Toyota, a trailblazer in automobile manufacturing, has unveiled a hydrogen fuel cell prototype of its Hilux model, marking another significant stride towards their zero-carbon goal. The prototype was developed in Toyota Manufacturing UK's Burnaston car plant, Derby, in collaboration with consortium partners, with the UK government's financial aid provided through the Advanced Propulsion Centre.
A Glimpse into the Hydrogen Hilux
Toyota's hydrogen Hilux prototype integrates core components from the Toyota Mirai hydrogen fuel cell electric saloon – a technology that has validated its quality in nearly a decade of commercial production. Remarkably, the fuel cell produces nothing but pure water, contributing to reduced carbon emissions.
Three high-pressure fuel tanks are incorporated in the Hilux, extending the driving range to over 365 miles – a considerable leap compared to a battery electric system. To ensure no compromise on cabin space, the battery, which stores the on-board produced electricity by the fuel cell, is tactically positioned in the rear load deck.
The Making of the Prototype
The project initiated with a feasibility study by TMUK and Toyota Motor Europe in early 2022. Following the UK Government's funding through the Advanced Propulsion Centre, the design and development programme commenced on 1 July 2022. The consortium partners included Ricardo, ETL, D2H Advanced Technologies, Thatcham Research, with additional support from Toyota Motor Corporation (TMC).
The prototype's construction began on 5 June this year, adhering to the Toyota Production System principles, in a dedicated area within the TMUK facility. Within three weeks, the first vehicle was completed, marking the onset of the 10 vehicles that will be built by the end of the year. These vehicles will undergo rigorous testing to ensure safety, dynamic performance, functionality, and durability meet the high standards required of a production model.
Consortium Members' Roles
The project has empowered TMUK members to develop and apply new skills related to fuel cell electrified vehicles and hydrogen system components. The consortium members have also significantly contributed to the initial phase of the programme.
Ricardo supported the prototype's preparations, undertaking design, development tasks, and confirming the complete manufacturing process alongside TMUK teams. Ricardo will also undertake a comprehensive evaluation of the vehicle in the coming months, prior to making a decision on a potential production model being introduced in the second half of this decade.
TMUK produces Corolla Hatchback, Touring Sports, and Commercial models at its production centre in Burnaston, Derbyshire, and hybrid engines at its facility in Deeside North Wales. TMUK started production in 1992 as Toyota's first fully-owned manufacturing business in Europe, and later became the company's first location for hybrid electric vehicle manufacturing outside Japan.
ETL (European Thermodynamics) is committed to delivering high-integrity thermal solutions through excellence in design and innovation. ETL has studied reversible and multi-fan arrangements for the project. D2H Advanced Technologies provides high-technology engineering services in simulation, modelling, aerodynamics, thermodynamics, and design for motorsport and other high-performance industries. D2H has completed CFD analysis to highlight where improvements could be made.
Thatcham Research, the automotive risk intelligence company dedicated to understanding the opportunities and risks of new vehicle technology, supported the project through the provision of sustainable repair consultancy and the preparation of hydrogen training for the repair market.
Toyota's Hydrogen Vision
Toyota is one of the automakers advocating that a battery-electric future isn't the only solution. Over the past decade, the company has explored hydrogen technology, notably through a partnership with BMW, and has now built an experimental hydrogen-powered Hilux truck equipped with Mirai-sourced technology.
The Hilux-based prototype is powered by a fuel cell, meaning the drivetrain uses hydrogen to produce electricity that's stored in a battery pack and used to power an electric motor. Interestingly, some of Toyota's earlier prototypes, including a Corolla Hatchback race car, used an internal combustion engine modified to burn hydrogen.
Hydrogen is stored in three high-pressure tanks installed between the frame's outer rails. The fuel cell is located under the hood, replacing the regular-production Hilux's four-cylinder turbodiesel engine, and the drive unit is integrated into the rear axle. The truck is expected to deliver over 365 miles of driving range, which Toyota notes is "significantly further than might be achieved using a battery-electric system."
The battery pack is installed in the cargo box to avoid compromising cabin space. However, details such as weight, payload, and towing capacity are yet to be released.
Looking Ahead
The Hilux prototype is the first of 10 units planned to be built by the end of 2023. These trucks will undergo a series of durability tests around the world to help Toyota gather data about the drivetrain. The future of the model hasn't been announced yet, but it's worth noting that this isn't the first experimental Hilux we've seen without an internal combustion engine. In 2022, Toyota unveiled an electric Hilux concept with up to 220 miles of range at a trade show in Thailand.
Final Thoughts
The unveiling of Toyota's hydrogen Hilux prototype showcases the brand's commitment to a multi-technology strategy for achieving carbon-free mobility. This strategy includes different powertrain solutions - hybrid electric, plug-in hybrid electric, battery electric, and fuel cell electric - to cater to different user needs and operating environments globally.
As Richard Kenworthy, TMUK Managing Director, stated, "The project team have accomplished an incredible job in a very short space of time, from creating the prototype build area to completion of the first vehicle." The UK government funding has enabled the development of a new vehicle in record time, and the upskilling of teams to work on hydrogen-related technologies, something we hope to build on in the future.
With the support of government funding and the dedicated consortium partners, Toyota continues to take bold strides towards a carbon-free future, demonstrating the potential of UK manufacturing to deliver carbon-free vehicles to meet future targets.