The 130 MPG INGOCAR is a medium size 5 seat passenger car. The driving comfort is improved and driving distance and space requirements fulfill currently established standards. However, driving performance, fuel consumption and emissions are significantly better.

The graph below shows the main technical data of the car:

The drastically increased mileage results from the new Hydrostatic Powertrain with Energy Storage. The powertrain is significantly smaller and lighter. Its main components are joined together to a drivable car platform. The structure is very rigid and includes energy absorbing active bumpers. Because of this structural arrangement, the car body is not exposed to high loads and crash forces, and is therefore lighter in weight and less costly.

The functioning of the Hydrostatic Powertrain with Energy Storage and the high power of its wheelmotors make it possible to recuperate the entire braking energy. A new type of combustion engine converts the fuel energy more effectively into mechanical power and reduces the emissions. Its small size and low heat radiation allows for a car body with low air drag.

Summarizing: The drastically increased mileage and reduced emissions are the result of the above factors: 

• Reduced weight
• Lower air drag
• Very efficient engine
• All braking energy recuperated.

Hydrostatic Powertrain.

The 130 MPG INGOCAR is driven by a new Hydrostatic Powertrain with Energy Storage. This type of powertrain concept is currently used to drive construction and other equipment where their ability of continuously variable speed is indispensable.

Hydrostatic powertrains use pressurized fluid to transmit the energy. Controlling the flow of power is here very easy and the storage of energy fast and efficient. The power density of the components is high when compared with other drive systems. However, currently, the hydraulic motors as main components of hydrostatic powertrains do not fulfill the very extensive requirements regarding speed range, efficiency, weight and cost as required for an automotive drive system.

The components of the new hydrostatic powertrain are specifically designed to overcome these shortcomings. As the result, the new powertrain fulfills the needs of an automobile better than the current systems.

The three main components of the new powertrain, building the platform of the car, are:

1.  Wheelmotors   driving the car.
2.  Accumulator   providing the wheelmotor with power.
3.  Engine   charging the accumulator with pressurized fluid.

1. The wheel drives the car:

The wheelmotor consists of a hydraulic axial-piston motor and a single planetary gear stage. The concept of using a hydrostatic drive, located directly in the wheel hub, is made possible by drastically improved technical data of the hydraulic motor. The main improvements are:

There is one hydraulic motor in each wheel, driven by pressurized fluid from the accumulator. They provide high power to accelerate and drive the car. The power at each wheel can be adjusted very fast and continuously by the powertrain computer to improve the driving and braking performance.

The motors are powerful enough to stop the car within the shortest possible distance. During braking, the motors are reversed to pumps, charging the entire braking energy back into the accumulator. Due to higher loads at the wheel during braking, the motors in the front are larger and have 230 hp each. The car has a total of 670 hp.

The wheelmotors are noticeably smaller and lighter than the disk brakes they replace.

2. The wheelmotor is driven by energy from the accumulator:

The accumulator is a container for pressurized fluid, the energy which drives the car. The bladder at the inside is charged with pressurized gas (Nitrogen) and fills the whole container when the accumulator is empty. When fluid is pumped into the accumulator to store energy, the size of the bladder shrinks and the pressure increases.

The maximum amount of stored energy is 1.8 MJ at 6,800 psi., an equivalent of 0.68 hp over a period of one hour. Or e.g. 600 hp for ca. four seconds when storing the recuperated energy during hard braking. Because of the high pressure, the accumulator has thick container walls and possesses therefore a very high flexural stiffness. It is fabricated from carbon fiber to reduce the weight.

The accumulator assembly is the load bearing backbone of the car platform. To fulfill the additional requirements, the wall thickness is increased slightly and suspension points are built in for attaching the engine and wheel suspension.

The container technology is comparable to that of currently used tanks for PNG (Pressurized Natural Gas). During an excessive impact, the non-flammable Nitrogen will be automatically released.

3. The engine charges the Accumulator with pressurized fluid:

The 2-stroke Diesel engine with two opposed free-pistons, transfers the combustion pressure directly into pressurized hydraulic fluid. This engine concept provides best air-exchange conditions, is very robust and basically free of vibrations. Crankshaft and valve mechanisms are not needed, reducing the frictional losses, and the size and the cost of the engine. In addition, a high bore to stroke ratio is applied to obtain a very desirable compact combustion chamber.

The drawback of free-piston engines has been an insufficient control of the piston movement. A new hydraulic control mechanism and the electronic powertrain computer determine now the piston movement and therefore the compression ratio, speed and dead center positions. These conditions allow for an optimized combustion process for basically all liquid and gaseous combustible fuels, simplifying supply and reducing consumption and emissions.

The engine charges the accumulator only for a short period of time, and will be turned on and off automatically by the powertrain computer. When operating, the engine runs only at constant speed and power. The new fuel injection system with peripheral micro-slot injection improves the preparation of the air-fuel mixture noticeably. These conditions allow for a highly optimized combustion process, minimizing fuel consumption and emissions.

The pulse-pressure charger transfers the exhaust pressure wave directly into the intake air pressure wave. Further improved combustion conditions and a higher power density are the expected outcome. EGR (Exhaust gas recirculation), a common measure to reduce the emissions further, can more easily be integrated.

4. All four wheel have a wheelmotor:

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