Last updated May 28, 2008

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Free Piston Power Pack

The FP3 is a most efficient, low cost, elegant electric generator module of exceptional power density. Operation is based on 'free pistons' (unrestrained by con-rods or crank shaft) being driven back and forth inside cylinders by controlled internal combustion. Permanent magnets are attached to these pistons and move through stator coils, thus generating electric power.

Compression ratio and stroke, as well as exhaust valve timing and lift, are software controlled rather than through conventional mechanical means. The result is mechanical simplicity, unequalled efficiency and extremely low harmful emissions.

freepiston
(Figure 1: 100kW generator module)

Salient features of a 100kW FP3 module:

  • Size: 660x280x280mm
  • Mass: 100kg
  • Two-stroke operation
  • Integral charge compressor
  • Power Density: 1kW/kg; 2 kW/litre
  • Fuelled by Gasoline, Diesel (Bio, JP8), LPG, Ethanol, Hydrogen, etc.
  • Direct, high pressure fuel injection
  • Variable exhaust valve lift and timing
  • Variable compression ratio and stroke
  • Mechanical simplicity (software ‘replaces’ conventional con-rods, cam and crankshaft)
  • Readily scalable from 25 to 500kW output power
  • Efficiency 50%

What problem does our technology solve?

The FP3 has the potential to make a greater single contribution to the reduction of greenhouse gas emissions than any other technology currently available. Installed in a Series Hybrid Electric vehicle, it offers a significant reduction in fuel consumption and harmful emissions when compared with a conventional power train. It provides a means for oil to continue to be the primary automotive energy source but in an economically viable and environmentally responsible manner. The FP3 is a sterling solution to the land transportation fossil fuel waste-and-pollution conundrum.

Primary Application

The exceptional power density of the FP3 makes it possible to construct a Series Hybrid Electric Motor Vehicle capable of regenerating, storing and subsequently re-using the kinetic energy, presently wasted, when slowing down and braking. This is achieved without any compromise in vehicle mass, performance, handling and payload capacity. The up-shot is a substantial reduction in fuel consumption and harmful emissions.

Figure 2: FP3 installed in a Series Hybrid Electric Family Sedan
(Figure 2: FP3 installed in a Series Hybrid Electric Family Sedan)
  • Kerb weight 1300kg (2860lb)
  • 100kW FP3 complete with power electronics and DSP control system
  • Installed lithium-Ion battery power 164kW
  • Electric wheel motors 4x50=200kW
  • 200kW wheel motor control
  • Wheel motor gear ration 6.75:1
  • Torque on wheels:
    • 2122Nm (1563ft/lb) 0-100km/h (62mph)
    • 1415Nm (1042ft/lb) 150km/h (93mph)
  • Acceleration 0-100km/h in 5.4 seconds
  • Full recovery and storage of kinetic energy when slowing down and braking
  • Fuel consumption (in accordance with NEDC): City= 2.4ltr/100km; Highway= 3.6ltr/100km
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