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Japanese automakers ramping production for renewed American sales

The 2011 earthquake and tsunami that struck Japan took quite the toll on the automotive industry in that nation. Not content to lean on that tragedy as excuse for slagging sales, the Japanese automakers are planning on a major production expansion in North America. The aim is to reclaim the market share lost from the Tsunami-based dip, and overcome a dollar/yen exchange rate that makes exporting to America unprofitable.
Following the Tsunami, Japanese automakers ramped up production in their North American facilities to compensate, but according to Automotive News, Nissan, Honda and others have all reported plans for still-further increased production in the year ahead. As part of this ramp-up, Mazda will open a facility in Salamnca, Mexico before March of 2014. Part of that increase in output is 50,000 units of a Toyota-badged compact car, which Mazda will produce.
Other Mexican production facilities opening include a Honda plant, which will open in Spring 2014 in Celaya, and a Nissan plant, set to open later this year in Aguascalientes. Nissan also said that it will need another plant in North America within the next five years. According to Nissan Boss Carlos Ghosn, the company aims to raise its stake in the US market from 8 percent to 10, and adding production will help achieve that goal. Even Mitsubishi is aiming to boost production at its Normal, Illinois plant. Production of the Outlander Sport is currently at 50,000, which Mitsubishi wants to raise to 70,000.

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.

The real reason automakers are giving away free hydrogen

Just like Hyundai did with its Tucson fuel cell, Toyota is offering free hydrogen fuel with the $57,500 Mirai H2 sedan. Toyota is being a bit vague about the details, saying simply that Mirai drivers will get, "complimentary hydrogen fuel for up to three years." Turns out, the reason that the hydrogen avant-garde will not be paying anything at the pump isn't because the automakers want to give them a boost or because the OEMs are kind. Instead, it's simply impossible to accurately charge people for hydrogen right now. It's simply impossible to accurately charge people for hydrogen right now. At an in-depth hydrogen seminar this week as part of the Mirai preview, three representatives from various hydrogen organizations revealed that the current hydrogen stations (most of which are in California) are not set up to accurately measure the hydrogen that is dispensed. Without this little bit of information, you can't charge customers for the fuel they use. Toyota is well aware of this, and Toyota Motor Sales' national manager of environmental, safety and quality communications, John Hanson, said that, "There are no set standards, so there is no way to charge people for anything." Alberto Ayala, the deputy executive officer for the California Air Resources Board, said CARB is in the middle of developing a way to sell a given amount of hydrogen, "which up to this point doesn't exist. If you think about it, it's a real simple yet real practical challenge. If you're going to pay for X amount of hydrogen, you're actually getting that amount of hydrogen." Ayala said it's not a difficult technical problem to measure the hydrogen as it goes into the car, but "we just have not done it. We are at a point where we are solving multiple remaining questions [with hydrogen infrastructure], and that just happens to be one of them." The National Institute of Standards and Technology says that there has been a discussion to change the current tolerance of two percent up to 10 or 20 percent, but that new technology should be able to measure accurately to within one percent. Air Liquide is working with Toyota to launch the Mirai in the US and Air Liquide CEO Ole Hofelmann told AutoblogGreen that being able to charge customers will be key to the technology's success. "We need to make sure we accurately measure the gas," he said.