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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.

Mazda announces Takata expansion in US to 472k vehicles [UPDATE]

Update: Mazda is revising the total number of vehicles affected by its Takata airbag inflator recall downward to 464,684 units, compared to the original NHTSA documents showing 472,056. According to Mazda Public Affairs Manager Tamara Mlynarczyk to Autoblog, "It is my understanding that Mazda Japan will be submitting a revised Part 573 on Monday that reflects our numbers." The company's official statement on the recall is now included below. Mazda is the latest automaker in the US to officially announce the details of its expanded Takata airbag inflator recall. The company is broadening its campaign to cover a total of 472,056 vehicles. Mazda's airbag inflator recall covers now the front driver's side for the 2003-2008 Mazda6 produced between May 29, 2002, and May 5, 2008, the 2004-2008 Mazda RX-8 from between April 10, 2003, and February 18, 2008, and the 2006-2007 Mazdaspeed6 made between August 4, 2005, and June 29, 2007. Among these three models there are 444,907 units affected. This is an expansion from of the previous total of about 330,000 examples from 2004-2008. The passenger-side airbag of the 2004-2006 B-Series pickup is also being recalled for those with build dates between April 17, 2003, and May 2, 2006. There are 27,149 of these vehicles in need of replacement parts. Takata's airbag inflator recalls have affected 34 million vehicles nationwide from 11 automakers. In a recent hearing before Congress, Takata said it was producing 740,000 replacement kits a month and hoped to grow that to a million. Other suppliers have also started making the parts. Related Video: RECALL Subject : Driver's Frontal Air Bag May Rupture Report Receipt Date: JUN 04, 2015 NHTSA Campaign Number: 15V345000 Component(s): AIR BAGS Potential Number of Units Affected: 444,907 All Products Associated with this Recall Vehicle Make Model Model Year(s) MAZDA MAZDA6 2003-2008 MAZDA MAZDASPEED6 2006-2007 MAZDA RX-8 2004-2008 Details Manufacturer: Mazda North American Operations SUMMARY: Mazda North American Operations (Mazda) is recalling certain model year 2003-2008 Mazda6 vehicles manufactured May 29, 2002, to May 5, 2008, 2004-2008 RX-8 vehicles manufactured April 10, 2003, to February 18, 2008, and 2006-2007 Mazdaspeed6 vehicles manufactured August 4, 2005, to June 29, 2007.

Feds investigating Mazda CX-9 over suspension problems

The National Highway Traffic Safety Administration is opening a preliminary evaluation into the 2007-2008 Mazda CX-9 because the lower ball joint in the front suspension can potentially separate while driving. An estimated 54,000 examples of the crossover might be affected. The investigation was prompted by six complaints of this happening on the road. Because the complaints are coming more rapidly as of late, NHTSA thinks the issue could be getting worse. The problem also appears to be more prevalent in states that use salt on their roads in the winter. None of the failures caused any injuries, and all but one happened at 20 miles per hour or slower. NHTSA's preliminary evaluations "assess the scope, frequency, and safety consequence" of a potential problem and can sometimes lead to recalls. Related Video: INVESTIGATION Subject : Front Suspension Ball Joint Separation Date Investigation Opened: JUN 09, 2015 Date Investigation Closed: Open NHTSA Action Number: PE15022 Component(s): SUSPENSION All Products Associated with this Investigation close Vehicle Make Model Model Year(s) MAZDA CX-9 2007-2008 Details Manufacturer: Mazda Motor Corp. SUMMARY: The Office of Defects Investigation (ODI) has received six (6) complaints (VOQs) alleging incidents of front suspension LBJ separation in MY 2007 through 2008 Mazda CX-9 vehicles. The reports appear to show an increasing trend. One of the separations allegedly occurred at 40 mph and the other 5 incidents occurred at speeds between 0 and 20 mph. The first VOQ was received in October 2013, followed by 2 reports in late 2014 and 3 reports in the first 5 months of 2015. Four of the VOQs are from states using high volumes of road salts (?salt states?) which, for purposes of this investigation, include: Connecticut, District of Columbia, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin. The other VOQs were from northern Virginia, which borders the ?salt state? region, and South Carolina. ODI also identified EWR field report data related to the alleged defect in the subject vehicles. A preliminary investigation is being opened to assess the scope, frequency, and safety consequence of the alleged defect. The six VOQs associated with this investigation are: 10717510, 10714469, 10695142, 10668978, 10640541, and 10546535.