Computer-aided engineering has been used in the Kenari’s construction with special attention paid to the effects For the front and rear, the structures are designed to crumple so as to An interesting safety feature in the engine bay is the use of a specially-designed frame which will bend Such features are particularly important in a small car like the Kenari which Other safety features in the Kenari include vented front disc brakes with Laminated glass is used for the windscreen and this type of glass – once Three-point inertia-reel seatbelts are provided for the front occupants but no seatbelts are provided at the rear However, the rear doors are equipped with childproof locks. A standard It is considered a hassle by some who use it as the door can only be opened |
The growing carbon dioxide levels in the atmosphere have been causing concern because they can cause global warming. While this gas is generated in nature, man has also increased its levels unnaturally in the 20th century with the use of the internal combustion engines for automobiles. Furthermore, as catalytic converter usage widens, more carbon dioxide is created since the catalyst converts the toxic components in exhaust gases into carbon dioxide and water vapour; unfortunately, while being non-toxic, carbon dioxide can cause other problems.
Toyota, like many other responsible automakers, has been actively looking for ways to improve combustion as this has direct implications on carbon dioxide emissions. As part of its Eco-Project, Toyota developed hybrid propulsion system suitable for mass-produced passenger cars which it called the Toyota Hybrid System (THS). This new system is the heart of the Prius which was the first mass-produced car with a hybrid powerplant when it went on sale in late 1997 in Japan. In factory tests comparing conventional vehicles powered by a 1.5-litre engine, the amount of carbon dioxide emissions of the THS are 50% lower.
28 KMS/LITRE
This new propulsion system uses both a petrol engine and an electric motor and the combination, running alternately or together according to driving conditions, has enabled the Prius to attain twice the fuel efficiency of conventional petrol engined cars; factory tests have returned up to 28 kms/litre (about 80 mpg). Moreover, with the use VVT-i (Toyota’s continuously-variable valve timing system) and the electric motor to reduce engine load during acceleration, the levels of toxic elements in exhaust fumes can be to about 1/10th of normal levels.
The system builds on earlier successes by Toyota to develop
environment-friendly, low fuel consumption engines such as the lean-burn engine in 1984, and the direct injection petrol engine in 1996 (which is now available in certain domestic models).
The THS comprises the technologies of clean, high-efficiency petrol engines, electric vehicle power systems using nickel-metal hydride (Ni-MH) batteries, advanced automatic transmissions, and computerised management.
The capacity of the Ni-MH batteries is kept at only 80% because a 100% capacity can make them pretty hot and, apparently, it is not good for battery life. Incidentally, the cost of the battery pack is presently very high but can last for as long as the first owner is likely to keep it (10 years is claimed).
The batteries impose one other disadvantage: weight. As anyone who has ever lifted a car battery will know, it is quite heavy, so imagine how heavy 40 units are! This bumps the weight of the Prius to 1,515 kgs, which is some 35% heavier than a conventionally-powered car of similar size. It would have been heavier too had there not been a concerted effort to keep weight down. The measures included using a special body frame, induction hardening of the centre roof pillar and a compact powertrain. The extra-economical nature of the Prius also meant that the fuel tank needed to contain only 50 litres, which indirectly means lower weight when running.
TWO POWER SOURCES
The THS has two motive power sources which engage depending on driving conditions. A small 1.5-litre high-efficiency 1Nz-FXE petrol engine provides the main power to drive the front wheels, as in conventional cars. Drive power can also be supplied by an electric motor, which derives its electricity from the batteries and an electric generator.
Fuel efficiency is further boosted by other measures, such as automatically switching off the engine when the vehicle is at a stop–a time when fuel is usually wasted. During braking, it is also possible to regenerate some of the energy, thereby extending the energy level of the batteries.
SPLITTING POWER
One of the major components is a power-split device in the hybrid transmission which allocates power from the petrol engine either directly to the vehicle’s wheels or to the electric generator. At the same time, the petrol engine is automatically controlled to keep its speed in the most efficient range at all times. The power to drive the vehicle is appropriated from the petrol engine or from the electric motor in response to driving conditions.
Besides incorporating the power-split device, the hybrid transmission also has the electric generator and the electric motor. The power-split device utilizes a planetary gear to constantly re-allocate the power supplied from the petrol engine. One of the output shafts of the power split device is linked to the electric motor and wheels, while the other connects to the electric generator.
The entire transmission system functions as an electronically-controlled continuously-variable transmission(CVT) by fluidly adjusting the engine rpm, electric generator and electric motor for optimum running.
EFFICIENT USE OF POWER
As part of the transmission’s control system, the petrol engine is regulated to keep it operating within the high torque zone, which is the most fuel efficient (ratio of power to fuel consumption). Its rpm is automatically controlled to keep it within a set range, so that the high torque zone can be used as much as driving conditions allow.
The distribution of the petrol engine’s power is determined by factors such as the amount of pressure on the accelerator, vehicle speed, and battery charge. The portion that is used to turn the wheels is balanced with that which is used to generate electrical power. Electrical power created by the generator may then be utilized to operate the electric motor, which, together
with the power derived directly from the petrol engine, helps propel the vehicle briskly.
THE ATKINSON CYCLE
The petrol engine is really the hybrid system’s main power source. It is a high expansion ratio petrol engine using the highly heat-efficient Atkinson Cycle. This concept is a heat cycle which was proposed by British engineer James Atkinson and has since evolved into an improved version called the Miller Cycle. The Atkinson Cycle is very heat-efficient compared to conventional engines, but is rarely applied because it does not produce enough power unless used with a supercharger. However, for the THS, this drawback has been minimised and it efficiency is further improved by the use of VVT-i and by reducing friction loss between its components.
The high expansion ratio heat cycle increases the expansion ratio by reducing the volume of the combustion chambers and allows combustion energy to be used more effectively. Engine knock is also avoided by delaying the timing intake valve closure, since this reduces compression pressure. Moreover, pumping loss is reduced because of decreased intake resistance during times of partial load.
The low-revving highly fuel-efficient 1.5-litre engine has a maximum speed of only 4000 rpm, thus requiring a lower degree of parts strength than higher-revving engines. Many moving parts are lighter, the crankshaft has a smaller diameter, the piston rings have lower tension, and the valve spring load is less, resulting in a large reduction of friction loss.
RECOVERING ENERGY
The THS’s high efficiency is partly the result of measures to reduce and recover energy that is normally lost in vehicles with conventional engines. When the vehicle stops or decelerates at low speed, the petrol engine automatically stops operating to reduce energy waste. When the vehicle accelerates from rest, the initial power for taking off comes from the electric motor; the engine only begins operating later.
Also, at extremely low speeds or when the petrol engine is operating in the low efficiency zone (low rpm), the fuel supply is cut off and the vehicle runs on its electric motor alone. During engine braking or normal driver-induced braking, the electric motor operates like a generator (remember the dynamo on bicycles?), converting the vehicle’s kinetic energy into electrical energy, which can then be used to charge the battery.
The system is particularly effective in recovering energy during city driving, where driving patterns with repeated acceleration and deceleration are common. To maintain a constant charge, the batteries receive charging energy from the electric motor and the engine-powered electric generator via an advanced charging control system. Unlike 100% electric vehicles, the battery of the THS does not require external charging.
The THS is just a start and there can be no doubt that its efficiency and performance will increase in future. In fact, for the US market where crusing speeds are higher and journeys are longer, modifications have been made to the operation to provide more brisk performance but Toyota says that it is still superior in terms of low pollution levels and economy. The engineers are striving to have the US models comply with the upcoming California Super Ultra Low Emission Vehicle (SULEV) standard. SULEV is approximately 85% cleaner than the strictest existing petrol vehicle standard, Ultra Low Emission Vehicle (ULEV).
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Singapore government gives incentives for cars like the Prius
I’m not sure if I like the looks of the Toyota Prius although it is described as a ‘futuristic style’ (the styling was done by Toyota’s studio in California). The nose, with a beak-like appearance, seems out of sync with the short rear end. But in aerodynamic terms, the bodywork (slightly longer than a Corolla) is class-average at 0.30 Cd. The compact body also makes for easy parking, with an impressive turning circle of 9.4 metres.
The suspension system gives a hint of the next generation of chassis layouts from Toyota with strut front and H-shaped torsion beam rear axle with toe-control links. You can see almost similar arrangements in some of the new Toyota models that have been introduced.
DASHBOARD OF THE FUTURE
The dashboard area reminds me of the ones in concept cars. To maximise legroom, there is no centre section going down to the floor. The shifter for the automatic transmission is to the left of the steering column. It has an odd pistol-grip shape but proved easy enough to operate. The parking brake is foot-operated.
The instrument panel is absent from the area ahead of the steering wheel, which gave an awkward feeling. And no heads-up display is projected on the windscreen either. Instead, a narrow display screen showing the warning lights and speed is recessed in the centre of the dashboard just below windscreen.
I questioned a designer about this location and obviously, I was not the first because the engineer confidently said that I should try driving the Prius and see if I felt it wasn’t good. Later on, I had to tell him that it wasn’t as dangerous as I thought it would be, requiring the driver to look away from the road ahead. Cleverly, the designers had enlarged the size of the speed display so that it is clearer. The location is not on the periphery of the driver’s view either so it is noticeable. The legibility also has something to do with the distance of the display; studies had shown that older drivers could read the more distant display 25% faster than when it was near the steering wheel.
DISTRACTING DISPLAY
But while I had to retract my scepticism of the speedometer position, I have to say that the 150 mm-wide information panel in the middle of the dashboard should be less ‘informative’. It shows, among other things, the modes in operation and how the energy is flowing in real-time. For instance, on deceleration, you can see that energy is flowing backwards to the batteries.
It’s a nice idea for a prototype and for test purposes, but I feel that it is really very distracting for the driver. The designers may argue that the novelty of seeing the display would wear off after a while – but then again, he or she could very well crash at the first corner after the Toyota showroom!
PRACTICAL, SPACIOUS CABIN
The rest of the Prius cabin, which is spacious with the 2.55-metre wheelbase, is quite conventional. It is designed according to the company’s Global Outstanding Assessment (GOA) criteria so the inside areas are suitably padded to minimise injuries. The front seats also have a special design to lessen whiplash injuries.
In the past, prototypes never had air-conditioning as it was a technical issue that was hard to resolve since the compressor usually needs a running engine. In the Prius, with its auto cut-off for the engine, this too presented some problems. However, the engineers couldn’t omit an air-conditioner since buyers expect it as standard these days.
So what they did was to improve the system to heighten efficiency and also use UV-blocking green glass that significantly reduces the introduction of radiant heat. The bodywork insulation prevents heat gain within the cabin. And finally, there is a mode which cancels the engine cut-off feature so that the a.c. compressor can be kept running to provide cool air.
Still, one wonders about the comfort in tropical climates like Malaysia. Mr Okamoto said that they had not found any problems in this area although he admitted that because the engine may be running more often to keep the compressor operating, the fuel economy may be affected very slightly.
The same consideration was given to power steering–another power-robbing ancillary. In the Prius, the system is run by an electric motor (not a new idea) so whether the engine is running or not doesn’t matter.
ON THE MOVE
It was a bit exciting getting to drive the Prius since there was so much hype about it. At rest, it was silent since the electric motor provides the initial propulsion. I applied a bit of pressure on the pedal and the car moved forward gently. Only tyre noise was audible as the petrol engine was not running (and I knew this from the display). Pressing harder, the power flow arrows showed that the engine had kicked in. But the electric motor had disengaged and when I pushed the pedal right to the floor, the electric motor started to run again. I got the Prius up to 100 km/h easily but the acceleration was not particularly inspiring. More impressive was the torque which permitted brisk acceleration on the move.
Deceleration was smooth and the display told me that energy was actually flowing backwards to recharge the batteries. In fact, each time I lifted off and coasted, the regenerative effect went into action. To see how fast the system could react, I coasted and then floored the pedal – the arrows switched direction almost instantly and there was no judder at all as both motor and engine cut in suddenly.
Coming to a quiet stop, I waited for the engine to cut off… but it had already done so earlier when I started braking! So stopping was really a matter of the car ceasing motion, that’s all.
In the handling department, the Prius felt like any other car and rode comfortably as well. I must say, though, that the ‘drive-by-wire’ concept is fine and doesn’t take away any of the feel a driver is used to. A Toyota engineer said they worked very hard to have just the right sort of feel and weighting to the steering and pedals as they were aware that the absence of such tactile cues would be detrimental.
If the Prius were to cost as much as a 1.6-litre petrol-engined car, it would probably be quite popular among those who want the best in fuel economy. Surveys showed that the initial group of buyers in Japan and the US were mostly academics who were curious about the technology and young people who had strong views about protecting the environment. This buyer profile should change eventually but the main thing for Toyota is to get as many people as possible to use cars with the hybrid system. Not just to make money (obviously they would want to profit as well) but to make a significant and positive impact on reducing pollution and conserving energy resources which are not unlimited.
Chips Yap
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Singapore government gives incentives for cars like the Prius
Singaporeans who buy eco-friendly cars using hybrid or electric powerplants will get special incentives between January 2nd 2001 and December 31st 2003. In an official statement, the government says it is giving rebates for an initial 3-year period (with a review after that) to help lower the cost differential between electric and hybrid cars, and conventional cars. This is because electric and hybrid cars cause less pollution than conventional petrol-powered cars, but cost significantly more. The rebates are aimed at encouraging motorists to consider buying electric and hybrid cars instead of conventional cars.
The rebates will be in the form of a 20% reduction in the open-market values that form the basis for the value of the Certificate of Entitlement (CoE) which every new car buyer must obtain in order to buy a car in the island republic. The CoE can amount to as much (or more) as the cost of the car but is deemed necessary as a means to control the vehicle population on the island.
In classifying electric cars for the COE categories (there are different categories based on engine size), those with power outputs of up to 57.5 kW are considered as equivalent to 1.6-litre petrol-engined cars while those with motors generating more than 57.5 kW will be classified as being above equivalent 1.6-litre petrol-engined cars. Hybrid-engined cars will be classified according to their engine size or power output, whichever is higher.
Cars with electric motors only will be subject to a 20% reduction in annual roadtax according to their power output while those with hybrid units – an electric motor coupled to a small petrol engine – will have 10% reduction. The roadtax calculations will be based on either the power output or the engine size, whichever is the higher amount.
The licensing authority has formulated a correlation table which was established by examining the relationship between the engine capacity and the maximum power ratings of existing conventional cars; and equating the engine capacities of conventional cars with the maximum motor power ratings of electric cars taking into consideration the differences in engine and motor power output characteristics and transmission efficiency.
Like conventional vehicles, this special class of vehicles will also be required to have compulsory inspections at the same intervals. In Singapore, the inspections are not required for the first three years after registration of a new vehicle; every two years for vehicles between 3 and 10 years old, and every year for vehicles older than 10 years. Depending on the sophistication of the built-in safety features of the electric/hybrid cars, there may also be a requirement for other safety checks by the manufacturers’ agents as part of the compulsory periodic inspection.
A few companies already have hybrid-engined models in production, the most widely sold (50,000 units worldwide to date) being the Toyota Prius which was introduced in Japan in early 1998 and is now also on sale in the USA. Honda also produces a sleek hybrid-engined car known as the Insight which is claimed to be more economical than the Prius due to its light aluminium bodyshell.
About two years ago, Toyota had brought the Prius around the region for demonstrations to the respective governments and to lobby for special incentives for the car in view of its very low emission levels and high fuel efficiency. The approach was taken because most ASEAN countries have prohibitive import taxes (particularly in Malaysia) on cars and if the Prius, which is made in Japan, were to be sold, it would cost more than a Toyota Camry.
As such, Toyota felt that it would be pointless introducing the model if it cost so much because it would then become a novelty for the rich, rather than an affordable widely-adopted solution to reducing pollution and depletion of energy resources. It is Toyota’s aim to get its hybrid system popularised globally and the way to do that is to ensure that the Prius has an affordable pricetag.
When the Prius was launched in Japan, it was rumoured that the car’s production cost was high and that Toyota was subsidising its cost to achieve a reasonable price. It was believed that that the Prius cost Toyota 5 million yen to make but the market price was 2.15 million.
Kazuo Okamoto, the director involved in the 6-year project, denied that the Prius was being sold at a loss. “No matter what our financial strength is, it would not be a good business practice to lose that much money on each car, especially since we are planning to sell 12 thousand annually!” he said.
“Yes, technology and R&D costs were very high, but that’s normal in the initial stage of such an advanced new model. As volumes rise, the real costs would fall rapidly,” he added. But he did also suggest that Toyota was ‘breaking even’ [at that time]. Last year, another Toyota executive commented that rapidly rising volumes have given the company the required economies of scale and that the cost of producing the Prius has ‘come down quickly’.
Besides Toyota and Honda, Ford and Peugeot also have electrically-powered vehicles and it is likely that these manufacturers will be quick to introduce their products in Singapore. However, for some of the 100% electrically-powered cars, the issue of recharging stations needs to be addressed as they cannot be charged using ordinary household power points. This will mean that recharging stations will need to be established around the island which is, fortunately, not a large area to cover.
For hybrid cars, however, recharging is not an issue because the batteries are recharged as the car runs and recharging is only necessary if for some reason the batteries go completely flat. But in an emergency, the petrol engine can still be used to provide power.
So far, the Malaysian government has not announced any incentives for such eco-friendly cars and it seems unlikely that the matter would receive a high priority unless Proton or Perodua begin developing such systems. Some years ago, Proton had commissioned an American company to develop an electrically-powered Wira but the project was terminated because the company went bankrupt. It is not out of the question for Perodua to embark on such a program, though, as its technical partner, Daihatsu, has done a lot of work on electric vehicles and besides, it is a part of the Toyota Group too.
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At the coming 2001 North American Auto Show in Detroit next month, Volvo will present two concept cars that are said to ‘put safety into a new dimension’. One of these is the Safety Concept Car (SCC) which was developed with the main ambition to create ‘superior vision’. Another ambition was to implement modern technology in order to support the driver and make driving safer. This was achieved by combining traditional engineering with advanced electronics.
The SCC does not mainly display safety in the traditional way, with new airbags and further developed crumple zones but instead focusses on active safety and on features that will help any driver become a safer one.
Autoworld.com.my provided details of the features in the SCC two months ago and to read that article, click on the links below.
Volvo Eye Car
Volvo Secure Car
NUMBER ONE IN SAFETY
“The Volvo SCC demonstrates that we have knowledge and competence to stay Number One in the world within car safety. The car contains a large number of technological systems and features which are associated with driving safety and the interplay between man and machine,” says Helen Petrauskas, head of Environmental and Safety Engineering at Ford Motor Company, which Volvo belongs to.
It goes without saying that car drivers play a decisive part in the pursuit of safer traffic. The Volvo SCC therefore makes drivers the focal point by giving them increased control and a better chance of making the right decisions in difficult traffic situations. Research has shown that drivers receive more than 90% of the most critical information from outside the vehicle. Thus if the quality of this visual information can be enhanced, the drivers can have a better chance of avoiding collisions.
4-POINT SAFETY BELT
Two kinds of 4r-point safety belts integrated in the seat frame will be shown in SCC: the CrissCross Belt (X4) and the Centre Buckle Belt (V4).
The CrissCross Belt is a conventional 3-point belt supplemented with an extending diagonal chest belt from the shoulder to the hip. The Centre Buckle Belt is similar to the type of safety belt that previously was used in rally and racing cars.
In order to find out which type of the two that is most comfortable and most user-friendly, a special evaluation will be made at motorshow. The second Volvo concept car remains a secret at this time but insiders say it is a model that has never before been shown in public.