A project to develop a hydrogen fuel cell Toyota Hilux pick-up has moved to its final phase, as the vehicle manufacturer progresses towards a zero carbon future
Since the unveiling of the first prototype vehicle in September 2023, Toyota and its consortium partners, supported by UK Government funding, have successfully progressed their joint development project to the stage of intensive prototype evaluation and demonstration.
Ten fuel cell Hilux prototypes have been built at TMUK’s Burnaston facility in Derbyshire. Five vehicles are undergoing rigorous field testing to assess safety, performance, functionality and durability, generating test drive data in real-world situations.
A further five vehicles are engaged in customer and media demonstrations, including at the forthcoming Olympic and Paralympic Games Paris 2024.
Toyota expects Europe to be one of the world’s largest hydrogen fuel markets by 2030, with steady growth in mobility and power generation applications.
A Toyota spokesperson said: “This latest project landmark further demonstrates the broad scope of Toyota’s multi-path strategy towards carbon neutrality, applying different powertrain technologies – hybrid electric, plug-in hybrid electric, battery electric, fuel cell electric and e-fuels – to suit different user needs and local infrastructure.
“The hydrogen fuel cell prototype Toyota Hilux showcases how fuel cell technology can be integrated into a pick-up vehicle.”
Externally, the fuel cell model has the same dimensions and appearance as the latest Hilux generation. Using an extra-cab body style, it is 5,325mm long, 1,855mm wide and 1,810mm tall.
Power is delivered using core elements from the fuel cell system featured in the Toyota Mirai.
The fuel cell Hilux has an expected driving range of up to 373 miles/600km – further than might be achieved using a battery electric system. And due to hydrogen’s light weight, Toyota says a higher payload and towing capability can be achieved, compared to other zero emission alternatives.
Hydrogen is stored in three high-pressure fuel tanks, each containing 2.6kg to give a total capacity of 7.8kg. The tanks are mounted within the vehicle’s ladder frame chassis. The polymer electrolyte fuel cell stack contains 330 cells and is mounted above the front axle.
The fuel cell Hilux is rear-wheel drive, via an e-motor on the rear axle delivering a maximum 134kW (180bhp, 182 DIN hp) and 300Nm of torque. When the vehicle is driven, the fuel cell produces no tailpipe emissions, only pure water.
A lithium-ion battery stores the electricity produced on board by the fuel cell. This is located in the rear load deck, above the hydrogen tanks, and avoids any loss of cabin space.
The hydrogen fuel cell Toyota Hilux prototype project began with a feasibility study in early 2022 and has moved at pace towards its concluding phase.
This initial study, undertaken by TMUK and TME, enabled subsequent funding from the UK Government through the Advanced Propulsion Centre, a non-profit organisation which supports the development of cleaner technologies and new mobility concepts.
An intense design and development programme ran from July 2022 to January 2023, also involving consortium partners Ricardo, ETL, D2H, Advanced Technologies and Thatcham Research, with additional support from Toyota Motor Corporation.
Parts manufacturing, including chassis frame welding, took place between February and May 2023, prior to prototype construction following Toyota Production System principles in a dedicated area within TMUK’s Burnaston plant. Ricardo supported preparations for the prototype build, carrying out design and development tasks and confirming the complete manufacturing process in parallel with teams at TMUK.
Construction took place in June and July 2023 and the first vehicle was completed in just three weeks. A further nine were assembled between July and December, ahead of a thorough evaluation phase that included test rig and track testing.
A Toyota spokesperson said: “The fuel cell Hilux prototype project is an important stepping stone to the further development of hydrogen technology and stimulate a wider roll-out of hydrogen eco-systems and infrastructure across Europe.”
Since the start of its hydrogen fuel cell development in 1992, Toyota has expanded its knowledge of the technology and encouraged its adoption across a range of different mobility uses, with more than 20 hydrogen partnerships currently active in Europe.
These include a five-year trial with hydrogen-fuelled VDL trucks to decarbonise Toyota’s logistics operations and stimulate further development of a sustainable hydrogen infrastructure across Europe.
Since July 2021, Toyota has co-branded fuel cell buses with its partner manufacturer CaetanoBus, while French clean mobility company GCK is using Toyota’s fuel cell modules to convert 10 diesel coaches to zero tailpipe emission vehicles which will be used to transport more than 5,000 visitors during the Olympic and Paralympic Games Paris 2024.
A partnership with Corvus in Norway has produced one of the safest and most advanced marine fuel cell systems yet available. Furthermore, Toyota worked closely with Energy Observer to create the first hydrogen-powered, zero emission boat that is self-sufficient in energy.
