(Ebook) Mazda Hydrogen Car.pdf

New Technology

[Reference exhibit]

The Mazda way to improve relations between

people, the automobile and the planet

Mazda is committed to creating better relations

between the motorized society and the global environ-

ment of the 21st century, while, at the same time, main-

taining and advancing the company’s characteristic

Zoom-Zoom spirit. Thoughtful, innovative products

developed by Mazda can balance the dual needs of

both the environment and the driving enthusiast.

One example of Mazda’s most recent efforts — the

RENESIS Hydrogen Rotary Engine —is being show-

cased at the 2003 Tokyo Motor Show.

As the world’s only manufacturer of rotary engines,

Mazda continues to develop and explore all the poten-

tial and possibilities of this unique internal combustion

engine. The RENESIS is Mazda’s next-generation rotary

engine that was launched in early 2003 in the all-new

Mazda RX-8. By virtue of its smooth performance,

compact size and unique driving characteristics,

RENESIS was named International Engine of the Year

in June 2003. It delivers high power output for a natu-

rally aspirated engine of its size and demonstrates sig-

nificantly improved fuel economy and reduced emis-

sions compared with previous generation rotary engines.

First hydrogen-fuelled

rotary engine car, HR-X

Second hydrogen-fuelled

rotary engine car, the HR-X2

MX-5 roadster powered by

hydrogen rotary engine

Capella Cargo powered by

hydrogen rotary engine

Demio FC-EV

Premacy FC-EV

RX-8 Hydrogen RE

1991

1993

1995

1997

2001

2003

1991

Mazda develops its first hydrogen-fuelled rotary engine car,

HR-X ( hydrogen storage tank with metal hydride )

Test drives fuel cell golf cart

Mazda develops its second hydrogen-fuelled rotary engine car, the HR-X2.

Develops experimental MX-5 roadster powered by hydrogen rotary engine.

Conducts on-road tests for two years of Capella Cargo powered by

hydrogen rotary engine.

Develops Demio FC-EV (direct hydrogen fuel cell )

Develops Premacy FC-EV (methanol reforming fuel cell )

Develops RX-8 Hydrogen RE (electronically-controlled hydrogen

direct-injection rotary engine with high-pressure hydrogen fuel tank )

1992

1993

1995

1997

2001

2003

Mazda RENESIS Hydrogen Rotary Engine

Now, as the auto industry’s attention turns to hydro-

gen as a potential source of power for fuel cell vehi-

cles, Mazda confidently presents a realistic example

of its hydrogen-power technology, embodied in the

hydrogen-powered version of the RENESIS.

Fun to drive and environmentally sound, the

RENESIS Hydrogen Rotary Engine is a Mazda-unique

alternative-fuel vehicle. It is the ultimate demonstra-

tion of the flexibility of the unique rotary engine, main-

taining a traditional driving feel, yet realizing extreme-

ly clean emissions through the use of hydrogen.

The RENESIS Hydrogen Rotary Engine capitalizes on

the advantages of the rotary engine to assure the same

ease-of-operation and reliability whether the engine is

running on gasoline or hydrogen fuel. Moreover, since

the engine requires modifications to run on hydrogen,

it could enable production of a relatively low-cost

hydrogen-powered alternative-fuel vehicle.

The engine has been developed with a dual-fuel

system, allowing it to run on either gasoline or hydro-

gen, as Mazda believes desirable, flexible automotive

choices will help effectively promote the usage of

hydrogen fuel and the development of a supporting

infrastructure.

The fruit of over ten years of research and

development of hydrogen power

The RENESIS Hydrogen Rotary Engine is not

Mazda’s first effort in this area of advanced R&D. In

1991, Mazda developed and tested its first hydrogen

rotary-powered prototype vehicle, known as the

Mazda HR-X. Concurrent with the development of the

HR-X2, the engineering team also developed an

experimental version of the MX-5 roadster in 1993,

Two years later, in 1995, Mazda was granted

approval by Japan’s then Ministry of Transport to

conduct on-road tests of two hydrogen rotary-

powered Capella Cargos. At this time, Mazda also

began to experiment with fuel cell electric vehicles

(FC-EV) alongside its hydrogen rotary engine pro-

gram. In 1992, Mazda developed a prototype vehicle

with fuel cell electric battery, and in 1997, created a

Mazda Demio FC-EV.

In 2001, Mazda began conducting public road

tests of the methanol-reforming type Premacy

FC-EV. Data on driving performance, fuel consump-

tion, exhaust emissions and other parameters were

collected during on-road tests to advance studies

aimed at commercialization.

The RENESIS Hydrogen Rotary Engine, as presented

at the 2003 Tokyo Motor Show, is another step forward

in these ongoing efforts to experiment and develop

alternative-fuel solutions.

*Sanctioned by the Ministry of Land, Infrastructure and Transport

Mazda RENESIS Hydrogen Rotary Engine

technologies

The RENESIS Hydrogen Rotary Engine incorporates

an electronically-controlled hydrogen injector system

(the hydrogen is injected in a gaseous state). The

system draws air from the side port during the induc-

tion cycle and uses dual hydrogen injectors in each

of the engine’s twin rotor housings to directly inject

hydrogen into the intake chambers. The following

technologies have been introduced to help maximize

the benefits of the rotary engine in hydrogen com-

bustion mode.

Direct injection system

By virtue of its construction — with separate cham-

bers for induction and combustion—the rotary engine is

ideally suited to burn hydrogen without inviting the

backfiring that can occur when hydrogen is burned in

a traditional piston engine. The separate induction

chamber also provides a safer temperature for fitting

the dual hydrogen injectors with their rubber seals,

which are susceptible to the high temperatures

encountered in a conventional reciprocating engine.

Twin hydrogen injectors

Because hydrogen has an extremely low density, a

much greater injection volume is required compared

with gasoline. This demands the use of more than one

injector, which can be difficult to achieve with a

conventional reciprocating engine because of the

structural constraints that prevent directly mounting

injectors in the combustion chamber. In contrast, the

rotary engine provides adequate space for installation

of two injectors per induction chamber. With its twin

hydrogen injectors, Mazda’s hydrogen rotary engine

is both practicable and able to deliver sufficient power.

Excellent mixing of hydrogen intake charge

In a reciprocating engine, the output shaft turns

through 180 degrees in one cycle, whereas the rotary

engine’s output shaft covers a greater angle of 270

degrees, enabling a more vigorous intake flow for

ample mixing of the hydrogen-air intake charge. This

promotes production of a uniform mixture, which is

critical for hydrogen combustion.

Hydrogen gas

Electronically-controlled

hydrogen gas injector

Side seal

Apex seal

Air

Exhaust gas

Corner seal

Spark plugs

Electronically-controlled hydrogen gas injector

Rotors

Mazda RENESIS Hydrogen Rotary Engine

Mazda RX-8 Hydrogen RE

Hydrogen meter

High-pressure hydrogen tank

The RENESIS Hydrogen Rotary Engine is currently

undergoing running tests in a special-edition Mazda

RX-8 Hydrogen RE test vehicle. The test vehicle is

equipped with a dual-fuel system that consists of a

high-pressure hydrogen tank and separate gasoline

tank, and can run on either hydrogen or gasoline. It is

as reliable and easy to operate when running on

hydrogen as on gasoline.

In addition to the revolutionary RENESIS rotary

engine, the Mazda RX-8 Hydrogen RE test vehicle

benefits from improved aerodynamics, optimised tires

and weight-saving measures, as well as a host of tech-

nologies for exceptional environmental compatibility.

Hydrogen gas filler

RENESIS Hydrogen Rotary Engine

Electronically-controlled

hydrogen gas direct injection

rotary engine based on RENESIS

Hydrogen meter

Hydrogen sensors in four

locations for safety backup

Gas-tight bulkhead between

boot and cabin

High-pressure (35 MPa)

hydrogen tank (capacity:74 litres )

Extractor

Selector switch for hydrogen/gasoline

mode switching

Gasoline tank (capacity: 61 litres,

same as conventional RX-8)

Regulator with built-in hydrogen

cut-off valve depressurises

hydrogen from the high-pressure

fuel tank to 0.5 MPa

Mazda RENESIS Hydrogen Rotary Engine

Three layer wet-on paint: This water-based paint

dramatically reduces emission of organic solvents,

saves energy by shortening the drying process and

reduces CO 2 .

Mazda RX-8 Hydrogen RE Main Specifications

Dimensions

Overall length

4435mm

Overall width

1770mm

Overall height

1340mm

Wheelbase

2700mm

Track: front/rear

1500mm/1505mm

Plant-based plastic for interior parts: Plant-based

plastic is an attractive alternative to plastics derived

from fossil fuels such as petroleum. Plant-based plastic

fiber-reinforced extrusion-molded plastic employing

cellulose extracted from timber is used for quarter

panels, and reduces CO 2 emission.

Occupancy

4 persons

Engine

Type

Mazda RENESIS hydrogen rotary

engine with ISG

Maximum power

Using Gasoline: 154 kW (210 PS)

@7200 rpm

Using Hydrogen: 81 kW (110 PS)

@7200 rpm (target)

Maximum torque

Using Gasoline: 222 N • m@5000 rpm

Using Hydrogen: 120 N • m@5000 rpm

(target)

Low-resistance brakes: Use of a fast-fill tandem

master cylinder reduces brake drag.

Transmission

Type

5MT

Suspension

Suspension system:

front/rear

Double wishbone/Multi-link

Brakes

Main brake system

front/rear

Low-resistance hub carriers: Reduced friction hub

carriers help cut power losses.

Ventilated disc

Tires and wheels Tires

front/rear

225/45R18

Wheels front/rear

8JJ

Future Systems of Hydrogen

Rotary Engine Cars

technologies, Mazda is aiming to achieve advanced

clean-running vehicles that also deliver an exceptional

driving experience in line with the company’s Zoom-

Zoom spirit.

Electronically-controlled hydrogen

gas direct injection

Gasoline injection

Hybrid motor

Electric-motor-assist turbocharger

An electric-motor-assist turbocharger is used to max-

imize the effectiveness of forced induction throughout

the rev range. At low rpm, beginning at approximate-

ly 1000 rpm, an electric motor operates to assist the

turbocharger and increase induction efficiency. At

high rpm, the turbocharger is driven in a traditional

fashion, by the flow of exhaust gas alone.

High-pressure

hydrogen tank

Gasoline tank

Lean NOx

catalyst

3-way

catalyst

Electric motor-assist

turbocharger

144 volt battery

Inverter

At the 2003 Tokyo Motor Show, Mazda is also pre-

senting a number of technologies currently being

developed that could help support the potential for a

futuristic hydrogen rotary system.

These next-generation technologies are being

refined to help achieve the dual goals of drivability

comparable with gasoline cars and excellent efficiency

derived from the practical use of energy. An example

of these technologies includes an electric-motor-

assisted turbocharger to enhance the efficiency of

hydrogen combustion and regeneration of energy

from the car’s exhaust. Additionally, in an effort to

capitalize on existing hybrid technology, Mazda con-

tinues to refine the idle-stop system; regenerative

braking systems; electric acceleration assistance

systems; and other means of improving the efficiency

of the entire vehicle. By combining these various

Mazda Hybrid System

The Mazda Hybrid System is composed of a motor,

inverter and a 144-volt battery. When the vehicle is

stationary — for example, when waiting at traffic

signals—the system normally stops the engine to

reduce fuel consumption and exhaust gas emissions,

and restarts it automatically with the electric motor

when the driver is ready to accelerate.

Additionally, when the engine is running at low rpm,

the electric motor is used to boost engine torque and

effectively improve response. During deceleration,

the motor operates as an electrical generator, recover-

ing the braking energy and using this energy to

recharge the battery.

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