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Mazda reports strong Skyactiv sales, plans to boost output 25%

Mazda is set to expand production of its Skyactiv engines after critical and commercial acclaim for the fuel-sipping powerplants. The Japanese manufacturer has a number of plans in the works to bump up production, with the first being a 25-percent increase in output from its Hiroshima, Japan engine facility.
Besides adding a new line, Mazda will modify the line that built MZR engines, a family of mills that includes the 2.3-liter, turbocharged four-cylinder found in the Mazdaspeed3 and the 2.0-liter found in the MX-5 Miata. The bump in production is just part of Mazda's goal of selling 1.7 million vehicles globally by 2016, with 80 percent of those vehicles expected to wear a Skyactiv badge.
Mazda also builds Skyactiv engines at a joint-venture facility with Ford, in Changan, China, while a Mexican facility will go online by March of 2014. Skyactiv engines currently power the Mazda3, Mazda6 and CX-5.

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 considering a 'hyper' Mazda3 with the 250-hp 2.5-liter turbo four

Mazda boss Akira Marumoto said last year there'd be no Mazdaspeed version of the new Mazda3 because the hot hatch segment wasn't a priority for the carmaker. Then Mazda engineer Dave Coleman told Road & Track that without "an engine on the shelf that would fit properly," an MPS variant made no sense. The first reader comment on our Coleman post read, "Engine — you have it; cue up the 2.5T." Mazda might have been listening. Program manager Kota Beppu told Autocar he'd like a "hyper" Mazda3, the outlet figuring the 2.5-liter four-cylinder turbo would make the most sense for power. Autocar wrote "the project had not been officially signed off, [but] insiders suggest that is a formality." When Car and Driver queried Mazda and its sources about the report, the magazine realized "the company is seriously considering a high-performance hot hatch." What's more, "Drew Cary, senior manager for brand communications, said, 'We encourage people to ask for it, though. Our planners and executives are watching and listening to fans.'" The turbocharged 2.5-liter SkyActiv-G four-cylinder — which doesn't sell in Europe — makes 250 hp on premium gasoline and 310 pound-feet of torque in the Mazda6, CX-5 and CX-9. A next-generation SkyActiv-G is predicted on the way next year, bringing more boost and power. Even as is, we're talking a chunky lump of power to send to the front wheels, and Beppu mentioned torque steer. The new Mazda3's all-wheel drive would alleviate that bugbear. Unlike the raw, fast-twitch reflexes of the last Mazdaspeed3 from 2013, Beppu says a new model "needs to be responsible and friendly ... more friendly than a Golf GTI." And, "It should be fast." The polished looks and interior address the necessary perceptions. CD's done the math on the current 2.5-liter and predicts a five-second sprint to 60 miles per hour, which is Volkswagen Golf R and Honda Civic Type R territory, so GTI comparisons could be a case of aiming low. Imagine a 300-hp engine with a touch more torque and a six-speed manual ... If Mazda follows through with such a product, it could take two years to get the green light. However, we're told that Mazda's Los Angeles research and development center has already built a proof-of-concept to encourage and anticipate that green light.