FCEV Archives

Plug-in Hybrid Electric Vehicles: Are They All the Same?

*Visit www.bhpetrol.com.my to know more about promotions at BHPetromart.*

Just as Euro NCAP (New Car Assessment Program) assesses the safety performance of new models sold in Europe, Green NCAP evaluates the environmental performance of new vehicles. Periodically, it compiles a list of models and recently release information on 25 new models. These include, for the first time, plug-in hybrid electric vehicles (PHEVs).

The results of three models – the Kia Niro, Mitsubishi Outlander and Toyota Prius – show that not all plug-in hybrids offer the same environmental benefits. The Hyundai NEXO – a hydrogen fuel-cell electric vehicle (FCEV) – demonstrates the promise of this developing technology. The vehicles on the latest list include the fully electric Volkswagen ID.3 and 19 combustion engine cars, of which two – the Skoda Octavia Combi 2.0 TDI and VW Golf 1.5 TSI – stand out from the rest.

2020 Hyundai NEXO FCV — *Hyundai NEXO FCV*

Nothing beats pure electric vehicles
When it comes to environmental cleanliness, pure electric vehicles outshine the competition – which shouldn’t really be surprising. With rising consumer interest, more and more traditional carmakers are getting serious about electric vehicles and have comprehensive electrification programs for the coming years.

Volkswagen’s first standalone electric car, the ID.3, reinforces this message, joining the Battery Electric Vehicles (BEVs) previously tested by Green NCAP with a maximum 5-star rating. The NEXO, a hydrogen fuel-cell car, also achieved 5 stars, as it proved to be just as clean as a BEV and very nearly as energy efficient.

*Layout of fuel-cell electric vehicle (2015 Toyota Mirai)*

Huge potential in fuel cell technology but…
Using a fuel-cell to convert hydrogen into electricity, the NEXO emits only water at the tailpipe and can offer a driving range unmatched by any available pure electric vehicle at this time. Refilling of the hydrogen tank is also as quick and easy as a refuelling a car with petrol or diesel. The NEXO result clearly shows the huge potential of the technology, but fuel-cell cars can only grow in numbers when consumers see sufficient hydrogen fuelling stations around their country.

PHEV technology is currently much favoured by manufacturers seeking to reduce their carbon footprint and comply with new emissions legislation. Marketed as offering ‘the best of both worlds’ – battery-powered cleanliness when it is needed with the driving range of a combustion-engined car – Green NCAP’s tests revealed that, even when optimally charged, not all PHEVs are the same.

2021 Toyota Prius PHEV — *Toyota Prius PHEV*

Toyota’s Prius impressed most with a 4-star rating that beats all but pure electric and hydrogen fuel cell cars. The Niro followed closely with 3½ stars, but the Outlander only achieved 2 stars, less than some of the latest Euro6-compliant petrol or diesel cars.

“People want independent, transparent information about the environmental impact of cars. These PHEV results show why that is so important. Consumers could be forgiven for thinking that, by buying a car labelled ‘PHEV’ and keeping it charged all the time, they will be doing their bit for the environment, but these results show that this is not necessarily the case,” said Euro NCAP Chairman, Niels Jacobsen.

2020 Mitsubishi Outlander PHEV — *Mitsubishi Outlander PHEV*

“The Outlander shows that a big, heavy vehicle with a limited driving range is unlikely to offer any benefit over a conventional car. On the other hand, Toyota, with its long experience of hybrid technology, has done a terrific job and the Prius, properly used, can offer clean, efficient transport. It depends on the implementation and hybridisation strategy but what is true of all PHEVs is that they need to be charged regularly and driven as much as possible on battery power if they are to fulfil their potential,” noted Jacobsen.

2021 Volkswagen Golf 8 — *Volkswagen Golf 1.5 TSI*

Some non-electrified cars still very clean
The Toyota Yaris Hybrid further underlines Toyota’s expertise in the field of electrification with a respectable 3½ star rating. But it is matched by two conventionally-engined cars – the diesel-powered Skoda Octavia Combi 2.0 TDI and the petrol-fuelled VW Golf 1.5 TSI. These are the best results achieved so far by non-electrified cars.

“Euro6 legislation has made a real difference. For the first time, we’re seeing cars perform in real- world driving the way they promise on the test bench and we should congratulate car manufacturers and emissions engineers for the huge strides they have made in the last few years,” Jacobsen observed.

*For FCEVs to grow in numbers, consumers will have to see a sizable network of hydrogen refuelling stations n their country.*

“The future looks like it belongs to electric cars of one sort or another but, for now, consumers face a bewildering choice. Green NCAP is here to help them make informed decisions so that we can all contribute now to a cleaner, more sustainable future,” he said.

About Green NCAP
Green NCAP is an independent initiative which promotes the development of cars which are clean, energy efficient and not harmful to the environment. Emissions of several pollutant gases are regulated by legislation in the EU. All cars sold in Europe must pass type-approval tests to demonstrate that their emissions of carbon monoxide, oxides of nitrogen, unburnt hydrocarbons and particulate matter do not exceed certain critical values. However, regulation offers no reward to manufacturers who go beyond the minimum standards of approval testing.

Green NCAP rewards manufacturers whose vehicles go beyond the minimum legislative requirements and offer excellent real-world performance. The organisation uses a broad range of tests to address the flaws in approval tests and, through consumer information, rewards those manufacturers whose vehicles go beyond the minimum requirements and offer excellent, robust, real-world performance. Regulatory testing is a good starting point, and Green NCAP’s tests are an addition and complementary to the legislative requirements.

First look at the hydrogen fuel cell powertrain being developed by BMW and Toyota

Second generation of Toyota’s Mirai hydrogen fuel-cell car goes on sale today

The Mirai, Toyota’s electric vehicle powered by a hydrogen fuel cell (FCEV) has started its second generation with its market launch in Japan, on schedule, today. The company had given an early glimpse of the new model a year ago at the Tokyo Motorshow and said it would begin selling the car by the end of 2020.

After beginning serious development of FCEVs in 1992, the Mirai’s predecessor was launched in 2014 and was a revolutionary model. Like the Prius hybrid, it was a global forerunner in mass production of FCEVs. However, it was sold only in a limited number of markets where hydrogen refuelling stations were available.

2021 Toyota Mirai FCEV — *2021 Mirai second generation*

Feedback from customers indicated that more seating space was desired, so the new Mirai has space for 5 persons instead of 4. Its cruising range has also been increased by approximately 30% compared to the first generation, with up to 650 kms claimed.

Also following the way the Prius design evolved, the new Mirai’s appearance is less radical and has been given a more premium image. The concept of ‘silent dynamism’ was incorporated into the design with the aim of creating an emotional appeal not just because it is an eco-car, but because of its styling.

Sleeker, less radical styling
The new Mirai has sleeker proportions with overall height by 65 mm and 140 mm added to the wheelbase to extend it to 2920 mm. With the rear overhang extended by 85 mm, overall vehicle length is now 4975 mm.

“We have pursued the goal of making a car that customers will feel they want to drive all time, a car that has an emotional and attractive design and the kind of dynamic and responsive performance that can bring a smile to the driver’s face,” said Yoshikazu Tanaka, the new Mirai’s Chief Engineer who also headed the team for the development of the first generation.

“I want customers to say ‘I chose the Mirai not just because it’s an FCEV, but because I simply wanted this car; it just happens to be an FCEV.’ We will continue our development work focusing on that feeling, and we hope that with the new Mirai, we will be a leader in helping realise a hydrogen energy society,” he added.

Simple, modern cabin
The interior has been conceived as a simple, modern space with a warm, comfortable. Key elements include a 12.3-inch centre display and an instrument panel that wraps around the driver. As the Mirai runs only with an electric motor, there is no engine vibration or noise and with the enhanced body rigidity and additional soundproofing measures, the low level of quietness is significant.

A Toyota innovation is the catalyst-type filter is incorporated in the air intake. As air is drawn into the car to supply the fuel cell, an electric charge on the non-woven fabric filter element captures microscopic particles of pollutants, including sulphur dioxide, nitrous oxides and PM 2.5 particulates. The system is effective in removing 90 to 100% of particles between 0 and 2.5 microns in diameter from the air as it passes into the fuel cell system.

The Mirai sits on the TNGA-based GA-L platform which is intended for high-end rear-wheel-drive vehicles. The structures of various parts including the rear have been redesigned to create greatly enhanced body rigidity. This has a positive effect on ride and handling, enhancing driving dynamics and comfort.

The more rigid body also contributes to better occupant protection and with advanced driver assistance systems, the Mirai offers higher standards of motoring safety than before with the latest Toyota Safety Sense suite.

The driver assist functions are based on the Mobility Teammate Concept, a unique Toyota concept for automated driving whereby the car and driver act as partners to enhance each other’s capabilities and drive together. AI technology is used with on deep learning capability to forecast various situations that may be encountered while driving and provide support for driver responses.

Increased used of hydrogen for mobility
Since launching the first generation 6 years ago, hydrogen use for mobility has progressed widely to include trucks and buses. Toyota has continued to improve and advance its fuel cell (FC) systems in areas such as size, efficiency, and productivity.

There are three tanks which together increase the fuel capacity by around 1 kg (compared to the first generation), increasing hydrogen capacity by approximately 20% which, in turn, extends range. One of the tanks is now installed inside the floor tunnel space, which also helps in weight distribution for better stability and handling.

Though the Mirai is also powered by electricity, the hydrogen it uses can be pumped in much faster than the fastest recharging time for an electric vehicle which can be up to 25 minutes. The FCEV is said to be able to fully refuel in about 3 minutes from high-pressure pumps, certainly something that will appeal to potential buyers.

Compact and more powerful FC system

The compact, high-output FC stack is located in what is traditionally the ‘engine compartment’ but the motor and battery are at the rear. Toyota’s new FC stack and fuel cell power converter (FCPC) have been developed specifically for use with the GA-L platform. The designers have been able to bring all the elements together in the stack frame with each part made smaller and lighter, while at the same time improving performance.

The FC stack uses a solid polymer, as in the current Mirai, but has been made smaller and has fewer cells (330 instead of 370). Nonetheless, it sets a new record for specific power density at 5.4 kW/litre as maximum power has risen from 114 kW to 128 kW. Cold weather performance is also said to have been improved with start-up now possible at temperatures from as low as -30˚.

The car is equipped with lithium-ion high-voltage battery in place of the previous nickel-metal hydride unit. Although smaller in size, it is more energy-dense, giving higher output and superior environmental performance. Containing 84 cells, it has a 310.8 rated voltage compared to 244.8, and a 4.0 Ah capacity, versus 6.5 Ah. Overall weight has been reduced from 46.9 to 44.6 kgs.

Aiming for higher sales volumes
The introduction of the new Mirai will see Toyota target deeper market penetration with a 10-fold expansion in sales volume. To achieve this, the carmaker has adjusted the price downwards by around 20%. In Japan, where two grades are offered, prices start from 7,100,000 yen (about RM277,200) while the pricing in Europe is expected to start from 64,000 euros (about RM316,000) which is less than what Tesla charges for its similarly-sized EV.

Of course, actual prices customers pay will depend on incentives and rebates that governments in different countries offer. As with hybrids, the acceptance of FCEVs will depend on how much they are sold for and right now, with the advanced technologies being new, they are expensive. Therefore, governments have to help to make them affordable while the carmakers boost volumes so that economies of scale can kick in to lower costs. This has already happened with hybrids and next would be EVs, before FCEVs.

There is also the matter of refuelling stations which is an even greater challenge because it involves hydrogen supply. Even with plug-in hybrids (PHEVs) and full EVs, the issue of recharging stations has been one that consumers think about. This is being addressed by rapid expansion of the recharging station network in some countries, as well as the improvements in technology to provide longer range.

Don’t expect it in Malaysia anytime soon
Vehicles with petrol and diesel engines will be phased out eventually and in fact, they will be banned in some countries, including Japan, by the end of the decade. It’s uncertain how the situation will be in Malaysia given the instability of policies and the way they are executed. The aspiration to become the ‘EV hub of ASEAN’ is pretty much a dream, especially the governments of Thailand and Indonesia are already pushing ahead with clearly-defined programs to increase EV usage, which attracts some of the carmakers to make further investments as well.

Click here for other news and articles about Toyota.

Toyota Mirai FCEV fleet in Germany clocks total of over 5 million kms

As Toyota prepares to start production of the second generation of its Mirai fuel cell electric vehicle (FCEV), one of its customers in Europe has covered over 5 million kilometres with its Mirai fleet. CleverShuttle, a ride pooling service in Germany, has set a record of sorts for having the most used Mirai fleet in the world.

During the two and a half years that the company has been running the Mira, its cars have covered a distance equivalent to six and a half times the distance from Earth to the moon and back.

“Fuel cell electric vehicles such as Toyota Mirai became an important pillar for us, thanks to their reliability. They have allowed us to provide countless passengers with comfortable rides, emitting nothing but water vapour,” said Jan Hofmann, COO & CO-Founder of CleverShuttle

CleverShuttle acquired its first batch of Mirais in September 2017 with 20 units initially which were offered in Hamburg. The fleet was progressively expanded up to 45 cars which were distributed at several German locations.

Reliability a strong point
Throughout this period, no repairs or parts replacements were needed, apart from regular maintenance, according to Ferry M.M. Franz, Director of Toyota Motor Europe in Berlin. “The experience of driving 5 million kilometres shows that fuel cell vehicles are already perfectly suitable for everyday use. No technical defects whatsoever and the unrestricted performance of the fuel cell, with mileage up to 180,000 kilometres per car so far, demonstrate the maturity and durability of Toyota’s fuel cell system,” he said.

The Mirai was introduced in 2014 and has been available in Europe since 2015. It is available to both private and commercial customers. The 4-seater is emission-free, requiring only hydrogen which the fuel cell converts into electrical energy to power the motors.

The combined output of the electric motors is 113 kW (154 ps) and on a full tank of hydrogen, the Mirai can travel up to 500 kms. Unlike a battery pack which requires some time to recharge, refuelling the Mirai is said to take just under 3 minutes. Of course, hydrogen stations are limited at this time and it will be a while before a widespread network is established.

Technically sophisticated with its advanced technology, the Mirai has served as a catalyst for increasing global awareness of how a future clean and sustainable hydrogen society might be achieved. Just as the Prius hybrid has been progressively improved since it was launched in the late 1990s, the next Mirai will mark a new stage for FCEV technology. Improvements in fuel cell system performance and increased hydrogen storage capacity will extend its driving range.

Toyota Mirai Concept previews next generation of FCEV to be launched at the end of 2020

Nikola Badger electric pick-up truck to use hydrogen fuel cell tech to achieve a range of 965 kms

Ever since Elon Musk unveiled the Tesla Cybertruck, the prospects for electrically-powered pick-up trucks have been increasing as other manufacturers (not the mainstream carmakers though) have announced plans for their own models.

The latest is Nikola Corporation which will show the first prototype later this year in Nevada. Design-wise, the Badger, as it is to be called, looks like the typical truck of today with a 5-seat cab and an overall length of 5900 mm. What is going to be game-changing is the performance which the company says will ‘target and exceed every electric or petrol pickup in its class’. To reduce development and production cost, the Badger will be built in conjunction with another manufacturer utilizing their certified parts and manufacturing facilities.

With a 150 kWh lithium-ion battery pack ‘refilled’ by a 120 kW hydrogen fuel cell that generates the electricity, the Badger is expected to have an output of up to 900 bhp with at least 50% available continuously, and almost 1,330 Nm of torque. Very impressive is the claim of an estimated 965 kms of range on a full battery pack and using the fuel cell but without the fuel cell support, the range will be about 480 kms.

The Badger is being designed to handle take-offs with minimal loss of performance and to operate on grades up to 40% through advanced software blending of batteries and fuel-cell. With a fully loaded trailer and combined vehicle weight of 8,180 kgs, the Badger will be able to launch from a standstill on a 30% grade without motor stall.

The electric pick-up will also be engineered to outperform all electric pick-up trucks on the market in continuous towing. It will have a 15-kW power outlet for tools, lights and compressors, which is enough power to assist a construction site for approximately 12 hours without a generator.

“Nikola has billions worth of technology in our semi-truck program, so why not build it into a pick-up truck?” said Trevor Milton, CEO, Nikola Corporation. “I have been working on this pick-up program for years and believe the market is now ready for something that can handle a full day’s worth of work without running out of energy. This electric truck can be used for work, weekend getaways, towing, off-roading or to hit the ski slopes without performance loss. No other electric pick-up can operate in these temperatures and conditions.”

“The Nikola Badger is a game-changer. The program will help drive down the cost of the fuel-cell components on our semi-truck while accelerating the hydrogen station roll-out. Giving customers the option to order a fuel-cell or battery electric version will ensure we drive the cost down for everyone across our line-up,” added Mark Russell, President of Nikola Corporation.

Toyota to start selling second generation of Mirai hydrogen fuel-cell vehicle in late 2020

Toyota introduced its first commercially-available hydrogen-powered fuel cell vehicle (FCEV) – the Mirai – in 2014. Technically sophisticated with its advanced technology, the Mirai has served as a catalyst for increasing global awareness of how a future clean and sustainable hydrogen society might be achieved.

Now, 5 years later, after real-world usage and further developments in fuel cell technology, the second generation is due for introduction towards the end of this year. It will be available initially in Japan, North America and Europe.

At the 2019 Tokyo Motor Show, Toyota provided an early glimpse of the advances it is making across the board with the new Mirai, in terms of technical excellence, dynamic performance, and desirable design. Efficiency is still a critical area, and Toyota is targeting a 30% increase in the Mirai’s driving range (around 500 kms with the first generation model) through improvements to the fuel cell system and the use of larger on-board hydrogen tanks.

The new Mirai sits on Toyota’s latest rear wheel drive modular platform (TNGA-based) which has been engineered to accommodate different powertrains – including a hydrogen fuel cell – at the outset. It further gives the new Mirai a higher degree of body rigidity, which contributes to greater agility and responsiveness, and a lower centre of gravity, which makes for nimble, rewarding handling.

There will be three tanks – one long, two short – which together increase the fuel capacity by around one kilogram of hydrogen compared to the current model. As well as extending the potential driving range, improvements in the performance of the fuel cell system give more linear, smooth response when moving off. Handling is also said to be light and easy on winding roads.

2015 Toyota Mirai FC — *First generation of the Mirai. Some 10,000 units have been sold since 2015.*

The big change for the new Mirai’s is its exterior design, with low lines and a sleek, taut bodywork with large, 20-inch diameter wheels that together generate a powerful and distinctive look.

The interior has been conceived as a simple, modern space with a warm, comfortable ambience that adds to the sense this is a car that’s genuinely enjoyable to drive and travel in. Key elements include a 12.3-inch centre display and an instrument panel that wraps around the driver. The platform and intelligent packaging allow for five seats to be provided in place of the current Mirai’s four.