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Toyota finds 10% MPG improvement in hybrid PCU

Keeping up its from-all-angles approach to efficiency, Toyota has found yet another way to eke out up to ten percent more precious MPGs in its hybrid vehicles, this time electronically. The automaker has announced the development of new silicon carbide (SiC) power semiconductors for use in power control units, which it will begin testing on Japanese roads within the next year. The PCU using the silicon carbide compound offers less electrical resistance, which improves efficiency when passing current between the battery and electric motor. It also loses less power after shutting off, and can operate at a higher frequency. The net power loss of the new PCU is just one-tenth of the current silicone-only version (the latter accounting for 20 percent of total electrical power loss in today's hybrids). The result, so far, is a claimed five-percent improvement in fuel economy in test vehicles, with the potential of ten percent by the time the new SiC power semiconductor comes to market. Additionally, the carbide wafers allow for smaller a power module, coil and capacitor, thus allowing the entire PCU to be 80 percent smaller (see the side-by-side comparison in the accompanying photo, which you can click to enlarge). We've got a while to wait before we start to see the carbide technology to start making a real-world impact. Toyota aims to begin using the SiC units in 2020. By then, with improvements in the company's other key efficiency factors - engine technology and aerodynamics - cars like the Prius will likely see significant gains in fuel economy. Read more in the press release below. Toyota Develops 'Diamond-like' Computer Chips to Boost Hybrid Mileage May 20, 2014 Toyota City, Japan – Toyota is using one of the hardest materials in nature after diamonds to develop a semiconductor chip it hopes will improve the fuel efficiency of its hybrids, such as the Prius, by as much at 10 percent. The company and its partners announced today that they have developed a silicon carbide (SiC) power semiconductor for use in automotive power control units. Toyota plans to begin test-driving vehicles with the technology on public roads in Japan within a year. The chips, made from carbide - one of the hardest materials in nature, theoretically have superior characteristics such as one-tenth the electrical power loss and 10 times the drive frequency. Toyota said the chips would also allow it to reduce the size of current automotive power control units by 80 percent.

Tier 1 suppliers call GM the worst OEM to work with

Among automakers with a big US presence, General Motors is the worst to work for, according to a new survey from Tier 1 automotive suppliers, conducted by Planning Perspectives, Inc.
The Detroit-based manufacturer, which has been under fire following the ignition switch recall and its accompanying scandal, finished behind six other automakers with big US manufacturing operations. Suppliers had issues with trust and communications, as well as intellectual property protection. GM was also the least likely to allow suppliers to raise their prices in the face of unexpected increases in material cost, all of which contributed to 55 percent of suppliers saying their relationship with GM was "poor to very poor."
GM's cross-town competitors didn't fare much better. Chrysler finished in fifth place, ahead of GM and behind Dearborn-based Ford, which was passed for third place this year by Nissan. Toyota took the top marks, while Honda captured second place.

Toyota calling for independent, industry-wide Takata airbag testing

The initiative is still very new, and there's no set timeframe for this third-party testing to begin. With Takata's airbag inflator recall expanding nationwide soon, the scope of this safety campaign is only growing, and is set to affect millions of additional vehicles. Toyota thinks that it can help, though. The Japanese automaker has announced an initiative to get all of the affected companies to band together to fund independent, third-party testing of the faulty components. The goal of this work is to "ensure the inflators that require replacement are accurately identified and promptly fixed," according to Toyota. All of the data would be shared among the participating automakers to better understand the causes of these problems, which still aren't entirely known, and come up with the best way to repair the affected vehicles. "By combining our collective efforts behind a coordinated, comprehensive testing program, we believe we can achieve greater results. Together we will be better equipped to address this issue more rapidly for all customers," said Simon Nagata, President and CEO, Toyota Motor Engineering and Manufacturing North America, in the company's release. According to Toyota spokesperson Cindy Knight speaking to Autoblog, the initiative is still very new, and there's no set timeframe for this third-party testing to begin. The automaker's first step is simply getting the word out that it's looking for partners. She said Toyota "has spoken with colleagues in the industry" about setting up the independent evaluations and specifically said the company has already reached out to Honda and Ford about possibly working together on this. Honda also released a statement calling for similar third party testing, and when reached for comment about Toyota's proposal, Ford spokesperson Kelli Felker responded: "Ford takes the safety of our customers very seriously. We plan to join the proposed industry wide effort to investigate and develop solutions to address this critical issue. We look forward to discussing next steps with NHTSA and other automakers." Scroll down to read Toyota and Honda's full announcements of these safety initiative.