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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 tops Toyota in annual CarMD Vehicle Health Index

CarMD has released its third annual Vehicle Health Index, which for the 2013 tracked the frequency and cost of repairs for "check engine" problems of 119-million vehicles built between the 2003 and 2013 model years. For the first two years of the index, Toyota ranked at the top of the list, but this year's results see Hyundai moved to number one, pushing Toyota down a spot.
The Korean automaker's rise to the top has been "fueled by its low repair frequency," according to CarMD. Toyota is second to Hyundai in lowest repair frequency, but Toyotas also have the highest average cost of repair. (Interestingly, General Motors vehicles have the lowest average.) Both Toyota's and Hyundai's manufacturer "health" ratings suffered this year, but Toyota took a bigger hit, which also is what helped Hyundai achieve the top ranking.
While Hyundai is the top manufacturer in the index, the 2012 Toyota Camry is the top vehicle. The best-ranking Hyundai was the 2010 Elantra (behind three Nissan models and four Toyotas), which took the number eight spot. Hyundai has six other vehicles in the top 100.

Weekly Recap: Toyota wants cars to be your 'close friends' around 2020

Toyota confirmed plans this week to launch autonomous technology in its production cars around 2020. The automaker's version is called Highway Teammate, and it's one element of a broader mobility strategy that includes vehicles communicating with each other and the grid. "Toyota believes that interactions between drivers and cars should mirror those between close friends who share a common purpose, sometimes watching over each other and sometimes helping each other out," the company said in a statement. That sounds utopian, and perhaps a bit cheesy, but it's an acknowledgment that autonomous driving requires more than technology developed in a vacuum. Toyota is looking at its research in a broader context, and dubs its overall strategy the Mobility Teammate Concept. Highway Teammate is the first step. Its test vehicle is a modified Lexus GS, which uses road-mapping data and external sensors to merge or exit highways, change lanes, and maintain safe distances during driving. It's operated on the Shuto Expressway in Tokyo. Toyota has been working on autonomous tech since the 1990s, with the goal of providing mobility for older people and the disabled, as well as lowering the frequency of traffic accidents. Toyota's push comes as an early adopter, Nissan, is hedging on its own deadline to implement the autonomous tech by 2020 due to a lack of firm laws governing self-driving cars around the world. Conversely, Volvo took the landmark step of being the first automaker to accept liability for when its cars will operate in autonomous mode, and urged the US government to set federal guidelines to regulate the technology. OTHER NEWS & NOTES 2016 BMW M4 GTS: Your water-injected, turbo-boosted demon BMW is unleashing its most powerful M4 ever, a 493-horsepower special edition that's road legal yet bred for the track. The company is making 700 copies for sale around the world, and 300 of them will come to the United States. The twin-turbocharged 3.0-liter six-cylinder revs to 7,600 rpm and uses a water-injection technology to cool the intake air and lower the compression temperature. BMW says this allows it to wring more power out of the inline six. The car also uses carbon-fiber reinforced plastic for the roof, hood, engine compartment strut brace, drive shaft, and rear spoiler to reduce weight. The M4 features BMW's organic light-emitting diode taillights, which are said to be an industry first.