Toyota Motor said it had developed a new continuously variable transmission (CVT), six speed manual transmission, two litre engine, two litre hybrid system, and 4WD systems based on its Toyota New Global Architecture (TNGA).
The new CVT has a launch gear, a claimed world first, to, the automaker said, “significantly improve transmission efficiency at low speeds when compared to existing CVTs. It realizes both direct and smooth driving response to accelerator application, as well as superior fuel efficiency”.
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Direct Shift-CVT: A New Type of Continuously Variable
Toyota has aimed to reduce mechanical loss, adopt a wider gear range, and improve shift tracking. These initiatives have resulted in a direct and smooth driving experience with superior fuel efficiency, which has been improved by 6% over the existing transmission system.
Reduced mechanical loss
The new powertrain has a launch gear which facilitates improved transmission efficiency in lower gear ratios where belt efficiency is poor. The transmission system uses gear drive when starting from a full stop, resulting in powerful acceleration while at the same time resolving the momentary sluggish feeling that was previously present during accelerator operation. Both smooth and comfortable launch performance are achieved. When switching from gear drive to belt drive, the transmission system uses highly responsive gear change control technologies developed from AT technology.
Conversion to wider gear ranges
In line with the adoption of a launch gear, belt use is now specified for higher gear ratios. This new setup not only improves the efficiency of belt use, but also enables the adoption of wider gear ranges, thereby realising a class-leading gear ratio range of 7.5 for the two litre.
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By GlobalDataImproved shift tracking
The adoption of launch gears results in reduced input load. This enables the size of both belt and pulley components to be reduced. The belt angle has been narrowed and pulley diameters reduced, resulting in shifting speeds that are 20% faster.
New 6-speed Manual Transmission (6MT)
Toyota has also developed a new manual transmission in response to global needs, particularly those in Europe. Compared to the existing version, the mass of the new system has been reduced by 7kg and total length by 24mm. This makes it one of the world’s smallest transmissions and its small size contributes to improved fuel efficiency. The 6MT also offers claimed world leading transmission efficiency while the use of iMT (Intelligent Manual Transmission) controls, which automatically adjust engine rotations when changing gears, ensures smooth gear shifting free of uncomfortable recoils for the driver.
Two litre ‘Dynamic Force Engine’ I4, direct injection, I4, petrol
The new Dynamic Force Engine adopts high speed combustion technologies and a variable control system. It also achieves greater thermal efficiency, resulting in high output, due to a reduction in energy loss associated with exhaust and cooling systems, the movement of mechanical parts, and other aspects. As a result, the newly developed petrol vehicle and hybrid vehicle engines achieve claimed world leading thermal efficiencies of 40% and 41% respectively. In addition, compared to existing engines, the new engines achieve increased torque at all engine speeds and will comply with expected future exhaust regulations in each country in advance.
Two-litre Toyota Hybrid System (THS II)
Toyota has developed a new hybrid system for two litre engines which applies the same size-, weight- and loss reducing technologies used in the fourth generation Prius. The new system achieves improved driving performance while retaining superior fuel efficiency. When accelerating, the hybrid system reduces engine rotations while drawing increased electric power from the battery, thereby delivering a linear and lengthened sense of acceleration.
New Dynamic Torque Vectoring AWD and E-Four 4WD Systems
Toyota has developed two new 4WD systems with the aim of improving fuel efficiency and achieving high 4WD handling, stability, and off road performance.
The new Dynamic Torque Vectoring AWD system is used in petrol engine vehicles. By adopting a torque vectoring mechanism, which independently distributes torque to the left and right rear wheels according to driving conditions, the system enables the driver to steer the vehicle exactly as intended. It also incorporates a disconnect mechanism, which features the claimed world’s first ratchet-type dog clutches on both the front and rear wheel shafts. These clutches stop the drive system rotations, which transmit driving force to rear wheels when in 2WD mode, significantly reducing energy loss and improving fuel efficiency.
The new E-Four system will be used in hybrid vehicles. The system increases total torque to the electrically driven rear wheels by 30% compared to existing versions. By adopting a new control system that optimally distributes torque to the rear wheels based on the driving conditions, the E-Four system offers high off road performance, handling, and stability.
Both feature AWD Integrated Management (AIM), which harmonises engine, transmission, braking, and 4WD systems.
Toyota intends to expand the number of models equipped with the new powertrains worldwide from this spring.
Regarding TNGA-based powertrains, Toyota has already announced plans to introduce 17 versions of nine engines, 10 versions of four transmissions, and 10 versions of six hybrid systems by the end of 2021. The new CVT, MT and the two engine are four of the planned components.
Within the next five years, Toyota aims to have TNGA-based powertrain units installed in approximately 80% of Toyota- and Lexus brand vehicles sold annually in Japan, the United States, Europe, and China. It forecasts that the new powertrains alone will improve fuel efficiency enough to reduce CO2 emissions from Toyota vehicles by more than 18%.
