Lotus Engineering is set to go into series production with a new range extender engine in collaboration with Fagor Ederlan.

The firm, a division of Lotus Cars Ltd has agreed a to begin production of the engine while Fagor Ederlan, part of the Mondragon Corporation Cooperativa will handle the sales of the new engine for the global automotive market.

The two firms collaborated over a technical and market study analysing the best route to production for the Lotus Range Extender engine before agreeing to begin production.

The three-cylinder, 1.2 litre Range Extender engine has been designed specifically for series hybrid vehicles. The engine could offer an ideal solution for carmakers who want a fast route into the market for range extended electric cars. The high efficiency, low mass design will enable low emissions vehicles to be produced cost effectively across a wide range of hybrid vehicle applications, as already demonstrated in both the Lotus Evora 414E Hybrid and the PROTON Emas concepts, which were shown at the 80^th International Geneva Motor Show this year.

Share on Facebook

Vehicle mass could be slashed by 38 per cent – for just a three per cent increase in component costs.

That’s the result of a detailed study by Lotus Engineering as it attempted to develop a commercially viable mass reduction strategy for mainstream passenger vehicles. The study focused on the use of lightweight materials and efficient design. It compared a benchmark Toyota Venza crossover utility vehicle (pictured below) and found that the 38 per cent reduction in vehicle mass, excluding the powertrain, could be achieved for only a three per cent increase in component costs by using engineering techniques and technologies that are viable for mainstream production programmes.

The Toyota Venza.

Lighter vehicles are seen as cleaner and more efficient. According to US Department of Energy estimates, a total vehicle mass reduction of 33 per cent would result in a 23 per cent reduction in fuel consumption.

During the study, the Toyota Venza was disassembled, analysed and weighed to develop a bill of materials and understand component masses. Then Lotus Engineering employed a total mass reduction strategy while maintaining all key interior and exterior dimensions and volumes so that the new vehicle retained the vision, sight line, comfort and occupant package of the original.

For information on how the remarkable reductions were achieved, check out this paper.

Share on Facebook

The brand new Lotus Elise has a unique claim to fame – for its performance level it has the lowest CO2 emissions of any petrol sports car in the world.

That’s the statement after the new entry level 2011 Lotus Elise was certified with an emissions figure of 149g/km of CO2 – that’s a reduction of 16 per cent when compared to the previous Lotus Elise S. In fact, the figure beats even Lotus’s own expectations with the manufacturer having previously indicated that it would come in somewhere below the 155g/km barrier.

This means that the Elise consumes 46.7mpg on the extra urban cycle thanks in part to its Toyota 1ZR-FAE 1.6litre engine with Valvematic and Dual Variable Valve Timing-intelligent technology that controls intake valve opening/closing timing and the intake valve lift for significant improvements in efficiency and economy.

With optimal performance, the Elise achieves both high fuel efficiency and high performance. It weighs just 876kg, boasts improved aerodynamics and its new 1.6litre Euro 5 Valvematic engine is 200cc smaller than the previous Elise S model despite boasting similar power with a maximum torque of 160Nm at 4,400rpm.

Share on Facebook

The Geneva Motor Show may have closed its doors, but there was still time for another series of exciting range extended electric car concepts to be revealed.

This time it was the turn of Malaysian car manufacturer Proton, which unveiled the five-door, four-seat hatchback EMAS; a three-door, five-seat hatchback EMAS Country for country driving; and a three-door, 3+1 seat EMAS3 for city driving.

Proton EMAS drive system elements.

As it bids to expand its global footprint, Proton is focusing on eco-friendly vehicles with EMAS standing for Eco Mobility Advance Solution, while also meaning “gold” in the Malay language. The EMAS vehicles are the result of collaboration between Proton, its subsidiary Lotus, and Italian design house Italdesign Giugiaro. 

The drivetrain for the vehicles has been developed by Lotus Engineering and includes the Lotus Range Extender three-cylinder, 1.2litre internal combustion engine. It can develop 38kW at 3,500rpm and can run on petrol, natural gas, ethanol or methanol. The front transverse internal combustion engine is coupled with a generator that recharges the 11.47kWh lithium-ion battery pack.

Five-door hatchback Proton EMAS.

The engine boasts some impressive performance statistics. Its top speed is 106mph and it can accelerate from 0-62mph in 14 seconds. Battery range in the hybrid configuration is 31miles.  

Proton is now hoping that the EMAS3 can be fitted with a larger battery pack so that a full electric version can be made available.

Share on Facebook

Ferrari, Lotus or Porsche: close your eyes and picture a vehicle from any of those world-famous manufacturers and you’re likely to envision a dream car with sleek lines, an eye-catching body and incredible power. Fuel efficiency and reduced greenhouse gas emissions are unlikely to creep into the fantasy image.

Indeed just a month ago the Green Piece Column (see article) examined some of the green sports cars headed our way – but they were generally restricted to offerings from relative upstarts like Tesla Motors and Fisker Automotive. The big name sports car makers it seemed were just carrying on, business as usual.

However, this year’s Geneva Motor Show has changed all that as one after the other, some of the biggest names in the sports car field revealed that they too have developed a green conscience. Let’s take a look at what’s coming from some of the motoring industry’s most respected car makers:

Ferrari – F1 technology goes green

Based on the Ferrari 599 GTB Fiorano, the Italian carmaker unveiled the Ferrari HY-KERS in Geneva – a vehicle that features a lightweight hybrid drivetrain with system components located below the centre of gravity (see article).

The HY-KERS still has F1 technology and the performance characteristics of a typical Ferrari but manages to reduce CO2 emissions by around 35 per cent. It can even operate as a full electric vehicle in city traffic.

In addition, Ferrari has also introduced a stop and start system into the Ferrari California model that slashes fuel consumption and emissions by six per cent.

Lotus – A green triple threat

The Lotus Elise is one of the most sought-after super cars in the world and its transformation in Geneva is perhaps the most telling of all (see article). The new Elise now has the lowest CO2 performance for a petrol sports car in the world at less than 155g/km with fuel efficiency at 38mpg – yet it can still race from 0-60mph in just six seconds and achieve a top speed of 124mph.

However, Lotus’s green contributions to the show did not end there. It also unveiled the PROTON Concept (see article), a plug-in hybrid car which uses the Lotus Range Extender engine and can be charged using a domestic outlet to achieve electric-only operation when the vehicle is first used.

Also making its debut was the Lotus Evora 414E Hybrid Concept which produces 414PS of power and can accelerate from 0-60mph in less than four seconds (see article). It has an electric range of 35miles; a total hybrid range in excess of 300miles; and, according to Lotus, its total lifetime CO2 emissions is lower than that of a fully electric car with comparable performance.

Porsche – A hat-trick of hybrids

Few manufacturers have been as busy at Geneva as Porsche, which has introduced a hat-trick of hybrid cars at the event.

Perhaps the most eye-catching is the plug-in hybrid Porsche 918 Spyder concept car (see article) that is powered by a high-speed V8, can accelerate from 0-62mph in less than three seconds and can achieve a top speed of 198mph. However, despite these remarkable performance statistics, the plug-in hybrid technology makes it strikingly efficient with fuel consumption at 74.8mpg and emissions at 70g/km of CO2.

Also revealed at the event was the new Cayenne S Hybrid (see article), which slashes fuel consumption by 23 per cent compared to the previous model thanks to features such as auto stop-start, thermal management and intelligent lightweight construction. Fuel consumption is 28.75mpg and CO2 emissions are just 193g/km. Completing the set for Porsche is the 911 GT3 R Hybrid that includes a flywheel energy recovery system developed by Williams for F1 racing (see article).

And don’t forget…

Though Ferrari, Lotus and Porsche may have stolen the show in Geneva, they aren’t the only manufacturers with exciting green sports cars in their line-up.

Others to look out for include the Honda CR-Z (see article), dubbed the world’s first hybrid sports car and that is scheduled to be released in Europe this summer. Also coming is the Vauxhall/Opel Flextreme (see article), a range-extended concept with a total range in excess of 300miles and fuel consumption at 174mpg; and the Bentley SuperSports Convertible (see article) that boasts an impressive top speed of 202mph and yet is able to run on petrol or E85 bio-ethanol; and all of these on top of the aforementioned Fisker Karma and Tesla Roadster.

What now appears blatantly apparent is that no leading car maker can afford to rest on its laurels with regards to green technology. Consumers want fast, powerful, exciting super cars that still save money in the forecourt and slash emissions – and now it seems they are going to get them.

Faye Sunderland

Share on Facebook

Lotus isn’t a name we feature too regularly here at TheGreenCarWebsite.co.uk but with the Geneva Motor Show approaching the company has been all over the news.

Originally announcing a leaner, greener version of the Lotus Elise (see article) and then revealing plans to unveil the Lotus Range extender engine at the event (see article), the company will now debut the Lotus Evora 414E Hybrid Concept at the Swiss showcase.

The Lotus Evora 414E is so named because it produces 414PS of power with Lotus having developed a drivetrain system that consists of twin motors that provide 152PS of power and 400Nm of torque to each wheel via independent transmissions. Indeed power is no problem for this eye-catching model which can accelerate from 0-60mph in less than four seconds.

The 1.2litre, three-cylinder Lotus Range Extender engine offers the vehicle an additional 35kW of power at 3,500rpm and with innovative architecture there are improvements in engine mass, assembly costs, package size and emissions.

The “green” element of the vehicle comes courtesy of a lithium polymer battery pack that provides 17kWh of energy storage capacity and has been optimised for energy density efficiency with more than 100kW discharge capability. It has an all-electric range of up to 35miles and a total hybrid range of more than 300miles.

According to Lotus, the total lifetime carbon dioxide (CO2) emissions of the vehicle with the range extender solution, which includes the energy required to manufacture and run it, is actually lower than a fully electric car with comparable performance.

The Geneva Motor Show opens to the Press on March 2 before the public get their first glance at these eagerly anticipated new vehicles on March 4.

Share on Facebook

Not content with debuting a sleeker, greener version of the Lotus Elise in Geneva (see article), now Lotus Engineering is lining up its PROTON concept for the 80^th edition of the international motor show.

The city car uses a complete hybrid drivetrain developed by Lotus Engineering alongside the Lotus Range Extender engine that is designed for hybrid vehicles. It is a plug-in hybrid, and, for longer journeys, when the battery charge level falls, the 1.2litre range extender engine replenishes the charge and provides electrical power for the drive motors. The battery can also be charged using an AC mains domestic outlet to achieve electric only operation when the vehicle is first used.

According to Dr Robert Hentschel, director of Lotus Engineering, the Lotus Range Extender engine is perfectly suited for an advanced series hybrid.

If you’re thinking the name PROTON sounds familiar then you’re not wrong – the group has been Malaysia’s largest manufacturer of cars since it was established in 1983 and now owns Group Lotus. Just three years ago, Lotus Engineering unveiled the Efficient, Viable, Environmental (EVE) Hybrid that was developed in close operation with PROTON and showcased how manufacturers can introduce low emission variants to existing model ranges.

According to PROTON Holdings Berhad Group managing director Dato’ Haji Syed Zainal Abidin Syed Mohd Tahir the collaboration will propel the brand’s competitiveness in the world market.

Share on Facebook

A fleet of hydrogen-fuelled black cabs could be in service in time for the London Olympics in 2012.

A taxi cab, identical to the traditional London black cabs is currently being tested, with the aim that it will be ready for full road trials in time for the capital’s Olympic games.

The cab, developed by Lotus and Intelligent Energy uses hydrogen fuel cell technology and is capable of a top speed of 81mph, achieve a range of up to 250 miles on a full tank of hydrogen and reach 60mph in less than 14 seconds.

Henri Winand, of Intelligent Energy told the Guardian: "The intent is to take the taxis and retrofit a powertrain that has zero tailpipe emissions. But also it has to deliver some very important things: a reasonable range, very quick refuelling time and no modifying the passenger or driver space."

Unlike electric vehicles, the hydrogen-fuelled cabs will only take seconds to refuel while still offering the chance to generate their fuel source from clean source. In time, it is hope that hydrogen can be split from water using green energy sources such as solar power or wind energy.

London’s deputy mayor, Kit Malthouse, confirmed last year that by 2012 there would be six hydrogen filling stations in the capital, which will assist in the use of a hydrogen fleet. He also said that the city would aim for a fleet of around 20 to50 taxis in operation by then fuelled from green technology as part of the  Black Cabs Go Green programme, as well as 150 hydrogen-powered buses.

Intelligent Energy designed and built the fuel cell, which uses hydrogen from a storage tank situated where the internal combustion engine usually sits. Electricity is generated when the hydrogen reacts with atmospheric oxygen in the fuel cell. The electricity is then feed to a battery pack under the floor of the taxi’s passenger area which then powers the wheels while the only emission from the tailpipe is water. Lotus is responsible for integrating the technology into the body of the traditional black cab.

Share on Facebook

Take one look at the new Lotus Elise and the words ‘green car’ are unlikely to be on your mind – but this breathtaking new super car manages to match incredible beauty and performance with remarkably low fuel consumption.

The new Elise line-up, which will debut at the Geneva Motor Show on March 2, includes a new entry level vehicle that incorporates a Toyota 1ZR-FAE 1.6litre engine with a variable valve lift mechanism and dual variable valve timing intelligent technology. It emits less than 155g/km of carbon dioxide (CO2) and offers more than 38mpg.

The 1.6litre engine is 200cc smaller than the previous Elise S model but produces similar power at 160Nm at 4,400rpm even though fuel economy has improved by more than 23 per cent. This means the Elise has the lowest CO2 performance for a petrol sports car in the world. It is mated with a six-speed manual gearbox and the engine with the Valvematic system and dual VVT-I continuously controls intake and valve opening and closing to vary the volume of the intake airflow and offer significant improvements in fuel economy and efficiency.

All of these improvements come without sacrificing performance, as the Elise can still accelerate from 0-60mph in a mere 6.0seconds while boasting a top speed of 124mph.

The entry level version of the Lotus Elise weighs a mere 876kg, so it is one of the lightest fully homologated sports cars in the world.

Share on Facebook

Another innovation is headed to the Frankfurt Motor Show next week, where Lotus Engineering will unveil its range extender engine.

The engine is attached to an electricity generator and provides an efficient source of energy to power an electric motor directly or charge the vehicle’s battery. As the battery can also power the electric motor, the result is a drivetrain with low emissions and optimised performance.

The three-cylinder, 1.2litre range extender engine offers 15kW of electrical power at 1,500rpm and 35kW at 3,500rpm. It features an innovative architecture that consists of an aluminium monoblock construction that reduces the engine mass and offers improved emissions and durability.

Thanks to its high efficiency and low mass it will be possible to downsize expensive batteries while maintaining efficiency and range, according to Lotus.

The company developed the engine as part of the Limo Green project that was funded by the UK’s Technology Strategy Board and featured collaboration between Lotus Engineering, Jaguar Cars Ltd, Caparo Vehicle Technologies and MIRA Ltd demonstrating a large saloon car with less than 120g/km carbon dioxide (CO2) emissions.

Share on Facebook