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Toyota finds 10% MPG improvement in hybrid PCU

Keeping up its from-all-angles approach to efficiency, Toyota has found yet another way to eke out up to ten percent more precious MPGs in its hybrid vehicles, this time electronically. The automaker has announced the development of new silicon carbide (SiC) power semiconductors for use in power control units, which it will begin testing on Japanese roads within the next year. The PCU using the silicon carbide compound offers less electrical resistance, which improves efficiency when passing current between the battery and electric motor. It also loses less power after shutting off, and can operate at a higher frequency. The net power loss of the new PCU is just one-tenth of the current silicone-only version (the latter accounting for 20 percent of total electrical power loss in today's hybrids). The result, so far, is a claimed five-percent improvement in fuel economy in test vehicles, with the potential of ten percent by the time the new SiC power semiconductor comes to market. Additionally, the carbide wafers allow for smaller a power module, coil and capacitor, thus allowing the entire PCU to be 80 percent smaller (see the side-by-side comparison in the accompanying photo, which you can click to enlarge). We've got a while to wait before we start to see the carbide technology to start making a real-world impact. Toyota aims to begin using the SiC units in 2020. By then, with improvements in the company's other key efficiency factors - engine technology and aerodynamics - cars like the Prius will likely see significant gains in fuel economy. Read more in the press release below. Toyota Develops 'Diamond-like' Computer Chips to Boost Hybrid Mileage May 20, 2014 Toyota City, Japan – Toyota is using one of the hardest materials in nature after diamonds to develop a semiconductor chip it hopes will improve the fuel efficiency of its hybrids, such as the Prius, by as much at 10 percent. The company and its partners announced today that they have developed a silicon carbide (SiC) power semiconductor for use in automotive power control units. Toyota plans to begin test-driving vehicles with the technology on public roads in Japan within a year. The chips, made from carbide - one of the hardest materials in nature, theoretically have superior characteristics such as one-tenth the electrical power loss and 10 times the drive frequency. Toyota said the chips would also allow it to reduce the size of current automotive power control units by 80 percent.

2015 24 Hours of Le Mans live race report

Check back regularly for more race updates every few hours. No, you don't need to stay up for the entire 24 Hours of Le Mans, but if you want to catch any of the action, Autoblog friend Reilly Brennan has a handy guide. And to keep you up to speed on the latest race events, we'll be posting live from Le Mans with regular race reports.Hour 1: Five laps in, Audi breaks up the three Porsches at the front, with the #19 919 Hybrid, driven by Nico Hulkenburg, passed by all three R18s. Hulkenburg eventually took back fifth position only to fall back again after the first pit stop. Meanwhile, clutch trouble kept the #23 Nissan GTR-LM in the pits until 15 minutes into the race. The other two Nissans were forced to start at the back of the grid after failing to the meet the 110 percent qualifying speed regulation. At the end of the first hour, just 7.5 seconds separated the first six cars. Then the factory team #92 Porsche GTE car caught fire, with the the #13 Rebellion P1 car taking frontal damage in the ensuing carnage. With the safety car out, the field is once again bunched up.Hour 2: The slugfest between Audi and Porsche continues, with neither side backing off. Halfway through the second hour the #7 R18 passes both leading Porsches for the top position. After another round of pits stops Porsche regains the lead until lap 30, when the Audi overtake once again and quickly pulls out a three-second gap. Nico Hulkenburg passes the other two Audis to join his Porsche teammates. At the beginning of the third hour it's Audi #7, Porsche #17, #18, and #19, followed by Audi #8 and #9. 33 seconds separates this group, with Toyota a minute back from the front car.Hour 3: On track the action refuses to stop. Although it's early, Audi is looking strong with the overall lead in the #7. What's more is that the Audis run four stints per set of tires, while the Porsche cars have to change rubber every third stop. But after a quick refueling, the lead R18 gets a tire puncture and comes back in 3 laps later, allowing Porsche to take over the top two spots. Then as the hour closes out a yellow flag causes traffic to bunch up and the #8 Audi gets stuck with nowhere to slow down. Driver Loic Duval dives for the side of the road but hits the guard rail and careens across the track, damaging the front and rear bodywork. The rest of the car is still intact, though, and once in the pits Audi replaces the entire front and rear of that in only three minutes.

Toyota asking NHTSA for fuel cell car safety exemption regarding electric shocks

Toyota is requesting an exemption from federal safety regulations that govern electric cars as it prepares to launch a small-scale hydrogen fuel-cell vehicle fleet.
The Japanese automaker is targeting Federal Motor Vehicle Safety Standard 305, which covers the packaging of high-voltage parts in electric cars. According to Uncle Sam, these systems need to be isolated so that passengers and first responders aren't electrocuted in the event of a crash. That seems pretty smart, but it's become a problem for Toyota's upcoming production fuel cell vehicle, as the mechanism that prevents electric shocks in low-speed crashes will apparently simply keep Toyota's car from even functioning.
Instead of the federally approved system, Bloomberg reports that Toyota plans to insulate the high-voltage wires and cables in the car, along with shielding electrical components like the fuel cells, electric motor and batteries with (presumably non-conductive) metal barriers.