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| Toyota D- 4D 180 Clean Power concept |
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Equipped with the innovative Toyota D-4D clean power concept engine |
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Establishing the concept of Clean PowerE high performance with the lowest emissions |
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Class-leading power and torque: around 180 DIN hp and 400 Nm |
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NOX and PM emissions are respectively about 50% and about 80% below EURO IV, thanks to Toyota D-CAT |
The Toyota D-4D 180 Clean Power concept is an original concept car that mixes luxury with refined performance. Some exterior clues announce this special personality, like the metallic mesh grille and the Quicksilver colour, usually exclusive to T Sport models.
Under the bonnet can be found the Toyota D-4D clean power concept engine, a prototype version of the new D-4D engine that will be launched in Europe next year. This innovative powerplant gives a whole new meaning to the expression Eb>Clean PowerEby setting the benchmark in the 1.9 to 2.2-litre category: class-leading power and torque, and the worlds lowest combined NOX (nitrous oxides) and PM (particulate matter) emissions for diesel engines (when installed in the Toyota D-4D 180 Clean Power Concept).
The Toyota D-4D Clean Power concept engine develops around 180 DIN hp, a figure substantially above the 1.9 to 2.2-litre category and only matched by higher-displacement V6 diesel engines. The same applies to the maximum torque of 400 Nm.
This no-compromise balance between performance and environment is only possible by using the best in diesel technology, including the unique Toyota D-CAT.
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| Revolutionary injection technology |
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Adoption of piezoelectric injectors |
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Highest injection pressure ever attained with this technology |
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Low compression ratio increases engine efficiency |
The Toyota D-4D Clean Power concept engine adopts a new piezoelectric common-rail system. This injection system operates at 180 MPa, the highest among all current piezoelectric systems.
The majority of current common-rail systems employ solenoid injectors Ethese are actuated by a magnetic field generated by electric current. However, the new D-4D engine injectors use piezoelectric technology.
Pierre and Jacques Curie discovered the principle of piezoelectricity as long ago as 1880. In essence, its the capacity of certain materials to deform upon the application of an electrical current and to return to their original state when the current is removed.
This is the principle used in the new D-4D engine piezoelectric injectors. Each injector is composed of a stack of piezoelectric ceramic elements. When an electric current is applied to the stack, the elements expand almost instantaneously. The expansion allows the fuel coming from the common-rail into the cylinder. This technique allows larger volumes of fuel to be injected in a shorter time than would be possible with solenoid injectors. In addition, it results in greater fuel atomisation that in turn ensures a more efficient combustion.
This revolutionary injection system has many advantages. For example, it is capable of performing up to 5 injections per cycle. With piezoelectric injector technology, pilot injection timing can be optimised, leading to a reduction in combustion noise.
The D-4D Clean Power Concept engine applies lower compression ratio in order to increase engine efficiency. Furthermore, by adopting high-response ceramic glow plugs, cold-stant performance is improved. In addition, the combination of piezoelectric injection with ceramic glow plugs contributes to a reduction of white smoke at low speeds. |
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| Leading-edge emission control systems |
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Toyota D-CAT makes massive reduction in NOX and PM |
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DPNR is the only catalyst that simultaneously reduces NOX and PM |
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EGR system improved for better performance |
The Toyota D-4D Clean Power concept engine is equipped with the revolutionary Toyota D-CAT (Diesel Clean Advanced Technology) package as standard. This advanced technology is already available in the Avensis model in which it produces the lowest harmful emissions (NOX and PM combined) of any modern diesel.
Toyota D-CAT, which resulted in more than 1,600 new patents being granted to Toyota, consists of a number of elements. At its heart is the DPNR (Diesel Particulate NOX Reduction system) 4-way catalyst Ewhich is the only catalyst in the world that can reduce NOX and PM simultaneously.
The DPNR catalyst, which is totally maintenance-free, operates in association with the sophisticated common-rail injection system. Within these core technologies, various other control systems and devices are integrated.
The effective operation of the DPNR catalyst relies on the engine management system varying the air-fuel ratio in the exhaust gasses. To do this, a fifth injector, known as Exhaust Port Injector (EPI), has been added and placed in the exhaust port. At the critical moment, fuel is injected into the exhaust gas flow in order to create stoichiometric conditions in the DPNR catalyst. This rich spikeEallows the DPNR catalyst to reduce NOX and PM.
EPI is also used to perform the sulphur discharge control. When the sulphur accumulated in DPNR catalyst reaches a certain level, the EPI will increase the catalysts bed temperature in order to release the sulphur.
Toyota D-CAT adopts a high-efficiency EGR cooler Ethis is used to reduce the temperature of the exhaust gasses being recirculated into the combustion chamber, increasing their density.
The EGR uses an electrically-activated valve that takes only 50 milliseconds to open for more accurate control from the engine ECU.
Toyota D-CAT puts this engine well ahead of the competition. This technology allows the Toyota D-4D 180 Clean Power concept to produce a level of NOX and PM emissions that is respectively about 50% and about 80% below EURO IV standards. |
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| The new D- 4D diesel engine to be produced in Europe |
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A brand new factory for a brand new engine |
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Production capacity of 150,000 engines per year |
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A total investment of 200 million and 500 new jobs |
Toyota Motor Industries Poland (TMIP) is the name of the production unit that, from the beginning of next year, will start producing the new D-4D diesel engine, the final version of the D-4D Clean Power concept engine.
TMIP is the second Toyota plant in Poland, after the establishment of TMMP (Toyota Motor Manufacturing Poland) in 1999 for the production of manual transmissions.
TMIP occupies a total area of 300,000 m2 and a floor space of 30,000 m2. These facilities can process up to 150,000 engines per year.
In total, Toyota has invested 200 million in this factory. Furthermore, it employs 500 people directly. |
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