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How Toyota's 100-year textile history influenced FCV hydrogen fuel cell car

Turns out, Toyota had a surprising ace in the hole when it came to building the new fuel tanks for the FCV hydrogen fuel cell car, which is coming next year. Well before Toyota became the Toyota Motor Company, it was the Toyota Industries Corporation and it made textile looms. This is important because the main structure of the hydrogen tank is wound carbon fiber. When Toyota set out to increase the strength of the tanks to hold hydrogen stored at 10,000 psi (up from 5,000 in the previous tanks), it was able to draw on its 100-year-old history as it designed its car of the future. "A lot of that textile experience came back when we did the tank wrapping." – Justin Ward "We have a lot of experience with textiles," Justin Ward told AutoblogGreen at the 21st World Congress on Intelligent Transport Systems (ITS) in Detroit this week, "and a lot of that textile experience came back when we did the tank wrapping." On top of being able to hold the higher-pressure hydrogen, Toyota's first attempt to build its own hydrogen tank was six times faster than the industry standard, so it saved time and money as well as working better. The company will also be able to inspect its own tanks. Ward is the general manager of powertrain system control at the Toyota Technical Center and hydrogen vehicles are something he knows a lot about. The reason for the stronger, 10,000-psi tanks is because the 5,000-psi tanks only offered around 180-200 miles of range, even with four tanks in the early $129,000 FCHV Highlander hydrogen prototypes. The FCV only has two, but they will able to deliver the 300-mile range that customers told Toyota they wanted. Dropping the number of tanks not only obviously reduced the cost for the tanks themselves but also the number of valves and hoses and other components you need. Despite the benefits of higher compression, going much higher doesn't make sense. 10,000 psi is the "natural progression," Ward said, because "you start to bump up against compression inefficiencies." Think of an air compressor. When hydrogen is produced at a wastewater treatment plant or a reforming site, Ward said, is it at around ambient pressure (14 psi). That has to be raised, using compressors, all the way to 10,000 psi. "That takes energy," Ward said, "and every doubling of pressure adds another doubling of energy needed, so it starts to add up pretty fast if you go too high." Component specifications are also fine at 10,00 psi, but more difficult at higher levels.

Hyundai, Kia, Genesis and Subaru clean up in IIHS 2018 safety ratings

Hyundai, its partner Kia and its Genesis division are the big winners in the latest vehicle safety ratings from the Insurance Institute for Highway Safety, accounting for six of the 15 models that earned the Top Safety Pick+ awards for 2018. Subaru was right behind with four, Mercedes-Benz had two, and Toyota, BMW and Ford each had one. Another 47 vehicles earned the Top Safety Pick designation, where Toyota had 10 vehicle models, with Hyundai recognized for nine models. All but one of the seven vehicles in Subaru's lineup, the BRZ, qualified for one of the awards. IIHS strengthened the criteria for the Top Safety Pick+ award for 2018 to require headlights to earn a "good" rating — an "acceptable" rating was previously enough to notch the "plus" award — and good or acceptable passenger-side protection in the small overlap front crash, which replicates a crash involving just the front corner of a vehicle. It also required vehicles to have acceptable or good headlights for the first time to earn a Top Safety Pick award. Most of winners for both awards qualified on the basis of optional upgrades. IIHS in October began evaluating the passenger side of vehicles in its small overlap front crash test after it said it became clear that automakers were neglecting that side of the vehicle as they focused on improving driver-side protections. IIHS first began conducting driver-side small overlap crashes in 2012. It began measuring both how well low and high beams illuminated the road and the amount of glare they produce for oncoming vehicles as part of its ratings in 2016. The Top Safety Pick+ winners are listed below. The list doesn't include any minivans, pickups or minicars, which don't appear on either list of awardees. Small cars Kia Forte Kia Soul Subaru Impreza (sedan and wagon) Subaru WRX Midsize cars Subaru Legacy Subaru Outback Toyota Camry Large luxury cars BMW 5 series Genesis G80 Genesis G90 Lincoln Continental Mercedes-Benz E-Class sedan Midsize SUVs Hyundai Santa Fe Hyundai Santa Fe Sport Midsize luxury SUV Mercedes-Benz GLC The full list of Top Safety Pick winners is available here.Related Video: Image Credit: IIHS BMW Genesis Hyundai Kia Lincoln Subaru Toyota Safety Crossover SUV Wagon Sedan crash test

Toyota turning landfill gas into hybrid vehicles, indirectly

Chamillionaire certainly wasn't referring to the Toyota Avalon or Camry when he rapped about "ridin' dirty" but maybe he'll change his tune soon. That's because some of the future energy sources for the Kentucky factory that makes those two models will come from gas created from the breakdown of solid waste. So the power behind some of the production at Toyota's largest North American factory will indeed be funky. Toyota is working with Waste Services of the Bluegrass to build a network of wells at a nearby landfill in order to collect the gases. Construction of the system starts next month and will be finished by early next year. The upshot is that the system will produce one megawatt of electricity per hour, which is the equivalent to the power used by 800 houses. Last spring, Toyota said it would start producing the Lexus ES at the Kentucky plant after getting almost a $150 million offer from the state. That's because that model is expected to add 50,000 vehicles to the existing production numbers at the plant. And those production numbers are already large, as Toyota makes both the standard and hybrid versions of both the Camry and Avalon there. Mind you, Toyota's not the first to go this route for factory-energy production. In 2011, General Motors' Orion Assembly Plant started getting about 40 percent of its energy for production of models such as the Chevy Sonic and Buick Verano from methane captured from a landfill nearby. The General estimated at the time that the process would cut the company's energy costs by about $1.1 million a year. Check out Toyota's press release about the Kentucky plant and its future landfill gas below. Landfill Gas to Build Cars and a Greener Community Partnership between Toyota and local landfill turns garbage into good March 24, 2014 GEORGETOWN, Ky. (MARCH, 24 2014) – Can a car company be a vehicle for change? Toyota thinks so. The Kentucky plant that manufactures some of the greenest cars on the road, including two hybrid models, will soon be powered in part by green electricity. Toyota Motor Manufacturing, Kentucky, Inc. has teamed up with Waste Services of the Bluegrass to generate power from local landfill waste, marking the region's first business to business landfill gas to energy initiative. Toyota estimates the locally-generated landfill gas will supply enough power each year for the production of 10,000 vehicles. How it Works As solid waste naturally breaks down in a landfill, it creates gas.