Twitter headlinesVehicle Systems
[Due to the increasing size of the archives, each topic page now contains only the prior 365 days of content. Access to older stories is now solely through the Monthly Archive pages or the site search function.]
Nissan Introduces New Dual Injector System for Improved Fuel Efficiency in Small-Displacement PFI Engines
July 14, 2009
| Nissan’s Dual Injector. Click to enlarge. |
Nissan Motor Co., Ltd. has developed a Dual Injector system designed to improve fuel efficiency in small-displacement gasoline engines using port fuel injection (PFI).
While most current port fuel injected gasoline engines utilize one injector per cylinder (furnishing fuel to two intake ports), the new Nissan Dual Injector system uses an injector for each intake port—i.e., doubling the number of injectors per cylinder.
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New Delphi Powertrain Mounts Use Magneto Rheological Fluids to Improve Performance, Safety and Refinement; Improved Handling of Transient Torque Events
July 09, 2009
| Delphi’s new MR Mount is the first technology that allows precise real-time management of all the relevant frequencies created by an automotive powertrain. Click to enlarge. |
Delphi Corporation has developed a new powertrain mount that uses magneto rheological (MR) fluid to change its dynamic rate in real time. MR fluid is a suspension of magnetically soft particles in a synthetic hydrocarbon fluid.
The new MR Mount prevents the build-up of resonance in a system by maintaining control of the mounted mass across all appropriate frequencies. As well as significantly reducing powertrain noise and vibration, the new mount can improve vehicle performance and stability and help isolate the occupants from torque step events such as those generated by start-stop operation.
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Integral Powertrain Developing New Variable Ratio Drive B-ISG System for Stop-Start Applications
June 18, 2009
| A variable ratio pulley allows improvements in cost and functionality. Click to enlarge. |
UK-based engineering consultancy Integral Powertrain has developed a new generation of belt-integrated starter generator (B-ISG systems) for stop-start applications using a new multi-mode, variable ratio drive pulley. The company anticipates that the total CO2 reduction achieved by the system will be greater than that possible with current B-ISG systems.
The core of the new system is the Variable Ratio Pulley, which packages a two-ratio epicyclic gearbox into the belt drive pulley hub. To start the engine, the high ratio (3.1:1 in the development system) is engaged to substantially reduce the torque requirement, allowing a medium-sized diesel engine to be cranked without the need for a high belt tension and the associated friction and wear.
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Fiat Launches MultiAir Combined with Start/Stop on the MiTo
June 15, 2009
| The MiTo Multiair. Click to enlarge. |
Fiat is launching a 1.4-liter turbocharged gasoline engine equipped with the new MultiAir air handling system (earlier post) on the Alfa Romeo MiTo (earlier post) in September. The MultiAir models will also feature the Start&Stop system (from Bosch, earlier post)—the first application in the MiTo. This also marks the first production engine using the MultiAir system, introduced at the Geneva Motor Show earlier this year.
MultiAir is an electro-hydraulic valve-timing system that provides dynamic and direct control of air and combustion, cylinder by cylinder and stroke by stroke. With direct control of the air through the intake engine valves without using the throttle, MultiAir helps reduce fuel consumption and pollutant emissions.
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BorgWarner Electric Butterfly EGR Valve to Debut with Diesel Engine OEM in 2010
| BorgWarner’s new electric butterfly EGR valve technology will debut with a leading commercial engine manufacturer in 2010. Click to enlarge. |
BorgWarner is introducing an electric butterfly EGR (exhaust gas recirculation) valve for diesel applications. The EGR valve was developed to deliver precise, responsive flow control combined with high flow capability, excellent sealing, corrosion resistance and reliable operation in the most severe operating environments. The technology will debut with a leading commercial engine manufacturer in 2010.
Recirculating exhaust gas and combining it with an air and fuel mixture reduces the combustion temperatures that produce NOx emissions. New engine concepts for commercial diesel vehicles require greater use of state-of-the-art EGR systems to meet ever stricter emissions standards, according to Roger Wood, BorgWarner Engine Group President.
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Ricardo Generic Battery Management System Designed to Provide Flexibility to OEMs
A battery management system is a key component of advanced automotive electric energy storage systems. Engineering firm Ricardo has developed a generic battery management system (BMS) for Li-ion batteries that is independent of cell size or chemistry. The effort is designed to help OEMs in response to the wide variety of cell-level Li-ion chemistries, with different cost, reliability, life, safety and availability factors. Overall, the BMS is designed to be universal—suitable for other energy storage systems such as NiMH or ultracapacitors as well as Li-ion batteries.
The availability of such a generic BMS could reduce the cost to OEMs of changing a cell supplier or even cell chemistry. It would provide flexibility for dual sourcing—e.g., if a current supplier could not meet production volumes—and would reduce risk by more cost-effectively supporting future changes. Dr. Peter Miller, Director of Ricardo’s Electrical/Electronic Engineering efforts, provided an overview of the project at the recent Advanced Automotive Battery Conference 2009 (AABC 2009) in Long Beach.
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COFs Among the Best Adsorbents for Storage of Hydrogen, Natural Gas and CO2
June 07, 2009
| High-pressure CH4 isotherms for COFs measured at 298 K. Credit: ACS. Click to enlarge. |
COFs (covalent organic frameworks)—thermally stable and highly functional crystalline organic networks—are among the most porous and the best adsorbents for hydrogen, methane, and carbon dioxide, according to a new study by Professor Omar Yaghi and postdoc Hiroyasu Furukawa at the Center for Reticular Chemistry at UCLA. A paper on their findings was published online 4 June in the Journal of the American Chemical Society.
Yaghi and his colleagues have been at the forefront of inventing new classes of crystalline porous materials: metal organic frameworks (MOFs), and then COFs, reported in the journal Science in 2007. (Earlier post.)
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Oil Drum Licenses On-Board Hydrogen Generator for Baltic States
June 03, 2009
University of Kent (UK) spin-off Oil Drum Ltd, has signed a licensing deal with UAB Hydro2 that will enable its on-board hydrogen generator technology to be manufactured, sold and installed in the Baltic States. The deal will allow UAB Hydro2 to manufacture, sell and install the Save-Fuel On Demand Hydrogen Technology for the truck, bus and coach industries in Lithuania, Latvia and Estonia.
The retrofit device reduces fuel consumption by adding hydrogen, produced by electrolysis, into the engine via the air intake of the vehicle before the combustion process. As a result the engine burns fuel more efficiently and produces less particulate emissions and reduces the vehicle’s environmental impact.
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BorgWarner Acquires ECCOS Radio Frequency Electrostatic Ignition Technology for Leaner Burning Engines
June 02, 2009
| Comparing standard and ECCOS combustion. Source: Etatech. Click to enlarge. |
BorgWarner Inc. has purchased the ECCOS (Electrically Controlled Combustion Optimization System) radio frequency electrostatic ignition technology targeted at lean-burn engines from Florida-based Etatech, Inc. Terms were not disclosed.
High-performance, lean-burn engines can significantly improve fuel economy and reduce emissions compared with conventional combustion technologies. Independent lab tests have shown peak energy efficiency improved up to 40%, NOx emissions decreased 80% and CO2 emissions fell 50%. However, current spark plug technology is unable to optimize the lean burning engines.
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Researchers Determine Key Intermediate Step in NOx Reduction on Alumina-Supported Silver Catalysts
May 22, 2009
| Reaction mechanisms for the deNOx reaction on an alumina-supported silver catalyst. Source: Thibault-Starzyk et al. Click to enlarge. |
Using a new experimental method, researchers in France and the UK have identified the key intermediate step in the reaction between carbon monoxide and nitric oxide on a silver-alumina catalyst for reduction of NOx in the exhaust from fuel-efficient lean-burn automotive engines.
Using femtosecond laser excitation followed by nanosecond time-resolved in situ Fourier-transform infrared spectroscopy to initiate a catalytic reaction on alumina-supported silver catalysts, they found that a cyanide group flips from a silver nanoparticle to the alumina support (with a lifetime of 2 microseconds).
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EngineLab Developing New Approach to Engine Control (updated)
May 20, 2009
by Bill Cooke
| EngineLab GUI. Source: EngineLab. Click to enlarge. |
EngineLab, a new technology company focused on automotive electronics embedded system design, is planning to revolutionize the engine control business by applying advanced technologies developed for consumer electronics to a vehicle’s Electronic Control Unit (ECU).
The company is especially excited about how this development has the potential to unleash the creativity of innovators with princely visions but pauper budgets by allowing them to monitor and control an engine’s inputs and outputs in real time using a graphical user interface. The company is evaluating producing ECUs for aftermarket tuners (performance and green) as well as licensing their technology to Tier 1s and OEMs.
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Controlled Power Introduces 12V Belt-Driven Integrated Starter Generator for Cars with Diesels
| Left: The SpeedStart B-ISG. Right: Installation in Volvo demonstrator with INA damper. Source: CPT. Click to enlarge. |
Controlled Power Technologies has developed the first belt-driven Integrated Starter Generator (B-ISG) to use a conventional 12-volt vehicle electrical system with the high power output necessary to provide excellent stop-start functionality on the majority of European cars equipped with diesel as well as gasoline engines.
The CPT SpeedStart B-ISG system can deliver up to a 5% reduction in CO2 emissions over the New European Drive Cycle when integrated into a modern powertrain, with the potential for even greater savings in real world urban driving situations.
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Optimized Series Hybrid-Electric System Delivers Best Fuel Consumption Results Yet for Double Deck Vehicle
May 14, 2009
| The Gemini 2 HEV. Click to enlarge. |
In a recent independent test cycle at the Millbrook Proving Ground in the UK, a Wrightbus Gemini 2 HEV achieved the best results for fuel consumption and CO2 emissions ever recorded from a double deck vehicle: 10 mpg UK (8.3 mpg US, 28 L/100km).
The test was part of the Wrightbus Product Development team’s collaboration with Queens University Belfast and key component suppliers including Siemens, Valence Technology and Ford. The series hybrid-electric drive system also uses an optimized engine management program developed by Revolve Technologies. Revolve Technologies was formerly the UK-based Roush Technologies Limited. An investor group acquired Roush Technologies from its US parent late in 2007, and changed the name to Revolve in December 2008.
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Sentience Project Intelligent Automotive Air Conditioning Control System Delivers Fuel Savings in Excess of 9% in Urban Cycle
May 11, 2009
| The Sentience project vehicle. Click to enlarge. |
Testing of an intelligent air conditioning control system integrated with a hybrid powertrain as part of the UK’s Sentience project (earlier post)—showed that, under conditions representative of UK summer weather, the new system consistently delivers fuel savings in excess of 9% over the urban portion of the NEDC drive cycle.
Sentience is a research collaboration led by Ricardo, and also involves Jaguar-Land Rover, TRL (Transport Research Laboratory), Ordnance Survey and Orange Business Services, with part-funding provided by innovITS, the UK center of excellence for intelligent transport systems and sustainable mobility.
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GM Previews First Two-Mode, Front-Wheel-Drive Hybrid Transaxle
May 09, 2009
by Jack Rosebro
| General Motors 2MT70 FWD two-mode hybrid transaxle, as seen from engine side. Click to enlarge. |
At the recent SAE 2009 World Congress in Detroit, General Motors engineers presented the first front-wheel-drive (FWD) iteration of their two-mode hybrid transaxle, termed the 2MT70 (earlier post), scheduled for its first application in the Saturn 2009 VUE 2-Mode Hybrid light sport-utility vehicle later this year (earlier post).
The two-mode design, itself originally adapted from a hybrid transmission designed by Allison for transit buses, has up to now been exclusively incorporated into rear-wheel-drive (RWD) transmissions with the intent of reducing the fuel consumption of heavier and larger passenger trucks and SUVs while preserving towing capacities.
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Audi Adds Start-Stop System, On-Board Computer with Efficiency Program; Targeting 20% Drop in Fuel Consumption by 2012
May 07, 2009
| Audi start-stop system display. Click to enlarge. |
Beginning in the second quarter of 2009, Audi will add a start-stop system and an on-board computer with an efficiency program to what it calls its modular efficiency platform. These new technologies complement the energy recovery system, already standard on many Audi models, which feeds energy back into the vehicle’s electrical system during deceleration phases.
The modular efficiency platform focuses on the further development of powertrain and transmission technologies, and the recovery and storage of mechanical, thermal and electrical energy. Audi also employs a number of measures to minimize driving resistance and optimize aerodynamics. By 2012 Audi plans to lower the fuel consumption of its model range by 20% compared with the 2007 level.
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Transonic Combustion Completes New Round of Venture Funding
May 06, 2009
Start-up Transonic Combustion, Inc., has raised a C-round of equity funding. Existing investors Venrock, Khosla Ventures, Rustic Canyon Partners and Saints Capital all increased their support of Transonic in the round.
Transonic Combustion is developing an advanced lean combustion process and associated gasoline fuel injection system which it projects will enable practical 100 mpg cars. The patented combustion process remains stable well above a 200:1 air/fuel ratio and can support vehicle cruise power at a 100:1 air/fuel ratio.
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Controlled Power Technologies and AVL Collaborate on Advanced Direct Injection Gasoline Engine Demonstrator
May 05, 2009
| CPT electric VTES installed in AVL demonstrator. Click to enlarge. |
Controlled Power Technologies (CPT) and AVL List GmbH (AVL) have developed a gasoline engine that retains all the traditional cost, weight, NVH refinement and emission benefits as well as the fun-to-drive factor, while reducing CO2 levels to that of an equivalent diesel powertrain.
The AVL demonstrator vehicle incorporates an advanced 2-liter 4-cylinder engine with gasoline direct injection (GDI), double cam phasing and single-scroll, waste-gated turbocharger to deliver high power and torque outputs of 200 PS (197 hp, 147 kW) and 400 N·m (295 lb-ft) respectively.
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Ford Conducts Design of Experiment Investigating Thermoelectric Energy Regeneration
May 04, 2009
by Jack Rosebro
| Conceptual schematic of direct thermoelectric generator mounted in a vehicle’s exhaust stream. Indirect configurations are also possible. Adapted from Hussain et al. Click to enlarge. |
At SAE 2009 World Congress in Detroit last month, Ford Motor Company presented a research paper that detailed the results of an initial investigation, termed a Design of Experiment, into thermoelectric exhaust heat energy recovery in conjunction with a hybrid powertrain.
The investigation, conducted by Ford engineers Quazi Hussain, Clay Maranville, and David Brigham, used computer modeling to predict the performance of TE devices of various physical configurations, using average highway-speed exhaust gas flows and temperatures of a 2.5L engine with an Atkinson-cycle engine, as used in Ford’s Escape hybrid SUV.
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BMW Study on Rankine Cycle for Waste Heat Recovery Shows Potential Additional 10% Power Output at Highway Speeds
May 03, 2009
| Energy utilization vs. complexity of different heat recovery systems. In this study, BMW focused on Rankine A (exhaust gas only) and Rankine B (exhaust gas and coolant). Adapted from Ringler et al. (2009) Click to enlarge. |
BMW is exploring two pathways for waste heat recovery in vehicles: one thermoelectric, the other thermodynamic. In 2005, BMW Group Research and Engineering announced it was developing a steam-powered auxiliary drive—the Turbosteamer—to use the waste heat present in the exhaust gases and cooling system from a conventional gasoline engine as its source of power. The long-term development goal articulated at the time was to have a system capable of volume production within ten years.(Earlier post.)
At the recent SAE 2009 World Congress, BMW presented an analysis of two basic configurations of the Rankine cycle applied to a thermodynamic heat recovery system for a four-cylinder combustion engine. Based on bench test measurements, BMW has concluded that waste heat recovery can provide an additional power output of about 10% at typical highway cruising speeds.
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Magneti Marelli and Flybrid Systems Collaborate on “Flywheel Capacitor” for KERS
April 30, 2009
Italian motorsport electronics specialist Magneti Marelli and UK high-speed flywheel specialist Flybrid Systems are collaborating to develop a new energy storage solution for Kinetic Energy Recovery Systems (KERS). The new product is targeted to be a high-power electrical storage system for hybrid racing cars capable of deep depths of discharge with no performance degradation and a long service life.
The new product—named the Flywheel Capacitor—consists of a high-speed carbon fiber flywheel incorporating Flybrid technology connected to a high-speed electric motor generator using technology from Magneti Marelli, all managed by Magneti Marelli’s control electronics.
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Use of a Low-Cost Electric Supercharger Could Significantly Reduce Smoke from Turbocharged Diesel Engines
April 27, 2009
| CPT electric supercharger test rig. Click to enlarge. |
Smoke emissions produced by turbocharged diesel engines under heavy load conditions—such as when accelerating from low engine speeds and other similar transient manoeuvres—can be all but eliminated under certain operating conditions by the addition of a relatively simple and low cost electric supercharger, suggests Controlled Power Technologies (CPT).
Controlled Power Technologies (CPT) is a UK startup working with switched reluctance motor technology to deliver cost-effective CO2-reducing solutions for vehicles. It is commercializing three initial products: Variable Torque Enhancement System, VTES, an electric supercharging system; SpeedStart12, an integrated belt-driven starter generator system; and TIGERS, an exhaust turbine-driven generator system. (Earlier post.)
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Ford E85 Direct Injection Boosting Study: A Less Expensive Alternative to Diesel
April 26, 2009
Using a separate E85 direct injection boosting system combined with gasoline port fuel injection (PFI) makes the engine more efficient in its use of gasoline, and can be viewed as a more cost-effective alternative to a modern diesel, according to a Ford study presented by Robert Stein, currently of AVL, formerly of Ford, at the SAE 2009 World Congress.
Proposed by John Heywood and colleagues at MIT in 2005, the basic premise of E85 boosting is that ethanol (or other lower alcohols) suppresses knock due to the large evaporative cooling effect it has on the air-fuel mixture when injected directly into the cylinder, supplemented by ethanol’s inherent high octane number. Using the E85 boosting concept requires two fuel tanks and vehicle owner acceptance of dual fueling.
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DENSO Develops Exhaust Gas Temperature Sensor With Improved Temperature Detection Accuracy
April 21, 2009
| DENSO extended the length of the probe and developed a vibration-resistant structure to support it. Click to enlarge. |
DENSO Corporation has improved the temperature detection accuracy of its newly developed diesel exhaust temperature sensor. The new sensor, which is located in front of the diesel particulate filter (DPF) and used to control temperature for DPF regeneration, helps reduce harmful diesel emissions and improves fuel efficiency by enabling more precise control of aftertreatment systems.
To improve the sensor’s temperature accuracy, DENSO increased the probe length to almost twice that of the conventional product and extended the sensing tip into the exhaust pipe. The company achieved this by developing a vibration-resistant structure with an anti-resonance pipe to support the probe, or sheath pin, at its optimal position.
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Hitachi Restructures, Spinning Off Automotive Systems Business; to Launch Group-Wide Strategies for Li-ion Battery and Renewables Businesses
March 16, 2009
As part of a major restructuring in announced in Tokyo on Monday, Hitachi Ltd. will spin off its Automotive Systems Business into a wholly-owned subsidiary on 1 July. The new automotive business will have a special focus on hybrid and electric drive system components, as well as technologies for enhancing the efficiency of internal combustion engines.
In addition, on 1 April, the company will introduce organizations to plan and propose R&D and business strategies for the whole Hitachi Group regarding lithium-ion battery and renewable energy-related businesses. Hitachi says that it will “take steps to quickly launch businesses in these areas.”
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Fallbrook Introduces Variable Accessory Drive Applications for NuVinci CVP
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| Basic design of the NuVinci CVP. Click to enlarge. |
Fallbrook Technologies Inc., the developer of the NuVinci continuously variable planetary (CVP) transmission (earlier post), introduced a new suite of automotive- and truck-related applications for the NuVinci CVP, referred to as continuously variable accessory drives (CVADs), at the Clean Heavy Duty Conference and Expo in Long Beach, Calif.
A CVAD is a device that helps the engine-driven accessories on a car or truck (alternator, air conditioner, water pump, etc.) run more efficiently. These accessories have, in the past, been connected directly to the engine by a serpentine belt, so their speeds are tied to engine speeds. A CVAD sits between the engine and these accessories, allowing accessory speed to vary according to performance needs rather than engine speed.
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Continental Introduces Its First Turbocharger
March 06, 2009
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| Section drawing: Fully-automated assembly delivers quality and cost advantages, according to Continental. Click to enlarge. |
Continental, the international automotive supplier, is expanding its product portfolio with its Powertrain Division’s first turbocharger system for internal combustion engines. The new turbocharger, designed to allow fully-automated assembly, will be installed in a European vehicle platform’s gasoline engines in 2011.
Continental says it has used an innovative production method for its turbocharger. All the main components have been designed for fully-automated assembly along a single axis, whereas conventional turbochargers have to be put together in several stages, partly by hand. Fully-automated assembly delivers quality benefits through lower defect rates; it also produces cost benefits and both are important in view of the fact that these turbochargers are to be installed in high-volume model series.
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Fiat Introduces Multiair Electro-Hydraulic Valve-Timing System
March 04, 2009
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| Multiair system components. Click to enlarge. |
Fiat Group and Fiat Powertrain Technology introduced their new air management technology Multiair at the Geneva Motor Show. Multiair is an electro-hydraulic valve-timing system that provides dynamic and direct control of air and combustion, cylinder by cylinder and stroke by stroke.
Fiat expects that Multiair, with direct control of the air through the intake engine valves without using the throttle, can help reduce fuel consumption by up to 10% for turbocharged or naturally aspirated gasoline engines. Pollutant emissions are likewise reduced through combustion control. Applied to a turbocharged, downsized engine, MultiAir can contribute to up to a 25% reduction in fuel consumption over conventional naturally aspirated engines with the same performance, according to Fiat.
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Volvo Adding Seven New DRIVe Models; Start/Stop, Regenerative Charging on Three
February 24, 2009
Volvo Cars is presenting seven new DRIVe models across its full range at the upcoming Geneva auto show, three of which are equipped with a start/stop system and regenerative charging. Volvo introduced its first three DRIVEe branded models—indicating uprated environmental properties—at the 2008 Paris motor show. (Earlier post.)
All the new DRIVe models are equipped with a conventional diesel engine and manual gearbox optimized for extra-low fuel consumption. These cars are also tailored specifically for low rolling resistance and reduced air drag.
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MIT Students Develop Hydraulic Energy-Generating Shock Absorbers
February 13, 2009
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| GenShock prototype. Click to enlarge. |
A team of MIT undergraduate students has invented a shock absorber that harnesses energy from small bumps in the road, generating electricity while it smoothes the ride more effectively than conventional shocks. MIT Senior Shakeel Avadhany and his teammates say they can produce up to a 10% improvement in overall vehicle fuel efficiency by using the regenerative shock absorbers.
Their prototype shock absorbers use a hydraulic system that forces fluid through a turbine attached to a generator. The system is controlled by an active electronic system that optimizes the damping, providing a smoother ride than conventional shocks while generating electricity to recharge the batteries or operate electrical equipment.
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New System for Managing Multiple Types of Power Units Could Reduce Cost of Hybrids and Plug-ins
January 18, 2009
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| Multi-Flex unit in a golf cart battery pack. Click to enlarge. |
An Indiana startup, Indy Power Systems, has developed a hardware platform that uses embedded software to manage the flow of energy between multiple types of power units—including different types of rechargeable batteries and fuel cells.
Indy Power System’s Multi-Flex Energy Management System blends two or more sources of power so that the cost and performance characteristics of each can be optimized. The system could potentially reduce the cost of a battery-electric vehicle energy storage system by around 50% per vehicle, according to internal company tests that combined power from lithium-ion batteries and lead-acid batteries.
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GM’s Burns Calls for New US Public/Private Partnership for Rapid Commercialization of Electrically Driven and Connected Vehicle Technologies; the New Automotive DNA
January 14, 2009
During his speech at the Chairman’s Luncheon of the Transportation Research Board (TRB) 88th Annual Meeting in Washington, DC, Larry Burns, GM vice president for Research & Development and Strategic Planning, called for the creation of a new public/private partnership to rapidly commercialize US automotive technologies in two strategic and converging areas: electrically driven vehicles and connected vehicles.
Burns said the partnership should include the US government, auto manufacturers and suppliers, the energy and infrastructure industries, and other key stakeholders. He said its focus should be on enabling technologies for electrically driven vehicles such as advanced batteries, electric motors, power electronics, fuel cells, hydrogen infrastructure and storage systems; and connected vehicle technologies such as sensors, actuators, wireless communications and GPS systems.
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Kia Begins Full-Scale Production of First Kia Models with Stop/Start Systems
Kia Motors Corporation has begun full scale production of the six new Kia cee’d ISG (Idle Stop & Go, Kia’s label for a stop/start system) models, which offer up to 15% fuel savings in city driving, at its facility in Zilina (Slovakia), with deliveries to customers across Europe scheduled to begin during the next two months. Kia introduced the ISG system at the Mondial de l’Automobile in Paris in September, 2008. (Earlier post.)
Made in Europe, the C-segment cee’d ISG cars are the first Kia production models with the microhybrid system.
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Eaton Licenses Clean Diesel Technologies’ ARIS Systems for HC Injection for Eaton Aftertreatment System
January 08, 2009
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| The Eaton Aftertreatment System combines a fuel reformer catalyst with doser, SCR and LNT technology. Click to enlarge. |
Eaton Corporation has entered into a global non-exclusive licensing agreement for Clean Diesel Technologies’s Advanced Reagent Injector System (ARIS) technology for injection of hydrocarbon (HC) fuel in emissions reduction applications, including the Eaton Aftertreatment System (EAS). (Earlier post.) ARIS technology can also be applied to regeneration of diesel particulate filters and lean NOx traps in various global applications.
The Eaton aftertreatment system combines a fuel reformer catalyst with doser, Selective Catalytic Reduction system (SCR) and Lean NOx Trap (LNT) technology to create an exhaust aftertreatment system capable of meeting 2010 EPA diesel emissions requirements without the need for a urea storage and injection system.
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UK Evaluating Intelligent Speed Adaptation Systems for Road Safety and GHG Emissions Reduction
January 03, 2009
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| Summary results of impact of ISA systems on CO2 emissions. Click to enlarge. |
The UK government’s Commission for Integrated Transport (CfIT) and the Motorists’ Forum (MF) recently issued a joint report evaluating the impact of implementing an Intelligent Speed Adaptation (ISA) system across the entire road network on reducing deaths and injuries on the UK roads and on reducing fuel consumption and emissions of CO2 and criteria pollutants. They partners commissioned the Institute for Transport Studies, University of Leeds to produce the report.
ISA systems use enhanced navigation systems which incorporate speed limit as a road attribute to compare the local speed limit to the vehicle speed. The ISA system automatically detects the road on which a vehicle is travelling—and hence the speed limit—without any user intervention. ISA systems take three basic forms:
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Ford ’s New Active Park Assist Leverages Electric Power Assisted Steering; Nearly 90% of Ford Lineup to Have EPAS by 2012
December 31, 2008
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| Ford’s Active Park Assist. Click to enlarge. |
Ford is introducing a new Active Park Assist technology on its 2010 Lincoln MKS flagship sedan and new Lincoln MKT seven-passenger luxury crossover. Available in mid-2009 as an option, Active Park Assist uses an ultrasonic-based sensing system and Electric Power Assisted Steering (EPAS) to position the vehicle for parallel parking, calculate the optimal steering angle and quickly steer the vehicle into a parking spot.
Active Park Assist is enabled by Ford’s advanced EPAS technology. In addition to helping with parallel parking, EPAS improves fuel economy up to 5%, while reducing CO2 emissions and enhancing steering performance compared with traditional hydraulic powered-assisted steering systems.
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Fiat Adding Bosch Stop-Start System to Fiat 500; Bosch Projects 50% of Euro New Vehicles to Have Stop-Start by 2012
December 04, 2008
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| A specially adapted starter and the engine control unit are the central components of the Bosch stop-start system. Click to enlarge. |
Beginning in March 2009, Fiat will feature a Bosch start/stop system on the Fiat 500. (Earlier post.) Bosch supplies the specially adapted starter, the engine management system, and the battery sensor. Bosch has been manufacturing this start/stop technology since 2007, and has already delivered more than 500,000 starters to BMW and Mini. (Earlier post.)
In the Fiat 500, the system will initially be available in combination with the Dualogic automated manual transmission and a 1.2-liter engine. Fiat plans to install the system in other variants and models as early as 2009.
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Delphi Direct Acting Piezo Injector Debuts on the Mercedes C250 CDI
December 01, 2008
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| Delphi Direct Acting Diesel Common Rail System includes (clockwise from top left): DFI3 Piezo Injectors with Common Rail, Series 9 Modular Fuel Filter, DCM4 Light Duty Controller, and DFP3 High Pressure Pump. Click to enlarge. |
Delphi Corporation’s new Direct Acting Piezo injector (earlier post) is making its debut in the new Direct Acting Diesel Common Rail System on the new Mercedes C250 CDI. In the new system, the injector needle is directly activated by a piezo ceramic actuator, removing the hydraulic circuit and its associated lag and energy consumption.
The piezo ceramic actuator directly operates the needle valve of the injector for initial lifts, such as those obtained in pilot injections, and a motion amplifier is used to help complete the lift for large injections. This enables the injector to spray fuel into the combustion chamber faster, with much improved spray momentum and accuracy, at higher pressures (up to 2,000 bar).
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Michelin to Commercialize Electric Active Wheel Technology
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| Michelin’s Active Wheel integrates brake disk, electric motor and suspension motor. Click to enlarge. |
Michelin’s Active Wheel, an in-wheel system comprising a brake, 30 kW (40 hp) electric traction motor and electric suspension motor system, will be used in the Heuliez-produced WILL electric vehicle (battery or fuel cell), due to be available to fleet owners in 2010. The WILL grew out of a concept developed by Heuliez and Michelin and features networked services innovated by Orange.
Michelin has shown earlier versions of the Active Wheel in concepts before, such as the Michelin/PSI Concept HY-LIGHT Fuel Cell Vehicle shown at the 2004 Challenge Bibendum in Shanghai. (Earlier post.) The two-wheel motor WILL is its first application in a series production-intent vehicle. The partners showed the WILL at the Paris Motor show in October. Venturi Automobiles also showed an application of the Active Wheel in the premier of its four-wheel motor Volage.
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Electric Truck Exclusively Options Regenerative Magnetic Shock Absorber Technology from Tufts
November 23, 2008
Electric Truck, LLC (ET) has exclusively optioned commercial rights to a technology from Tufts University that can recharge the batteries of any hybrid electric and electric-powered vehicle while it is driven. The regenerative electromagnetic shock absorber technology was developed by Tufts engineering professor emeritus Ronald Goldner and colleague Peter Zerigian within the School of Engineering and received additional support in subsequent years from Argonne National Laboratory.
At the SAE Government/Industry Meeting in Washington in 2001, Goldner, Zerigian and J.R. Hull from Argonne presented a paper estimating that the percentage of recoverable power/energy for a 2,500 lb vehicle that employs four optimized design regenerative magnetic shock absorbers and whose average speed is 20 meters/s (45 mph) on a typical US highway is likely to be between 20% and 70%.
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Daimler and Karlsruhe Institute of Technology Begin Research Collaboration on Electric Drive Systems
November 21, 2008
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Daimler AG and the Karlsruhe Institute of Technology (KIT) are beginning a research collaboration on electric drive systems: the “e-drive Project House” (Projekthaus e-drive). The effort will span the fields of power electronics and electric machines (PEEM), control systems, and electrical energy storage systems. Pooling expertise from science and industry across these fields is intended to expedite the market maturity of pure electric drive and hybrid vehicles, Daimler said.
The e-drive Project House is positioned as a strategic long-term undertaking, and is setting out to attract further scientific institutes and cooperation partners in order to extend the research consortium.
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Toyota Auris to Offer New 1.33L Dual VVT-i with Stop&Start
November 19, 2008
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| Toyota Optimal Drive 1.33-liter Dual VVT-i gasoline engine with Stop&Start. Click to enlarge. |
Toyota is applying its new 1.33-liter, Dual VVT-i gasoline engine with Stop&Start in the Auris. The engine is also to be applied in the iQ. (Earlier post.) The new 1.33L engine in the Auris delivers a 19% improvement in fuel consumption and a 17% decrease in CO2 emissions compared to the previous 1.4L VVT-i unit.
The new Auris 1.33 Dual VVT-i Stop&Start is being branded as an “Optimal Drive” vehicle. (Earlier post.) Toyota Optimal Drive covers a range of different technologies that can be applied to achieve real-world results in decreasing fuel consumption and emissions without compromising driving pleasure. This approach, Toyota says, is in contrast to “some car manufacturers which have elected to launch special eco-themed models with design, engineering and equipment tweaks to achieve lower emissions and better fuel consumption, often at the cost of comfort and driving pleasure.”
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Bosch Developing Modular KERS Systems for Range of Motorsport Applications
November 18, 2008
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| The KERS flywheel energy storage device can store up to 750 kilojoules of energy. Click to enlarge. |
Bosch Motorsport is developing a Kinetic Energy Recovery System (KERS) for use in motor racing. The modular KERS kit covers racing requirements from Formula 1 to series such as the DTM or 24-hour races. Bosch presented the variable, modular KERS kit at the Professional MotorSport World Expo 2008 (11-13 November) in Cologne, Germany.
Hybrid systems by Bosch Motorsport comprise an energy storage system, the electric motor, and the KERS controller, containing the power electronic, battery management, and management system for hybrid and engine functions.
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Novel Spoiler Design Reduces Fuel Consumption for Minivans, SUVs
November 12, 2008
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| Cross-sectional view of the new spoiler attached to the back of a modeled minivan. Click to enlarge. Source: Inchul Kim |
A team of researchers has used the principles of fluid dynamics and numerical simulation to design a new rear spoiler for bluff-backed vehicles (such as minivans and SUVs) that can reduce drag and lift significantly.
In a paper published in the International Journal of Vehicle Design, Inchul Kim of Metacomp Technologies, in Agoura Hills, California, working with Xin Geng and Hualei Chen of the University of Michigan-Dearborn report that the aerodynamic drag and lift on a mini-van moving at 108 kph (67 mph) are reduced by 5% and more than 100%, respectively, when the new spoiler is attached to it.
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Antonov Says that Dual-Speed Ancillaries Can Deliver a 5% Reduction in Fuel Consumption
November 07, 2008
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| Antonov two-speed alternator. Click to enlarge. |
Simple dual-speed drives can help alternators and other engine ancillaries operate more efficiently by better matching their drive speed to the vehicle requirements and also improve the re-charging of batteries, according to transmission specialist Antonov Automotive Technologies. (Earlier post.)
The characteristics of Antonov’s mechanical module (AMM), essentially a self-controlling automatic two-speed gearset, can be tuned to meet specific vehicle requirements.
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Developer of Syngas-Based Emissions Reduction System Closes $15.4 Million Investment Round; Picks Up Japanese Automaker as Investor
October 30, 2008
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| NxtGen Syngas Diesel Aftertreatment System. NxtGen components are in blue. Click to enlarge. |
NxtGen Emission Controls Inc., the developer of a syngas-based diesel emission reduction system (earlier post) has closed a US$15.4 million Series B investment led by Altira Group LLC.
The investment was led by Altira from its US$176 million Altira Technology V Fund L.P. Other new investors in the financing include the corporate venture capital arm of a major Japanese automobile company and ITOCHU Corporation, a major international trading company with headquarters in Tokyo, Japan. ITOCHU will distribute NxtGen’s products in Japanese and Asian markets. Current investors participated in the financing, including Yaletown Venture Partners, GrowthWorks Capital, BC Advantage Funds and Polygon Financial Investments.
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Ford Introducing New Instrument Cluster on Fusion and Milan Hybrids to Coach Drivers on Optimizing Performance
October 29, 2008
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| The SmartGauge instrument cluster in “Engage” configuration. Click to enlarge. |
Ford is introducing a new instrument cluster—SmartGauge with EcoGuide—on its upcoming Fusion and Milan hybrids to help drivers maximize their fuel efficiency. Ford collaborated with IDEO and Smart Design to develop the new cluster.
SmartGauge with EcoGuide uses two, high-resolution, full-color liquid crystal display (LCD) screens on either side of the analog speedometer that can be configured to show different levels of information, including fuel and battery power levels, average and instant miles-per-gallon. Growing leaves and vines can track and “reward” the driver’s efficiency.
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Freescale Introduces New High-Performance MCU Targeted at Fuel-Efficient, Low-Emission Engines
October 20, 2008
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| The MPC5674F is targeted at fuel-efficient, lower-emission applications in high-volume automobiles. |
Freescale Semiconductor has introduced a new high-performance microcontroller (MCU) that it says is the industry’s most powerful for engine control in mainstream, high-volume automobiles. The new MPC5674F is the latest addition to the company’s growing portfolio of 32-bit automotive MCUs built on its Power Architecture technology.
The MPC5674F addresses the automotive industry’s need for precise control of engine events, enabling developers to optimize combustion and tune engines for improved fuel efficiency and cleaner emissions, without sacrificing performance.
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VW Introduces Passat BlueTDI, BlueMotion 2 and Concept Variant BlueMotion II; Bin 5 and Euro 6 Compliance, Stop/Start and Regenerative Braking
October 06, 2008
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| The VW Passat Variant BlueMotion II. Click to enlarge. |
At the Paris Motor Show, Volkswagen unveiled the Passat BlueTDI (a Passat model with an SCR system to cut NOx to US Bin 5 and Euro-6 levels); the second-generation of the Passat BlueMotion, equipped with a stop/start system as standard; and a concept Passat Variant BlueMotion II, which takes the SCR system of the BlueTDI model and applies it in a more fuel-efficient BlueMotion variant featuring regenerative braking. The Passat BlueTDI is due to go into production in 2009; the new Passat BlueMotion is launching this year. VW plans to produce the BlueMotion II as well.
Among its other introductions at the show, VW highlighted the concept of the next Golf GTI with reduced fuel consumption; a new v6 FSI (gasoline direct injection) model of the Phaeton (which will now also feature stop/start systems as standard); and the sixth generation of the Golf (earlier post).
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Electric Supercharger Can Enable More Extreme, Cost-Effective Engine Downsizing
September 26, 2008
| VTES electric supercharger. Click to enlarge. |
UK-based Controlled Power Technologies (CPT) says that its switched reluctance motor-powered electric supercharger (earlier post)—VTES (Variable Torque Enhancement System)—is ready for production applications.
CPT suggests that configuring the high dynamic (10-90% rise time < 300 ms) VTES in series with a conventional fixed geometry turbocharger offers a combined transient effect which cannot be matched by other series air charging systems, and thus offers support for more extreme and more cost-effective—and therefore more broadly applied—engine downsizing.
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Delphi Launches Diesel Direct Acting Piezo Injection System; Lower Emissions and Fuel Consumption, More Power and Torque
September 06, 2008
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| Delphi Direct Acting Injector (DFI3) compared to a conventional servo-hydraulic injector. Click to enlarge. |
Delphi Corp. has launched the Delphi Direct Acting Common Rail system, its next generation of diesel fuel injection technology based on a new direct acting piezo injector, the DFI3 Piezo Injector. The new system is now entering production and will be available on a European production car to be launched later this year.
The DFI3 piezo injector needle is set in motion directly by a piezo ceramic actuator, rather than being moved via an electro-hydraulic circuit as with existing fuel injection technologies. This enables the injector to spray fuel into the combustion chamber faster and with much improved spray momentum and accuracy and provides extremely fast opening and closing of the needle valve, independent of injection pressure.
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BorgWarner Introduces Innovation in Variable Cam Timing Technology for 2009 Ford Escape
September 03, 2008
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| BorgWarner Morse Tec’s CTA creates cam torsionals from the opening and closing of the valves. Click to enlarge. |
BorgWarner will supply Cam Torque Actuated (CTA) variable cam timing technology for the upgraded Ford Duratec 3.0-liter V-6 engine, debuting in the 2009 Ford Escape. BorgWarner Morse TEC’s new, patented technology improves engine performance and fuel economy while reducing emissions.
Unlike traditional cam phasing methods which typically use engine oil pressure to rotate the camshaft, BorgWarner’s CTA technology captures the existing torsional energy in the valve train to accomplish this event, similar to a hydraulic ratchet.
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Clean Power Signs Steam and Heat Recovery Engine Development Agreement With Voith Turbo GmbH & Co. KG
August 11, 2008
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| Basic components of the CESAR system. Click to enlarge. |
Canada-based Clean Power Technologies Inc. (CPT), developer of a waste-heat powered steam hybrid system (CESAR, Clean Energy Storage and Recovery, earlier post), has signed a collaboration agreement with Voith Turbo GmbH & Co. KG to develop steam and heat energy recovery engines for Clean Power’s proprietary heat recovery technology for refrigeration trailers for the grocery market.
CESAR uses a heat exchanger to capture waste energy from a primary engine, which is then stored in the form of steam in an accumulator, for on-demand use either in the same primary engine, or in a secondary vapor engine. Power can be produced solely by the secondary vapor engine even after the primary combustion engine has shut down. The technology can provide up to 40% better fuel efficiency and a corresponding reduction in emission levels depending upon the application, according to the company.
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Sturman Industries Developing New “Distributed Rail” High Pressure Fuel Injection System
August 07, 2008
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| The Sturman Environmental Injector (bottom) vs. a common rail system (top). Click to enlarge. |
Sturman Industries—the digital valve company—is developing what it calls the Environmental Injector: a new fuel injection system that combines the benefits of current high pressure common rail injector technology (flexible timing, flexible injection pressure and multiple injection events) with the additional benefits of Sturman’s hydraulic intensified injector (higher injection pressures, improved safety and alternative fuel usage).
Sturman has been working on applying its digital valve technology to intensify fuel systems for more than a decade. The hydraulic intensified injector uses a portion of the fuel as a working fluid to increase the pressure of the charge prior to injection. The current S1 intensified injector supports an injection pressure of 2,400 bar (a 3,000-bar version is in development) and supports variable injection timing, pressure and duration, along with multiple events, small quantity control and low dwell.
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Lotus Engineering Develops Sound Simulation Technology for Electric Drive Vehicles
August 05, 2008
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| The Safe & Sound’ Hybrid system. Click to enlarge. |
Lotus Engineering has developed technologies to synthesize external sound on electric and hybrid vehicles to counteract the growing concern these ‘quiet’ vehicles pose to pedestrians and cyclists. Lotus applied the technology to a standard Toyota Prius to create a ‘Safe & Sound’ Hybrid technology demonstrator vehicle.
The solution that Lotus has devised is a novel reapplication and development of its Sound Synthesis technology. Sound Synthesis is one element in the Lotus suite of patented active noise technologies, comprising three main systems each of which can be used individually or in combination: Active Road Noise Cancellation, Engine Order Cancellation and Sound Synthesis.
