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Toyota R&D shows off free piston engine linear generator for future EVs

We often hear how an electric vehicle powertrain architecture allows vehicle designers much more freedom than a traditional ICE powertrain does. With differently shaped battery modules and small electric motors, there are lots of way to put the pieces together. With today's plug-in hybrid technology, engineers still need to put a decent-sized ICE somewhere, but new technology from Toyota could free up the gas-electric vehicle designers of the future. Presented at the recent SAE World Congress in Detroit, the idea from Toyota Central R&D Labs Inc. and involves what is called a Free Piston Engine Linear Generator (FPEG). Think of it as a sort of one-cylinder, two-stroke mini-engine that can work either as a generator (thank to magnets and a linear coil) or to directly drive a vehicle. The current prototype is a 10-kW unit that Toyota say would provide enough power to get a B- or C-segment electric vehicle up to highway speeds (75 miles per hour) when paired up to offer 20 kW. Pairing the FPEGs is also important to minimize vibrations. One system tested by Toyota had a 42 percent thermal efficiency, but the engineers are working to improve the overall efficiency even further. You can watch an animated video of the piston in action here (click on "Outline") and see the SAE papers here and here. More technical details are available at Green Car Congress. News Source: Toyota Labs via Green Car CongressTip: Thanks, Joe V. Green Misc. Auto Shows Toyota Technology Emerging Technologies Electric generator

Toyota recalling 342k Tacomas due to faulty seatbelt pretensioners

Toyota is voluntarily recalling 342,000 Tacoma Access Cab pickups, produced between 2004 and 2011. The wide-ranging recall is due to faults in the screws that attach the belt pre-tensioner to the belt retractor. There are concerns that the screws can loosen themselves over time, especially if the access door is opened and closed with too much force. It's important to note that the recall only covers the driver and front passenger seat, and is limited to just the Access Cab trucks. Other body styles aren't affected.
If the screws come loose, the pre-tensioner and retractor spring could separate from the belt entirely, which would be bad news in a crash. There's no mention of injuries or accidents due to the faulty pre-tensioners. Owners affected by the recall will be notified soon, and asked to come in for recall service.

Toyota will roll out solid-state battery EVs globally in a couple of years

GANDHINAGAR, India — Japan's Toyota Motor will in a couple of years globally launch vehicles with solid-state batteries that charge faster and last longer, an executive said on Thursday at an investment summit in India. Solid-state batteries promise to dramatically improve the driving range of electric vehicles (EVs), a key element of a strategic pivot Toyota unveiled in June to make up ground lost to Tesla and Chinese rivals, such as BYD, in the EV race. Last year, Toyota and oil refiner Idemitsu Kosan said they would tie up to develop and mass produce all-solid-state batteries, which they aim to commercialize in 2027 and 2028, followed by full-scale mass production. "We will be rolling out our electric vehicles with solid state batteries in a couple of years from now," said Vikram Gulati, the India head of Toyota Kirloskar Motor. It "will be a vehicle which will be charging in 10 minutes, giving a range of 1,200 kms (750 miles) and life expectancy will be very good". Gulati was speaking at the Vibrant Gujarat Global Summit where one focus of the Indian government is attracting more investments to scale up EV manufacturing capacity in the world's third largest auto market. At the start of the summit on Wednesday, Japan's Suzuki Motor said its Indian subsidiary and Toyota partner Maruti Suzuki would export the group's first battery EV to Japan and Europe — marking the first time for Maruti to export to its parent company's home country. Electric models made up around 2% of India's car sales last year, but the government is targeting 30% by 2030 and India's road transport minister said at the summit he sees annual EV sales in India reaching 10 million vehicles by 2030. On Toyota's plans for solid-state batteries in India, Gulati said the carmaker had various sustainable technology options that would differ based on the country, market and customer preferences. "Right now, for India, flex fuel and ethanol can be a no-brainer right away," he added India's trade department has backed lowering taxes on hybrid vehicles to help the transition to cleaner energy sources, following demands by Japanese carmakers, Reuters has reported. Gulati said the Indian government should consider a carbon-based tax structure for cars, which would make it technologically agnostic and more equitable.  Green Lexus Suzuki Toyota Electric