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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.

Jonas wreaks havoc on auto industry

Many folks along the East Coast are still stuck at home from Winter Storm Jonas' brutal snowfall over the weekend, but the blizzard had some nasty temporary effects on the auto industry, too. Winter weather emergencies kept people from leaving the house, and that spelled trouble for factories and dealers. The terrible conditions in Washington, DC, even prevented the the Washington Auto Show from opening. General Motors, Toyota, and BMW had to close factories due to the weather. BMW cited concerns for its workers driving to the plant for canceling some Friday and Saturday shifts in Spartanburg, SC, according to Automotive News. Toyota closed its Georgetown, KY, factory on Friday, and GM shut down the second shift at its Bowling Green, KY, site for that day, too. Showrooms in the blizzard's path saw a massive drop in sales over the weekend because the customers weren't coming. Some affected dealers are now trying to make the best of a bad situation by offering potential buyers even deeper discounts to get them through the door, according to Automotive News. The piles of snow also mean hours of work for employees to clean off all the cars on the lot. The good news is that none of these issues should pose longterm problems. Weather reports don't show much snow for the East Coast in the coming days, which should allow the industry quickly to return to normal.

Toyota wants you to meet an 'obsessed' hydrogen fuel cell engineer

Like a television-broadcasting company covering the Olympics, Toyota is looking to market its future in hydrogen fuel-cell vehicle production by taking the personal approach. In this case, the Japanese automaker is telling the backstory of Jackie Birdsall, an engineer at Toyota Technical Center who Toyota says is "obsessed" with fuel-cell technology. A Sacramento native, Birdsall is responsible for testing fuel-cell vehicles and making sure hydrogen stations fill the tanks of the cars in a "reasonable" timeframe. Long a gearhead, she attended Flint, MI's Kettering University (formerly General Motors Institute) and, among other places, worked for the California Fuel Cell Partnership before joining Toyota in 2012. Her first car was an '87 Camry. That's one personal side of Toyota's hydrogen push, and shows another way Toyota is introducing the world to this new powertrain (see also: winter performance). The nitty-gritty is made up of things like working with FirstElement Fuel Inc. on a hydrogen-refueling network in California. As for its fuel-cell sedan, which was displayed in FCV prototype form at the Consumer Electronics Show in Las Vegas in January and is due next year, Toyota said it expects the car to have a full-tank range of about 300 miles and a five-minute refueling time. That's if Ms. Birdsall has anything to say about it. Check out Toyota's press release about Birdsall below. Talkin' 'Bout a Revolution A healthy obsession leads Jackie Birdsall and TTC to the forefront of history The word she keeps using is "obsessed." Jackie Birdsall became "obsessed" with cars when she was a teenager. That made her "obsessed" with the history of auto icons like Henry Ford and Lee Iacocca. In 2003, she did an internship with Daimler-Chrysler, leading to an "obsession" with hydrogen fuel cell technology. And now, as an engineer at Toyota Technical Center, Birdsall is "obsessed" with bringing fuel cell technology to the masses. But perhaps you need to be obsessed when you're trying to change the world. After all, revolutions don't blossom from complacency. Leading an alternative fuel revolution is just what Birdsall and her partners on the Fuel Cell Hybrid Vehicle team are doing. Collectively, they're finding tangible ways to reduce fossil fuels in the automobile world and figuring out how hydrogen fuel cells can be useful and affordable. In 2015, that obsession will bear fruit when Toyota's FCV hits the markets in California, Japan and Europe.