Air-Powered Car Coming to Hit 1000-Mile Range

The Air Car caused a huge stir when we reported last year that Tata Motors would begin producing it in India. Now the little gas-free ride that could is headed Stateside in a big-time way.

Zero Pollution Motors (ZPM) confirmed on Thursday that it expects to produce the world’s first air-powered car for the United States by late 2009 or early 2010. As the U.S. licensee for Luxembourg-based MDI, which developed the Air Car as a compression-based alternative to the internal combustion engine, ZPM has attained rights to build the first of several modular plants, which are likely to begin manufacturing in the Northeast and grow for regional production around the country, at a clip of up to 10,000 Air Cars per year.

And while ZPM is also licensed to build MDI’s two-seater One CAT economy model (the one headed for India) and three-seat Mini CAT (like a Smart For Two without the gas), the New Paltz, N.Y., startup is aiming bigger: Company officials want to make the first air-powered car to hit U.S. roads a $17,800, 75-hp equivalent, six-seat modified version of MDI’s City CAT (pictured above) that, thanks to an even more radical engine, is said to travel as far as 1000 miles at up to 96 mph with each tiny fill-up.

We’ll believe that when we drive it, but MDI’s new dual-energy engine—currently being installed in models at MDI facilities overseas—is still pretty damn cool in concept. After using compressed air fed from the same Airbus-built tanks in earlier models to run its pistons, the next-gen Air Car has a supplemental energy source to kick in north of 35 mph, ZPM says. A custom heating chamber heats the air in a process officials refused to elaborate upon, though they insisted it would increase volume and thus the car’s range and speed.

“I want to stress that these are estimates, and that we’ll know soon more precisely from our engineers,” ZPM spokesman Kevin Haydon told PM, “but a vehicle with one tank of air and, say, 8 gal. of either conventional petrol, ethanol or biofuel could hit between 800 and 1000 miles.”

Those figures would make the Air Car, along with Aptera’s Typ-1 and Tesla’s Roadster, a favorite among early entrants for the Automotive X Prize, for which MDI and ZPM have already signed up. But with the family-size, four-door City CAT undergoing standard safety tests in Europe, then side-impact tests once it arrives in the States, could it be the first 100-mpg, nonelectric car you can actually buy?

Idling Stop Technology | i-stop

Idle stop systems save fuel by shutting down a vehicle’s engine automatically when the car is stationary and restarting it when the driver resumes driving. Especially in urban areas, drivers often let their car’s engine idle at traffic lights or when stopped in traffic jams. Switching off the engine to stop it idling in these situations enhances fuel economy by about 10% under Japan’s 10-15 mode tests.

Conventional idling stop systems restart a vehicle’s engine with an electric motor using exactly the same process as when the engine is started normally. Mazda’s ”i-stop”, on the other hand, restarts the engine through combustion. Mazda’s system initiates engine restart by injecting fuel directly into a cylinder while the engine is stopped, and igniting it to generate downward piston force. This system not only saves fuel, but also restarts the engine more quickly and quietly than a conventional idle-stop system.

• Piston stop position control and combustion restart technology

In order to restart the engine by combustion, it’s vital for the compression-stroke pistons and expansion-stroke pistons to be stopped at exactly the correct positions to create the right balance of air volumes. Consequently, Mazda’s ”i-stop” effects precise control over the piston positions during engine shutdown. With all the pistons stopped in their optimum position, the system restarts the engine by identifying the initial cylinder to fire, injecting fuel into it, and then igniting it. Even at extremely low rpm, cylinders are continuously selected for ignition, and the engine quickly picks up to idle speed.

Thanks to these technologies, the engine will restart with exactly the same timing every time and will return to idle speed in just 0.35 seconds, roughly half the time of a conventional electric motor idling stop system. As a result, drivers will feel no delay when resuming their drive. With the ”i-stop”, Mazda can offer a comfortable and stress-free ride as well as better fuel economy.