summer 2006 newsletter   SuperGen progress update   The SuperGen boosted hybrid technology has achieved a major project milestone with first prototypes commencing test. Customer interest has been extremely high and an active dialogue is on-going with global vehicle manufacturers in Europe, Japan and the USA as system development continues. Click here to visit the SuperGen library feature.   Detailed design of the first technology development prototypes commenced in September last year following concept level simulation and the selection of key supplier partners for the brushless permanent magnet DC motors and roller traction drive. These systems were integrated into a set of cast aluminium housings including bearing, sealing, lubrication and cooling systems.    The design of the first ever SuperGen required a ‘first principles’ approach to a range of issues from traction drive application calculations through to assembly sequence.  During the early stages the data management process was particularly critical as the specification of motors, traction drive and compressor evolved rapidly through a number of iterations. Dynamic simulation was employed throughout to ensure hardware reflected system performance requirements.   The first prototype completed its initial mechanical shakedown on the test rig in April. This proved the basic principle of controlling boost using the E2 control motor. These shake-down tests exercised the control motor at full power and showed we could run the compressor to its full speed of over 160,000rpm at a range of simulated engine speeds. No critical noise or vibration issues were noted. Following shakedown the unit was disassembled and, with no apparent wear issues, re-assembled for the next phase of testing. This will investigate the following: • Thermal rating of the system to confirm what levels of boost can be sustained in continuous operation • System efficiency • Transient throttle response • Engine cranking performance          Meanwhile the team has commenced the design of the production intent system with significant reductions in size and mass already delivered compared to the first prototype.