Toyota Unveils Prototype Hydrogen-Powered Toyota Hilux FCEV
Toyota has made significant progress in the development of hydrogen propulsion with the introduction of a prototype Toyota Hilux fuel cell electric vehicle (FCEV). While Toyota’s first FCEV was a car, the Toyota Mirai, commercial vehicles are better suited for this technology due to their need for quicker refuelling and longer range. The Hilux FCEV has a simulated range of 365 miles and a refuelling time similar to that of a diesel. This project, funded and developed in the UK at Toyota’s Burnaston plant, was completed in just 12 months.
Development of the Hilux FCEV involved a team of engineers from Toyota and specialists from Ricardo, European Thermodynamics, D2H Advanced Technologies, and Thatcham Research. They adapted 10 Hilux development vehicles to accept the Mirai’s powertrain and fuelling system. One vehicle has already undergone crash testing, while the others are being used for on-road development. Test vehicles will be placed with potential customers, including emergency services.
Despite the availability of FCEV cars like the Mirai and Hyundai Nexo, the UK has been relatively slow to embrace hydrogen technology. However, this project aims to change that by offering an alternative zero-emission vehicle for remote areas.
Turning the Hilux into a hydrogen vehicle was done without any noticeable changes to its exterior appearance. However, under the bonnet lies the Mirai-sourced fuel cell stack. Behind the cab bulkhead is a reinforced metal box containing a battery about the same size as that in a hybrid car. Three large cylinders, each containing 2.6kg of hydrogen, are located underneath, while a Mirai-sourced electric motor is positioned towards the rear. The modularity and flexibility of the fuel stack make it suitable for various applications.
The installation of the fuel stack in the Hilux presented several challenges. The Hilux’s engine bay tapers from front to back, and the stack is angled downwards slightly to aid water drainage. This made fitting ancillaries such as the air compressor, intercooler, and air cleaner a challenge. Cooling power is critical, as the fuel cell stack produces water instead of exhaust heat. To manage the heat, a bespoke radiator was designed.
The team also had to reconfigure the ladder-frame chassis to accommodate the three large hydrogen cylinders. They studied Toyota plants to understand the production processes for hydrogen tanks and ensure fuel safety. The South African plant, where the Hilux is manufactured for Europe, built and mounted bodies onto the modified chassis.
At the launch of the Hilux FCEV prototype, Toyota GB president Agustín Martín emphasized the company’s 30-year history of developing hydrogen fuel cell technology. However, he acknowledged that Toyota alone cannot lead the transition to hydrogen and that a long-term national strategy, including a hydrogen fuel production and delivery infrastructure, as well as government-supported vehicle purchase incentives, is necessary.
Despite the challenges ahead, Toyota believes it could be onto a winner with the Hilux FCEV. The demand for quick refuelling and longer range is confirmed, and the powertrain has been proven. This project represents a significant step towards creating an alternative zero-emission vehicle for remote areas in the UK.
In conclusion, Toyota’s unveiling of the prototype Toyota Hilux FCEV marks a major milestone in the development of hydrogen propulsion. With its impressive range and quick refuelling time, the Hilux FCEV offers a viable alternative for commercial vehicles in remote areas. The successful completion of this project within just 12 months demonstrates Toyota’s commitment to advancing hydrogen fuel cell technology. However, widespread adoption of hydrogen will require a long-term national strategy and government support. Despite the challenges, Toyota remains optimistic about the potential of the Hilux FCEV and its ability to meet customers’ requirements.