In a free-piston engine generator (FPEG), the power of the engine can be directly regenerated by linear generators without a crank. The mover motion of this system is interrelated with engine and power generation efficiencies due to the direct connection between the mover of the generator and the piston of the engine. The generator should be designed to improve the overall energy conversion efficiency. The dimensions and mass of the mover limit its operating stroke and drive frequency. Herein, we propose a method for designing linear generators and constructing FPEG systems, considering the mover operation to improve engine efficiency. We evaluated the effect of mover operation on the engine and generation efficiencies using thermal and electromagnetic field analysis software. The proposed design method improves the overall energy conversion efficiency compared with a generator that considers only the maximization of generation efficiency. Setting the mover operation for higher engine efficiency and designing a linear generator to realize the operation can effectively improve the energy conversion efficiency of FPEGs.

Free-piston engine generators without a crank mechanism are expected to be used in series hybrid vehicles because of their lower losses. The series hybrid system requires a low starting thrust because the engine frequently starts depending on the battery state. This study clarifies the effectiveness of the constant thrust resonance starting method that utilizes the compression pressure of the engine and the spring thrust. The piston must pass the combustion starting point with a predetermined speed to start combustion. Herein, we present a thrust setting method that uses the energy state diagram to optimize the velocity at the combustion start point. A simulation is performed assuming output when mounted on a vehicle. Consequently, the simulation results show that the maximum thrust can be reduced by more than 90% compared to that without resonance. Moreover, the speed at the combustion start point is in agreement with the value obtained using an energy state diagram. An impulse-like combustion pressure is generated in 180 ms, and combustion can be started using resonance, as shown in an experiment using a small-output engine and linear motor. The effectiveness of the constant thrust resonance starting method was confirmed.

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