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Toyota Cuts Weight of New Prius by Using More High-tensile Steel Plates

Discussion in 'Gen 4 Prius Main Forum' started by usbseawolf2000, Oct 25, 2015.

  1. usbseawolf2000

    usbseawolf2000 HSD PhD

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    [​IMG]
    The parts for which the high-tensile steel plate and Al alloy are used

    The body mass of the new Prius, which Toyota Motor Corp will release in December 2015, is about 60kg lighter than that of the current (third-generation) Prius.

    Toyota realized the light weight by using many high-tensile steel plates and aluminum (Al) alloy parts. The company increased the usage ratio (mass percent) of 1.5GPa-class (tensile strength) hot-pressed materials and 980MPa-class cold-pressed materials from 3 to 19% and used Al alloys for the back door, bonnet, etc.

    The 1.5GPa-class hot-pressed materials were employed as reinforcement materials for the center pillar, cross members, roof rails, toe boards (parts that separate the engine room and the vehicle interior), etc. They are used especially for parts that require a high strength to protect passengers from impacts caused by a collision, etc.

    The 980MPa-class cold-pressed materials were adopted as reinforcement materials for the center pillar, side sills, roof, doors, rear bumper, etc.

    Among the Al alloys, a 6000-series alloy press-formed product was employed for the back door and bonnet, and a 7000-series alloy extruded product, which is stronger than the 6000-series product, was adopted for the front bumper. Toyota used a high-tensile steel plate for the rear bumper and Al alloy for the front bumper in the aim of reducing the mass of the front part of the vehicle as much as possible, the company said.

    This time, Toyota employed a framework with a ring structure for the body of the new Prius based on the concept of the "TNGA (Toyota New Global Architecture)." Also, in addition to spot welding, the company used "laser screw welding (LSW)," which enables to shorten spot pitch more than spot welding, and a structural adhesive. As for the LSW, the company increased the number of spots by about 30%, especially near the four corners of each door frame.

    Through those improvements and the employment of light-weight materials, Toyota improved the torsional rigidity of the body by about 60%, compared with the current model, the company said.

    [​IMG]
    The reinforcing material for the front bumper uses a 7000-series Al alloy.

    More picture at the link: Toyota Cuts Weight of New Prius by Using More High-tensile Steel Plates - Nikkei Technology Online
     
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  2. bisco

    bisco cookie crumbler

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    wow, to pull that off without a cost increase is amazing!
     
  3. Netcub

    Netcub Active Member

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    Have they said anything about pricing yet?
     
  4. bisco

    bisco cookie crumbler

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    no, but it will be competitive.:)
     
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  5. David Beale

    David Beale Senior Member

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    The car will be $10, and the delivery fee will be $23,030. ;)
     
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  6. Netcub

    Netcub Active Member

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    Sounds like people sell things on eBay.
     
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  7. Mendel Leisk

    Mendel Leisk Senior Member

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    Just thinking about what happens when the car sustains a front end hit. The way that front portion is connected, looks like it'll all rotate:

    Capture.JPG
     
  8. spwolf

    spwolf Senior Member

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    looks like it will disperse the energy to the side... this new platform has a lot of new features for safety, it will probably end up scoring a lot better than previous cars since it has to meet standards not in play today. Previous platforms had issues with dispersing small front offset crashes which took them few years to correct.
     
  9. David Beale

    David Beale Senior Member

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    What, nobody else notices that the newest car out has the best crash rating? The engineers with the last crack at it do the best. Until the next group of engineers tops them.

    Which is why in the 20 year old Prius thread I wondered why anyone would WANT to drive a 20 year old car.
     
  10. bwilson4web

    bwilson4web BMW i3 and Model 3

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    To piss off the hybrid skeptics.

    Bob Wilson
     
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  11. E46Prius

    E46Prius Active Member

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    The lower bar is commonplace to increase crash compatibility with vehicles that have different bumper/structure heights. Basically it's there to engage the crash managing structures (crumple zones) of both vehicles.

    Besides whether it rotates or not doesn't matter. As long as it does the job. Those parts will be destroyed either way. I'm sure this new design will score well in current small offset tests.
     
  12. Mendel Leisk

    Mendel Leisk Senior Member

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    I guess I should have stressed: I'm not saying that's necessarily bad. Just my "structural" eye.
     
  13. chinna

    chinna Member

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    Toyota did not cut the weight, rather it is increased compared to Gen 3. Please take a look at press release which clearly given the weight of this new model being more than Gen 3. It is 100KG(224 pound heavier than Gen 2).
    Weight kg 1360 +10 1350 1260 1220

    With all this hi-funda (like reducing weight of battery, inverters, motors, gearbox, stamped steel etc) I thought(and hoped) Prius is going to be about 2800 pound(close to Gen 2). Now we know that is not the case, infact heavier than Gen 3, and we know it has less powerful motors, I lost confidence in Gen 4 Prius being better Prius. I bet it would be dog slow, being more heavier, less power. It makes it Gen 4 , all show, no go car.
     
    #13 chinna, Oct 29, 2015
    Last edited: Oct 29, 2015
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  14. KrPtNk

    KrPtNk Active Member

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    I think that the information shows the new Prius to be 10 kg more than the previous model, not 100. That would make the weight gain just 22 pounds.
     
  15. usbseawolf2000

    usbseawolf2000 HSD PhD

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    There seems to be confusion here.

    TNGA saved weight but Prius spent it on better suspension, more noise insulation, etc.

    The end result was a quieter car with better handling that weights about the same.
     
  16. Trollbait

    Trollbait It's a D&D thing

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    With lower power output based upon the figures seen so far. So it got better handling with slower acceleration.
     
  17. KrPtNk

    KrPtNk Active Member

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    Where have you gotten the acceleration numbers? I haven't seen them.
     
  18. Tideland Prius

    Tideland Prius Moderator of the North
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    See usbseawolf2000's explanation below. You're confusing "weight reduction using TNGA" to "entire weight of vehicle will be reduced". No, weight reductions were there. What Toyota does with the weight savings is entirely up to each vehicle. In the case of the Prius, they decided to use the weight savings to make the car quieter and to install a better rear suspension.

    Bingo.

    Depends on the gearing. The Prius v is 200kg heavier but has a shorter final drive ratio so acceleration is only slightly slower than the liftback. Also, the 1.8 litre engine in the Gen 4 has peak torque coming in at 3,600rpm. That's quite a bit sooner than in the Gen 3.
     
  19. chinna

    chinna Member

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    I gave the weights in line. As stated infact it is 100KG more than Gen 2, and 10KG more than Gen 3.
     
  20. chinna

    chinna Member

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    You seems to believe gearing addresses the lack of power. Shorter final drive ratio reduces fuel economy/efficieny, reduces top speed.

    I acknowledge early peak torque, (I also believe flatter torque curve) helps some what. But it is negated by the fact the torque rich electric motors are down sized and down rated with less torque and power. Electric motors are the ones that helps more in instant torque for acceleration.

    But again on the topic about weight reduction, all this hi-tech mentioned here did not materialize in the end result of lighter car. Insulation would not add 100 pounds, neither rear suspension adds that much either. At best insulation may account for 30 additional pounds, may be additional 30 pounds for rear suspension. Savings are pretty much nothing, if any at all.

    It is like claiming 20% reduction is transmission losses, which does not mean transmission efficiency improved from 70% to 90%. It is more like
    transmission losses decreased from 5% to 4% (means transmission efficiency increased by 1%), but losses went down by 20% (20% of 5%).

    IMHO, only real tangible/considerable improvements are, in Engine, and aero in this generation, but improvements in engine power/torue are more than negated by motor powers.

    I would have liked same mileage as G3 with better power and acceleration (something similar to Volt 2) making it more drivable, rather than mere 5 MPG gain (in real sense it does not save much at all).
     
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