Diesel-fueled medium and heavy trucks are responsible for about 40% of global automotive carbon dioxide emissions, plus a tremendous amount of particulate pollution. That fact makes the electrification of commercial vehicles a critical path for environmental cleanup efforts. 

To help address that need, Toyota will kick off production of hydrogen fuel-cell generators at its EV-oriented manufacturing facility in Georgetown, Kentucky before the end of 2023. The company is ramping up a dedicated production line at Toyota Motor Manufacturing Kentucky to assemble integrated dual fuel-cell (FC) modules for use in hydrogen-powered heavy-duty commercial trucks. 

The cells are designed to allow truck manufacturers to incorporate emission-free fuel-cell electric technology into existing platforms with technical support from Toyota.

“We’re bringing our proven electric technology to a whole new class of production vehicles,” said Tetsuo Ogawa, president and chief executive officer, Toyota Motor North America. “Heavy-duty truck manufacturers will be able to buy a fully integrated and validated fuel cell electric drive system, allowing them to offer their customers an emissions-free option in the Class 8 heavy-duty segment.”

What they’re making

The dual fuel-cell modules, which are a key component of an overall FC kit, weigh approximately 1,400 pounds and can deliver up to 160kW of continuous power. The FC kit also includes a high voltage battery, electric motors, transmission and hydrogen storage assembly from top-tier suppliers. 

Toyota will also offer its powertrain integration expertise that will help truck manufacturers adapt these emissions-free drivetrain systems to a wide variety of applications in the heavy-duty trucking sector.

“This second-generation fuel cell system is necessary for a carbon neutral future,” says David Rosier, Toyota Kentucky powertrain head. “It delivers over 300 miles of range at a full load weight of 80,000 pounds, all while demonstrating exceptional drivability, quiet operation and zero harmful emissions.”

Notably, most urban-area delivery trucks in classes 6-8 work from a central warehouse and make deliveries to retail locations within a given metropolitan region. Research by Daimler’s Freightliner brand indicates that most trucks working in this method actually travel less than 100 miles per day, making electric and fuel cell-powered heavy truck products well-suited to the needs of operators. 

Toyota partnerships with truck makers

Toyota’s expansion into heavy truck drivelines is consistent with the company’s industry partnerships. In late May, Toyota and Daimler Truck announced intentions to merge Toyota’s Hino and Daimler’s Mitsubishi Fuso brands and use the combined company to create new EV and fuel-cell commercial vehicles. 

The merger will also entail the establishment of a holding company, with shares split evenly between Daimler Truck and Toyota. Mitsubishi Fuso and Hino will become wholly owned subsidiaries of the new company. 

However, each company will retain its own brand and sales networks in Japan and abroad. The companies plan to finalize the agreement by March 2024, with the details of the merger to be carried out by the end of that year. The focus of the new company will be Asian markets, but the new trucks will be sold globally. 

In North America, Toyota Motor North America Inc. and PACCAR, the parent company of Peterbilt, Kenworth and DAF trucks, announced an expansion of joint efforts to develop and produce zero emissions, hydrogen fuel cell (FCEV) Kenworth and Peterbilt trucks powered by Toyota’s next-generation hydrogen fuel cell powertrain kit, with initial customer deliveries planned for 2024.

PACCAR and Toyota have collaborated on FCEV truck development for the past several years, including a successful pilot program which deployed ten Kenworth T680 FCEV trucks at the Port of Los Angeles in 2022. Toyota’s heavy-duty fuel cell electric powertrain kit was recently awarded the Zero Emission Powertrain certification by the California Air Resources Board (CARB). 

Separately, Daimler trucks has been producing battery electric trucks in classes 6-8 for several years, oriented towards local and short-haul drayage and delivery services. Daimler could become a customer of Toyota’s fuel cell drivelines in the future. 

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• Source: https://www.thedetroitbureau.com/2023/07/toyota-expands-u-s-fuel-cell-manufacturing-for-heavy-trucks/