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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's new Mexican plant capacity rises to 230,000

After the turmoil of last year, 2013 is getting off to a much better start for Mazda. The company has issued a release indicating that the forthcoming plant in Salamanca, Mexico has had its production capacity raised even though it isn't scheduled to go online until March 2014. The original plans called for a 140,000-unit capacity, 90,000 of that allotted for the Mazda2 and Mazda3, the remaining 50,000 for a small car Mazda would build for Toyota that would be based on the Mazda2. The new plans call for raising that by 90,000 units to a total of 230,000 units within two years, by the end of March 2016, and it looks like it will all go toward Mazda production to satisfy growing demand for Skyactiv vehciles. The Mexican plant's opening will be the return of Mazda manufacturing to North America, after Mazda6 production was moved back to Japan last year.
More good news for the company is that it projects 10 billion yen ($114 million) in net income for the financial year that will end in March. That would be a welcome turnaround from the 100-billion-yen loss in the previous financial year, part of a series of three annual losses in a four-year span.
You'll find the press release with the factory update below.

This California rally is vintage Japanese car heaven

What's so good about the future? This is what I was thinking when some folks at Mazda invited me and a handful of other journalists to join them on the second-annual Touge California. It's a rally for classic Japanese cars that covers a huge chunk of Southern California's twistier roads, where fans get to test their beloved machines. Oh, and it attracts swarms of admirers with cameras. "It is not a race. It is a vintage touring rally," said Ben Hsu, editor in chief of Japanese Nostalgic Car, and one of the coordinators of the event. "In Japan, touge most definitely refers to racing, whether timed, in touge battles, or drifting antics. Touge California was created to give drivers of Japanese classics a taste, as close as possible, of the types of roads their cars were forged on." Touge California was created to give drivers of Japanese classics a taste, as close as possible, of the types of roads their cars were forged on. We started the day on a mundane stop-and-go freeway drive from Mazda's Irvine headquarters to Escondido, me riding shotgun with my journalist co-driver in a 2016 Miata. But Mazda also brought along three heritage products on this trip – a 1985 RX-7 GSL-SE, a 1978 GLC three-door hatchback, and a 1975 REPU (rotary engined pickup) – serving as reminders of the company's history in the U.S. The group of Mazdas was joined in Escondido by many more Mazdas. And Toyotas, Hondas, Datsuns – so many 240Zs – and the odd Subaru and Mitsubishi. In total, 28 cars were at the start line. "We doubled the field this year, and made the route longer – 200 versus 120 miles," Hsu said. "We separated the cars into two run groups based on speed and a mix of makes and models." I spent the first part of the rally in the Mazda pickup to get a taste of rotary power. It was my first experience behind the wheel of a Wankel-powered vehicle, my first time driving a small Japanese truck from the '70s, and my God that thing has a lot of power. I had a few scares when I had to stand on the brakes, and I found the shift throw's immense length disconcerting – it felt like third gear engaged somewhere in front of the dashboard, with fourth somewhere in the bed. The truck was a great introduction to the rotary, however, and to '70s Japanese cars. Especially in Southern California, old Japanese cars aren't as novel to casual observers as they might be in other parts of the country.