CSR

Energy- and Global-Warming-Related Issues 3

Development of the Hydrogen Rotary Engine

Hydrogen is clean energy that offers excellent environmental performance with no CO2 emissions and that can be generated from various sources. Since the announcement of the Mazda HR-X, the first hydrogen rotary engine vehicle, at the 1991 Tokyo Motor Show, Mazda has been promoting research and development of hydrogen rotary engines. The RX-8 Hydrogen RE and the Premacy (Mazda5 overseas) Hydrogen RE Hybrid are equipped with a dual-fuel system, so the vehicles can run on gasoline if there is no hydrogen available. In November 2013, the Premacy Hydrogen RE Range Extender EV, an electric vehicle with a significantly improved driving range, based on the Premacy Hydrogen RE Hybrid, was released.

Premacy (Mazda5 overseas) Hydrogen RE Hybrid

The Premacy Hydrogen RE Hybrid incorporates a hybrid system that improves energy efficiency, delivering improved acceleration with a driving range of 200 km using hydrogen.

Premacy Hydrogen RE Hybrid Layout Image

Premacy Hydrogen RE Hybrid Layout Image

Overview of the Hydrogen RE Hybrid System

Overview of the Hydrogen RE Hybrid System

Premacy (Mazda5 overseas) Hydrogen RE Range Extender EV

The Premacy Hydrogen RE Range Extender EV adapts a larger high-voltage battery, plugin-system, and improved thermal-efficiency-improved engine. Its driving range with clean energy such as hydrogen and electricity is 150 km longer than that of the Premacy Hydrogen RE Hybrid. This is an ultimate gasoline-free zero-emissions vehicle.

Main Specifications of the Premacy Hydrogen RE Range Extender EV

Base model Mazda Premacy
Overall length 4,565mm
Overall width 1,745mm
Overall height 1,620mm
Seating capacity Five persons
Base engine Hydrogen rotary engine
Fuel Hydrogen/electricity (plug-in-system)
Fuel tank 35 MPa high-pressure tank for hydrogen gas
Maximum output 110kW
Motor AC synchronous motor
Generator AC synchronous generator
Battery High-capacity lithium ion

History of Mazda's Hydrogen Vehicle Development

1991 Announced the first hydrogen rotary engine vehicle, the HR-X, at the Tokyo Motor Show
1993 Announced the second hydrogen rotary engine vehicle, the HR-X2, at the Tokyo Motor Show Developed MX-5 test vehicle equipped with a hydrogen rotary engine
1995 Conducted Japan's first public road tests of a hydrogen rotary engine vehicle, the Capella Cargo
2003 Announced a prototype RX-8 with the hydrogen rotary engine at the Tokyo Motor Show
2004 Tested the prototype RX-8 with hydrogen rotary engine on public roads
2005 Announced Premacy Hydrogen RE Hybrid concept car
2006 Began leasing of the world's first hydrogen RE vehicle, the RX-8 Hydrogen RE
2007 Signed an agreement to provide RX-8 Hydrogen REs to HyNor, a Norwegian national transportation project
2008 Tested an RX-8 Hydrogen RE validation vehicle on public roads in Norway
2009 Commenced commercial leasing of the Premacy Hydrogen RE Hybrid in Japan Began leasing of RX-8 Hydrogen RE for the HyNor Project
2013 Developed the Premacy Hydrogen RE Range Extender EV
Commenced public road test of leased vehicles

Compatibility with Bioethanol Mixed Fuel

Mixed fuel consisting partly of bioethanol, which is made from plants, is attracting attention in North America and Europe for its effectiveness in reducing CO2 emissions. Mazda is proud to sell vehicles that are compatible with this eco-friendly fuel.


Present Status
  • ■ Mazda vehicles that are compatible with E10 (gasoline mixed with 10% ethanol) are sold in North America and Europe.
  • ■ In Thailand, the Mazda3, the Mazda2, the CX-5, and the MX-5, all compatible with E20 (gasoline mixed with 20% ethanol), became respectively available in FY March 2008, FY March 2010, FY March 2014, and FY March 2016.
    In FY March 2014, the Mazda3 compatible with E85 (gasoline mixed with 85% ethanol) became available, replacing the Mazda3 compatible with E20.
    In FY March 2016, the CX-3 compatible with E85 became available.
    In FY March 2016, the CX-5 compatible with E85 became available, replacing the CX-5 compatible with E20.
  • ■ In Japan, models equipped with a SKYACTIV-D 2.2 clean diesel engine compatible with B5 (diesel mixed with 5% biodiesel fuel) became available in FY March 2012 for the CX-5, in FY March 2013 for the Atenza (Mazda6 overseas), and in FY March 2014 for the Axela (Mazda3 overseas).
    In FY March 2015, models equipped with a SKYACTIV-D 1.5 clean diesel engine compatible with B5 (diesel mixed with 5% biodiesel fuel) became available for the Demio (Mazda2 overseas) and for the CX-3.

Reducing Use of “CFC Alternative” Greenhouse Gases

Mazda is working to reduce the amount of CFC alternatives, which constitute greenhouse gases, used as car air-conditioner refrigerants. The Company intends to promote development and early adoption of car air-conditioning systems using new refrigerants.

Development of Resin Material for Auto Parts For Weight Reduction

In addition to SKYACTIV TECHNOLOGY, which is developed with the whole concept of weight reduction, Mazda actively adopt new technologies for reducing weights in detailed parts. Mazda will continue to pursue weight reduction by using resin, aluminum, ultra-high tensile steel and other materials having both lightness and strength.

Offers a Bumper Which Is One of the Lightest in Its Class

Mazda has developed a new resin material for auto parts that can maintain the same level of rigidity as conventional materials while trimming vehicle weight. The new resin enables the manufacture of thinner parts, which results in a significant reduction in the amount of material used; when used for front and rear bumpers, this trims weight by around 20%. In the manufacturing process, thinner parts have enabled the shortening of cooling time upon shaping, and in addition, use of CAE analysis technology has enabled optimization of material liquidity, halving the shaping time of bumpers from approximately 60 seconds to 30 seconds. This drastically reduces the amount of energy used in manufacturing.
This new-resin bumper, one of the lightest in its class*1, has been used for the CX-5, the Atenza/ Mazda6, the Axela/Mazda3, the Demio/Mazda2, the CX-3, the Roadster/ MX-5, and the new CX-9. The Company also intends to use it for subsequent models.

Roadster/MX-5

New Mazda Roadster/MX-5

Top: front bumper face bar,
Bottom: rear bumper

Development of Light Weight Wiring Harness Using Aluminum Electric Wire

Mazda has adopted for some vehicles a light weight wiring harness using aluminum electric wire, which enables the Company to achieve vehicle weight reduction while keeping the connection reliability (quality) as before. The Company uses this light weight wiring harness for the Roadster/MX-5, launched in 2015, and has been increasing the number of models incorporating the material, including the Axela/Mazda3 and the Atenza/Mazda6, as well as the new CX-9, which was launched into the market in May 2016. For the Roadster/MX-5 case, the Company achieved a weight reduction of around 3% of the wiring harness, contributing to improving fuel economy. The Company also intends to use the light weight wiring harness for new models to be launched in the future.

Aluminum electric wire of the new Roadster/ MX-5
Connection between capacitor and DC-DC converter
Connection between DC-DC converter and battery

Aluminum electric wire of the new Roadster/ MX-5

*1 1,500 to 2,000 cc class, as of March 2015, according to Mazda data


TOPICS

The Lightweight and Compact Roadster/MX-5

In developing the Roadster/MX-5, Mazda completely redesigned the vehicle and drastically reduced weight to realize responsive driving performance.
In addition to adopting SKYACTIV TECHNOLOGY, which pursues the ideal structure in each domain, including body, chassis, and engine, the Company optimized the allocation of functions, reduced size, revamped structures, and increased the use of aluminum and other lightweight materials. The Gram Strategy, which thoroughly reviews every part looking for weight reductions as small as one gram, was also applied as it has been in previous Mazda sports cars. Under the development philosophy of “Innovate in Order to Preserve,” a combination of remarkable innovations and steady endeavors enabled the company to reduce the weight of the new Roadster/MX-5 by more than 100 kg*2 compared to its predecessor.

Roadster/MX-5 Curb Weight by Generation
(Figure in brackets shows change over preceding model)

  Base grade
Fourth generation S [1.5L 6MT] 990kg (-120kg)

Third generation (final model) [2.0L 5MT]

1,110kg (+80kg)

Second generation (final model) [1.6L 5MT]

1,030kg (+90kg)

First generation (debut model) [1.6L 5MT]

940kg

*2 Varies depending on specifications. Vehicle weight are between 990 kg to 1,060 kg