The Free Piston Power Pack: ICE and Genset All-In-One

[RAN]

I saw this mentioned on the FRT forum. I wish I could remember who posted it so I could give them credit: (edit: Thank you Tedge!)

Home Site (http://www.freepistonpower.com/Default.aspx)

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.

http://www.freepistonpower.com/images/4fp3-20.jpg
(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.

http://www.freepistonpower.com/images/homefig2.png
(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

__________________________________________________ ____________

If I entered the numbers correctly, that translates to 65-98 MPG. This model weighs 220 lbs, but, it's a 100kw generator. Surely lower kw ones could be made smaller and lighter. Although the website says it was last updated in May 2008, the last update said they were planning on testing their 2nd prototype by Dec 2007. They also said they were looking for partners to go in on the development costs. I hate companies that leave a site up and don't update it; either they're still working on it, or they've shelved it for some reason. Why continue to pay to host a site this way???

[ziggy951]

Ill take 3 =y:

1: 25kw version
2: 100kw version
3: 25kw version


1 for my V1.
1 for my Subie conversion.
1 for my Dagne...did I just say that?



Z

[rogwild]

Great IDEA, nice drawings, been 'working' on it since 2001........where are the videos of the 1st Prototype??? Are the 'Specs' from an actual operating prototype or 'theoretical'???

Seems like another 'good idea' that has STALLED!

[Miracleman89]

forgive my ignorance but what does this translate into as far as horsepower goes???

[RAN]

Seems like another 'good idea' that has STALLED!

Sure looks that way....
Coming up with a new ICE engine is going to be doubly tough these days.

[WarpedOne]

100kW = 136HP


We expect to be able to assemble and test our second-generation, Diesel prototype by December, 2007.


It is essential for successful commercialization of the FP3 that a working prototype be developed and its technical superiority demonstrated sooner rather than later. A qualified partner is needed to augment our technical expertise and additional funding is required to expedite development and commercialization.

Neat idea but I guess, it just won't happen. Saddly though. This thing could actually completely bypass the batteries. Only FP3 module nad electric motors. Would it be a hybrid or not? :)

[Hardtime11]

I want one for my house (and a few neighbors) backup generator. Or if it is really efficient I will drop TECO and use it. :-)

[rogwild]

forgive my ignorance but what does this translate into as far as horsepower goes???

This is just for generating the electricity (I believe); HP to the wheels would depend upon what electric motors were used to actually drive the vehicle.

But 100kW = 134 HP

[ziggy951]

It wouldnt be used for hp to the wheels because the Motor would have that rating. The hp doesnt really matter because this would not directly power a drive shaft or wheel.

FYI though, a great conversion site is http://www.calculateme.com/

Their site mentions needing funding to get a....second...prototype built. I wonder if $6 million would be enough!




Z

[westonlgray]

The idea seems pretty neat, but I wouldn't invest my money in the company without seeing some of the calculations they are using. Did anyone else notice that their numbers are, well strange...

i.e. a car with a 160kW battery? Even if you give them benefit of the doubt and say that they meant 160 kW-h, that is a huge battery... how much would that cost?

Also, a magnet can only be so strong which means that it would need a lot of coils to generate anywhere close to this much power. 100 kW electrical connections would be pretty large too. 100 kW / 100 V is 1000 Amps. How big of a winding do you need to carry 1000 A? Hint, it is big. Well, if you have large windings and you require a lot of windings to get the voltage up, now you are moving further away from the magnet; therefore, you need a bigger magnet or more windings. Also, there would be significant heat issues with the magnets and the windings...heat kills electrical insulation.

Although this idea seems simple and straight-forward, there are a lot of complexities. If I had to guess (and as always, it would be nice if I am wrong) I would say that they got money very easily from some investors, desperate to make money on the green revolation, to start the project (without having to provide much scientific proof) and now that the economy is slower, they would have to provide some real analysis and/or results to get an investment (and judging from their data above, I don't think they have it).

Let common sense rule. If their idea was possible with current (or even near term 10-20 year) technology, there would be quite a few people trampling themselves to get to their door.

Summary: I would file this under Star-Trek technology. These are ideas that are based in science but are not physically achievable either due to materials limitations or other physical laws of nature that they have chosen (consciously or unconsciously) to ignore.