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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 issues multiple recalls for 6.4 million vehicles worldwide

It looks like 2014 may go down as the year of recalls. We were already at a record pace, and now it seems Toyota is recalling 6.39 million vehicles worldwide, including about 30 of its models for a variety of problems. None of the faults have caused any injuries or fatalities, but there have been two reports of fires caused by a defective engine starter motor.
Toyota's numbers show 1.772 million vehicles being recalled in the US, but that includes some overlap because the Yaris is being repaired for multiple faults. According to The Detroit News, there are 2.36 million affected models in all of north North America, 1.09 million in Japan and 810,000 in Europe, plus smaller numbers in other regions.
Among the vehicles recalled in the US are 1.3 million units of the 2009-2010 Corolla, Matrix and Tacoma, the 2008-2010 Highlander, the 2006-2008 Rav4 and 2006-2010 Yaris. The problem is that the driver's airbag module is attached via a spiral electrical cable. The connections on the cable can be damaged when the steering wheel is turned, which deactivates the airbag and causes the airbag warning light to come on. Toyota is replacing the cable with an improved part, but it's still making preparations to begin the repair. The company is sending affected owners notifications in the mail. According to The Detroit News, an unspecified number of Pontiac Vibe vehicles are also included in this recall because it shares the part with the Matrix.

Kyle Busch breaks leg in big crash, will miss Daytona 500

NASCAR driver Kyle Busch suffered a compound fracture of the lower right leg and a mid-foot fracture of his left yesterday at Daytona during the 112th lap of the Alert Today Florida 300, the season-opening race of the 2015 NASCAR XFINITY Series. Busch came into contact with the infield wall just past the pit lane exit, an area where there is currently no SAFER barrier, which is designed to reduce the risk of injury in a crash. Fellow racer Ty Dillon, the third-place finisher in the race, expressed a common refrain following the news of Busch's injury. "I think we're to the point now in NASCAR we should have SAFER barriers at a place like this, we're going so fast. I think we could probably afford it," said Dillon. Matt Crafton will drive the No. 18 Toyota today at the Daytona 500 today as a substitute for Busch, but it's not yet clear if he will continue to drive the car following Daytona. Kurt Busch, Kyle's older brother, will also miss the Daytona 500 due to the domestic violence case against him in Delaware. Video footage of the wreck can be seen above. It goes without saying, but we wish Kyle a speedy recovery and a return to his stock car as quickly as possible.