specific numbers, Automotive News reports that FirstElement received a $27.6 million grant from the California Energy Commission to build 19 stations, which will be sited at existing fueling spots and spaced far enough apart to be reachable by anyone within the state. In all, California has granted $47 million for the deployment of 28 new stations. Additionally, Toyota will get Linde to build a refueling station on a Toyota-owned property in the San Francisco Bay Area's San Ramon, Calif. Toyota, which is targeting a full-tank range of 300 miles and a five-minute refueling time for its fuel-cell sedan, had its fuel-cell prototype make its North American debut at the Consumer Electronics Show in Las Vegas in January. The company said at the time that 68 stations could serve 10,000 hydrogen vehicles. And while that station number doesn't sound terribly high, consider that there are fewer than 10 hydrogen refueling stations in California now. Check out Toyota's press release below and Autoblog's impressions from a drive of one of Toyota's fuel-cell prototypes late last year here. Toyota Collaborates with FirstElement, Providing Financial Assistance to Facilitate a Hydrogen Refueling Network in Targeted California Locations Toyota also will collaborate with hydrogen provider Linde, which will build a public hydrogen refueling facility at the Toyota San Francisco Regional Office May 01, 2014 TORRANCE, Calif. (May 1, 2014) – "The issue of hydrogen refueling infrastructure is not so much about how many stations; but rather, location, location, location," stated Bob Carter, senior vice president, Automotive Operations, Toyota Motor Sales, U.S.A., Inc. (TMS), just four months ago at the Consumer Electronics Show in Las Vegas where he unveiled a hydrogen fuel cell sedan due to launch in 2015. "Solutions are being found through collaboration between government, academia, carmakers and energy providers.