This is a darn good thread and discusses things I have been thinking about.
You have learned the magic of P&G. You need hybrid mode and a fuel cut off switch now.
Larry is right that technically EOC will beat P&G but there is the practical aspect of doing it at high speed in traffic. I have done both EOC and P&G on the level at 60 mph. I don't shut the engine off as much as I used too. My Saturn seems to use a little extra fuel on restart for each pulse. At slower speeds EOC is easily my choice. I think it comes down to a personal preference and percievced stresses on the car. The penalty for P&G at higher speeds is not that severe if you take the time to calculate it out. My car uses .2 gph at idle.
I have thought that an ultru cap hybrid system would work for extending the pulse cycles. The cost and techonogly hinders this. Keep your fingers crossed for the Volt.
I have done back of the envelope calculations on dual engine systems. The small engine needs to have the BSfC of a DI diesel to make this effective. Yanmar clones are starting to be made in China. The price seems right and if the fuel specifics are accurately reported one could put together an aux drive that might pay for itself in the life of the car. The rational thing is to buy a modern DI diesel car. By the way I am not always rational
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CO's suggestion of liquid filled tires is truly elegant. I like it. The viscosity and velocity difference of the liquid would make the energy transfer smooth and of long duration. Texture or ribs inside the tire could be chosen for a more gentle or more agressive energy trasfer. This change alone could make long distance P&G possible for the rest of us.
Farm tractors have used liquid in tires for years. Sometimes it can get out of balance. The thought of 3 gallons of liquid flung to one side of a tire at 60 mph is a bit intimidating. The road speed of modern tractors can lead to a spot of trouble on a cold start with powdered metal weight in the tires
. I think this problem could be managed. This is an extension of the viscous torsional damper.
On my Saturn with heated intake air I am usually pulsing at about 1/3 throttle and low RPM. This is 85% LOD or so at that RPM. The warm intake air appears to be leaning out the engine. If it begins to run slightly irregular I increase the throttle and the engine smooths out and picks up torque. I think this is due to increased fuel at higher throttle. All I am saying is that optimum throttle for pulse may depend on other variables. In almost all cases I have checked less RPM is better. I can probably find an exception to that statement too.
Don't forget that Basjoos's steady state beats most of us while were doing P&G.