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Mazda files patents for a sequential twin-turbo setup

Mazda has a history of interesting engine technologies, from yesterday's rotary engine to tomorrow's compression ignition engine, and new patents show it still may have some internal combustion tricks up its sleeve. The one on display in these patents isn't especially new in concept, though. A sequential twin-turbocharger setup is something Mazda itself used on the third-generation RX-7. But it's something we haven't seen much of lately. It looks like it could have some possible advantages over older sequential systems, and it has some potential advantages for enthusiasts. First a quick and dirty primer for what makes a sequential twin-turbo system distinct from other twin-turbo systems. In many twin-turbo engines, there are simply two turbos that work together as one bigger turbo. They're the same size, and they spool up at the same time. With a sequential setup, at low rpm, a smaller turbocharger is spooled up first at low-rpm for quicker throttle response, and as the rpm and exhaust pressure increases, a valve opens up that allows a larger turbocharger to also spool up and provide high-rpm boost. That's basically how the Mazda design shown above functions. A big flap blocks off the larger turbocharger exhaust inlet, channeling all the exhaust to the smaller turbo. When more exhaust is available at high rpm, it looks like that flap opens up to spool up the big turbo, too. What's interesting here is that the way the turbochargers are packaged takes up less space than past systems. It looks like both turbos are contained in one unit that shares the same exhaust outlet, meaning the exhaust manifold could be kept simple and compact. In fact, the piping for compressed intake air could also be shared, reducing the amount of piping, which would further decrease the amount of materials and possible failure points. There are a number advantages of making this system smaller. The potential applications of the system are much greater, since it could fit in smaller cars with smaller engine bays. Making the system smaller also means that there won't be as much weight, which is important from both fuel economy and performance standpoints. Finally, the smaller setup likely uses fewer materials, which could make the system cheaper and thus easier to offer on a wider range of vehicles, or at least more profitable for Mazda.

Mazda to use rotary engine as a range-extender with its first electric vehicle

There's more news from Mazda at the Tokyo Motor Show, where the brand made a big splash, including new developments in its never-ending rotary engine saga. First, Mazda execs confirmed that the Japanese automaker will bring back the rotary engine as a range-extender and battery juicer for its first electric vehicle in 2019. But secondly, the company won't have a rotary-powered successor to its RX-7 and RX-8 sportscars in time for the company's centennial anniversary in 2020. Autoblog previously confirmed that Mazda is planning to have an EV in 2019 that will be available in both pure electric and range-extending versions. Now, the Australian website Motoring reports that the global EV will feature a powertrain similar to the experimental Japan-only Mazda2 (Demio) EV, which used a single-rotor engine as a generator to power the battery pack and increase its driving range. The publication says Mazda plans to release a series of plug-in hybrids based on existing models around 2020, then a pure electric car co-developed with Toyota and Denso in 2021 as part of the EV Common Architecture Spirit Company joint venture. A Mazda spokesman tells Autoblog the company couldn't confirm any details about future products. Meanwhile, enthusiasts shouldn't wait for a rotary-based production version of Mazda's RX-Vision concept from 2015. Motoring cites two executives who explain that the company simply lacks the capital necessary to invest in developing the new model in time for its 2020 centennial. Mazda debuted its rotary engine 50 years ago in the Cosmo Sport in part as a way to stand out from its larger Japanese competitors. The engine, which uses a spinning three-tipped rotor in place of pistons, is smaller and lighter than conventional piston engines, with a greater power-to-weight ratio and quieter, smoother operation. But it delivers less fuel economy and higher emissions — two weaknesses that could be improved via a stop-start system Mazda has developed, based on a pair of U.S. patents. The company has also been hard at work developing its next-generation Skyactiv-X engine, which uses highly precise combustion ignition technology to deliver significant gains in fuel economy and power.Related Video:

Mazda CEO says rotary not viable, so don't look for a new one

We have some very sad news to report, rotor-heads fans: Don't expect a new rotary-powered vehicle anytime soon. This comes straight from Masamichi Kogai, the CEO of Mazda, which is the only company to ever market a commercially successful rotary-powered automobile in the world. The issue, as it has pretty much always been, is environmental.
While the Wankel rotary engine does indeed make a lot of power in a small, lightweight package, it does so while burning lots of fuel and emitting lots of noxious gases into the atmosphere, at least when running on gasoline. And that means the rotary engine will likely only ever be able to power niche vehicles. And that, in turn, means that it is very difficult to turn a profit on vehicles with rotary engines, particularly for a small automaker like Mazda.
"It has to be a viable commercial proposition. If we are going to adopt it, it has to be a product that can generate at least sales of 100,000 units a year. We have to be able to achieve a profit," said Kogai in an interview with Automotive News. Mazda sold 56,203 RX-7 models in the United States (the automaker's biggest market) in 1986. Sales of the RX-8 peaked in 2004, its first full year on the market, with just 23,690 units.