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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

Japan plans real-world diesel emissions test after companies fail

Japan's transport ministry plans to start real-world diesel emissions tests after an experiment found four models from Toyota, Nissan, and Mitsubishi that produced more nitrogen oxide (NOx) emissions than the nation's rules allow, according to The Japan Times. Regulators there usually only perform emissions checks in the lab. The VW diesel scandal has everyone double-checking their figures. Diesel versions of the Toyota Hiace van, Land Cruiser Prado, and Nissan X-Trail produced up to 10 times more NOx than allowed. The Mitsubishi Delica D:5 was up to five times over the limit, The Wall Street Journal reports. There was no evidence of defeat devices in the vehicles. Mazda performed well in the experiment, though. The CX-5 passed with nearly the same results on the road and in the lab. The Demio, better known as the Mazda2, did nearly as well with only slighter higher figures in the real world than in the controlled setting. The experimenters theorized the reason for the excessive emissions was that cold weather caused the engines' software to shut off the exhaust gas recirculation to prevent damage, according to the WSJ. However, this behavior also increased NOx production. Toyota, Nissan, and Mitsubishi don't have to worry about punishment from the transport ministry because this check was just an experiment. Their models already passed the mandated lab tests, which was the only requirement, according to The Japan Times. As governments begin greater real-world emissions tests, the results suggests diesels aren't very clean. A recent check in France found models from Ford, Renault, and Mercedes-Benz that didn't perform up to the standards. Regulators in India conducted similar evaluations and ordered VW to recall over 300,000 vehicles. Related Video:

10 automakers sued over keyless ignitions

Keyless ignition has rapidly proliferated throughout the auto industry to become a fairly normal feature on new cars. It's supposed to offer the convenience of keeping the fob in your pocket and just pressing a button to drive away. However, ten major automakers are now being sued in US District Court over claims that the system is dangerous, Reuters reports. The suit alleges that people are forgetting to shut off the engine, and the lack of an idle timer is the cause for 13 deaths by carbon monoxide poisoning and multiple injuries. The suit currently includes 28 plaintiffs, according to Reuters, but the lawyers are asking for class-action status to potentially add many more. The case goes after a major swath of the industry, including BMW, Daimler, FCA, Ford, General Motors, Honda, Hyundai, Nissan, Toyota, and Volkswagen, plus their related brands like Acura, Infiniti, Mini, and Lexus. In all, over five million vehicles are affected. The assertion here is that people walk away from their vehicle without shutting it off because they believe the engine shuts off automatically. If parked in a garage, carbon monoxide can build up, leading to poisoning. The lawyers claim automakers know this is a problem and also cite 27 complaints to the National Highway Traffic Safety Administration about the issue, according to Reuters. The plaintiffs are asking for an automatic shut-off and damages from the companies. These concerns have come up before, though. Toyota previously faced a lawsuit over a carbon monoxide death after a woman accidentally left her Lexus running. Also earlier this year, GM recalled 64,186 examples of the 2011-2013 Chevrolet Volt because owners weren't shutting them off. The problem resulted in two injuries, and the company released a software update to limit the idling time.