Hydrogen development for LCV

Ricardo is working alongside Toyota, the Advanced Propulsion Centre (APC) and other consortium members on the development of the marque’s first hydrogen light commercial vehicle set for prototype production in the UK.

The Toyota Hilux hydrogen variant will be the first of its kind, manufactured and assembled at Toyota’s Derby-based facility and is scheduled for prototype production in 2023. Ricardo has been chosen as a partner by Toyota due to its proven experience in applying advanced propulsion technologies and expertise in hydrogen fuel cell integration, including for the UK’s first hydrogen transport hub.

Challenge

Toyota is leading a consortium to develop a prototype hydrogen fuel cell-powered version of its world-famous Hilux pick-up at the company’s UK vehicle plant in Burnaston, Derbyshire.

The company has successfully secured UK Government funding for the project through the Advanced Propulsion Centre (APC), an organisation supporting the development of cleaner technologies and new mobility concepts.

The opportunity will bring zero-emission technology to the commercial vehicle and reflects customer demand for sustainable mobility across all sectors.

Support is required to help Toyota to build their expertise and become self-sufficient in developing next generation hydrogen drivetrain technologies.

Approach

Ricardo is using the following approach to support Toyota and other consortium members on the project:  

• Ricardo’s role in the project will be to integrate the complete hydrogen fuel cell, fuel storage system, and controls including design, analysis, and validation
• The integration of the fuel cell systems to the Hilux chassis ensures efficient operation of all systems to give an excellent vehicle range and supports attributes for longevity and reliability. 
• Working as part of the consortium, Ricardo will support the delivery of a complete turnkey solution, which will create greater agility for Toyota in the UK supply base and a quicker turnaround in the design of low volume manufacturing.

Recommendations

• This new opportunity to bring zero-emission technology to the commercial vehicle market reflects evolving customer demand and Toyota’s 360-degree approach to sustainable mobility across all sectors. 
• The APC funding will enable TMUK to develop hydrogen technologies for this specific vehicle market segment during the next three years.
• Ricardo will work as part of a consortium to develop the fuel cell electric hydrogen Hilux, with highly skilled engineering partners ETL, D2H and Thatcham Research. 
• The project will make use of components from Toyota’s second-generation fuel cell system, as featured in the latest Toyota Mirai saloon, to transform a Hilux into an electric vehicle.

Results

• Client gains access to Ricardo expertise in the development of integrated hydrogen fuel cell, fuel storage systems and controls, including design, analysis, and validation
• The project is the first of its kind for Toyota in the UK, being a hydrogen powered Light Commercial Vehicle, so will support further research and development in the commercialisation of alternative fuel powered vehicles
• Over the course of the project, Ricardo will support Toyota with the delivery of the new product, helping increase visibility of our own expertise, and enabling the transfer of knowledge