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Mazda patent shows rotary placement in complex AWD hybrid layout

If we were playing alt-powertrain Bingo, a recent Mazda patent application filed in Japan would be one or two letters from victory. What's exciting about the patent, discovered by Japanese outlet T's Media via Motor Trend, is that while it makes a case for an internal combustion engine of any configuration, one of the drawings showing a rotary engine. The wild bit is that the whole powertrain comprises the ICE, a transaxle, two tiny in-wheel electric motors turning the front wheels, a third electric motor in the driveline, a capacitor, a lithium-ion battery, and three inverters. Motor Trend parsed the mechanics, and the way it reads, Doc Brown couldn't have done a better job. The rotary engine at the front turns the rear wheels, but not directly. Instead of a flywheel on back of the engine, the drawing shows a 25-kW electric motor and an inverter, then a driveshaft running to the transaxle. Along the axis of the transmission tunnel in a normal car, between the inverter and the transaxle, lies a 3.5-kWh battery running at 48 volts. MT writes that the electric motor can add its output to the ICE output to drive the rear wheels, or the e-motor can turn the rear axle on its own. Up front, two inverters and a double-layer capacitor join the ICE in the engine bay. The capacitor and tiny hub motors in the front wheels run at 120 volts, a higher voltage than the rest of the electrical system, so that the small in-wheel motors can generate the same torque as a larger motor running at a lower voltage. The AWD system acts on-demand. Given the signal, the capacitors discharge their energy to the wheel motors, and recover energy from braking. When the capacitors are at full charge, they send excess regen energy to the lithium-ion battery; conversely, the battery can recharge the capacitors when they're low and the front hub motors need power. The patent explains that the ICE works with the rear e-motor to drive the rear wheels at low speeds, the front motors called on to "generate an output only when a large output is required in the high vehicle speed range." The rather complicated system is focused on providing the benefits of a hybrid system and all-wheel drive, but at lower weight than one would expect. A rotary serves due to its compactness, but one of the drawings shows an engine with a V layout. Hub motors get dinged for adding unsprung weight, hence the small motors here.

2019 Mazda CX-5 Signature AWD diesel unveiled in New York

NEW YORK —It seems like we've been waiting forever, but the wait is finally over. Mazda has finally launched a diesel version of the CX-5 for the U.S. market, unveiled at the 2019 New York International Auto Show. Specifically, the 2.2-liter Skyactiv-D turbo-diesel engine will be offered in the higher-end CX-5 Signature AWD, part of what Mazda calls its "path to premium," as the company continues to set its sights on some of the more expensive competition. The Skyactiv-D 2.2 makes use of a sequential twin turbocharger that employs a smaller turbocharger first at low rpm for quick throttle response, after which a valve opens to spool up a larger turbocharger at higher rpm. Mazda says this provides "smooth and linear response from low to high engine speeds, and greatly increases low- and high-end torque." Mazda estimates the output of the engine to be 168 horsepower at 4,000 rpm and 290 pound-feet of torque from a low 2,000 rpm. The engine has a rev limit of 5,500 rpm. As of right now, it's only in the all-wheel-drive version and only in the Signature trim level. As such, it gets a ho-hum EPA fuel economy rating of 27 mpg city, 30 highway and 28 combined. We previously saw fuel economy figures for a potential front-drive diesel CX-5 getting just slightly better fuel economy, at 28 city, 31 highway and 29 combined, but no word yet on if and when that'll be made available. The mediocre diesel fuel economy, while expected given the midstream shift from one emissions strategy to another, is particularly disappointing in context. The non-turbo CX-5 AWD, which makes 187 hp and 186 lb-ft, gets 24 city and 30 highway for 26 combined mpg – just 3 mpg less in the city and 2 mpg less overall than the diesel. The much more powerful CX-5 Turbo, which makes 250 hp and 310 lb-ft, gets 22 city, 27 highway, and 24 combined. Mazda is taking pre-orders for the 2019 CX-5 Signature AWD with Skyactiv-D 2.2 starting now, at an MSRP of $42,045, including $1,045 in destination fees. We have to point out that this is a sizable jump in MSRP from a CX-5 Signature AWD with the more powerful turbo engine, which lists for $38,235 – a $3,810 difference in fact. Given the lackluster fuel economy and considerable decrease in power and torque, we're concerned that the diesel may be a tough sell at this sort of premium.

Japan carmakers vouch for safety of some Kobe Steel parts

TOKYO — Four Japanese automakers on Thursday said they found no safety issues with aluminum parts supplied by Kobe Steel Ltd, allaying some concerns that falsified quality data on products from the steelmaker had compromised their vehicles. Kobe Steel shares surged after the car makers' statements, but the steelmaker still has to contend with a U.S. Justice Department probe, while checks continue at hundreds of companies involved in complex supply chains spanning the globe. Japan's third-biggest steelmaker admitted earlier this month it falsified specifications on the strength and durability of aluminum, copper and steel products, along with materials for optical disks. The falsifications stretch back for more than 10 years, a senior executive told Reuters this week. Since then, global automakers, aircraft companies and other manufacturers have scrambled to identify potential hazards in their products. Toyota, Honda, Nissan and Mazda said that hoods and other exterior parts used in their cars which were made from aluminum directly supplied by Kobe Steel were safe. Kobe Steel shares ended the day nearly 7 percent higher but are still down by more than a third since it announced the data falsification. Automakers are still making checks on other parts, including those that they received through their parts suppliers. "We confirmed that the materials satisfy applicable statutory standards, and our own internal standard, for key safety and durability requirements for vehicles," Toyota said in a statement. Toyota, one of the world's largest automakers, identified aluminum plates supplied by Kobe Steel for the hoods and rear hatches of Toyota and Lexus brand vehicles. Though outside the automaker's specifications, they were still safe to use. While Subaru and other carmakers said they were still investigating the issue, the announcements by Toyota, Honda, Nissan and Mazda suggest that Kobe Steel's cheating scandal may have a limited impact on product safety."SERIOUS SITUATION" Nonetheless, the company's fate hangs in the balance while checks are being carried out. It must report to Japan's industry ministry by around the end of next week on any safety concerns and provide a more extensive account of the problems a fortnight later. Industry leaders have reached a consensus that Kobe Steel is in a "serious situation," a senior Japanese manufacturing executive told Reuters.