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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.

West Coast labor dispute hampers Japanese automakers' US plants

The ongoing labor dispute between the International Longshore and Warehouse Union and port owners along the West Coast is starting to affect more Japanese automakers building vehicles in the US. The issue already forced Honda and Subaru to take the expensive option of airlifting some parts into the US weeks ago, and according to USA Today, Toyota and Nissan have begun doing so, as well. The choice hasn't been cheap, though, and Subaru's chief financial officer estimated that the decision cost around $60 million more per month than sending components by cargo ship. The effects continue to radiate, according to USA Today, and shortages of some models are possible. Honda is slowing production at its factories in Ohio, Indiana and Canada because the automaker doesn't have enough transmissions and electronics for some vehicles. Toyota already cut back on overtime at some factories. Nissan has only seen a small effect from the issue, though, because of its local suppliers. Dock workers and port owners have been negotiating on a new contract since last year, and the union has organized work slowdowns in response. According to USA Today, the automakers could move shipments to Canada or Mexico, but it would take longer for parts to arrive. News Source: USA TodayImage Credit: Mark Ralston / AFP / Getty Images Earnings/Financials Plants/Manufacturing UAW/Unions Honda Nissan Subaru Toyota shipping port labor dispute

Recharge Wrap-up: Q50 Hybrid video, Iran's biodiesel weed

A new video from Infiniti showcases the Q50 Hybrid's kinetic energy recovery technology, borrowed from Formula One. The video details what is going on inside both the Q50 Hybrid and the racecar when it gathers energy to store for later use, offering better performance than an internal combustion engine alone. In the Q50 Hybrid, that electric energy helps the car accelerate from 0-60 in 4.9 seconds. The video also serves to highlight the relationship between racing innovation and performance and efficiency improvements in production vehicles. See the video above. The 2015 Toyota Prius C has been named a Top Safety Pick by the Insurance Institute for Highway Safety (IIHS). The compact hybrid, updated for the 2015 model year, has been upgraded from a "poor" to "acceptable" rating in the small overlap crash test, placing it on the Top Safety Pick list. Beginning in the 2016 model year, cars will have to score a "good" rating on the test to make the list, which means further improvements will be necessary if Toyota wants the Prius C to maintain its safety status with the IIHS. Read more at Green Car Reports. A couple in Tennessee have been found guilty of scamming the state in a fake biodiesel scheme. John and Lisa Brichetto's Northington Energy LLC received a state loan to produce biodiesel in 2011, but the facility never started production and was later foreclosed upon. In addition to the $142,215 the Brichettos defrauded from Tennessee, the state also invested in utilities and roads, while the US Department of Agriculture also paid for site improvements. Read more from the Times Free Press. Researchers in Iran have developed a way to make biodiesel from a weed. Scientists at the Islamic Azad University have created two liters of biomass for biofuel from flixweed. Flixweed, also called herb-Sophia and tansy mustard, is a non-edible weed that grows in various climates with little to no effort. It was found to contain 22 percent oil and fatty acids, and the biomass contains oxygenated chemical components. "This issue is important because the atomic oxygen in the fuel of a car directly cuts exhaust and the dangerous carbon monoxide and cancerous particles suspended in air," says Mehdi Alami, a chemistry graduate working on the project. Read more at Press TV.