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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

Toyota and Lexus recalling 235,000 hybrid CUVs and sedans over separate issues

When it rains, it pours. Toyota has announced a pair of separate but voluntary North America recalls covering approximately 235,000 vehicles built between 2006 and 2011. The larger of the two recalls targets Toyota's hybridized crossovers, the Lexus RX400h and Toyota Highlander Hybrid. 133,000 units, including 2006-2010 Highlander and 2006-2008 RX crossovers are covered in the campaign. The other recall affects 102,000 IS350 sedans, IS350C convertibles and GS350 sedans built between 2006 and 2011.
With the CUVs, the faults in the parallel circuits of the transistors can cause heat damage in the inverter assembly, triggering an abundance of warning lamps and sending the vehicle into limp mode. The Lexus sedans are being recalled due to loose bolts on the variable valve timing controller. Detected by unusual underhood sounds on startup, the issue can cause the engine to stop while driving. The inverter issue is also triggering similar recalls in Japan and Europe.
At the moment, it's unclear if any of these issues have caused any crashes or injuries. Toyota says it plans to notify owners of the recall via snail mail. Additional information for owners can be found on the recall sites for Toyota and Lexus or by calling Toyota's customer service line, at 1-800-331-4331. Scroll down for the complete recall notice from Toyota.

Linde spending $4.3 million on two new hydrogen stations in California

If California is going to sink millions upon millions to expand its hydrogen-refueling infrastructure, shouldn't at least some of that infrastructure be operated by a company that actually produces hydrogen fuel? Why, yes, and that's the case with Linde North America. The company has announced it will build two publicly-accessible hydrogen stations in Northern California, courtesy of a $4.3 million grant from the California Energy Commission (CEC). One of the stations will be at Oakland International Airport while the other will be about 20 miles east in San Ramon, next to Toyota's regional office and parts distribution center for the San Francisco Bay Area. That's only fitting, considering that Toyota is going to release a production fuel cell vehicle next year, first in Japan, then in the US (it will be limited to California at the beginning). The California Air Resources Board recently outlined the Golden State's intention to spend $50 million on getting 28 hydrogen refueling stations up and running by the end of next year and as many as 100 new stations added during the next decade. A large chunk of those (19, to be exact) will be built through a partnership betweetn Toyota and FirstElement Fuel Inc., so things are happening. Check out Linde's press release below. Linde to build two additional retail hydrogen fueling stations in northern California - Receives $4 million grant from California Energy Commission - Fueling stations slated for Oakland International Airport and San Ramon MURRAY HILL, N.J., and NEW PROVIDENCE, N.J., Aug. 5, 2014 /PRNewswire/ -- The California Energy Commission (CEC) awarded $4.3 million to Linde North America to construct retail hydrogen fueling stations in Northern California. The stations will be located at the Oakland International Airport and on Toyota owned property in San Ramon, California, adjacent to Toyota's San Francisco Regional Office and Parts Distribution Center. The award is part of $46.6 million funding program the CEC has committed this year to expand the retail hydrogen fueling infrastructure within the state. The grants, made through CEC's Alternative and Renewable Fuel and Vehicle Technology Program, were made to eight applicants and will add 13 new hydrogen fueling locations in Northern California and 15 in Southern California, strategically located to create a refueling network along major corridors and in regional centers.