DeepForm
On Wednesday I went to the TDAP Wave 8 Demo Day, which was organised by the Advanced Propulsion Centre.
One of the cohort of companies there was DeepForm, who were described like this.
DeepForm is transforming sheet metal pressing with its patented cold-shear press design, which reduces blank sizes by up to 45 % and trimming waste by up to 85%. This drop-in technology lowers material costs and embodied CO2 in existing press lines without compromising performance, quality or speed. Spun out of the University of Cambridge in 2022, DeepForm enables OEMs and Tier 1 suppliers to adopt the breakthrough through IP licensing, simulation and design support.
The company have an impressive web site, which deserves a very full read.
In their presentation, they showed two products, that could benefit from their innovation; a large steel component for Jaguar Land Rover and a humble aluminium drink can.
As I walked home ntoday, I saw this advert displayed on a bus stop.
The cans for BuzzBallz are also shown on the company’s web site.
But these products are are only the start.
For instance, I can see lots of small plastic items and components, that can’t be recycled, could be made from aluminium, which is easy to be recycle.
I also think companies like IKEA will love the design freedom, the technology will give.
What Happened To The Toyota Hydrogen-Powered HiLux?
I wrote about this vehicle in Toyota Unveils Prototype Hydrogen Fuel Cell Hilux, but I’ve not heard any more.
So I asked Google AI, the question in the title of this post and received this reply.
The Toyota hydrogen-powered Hilux is currently in the demonstration and evaluation phase and has not been officially confirmed for mass production. Ten prototypes were built in the UK and are undergoing testing, with some being used for customer and media demonstrations at events like the Paris Olympics. Toyota is using this project to gather data, refine its hydrogen technology, and prepare for a future European market that could see the vehicle go on sale around 2028.
A simple Google search produced this YouTube video and this article in the Toyota UK magazine.
I don’t want to drive one, as that would be illegal, but I have just added riding in one of these beasts to my bucket list.
Toyota Have Gone To The Advanced Propulsion Centre For Their Latest Project
In Toyota Leads Multi-Million-Pound Micromobility Research Project, I write about another project, where Toyota have approached the Advanced Propulsion Centre for funding and technical help. So the Advanced Propulsion Centre must be doing something right, to attract another project from Toyota.
In CoacH2 – The Next Generation Coach, I write about how the Advanced Propulsion Centre are helping to develop the powertrain for Wrightbus’s upcoming hydrogen-powered coach.
It certainly looks like the Advanced Propulsion Centre are in the middle of the net-zero transport revolution.
Toyota Leads Multi-Million-Pound Micromobility Research Project
The title of this post, is the same as that of this news item from the Advanced Propulsion Centre.
These five paragraphs introduce the project.
he Advanced Propulsion Centre UK (APC) has announced the latest project funded through the UK Government’s DRIVE35 Collaborate programme.
Toyota will lead a consortium to research and develop a new lightweight battery electric vehicle in Derbyshire.
The project aims to meet the evolving needs of urban populations while accelerating the shift to zero tailpipe emission transport by validating a novel, lightweight battery electric vehicle (BEV) in the L6e category.
Underlining Toyota’s commitment to investing in the UK’s R&D capabilities, it will be manufactured at Toyota Manufacturing UK’s (TMUK) Burnaston site.
The vehicle addresses the growing demand for sustainable micro-mobility solutions and includes an integrated solar roof, increased connectivity, and lightweight sustainable materials supporting recovery and recycling.
Note.
- The vehicle will be light in weight.
- Toyota is investing in UK R & D.
- The vehicle will be built in Derbyshire at Burnaston.
I asked Google AI, what is an L6e Car and received this reply.
An L6e car is a light quadricycle in the EU vehicle classification system, defined as a light, four-wheeled vehicle with a maximum speed of 45 kph}) (28 mph)) and an unladen mass of no more than 425 kg. (excluding batteries for electric versions). It can be powered by small internal combustion engines or electric motors, and vehicles in this category are often used for urban commuting or small delivery tasks.
Note.
- Sir Alec Issigonis’s famous ADO15 Mini, which was launched in 1962, weighed 580 Kg, seated four and had an initial top speed of 75 mph.
- Sir Alec also designed racing cars and high performance Mini Coopers.
- Another partner in the project specialises in urban delivery vehicles.
I always wonder what sort of electric vehicle, the great car designer would have designed.
These are some further thoughts.
Do Toyota Build Microcars In Japan?
I asked Google AI, the question in the title of this section and received this answer.
Yes, Toyota builds microcars in Japan, and the Toyota C+pod is one example. While Toyota previously focused on larger vehicles, it now manufactures ultra-compact electric vehicles like the C+pod for the Japanese market to meet customer demand for small city cars.
The Toyota C+Pod has this Wikipedia entry, which gives these details.
- Two seats.
- 9.2 KW electric motor.
- 670-690 Kg weight.
- 37 mph.
- 93 mile range.
- The car has air conditioning, air-bags and heated seats.
The number of seats, speed and range would appear to be ideal for a city-car.
Could The Vehicle Be Hydrogen Powered?
I asked Google AI, if small lightweight hydrogen fuel cells exist and received this answer.
Yes, small, lightweight hydrogen fuel cells do exist and are commercially available for various applications, ranging from educational kits to power sources for drones and portable electronics.
I wouldn’t be surprised if the project needed a hydrogen fuel cell of a particular weight, size and power, someone could built it, by scaling an existing design.
Could The Vehicles Be Self Driving?
Not probably now, but as the technology gets more sophisticated, I suspect that it will happen.
Could The Vehicles Replace The Invacar?
This article in The Times is entitled Bring Back Three-Wheeled Cars For Disabled Drivers, Reform Urges.
I would expect that, if Toyota, the Advanced Propulsion Centre and their partners did a comprehensive job, then Toyota’s new car could serve the same purpose as an Invacar, much better in a zero-carbon manner.
There Is This Video Of A Toyota C-Pod.
Conclusion
I believe this project could come up with something special.
CoacH2 – The Next Generation Coach
This page on the Advanced Propulsion Centre UK web site is entitled CoacH2 – Next Generation Hydrogen Fuel-Cell Coach Powertrain Demonstrator.
This is the sub-heading.
Accelerating the development of zero-emission hydrogen fuel-cell electric coaches, with a full on-vehicle technology demonstrator.
These are the first two paragraphs.
Coaches are an integral part of the public transport network, with over 30,000 diesel coaches operating across the UK and Ireland. Due to the specific demands of coach operation (motorway driving, long-range, high passenger and luggage loading capacity) decarbonisation options for this sector are extremely limited with hydrogen fuel-cell technology considered the most viable choice. This project will tackle this difficult to decarbonise sector by developing, testing and validating an innovative hydrogen fuel-cell powertrain suitable for coach applications.
Delivered by a Northern Irish consortium spanning OEM, coach operator and academia, CoacH2 will accelerate the development of zero-emission, fuel-cell electric coaches, with a full on-vehicle technology demonstrator to be manufactured and showcased at Cenex Expo 2024.
As I indicated in British Buses For British Bottoms, Wrightbus build a good well-built, smooth-riding and comfortable bus, so now they can add hydrogen-powered coaches to the product range.
This press release on the Wrightbus web site is entitled Wrightbus Coach Demonstrator Unveiled At Cenex Expo, gives more information on CoacH2.
- The demonstrator has a power of 300 Kw.
- It has a range of 1,000 km. on one refueling.
- An internet search reveals a launch date of 2026 for the hydrogen-powered coach.
I wonder, if this will be the killer application for hydrogen-powered road transport.
Hydrogen Fuel Cell-Electric Coach Driveline Coming From Wrightbus
The title of this post, is the same as that of this article on RouteOne.
These are the first two paragraphs.
Wrightbus has been awarded up to £534,000 of government funding via the Advanced Propulsion Centre (APC) for the development, testing and validation of a hydrogen fuel cell-electric coach driveline.
The Ballymena manufacturer will receive the money from an £11 million pot administered by APC as a second round of the Advanced Route to Market Demonstrator scheme (ARMD2), which itself is part of over £50 million of public funding towards 30 “cutting edge manufacturing projects” in the UK.
I have never driven a coach, but I do feel that this project could be a winner.
- From riding in hundreds of their products over the years, I’m sure Wrightbus could produce a coach that satisfies the demands of coach companies and their passengers.
- Long routes like London and Scotland are popular coach routes and are of the order of 400 miles. Would passengers tolerate a thirty minute stop halfway to charge the batteries on an electric coach?
- Through, the experiences of the vehicle leasing company, I owned, I know that finance for quality coaches is not hard to come by and they are a good investment.
I also believe that a hydrogen-powered coach could be a flagship product for the hydrogen-powered transport sector.
We’ve all been on a motorway and seen coaches in the fast lane at 70 mph.
What effect will that have if the coach was emblazoned with “Green Hydrogen Coach – London-Glasgow Non-Stop In 7 Hrs”?
Toyota Unveils Prototype Hydrogen Fuel Cell Hilux
The title of this post, is the same as that of this article in The Engineer.
This is the sub-heading.
Toyota has today (September 5, 2023) unveiled a prototype hydrogen fuel cell-powered Hilux at Toyota Manufacturing UK’s Burnaston car plant in Derby.
This is the first paragraph.
The pick-up has been developed in a joint project with consortium partners Ricardo, ETL, D2H Advanced Technologies and Thatcham Research. and funding from the government via the Advanced Propulsion Centre (APC).
It would appear to be a consortium of some of the important great and good of British automobile engineering.
- Ricardo are a well-respected environmental and engineering consultancy, who probably know more about powering vehicles, than most companies have forgotten.
- Thatcham Research is the motor insurers’ automotive research centre.
- The Advanced Propulsion Centre collaborates with UK government, the automotive industry and academia to accelerate the industrialisation of technologies.
To my mind, the great advantage is that they are starting with a vehicle that has a formidable reputation.
When I outlined, the product to a friend, who had owned vehicles of this type, his reply was “Wow!”
Points from the article include.
- The expected driving range is more than 365 miles.
- The project began in early 2022 with a feasibility study undertaken by TMUK and Toyota Motor Europe with the consortium partners.
- Design and development started at July 1, 2022.
- Prototype construction began on June 5, 2023.
- The first vehicle was completed in three weeks.
- Ten preproduction examples will be produced before the end of the year.
- Ricardo supported preparations for the prototype build and will undertake complete evaluation of the vehicle over the coming months.
- Thatcham Research supported the project through the provision of sustainable repair consultancy and the preparation of hydrogen training for the repair market.
On paper, it looks like the consortium have taken an extremely useful vehicle and updated it for the 21st century.
Inly time will tell, if the design is right.
I have a few questions.
What Is The Towing Performance?
In my experience, many owners will want to tow heavy trailers, horse boxes or portable cafes and toilets for events like music festivals and agricultural and country shows.
If the towing performance matches that of a diesel Hilux, Toyota will probably have got it right.
How Many Miles Does The v Average Small Builder Or Smallholder Do In A Week?
Toyota must know this from servicing records of the diesel HiLux fleet.
I would suspect for many, 365 miles would allow a weekly or twice weekly refuelling!
Where Would Owners Refuel Their Hydrogen-Powered HiLux?
I suspect that Toyota dealerships Selling Hydrogen-Powered HiLux and Mirai, would make their own arrangements.
Would A Hydrogen-Powered HiLux Help To Decarbonise Work Sites?
I suspect it would and the electrical system could probably be used to power and charge small electrical tools.
Would A Hydrogen-Powered HiLux Be An Ideal Farm Runabout?
I am thinking about a friend of mine, who is a Suffolk farmer, who farms rare breed sheep.
He uses a big pick-up to tow a large trailer to take the sheep to market and shows and to move them around the country to other breeders. He has in the past used a golf buggy to check on his flocks and help with the welfare of the animals.
Some of his sheep are raised on the saltings, which gives them a unique flavour, but does involve the occasional accident, and sometimes needs a tricky recovery.
I spoke to him last night and he will be looking at this Toyota. His current vehicle does tend to frighten the sheep as it is too noisy.
Would A Hydrogen-Powered HiLux Work Well In Hot Countries?
The current HiLux is built in South Africa and those for Europe were generally made there.
So I would expect some African examples could have been made there.
Some hydrogen fuel cells need to be cooled, so would this be a problem in hot countries?
On the other hand , it does seem that hydrogen production in hot countries, with all that sun, might not be a problem.
Would A Hydrogen-Powered HiLux Make A Good Technical?
Diesel HiLux are popular as technicals and I suspect that the hydrogen-powered HiLux will be just as good.
Although the low-down mounting of the hydrogen tanks may make them susceptible to landmines.
Why Is It Not Called A HyLux?
I couldn’t resist asking that.
Conclusion
I like the hydrogen-powered HiLux and feel it will be a winner.
£77 Million Investment For UK Heavy Duty And Commercial Vehicle Projects
The title of this post is the same as that of this press release from the Advanced Propulsion Centre.
These are the projects.
Ford to design, develop, and build a fleet of 8 hydrogen fuel cell powered Transit vans, with the latest advances in technology
£8 million awarded by government, matched by industry to a total £16.3 million.
This research project will design and develop a hydrogen fuel cell-powered version of the Ford Transit van, with a Ford Dagenham estate facility re-purposed for upfitting of the vehicle. By bringing the manufacturer, vehicle operator and supply chain businesses together, this project aims to establish a business case for the wider rollout of hydrogen Light Commercial Vehicles.
Project partners include: Ocado, BP, Cygnet Texkimp, Cambustion, Viritech.
Note.
- I suspect Ocado will do the road testing.
- BP will probably supply the hydrogen.
- Cygnet Texkimp are a company based in Northwich and is a leading global provider of fibre handling and converting technology. Have they developed a machine for knitting hydrogen fuel tanks?
- Cambustion‘s Engineering Services team provides powertrain development and testing services to a range of global clients from our Cambridge, UK base.
- Viritech’s web site has a mission statement of Rewiring the DNA of Hydrogen Powertrains.
Ford seem to have assembled a team of all the talents.
Wrightbus to develop a new world-leading zero-emission battery and hydrogen fuel-cell electric, multi-axle vehicles
£6.4 million awarded by government, matched by industry to a total £12.7 million.
This project will produce a new, market-leading platform for battery and fuel cell electric driven buses. Whilst demand is growing for zero-emission vehicles, there are currently few options available for heavy, multi-axle vehicles like large buses.
Project partners include: Queens University Belfast, Grayson Thermal Systems, Hutchinson Engineering, Translink.
Note.
- Grayson Thermal Systems are based in Birmingham and specialise in providing HVAC for vehicles and especially zero-carbon ones.
- Hutchinson Engineering are based in Widnes and invest in state-of-the-art machinery and technology to give our customers the most advanced, cost-effective solutions in design, fabrication and manufacturing.
- Translink provides public transport in Northern Ireland.
It looks like Wrightbus have excellent partners.
ULEMCo creating a zero-emission hydrogen fuel cell range extender for prototype ambulance, fire engine and road sweepers
£3.9 million awarded by government, matched by industry to a total £7.9 million.
This project will develop a hydrogen fuel cell range extender for electric vehicles used for special purposes, such as ambulances, fire engines and street sweepers. The zero-emissions range extender will be based on existing, proven technology from the Toyota Mirai, and demonstrate how zero emissions vehicles can be used in a wide range of specialised and challenging settings.
Project partners include: Altair Engineering, Emergency One, Technical Services Ltd, Oxon Fire & Rescue Services
Note.
- ULEMCo are based in the Liverpool City Region and it is very much in Liverpudlian DNA to repurpose something that works. Hence the use of The Toyota technology.
- Altair Engineering is a multinational engineering and technology company.
- Emergency One is a Scottish manufacturer of fire engines and emergency vehicles.
- Technical Services Ltd, who are based in Cleckheaton, supply thermal management systems and solutions.
- Oxon Fire & Rescue Services will obviously be doing the testing.
In Hydrogen-Powered Ambulance Drives Into Glasgow Ahead Of London Trial, I wrote about a prototype hydrogen-powered ambulance, that was built by ULEMCo and industry partners, that was shown at COP26.
Is this project turning the prototype into a system, that can be manufactured in large volumes?
Bramble Energy developing a hydrogen double-deck bus, using innovative, low-cost fuel cell technology
£6.3 million awarded by government, matched by industry to a total £12.7 million.
This project will demonstrate a fuel cell/battery hybrid powertrain on a double-decker bus. This novel product will be cheaper than the equivalents currently available for large vehicles like buses and uses innovative new electronics and energy recovery technologies.
Project partners include: University of Bath, Equipmake, Aeristech
Note.
- Bramble Energy‘s Printed Circuit Board Fuel Cell (PCBFC™) is a patent protected, revolutionary design which leverages existing manufacturing routes from the printed circuit board industry to offer a cost-effective, scalable hydrogen fuel cell solution.
- Equipmake are based at Snetterton in Norfolk.
- In Equipmake Hybrid To Battery Powered LT11, I describe Equipmake’s conversion of a New Routemaster to battery operation.
- Aeristech are based in Crawley and have developed a range of award-winning compressors for Tier-1, OEMs and other customers.
- Is the compressor needed to pump a mixture of hydrogen and air through the fuel cell?
I have a feeling, that this could be a very revolutionary design.
BorgWarner developing hydrogen combustion systems for heavy-duty commercial transport
£4.9 million awarded by government, matched by industry to a total £9.8 million.
This project aims to speed up the rollout of hydrogen-burning internal combustion engines, as an alternative to diesel. Hydrogen is a clean fuel, producing only water when burned. Project Cavendish will develop new fuel and air management systems, so that existing heavy duty diesel technologies can be repurposed to use hydrogen as fuel.
Project partners include: Mahle, Cambustion, Hartridge
Note.
- BorgWarner is a large American automotive supplier.
- Mahle is a large German automotive supplier.
- Cambustion‘s Engineering Services team provides powertrain development and testing services to a range of global clients from our Cambridge, UK base.
- Since the brand formation in 1930 Hartridge, who are based in Buckingham, has become a world leader in diesel fuel injection test equipment.
- Project Cavendish is obviously named after Henry Cavendish, who discovered hydrogen.
In Ricardo Supports Industry Leaders To Develop Innovative Dedicated Hydrogen Engine, I talk about another project involving BorgWarner. Is Project Cavendish a follow-on from the original project or a new one?
Leyland Trucks scaling up the production of electric trucks through innovations in automation and advanced testing
£2.6 million awarded by government, matched by industry to a total £5.1 million.
By better use of automation and advanced testing, Leyland Trucks aim to increase productivity and step up their production of battery electric trucks. A ‘digital twin’ of the Leyland production line will be set up, meaning any changes can be run in simulation before being rolled out physically.
Project partners include: Expert Tooling, HSSMI
Note.
- Leyland Trucks is one of Britain’s leading manufacturing companies. It is PACCAR’s established centre for light and medium duty truck design, development and manufacture. The company is based in Leyland.
- Expert Technologies are specialists in delivering industrial automation solutions. The company is based in Coventry.
- HSSMI is a sustainable manufacturing consultancy.
As I have done a lot of simulation in my time, I’m very much in favour of digital twins.
JLR leading a consortium research project to develop a high-efficiency and highly integrated 800V inverter designed and built in the UK
£6.3 million awarded by government, matched by industry to a total £12.6 million.
This project will explore and develop technology for inverters – a key component in electric vehicles. As well as developing a best-in-class product, this work will support the growth of a UK supply chain in components for electric vehicles.
Project partners include: University of Bristol, Custom Interconnect Ltd, API Capacitors Ltd
Note.
- JLR is Jaguar Land Rover.
- Custom Interconnect is an advanced electronics manufacturing company, which is based in Andover.
- API Capacitors is the UK’s leading designer and manufacturer of high quality power capacitors for power electronic applications. The company is based in Great Yarmouth.
I suspect this invertor will have several applications.
Conclusion
The grants seem to have been widely spread around the UK.
The Anonymous Widower 