Toyota has built, tested and delivered 6 fuel cell modules for the next phase in the project. These modules include the latest Gen2 technology offering more power and higher density in a more compact package. It was decided to use the flat module configuration, allowing the most efficient integration in the demonstration train’s roof.

Three of the modules have already been delivered  to CNH2. These fuel cell modules will first be tested together with the batteries in the full system on a test bench, before moving to CAF. The remaining 3 modules will go directly to CAF by mid-February, where all 6 modules will be installed in the demo train.

With the delivery of Toyota’s fuel cell modules, the teams can now develop the Fuel Cell Hybrid Power Pack for the hybrid, bi-modal drive system powering of the train. This system combines the electrical power supplied from the overhead line with the fuel cell hybrid power pack that works independently, powering the train. This demonstrator train, a CIVIA electric commuter train manufactured by CAF, is provided by Renfe; both FCH2RAIL consortium partners. CAF will install the fuel cell modules, as part of the hybrid power pack into the train.

Once the integration is complete the consortium will begin the initial functional tests and trial runs for the approval process within the Spanish and Portuguese tracks. The project aims at testing the energy management and validating whether it can be a reliable and viable solution for hydrogen zero-emission trains. The FCH2Rail project is funded by the Fuel Cells and Hydrogen Joint Undertaking (FCHJU).

Toyota Motor Europe’s new project with EODev follows last year’s successful integration of the Toyota fuel cell module into the Energy Observer boat. EODev’s ambition is to deploy the learnings from the Energy Observer boat and provide sustainable hydrogen solutions across a diverse range of applications. Both companies share a common mission to raise awareness about the versatility of hydrogen and the transition to a Hydrogen Society.

The fuel cell module in the GEH2 generator, was developed around the existing hydrogen technology that already powers the Toyota Mirai. The total unit is packaged in a compact module weighing about 290kg and has a rated net power of 60kW with a peak net power of 92kW.

Projects come with Toyota technical support and the know-how to integrate the module into customers’ power applications. The Fuel Cell Business Unit at Toyota Motor Europe serves as the interface to guarantee the optimal use of the module. Toyota has been integrating their fuel cell technology into a variety of applications lately, including buses, trucks and boats.

Expansion of production facilities

To increase FC stack output, Toyota will move production from its current location, within one of the existing buildings at its Honsha Plant in Toyota City, to a brand-new, eight-floor high-tech facility on the same premises, near the original site of the company’s very first automobile factory in 1938.

The production of high-pressure hydrogen tanks will be handled by a new, dedicated line to be added inside the nearby Shimoyama Plant (No. 3) in Miyoshi City (Aichi Prefecture). Previously, the hydrogen tanks were assembled at the Honsha plant on a smaller scale. Toyota’s hydrogen tanks are made of extra-thick carbon fiber and are built to withstand major impacts.

Outline of the production facilities

The new facilities are expected to help significantly reduce CO₂ emissions during the production stage. This is one of the initiatives for the Plant Zero CO₂ Emissions Challenge in the Toyota Environmental Challenge 2050 announced in October 2015.

Construction of the new hydrogen tank line at Shimoyama is starting now, while the exterior for the new stack production facility is already finished and work will now begin on the interior. Details of the respective facilities will be announced later with a view to start operations around 2020.

Expanding FCEV sales to more countries and regions

As a technology, fuel cells are mature and ready to scale up. Toyota took the lead in bringing to market the mass-produced fuel cell sedan, the Mirai, in December 2014. Annual production and sales have increased yearly, going from about 700 units in 2015, to around 2,000 units in 2016, and, most recently, approximately 3,000 units in 2017. However, in order to encourage more widespread use of hydrogen-powered zero-emission vehicles, popularization needs to start by the 2020s. Toyota aims for annual sales of FCEVs to top 30,000 units globally from around that time.

At present, Mirai is sold in eleven countries: Japan, the United States, and nine countries in Europe. Toyota is working to develop an environment that will allow FCEVs to be sold in more countries and regions in the future. As part of this, demonstration tests of Mirai are currently under way in Australia, Canada, China, and the U.A.E., and Toyota is examining demand for FCEVs while continuing to help with initiatives to promote hydrogen infrastructure development.

In the Japanese market, Toyota aims to reach sales of at least 1,000 FCEV units per month and over 10,000 units annually, from around 2020. Sales regions within Japan will be expanded further from the current four major metropolitan areas to allow even more customers to enjoy Mirai.

On the commercial side, Toyota started sales of FC buses to the Tokyo Metropolitan Government in February 2017, and introduced the final version, the Sora, in 2018 with three additional units. Toyota aims to sell at least 100 such buses ahead of the Olympic and Paralympic Games Tokyo 2020.

Going forward, Toyota will expand its FCEV product range and continue to strengthen product appeal, aiming to bring the cost down. Also, Toyota will keep working with Toyota Group and other companies to develop a hydrogen supply infrastructure and construct a low-carbon hydrogen supply chain. Through these and other initiatives, the company is actively contributing to the realization of a hydrogen-based society.