HybridAuto’s UltraCommuter represents a step change in vehicle technology.  Using an aerodynamic body shape, advanced light weight materials and an extremely efficient series hybrid (electric-only drive) powertrain, we have designed a vehicle with substantially reduced energy requirements which offers the possibility of daily commuting powered only by the sun falling on the rear glass and bonnet of UltraCommuter.

UltraCommuter is full of unique technologies, but a key area of innovation is in the direct drive wheel motors placed in each of the rear wheels.  The motors have been designed to overcome the known disadvantages of wheel motors and have exceptional power density.    

The key technical attributes in the UltraCommuter design follow Hypercar® principles:

a) Low vehicle mass (650kg) and drag, including low rolling resistance

b) Series hybrid electric drive powertrain[1]

c) Sports performance (acceleration and handling) with ample driving range

d) Minimum energy consumption and emissions in both urban and highway driving conditions

e) Zero-emissions and plug-in recharge capability (see below)

Low Vehicle Mass:

Low curb mass is achieved through a synergistic combination of lightweight materials (featuring aluminium alloys and carbon fibre composites), low-drag design, high-power-density powertrain components and an efficient electric (or series-hybrid) powertrain architecture with full regenerative braking.  In concert, these design elements result in the mass-decompounding effect in which reductions in masses and energy requirements build on each other iteratively.

Series Hybrid-Electric Powertrain

Key components of the series hybrid-electric powertrain in the UltraCommuter include:

Ø       Direct drive wheel motors: Patent pending high-torque (500Nm each), ironless, brushless, DC, rare earth permanent magnet wheel motors – one in each rear wheel

Ø       2 custom-designed 200V, 200A Tritium “WaveSculptor” motor controllers for each wheel motor

Ø       Lithium-ion batteries, 100 cells, 360V nominal, 8.6kWh, 62kW or equivalent

Ø       Body-integrated solar array – 2.5m2, 400W – with integral maximum power point trackers.

Ø       Intelligent powertrain controller

Ø       All-electric accessories

Ø       On-board ICE generator with fuel flexible capability (unleaded petrol, natural gas or ethanol) mated directly to custom permanent magnet generator (based on our wheel motor)

Performance:

0 to 100kph in less than 8 seconds ▪ Top speed in excess of 160km/h ▪ Aluminium double-wishbone front and rear suspension ▪ Use of regenerative braking allows the removal of friction brakes from the rear wheels, to reduces un-sprung mass ▪ Series hybrid architecture and electric drive allow heavier powertrain components to be placed low and centre for optimal weight distribution.

Minimum Energy Consumption and Emissions in Urban and Highway Driving Conditions:

With its ICE generator only running when battery charge dips below a pre-determined level, UltraCommuter’s combined urban/highway fuel consumption using unleaded petrol is approx 2.0l/100km – or 118 MPG (US).  Predicted Urban energy consumption is around 50Wh per km, which is now backed by new WSC race data suggesting 60Wh/km while cruising at high speed.  Greenhouse gas emissions of the UltraCommuter will be less than 50g CO2 per kilometre when running on unleaded petrol[2]. The series hybrid architecture allows the engine load (speed and torque) to be decoupled from the wheels, yielding optimal engine efficiency for lowest possible emissions. 

Zero-Emissions Capability

The series hybrid-electric architecture has an inherent all-electric, zero emissions capability – a driving mode where the engine is turned off.  The UltraCommuter will be equipped with a 400W, 2.5m2 on-board solar array.  Research shows that the UltraCommuter can travel up to 60km per day or 12,500km annually with the solar energy collected.  The ~200km zero-emissions driving range of the battery pack provides tolerance to several days of poor weather.  If necessary, the UltraCommuter battery can be recharged from a conventional 240V socket in approx 4 hours using the integrated on-board charger.  On an annual basis, by utilising solar-powered commuting, the UltraCommuter can achieve a greenhouse gas emissions reduction of 97% below that of the average Australian passenger vehicle, multiplied by vehicles sold.

The story thus far...