Mazda - SKYACTIV Technologies

Breakthrough

via technological

innovation

Common architectureconcept

Flexible manufacturingconcept

Production DevelopmentBundled product planning

P2

Plan to raise averagefuel economy of Mazda carssold globally by approx.

　　

2001　　　　　　　　　2008　　　　　　　　2015

(Calender year)

30％Average fuel economy improvement ratio for cars sold in Japan : approx.

30％

Average fuel economy for all cars

Fig.1-1 Target of Average Fuel Consumption

Fig.1-2 Anticipated Expansion in Adoption of 　　　 Environmental Technologies

ICE

ICE

Introduction : Offering all our customers “driving pleasure and outstanding environmental and safety performance”

　Finding solutions to global warming and other environmental problems that we currently face is certainly an urgent issue. As an automaker concerned with offering our customers exceptional value, Mazda is striving to meet the need for ever-better environmental and safety performance in automobiles. We believe our job is to address such requirements while continuing to ensure the kind of driving pleasure that only Mazda can deliver.　The next-generation SKYACTIV technology introduced here is designed to simultaneously achieve the seemingly conflicting goals of driving pleasure and environmental and safety performance without the slightest compromise.　We will begin to equip SKYACTIV technology in new Mazda vehicles sold from 2011 onwards. Our approach is to provide driving pleasure while reducing overall CO2

emissions by improving the core performance attributes of all Mazda vehicles. 　We have set ourselves the goal of offering all our customers driving pleasure along with outstanding environmental and safety performance. Look forward to exciting developments from Mazda as we move towards a sustainable future for people and the automobile.

Internal Combustion Engines (ICE)

Breakthrough

via technological

innovation

Electric vehicle

Hybrids　　Regenerative braking

Idling stop system

Electric vehicle

Plug-in Hybrids　　Hybrids

　　 Regenerative braking

Electric vehicle

Plug-in Hybrids　　 Hybrids　　

Idling stop system

Regenerative braking

Electric Devices

Base engines (ICE)2020



“Sustainable Zoom-Zoom”- Long-term vision for technology development -

　In March 2007, Mazda announced the “Sustainable

Zoom-Zoom” plan, detailing the company’s long-term

vision for technology development. This vision

commits us to make “cars that always excite, look

inviting to drive, are fun to drive, and make you want

to drive them again,” and to help achieve “an exciting,

sustainable future for cars, people and the Earth.”

Based on this plan, we have announced that by 2015

we intend to make a 30% improvement on the 2008

average fuel economy of Mazda vehicles sold

worldwide.

“Building Block Strategy”- Contributing as it expands -

In recent years, new electric devices have been

introduced that have led to the development of

automobiles such as hybrids and electric vehicles. We

have entered an era in which performance delivered

by the engine, transmission, body, chassis and other

vehicle parts is being augmented through their

combination with electrical components. Nevertheless,

it is forecast that internal combustion engines will still

account for a high percentage of automobile

powertrains even as far ahead as 2020 ( Fig 1-2 ).

Electric Devices

Electric Devices Idling stop system




P3

Challenge B

Best balance approach

Fig.1-4 Breakthrough

Fig.1-5 Monotsukuri Innovation

Fig.1-3 Building Block Strategy

Motor

Step-1　

Step-2　Regenerative Braking

Base Technology

Fig.1-3 Building Block Strategy

Step-1　

Step-2Regenerative Brakig

Base Technology

i-stop

Step-1　 Drive technology

Challenge A

Breakthrough

Breakthrough

via technological

via technological

innovation

innovationBreakthrough

via technological

innovation

Fig.1-5 Monotsukuri Innovation

Support for common production processes to raise volume efficiencySupport for common production processes to raise volume efficiencyuu ii

iupport for common productiupport for common producticesses to raise volume effici

Fi 1 5 M t k i I t

Consequently, Mazda is prioritizing improvement of the base technologies that are responsible for the core performance of our cars while adopting a Building Block Strategy of gradually introducing electric devices such as regenerative braking, hybrid and other systems ( Fig.1-3). This approach aims to effectively reduce total CO2 emissions with cars that offer a winning combination of driving pleasure and excellent environmental and safety performance to all our customers, without relying heavily on vehicles that are strictly dedicated to meeting environmental needs.

“SKYACTIV” - Next-generation technologies embodying Sustainable Zoom-Zoom -

　SKYACTIV is the name we have given to our next-generation technologies whose purpose is to realize Mazda’s Sustainable Zoom-Zoom long-term vision for technology development. SKYACTIV is a term we coined to suggest harmony between driving pleasure and excellent environmental and safety performance. All of Mazda’s next-generation technologies associated with the Building Block Strategy are included under this umbrella concept.

“Breakthrough” - The Mazda approach to solving mutually conflicting issues -

　SKYACTIV technology is characterized by theprinciple of breakthroughs. A good example is the conflicting challenge of improving fuel economy while boosting torque. Rather than aiming solely for an ideal balance between the two, we instead employed the breakthrough approach of technical innovation to improve both fuel economy and torque. We applied the same approach to address problems in all areas. This enabled us to vastly improve performance. In our latest effort, we pursued the ideal vehicle structure from scratch, with no preconceptions. In this way, we were able to radically transform powertrains and platforms concurrently, greatly increasing the possibility of achieving breakthroughs.

“Monotsukuri Innovation” (innovative manufacturing)

- Process-innovation in car building -

　Since 2007, even before we introduced SKYACTIV, Mazda has been reforming all the processes involved in making cars, from research and development through to manufacturing. This company-wide project, which we call Monotsukuri Innovation, is organized around a common architecture concept and a flexible manufacturing concept based Bundled Product Planning. Through breakthroughs in both diversification to meet varying customer needs, and commonization for increased efficiency, the project has enabled us to deploy high-grade, high-performance technologies over a wider range of vehicle models, and to respond quickly to changes in customer demands.

Support for competitive multi-product manufacturing

Common architectureCommon architectureconceptconcept

Flexible manufacturingFlexible manufacturingconceptconcept

ProductionProduction DevelopmentDevelopment



Production DevelopmentBundled product planningBundled product planningBundled product planning

P4

Fig.1-7 SKYACTIV-D

Fig.1-6 SKYACTIV -G

Breakthrough

via technological

innovation

(1) Highly efficient engines with a world-beating compression ratio developed in pursuit of ideal combustion

(2) Highly efficient transmissions developed in pursuit of the ideal transmission

(3) Highly-rigid body and chassis that achieve outstanding crash safety

performance through comprehensive weight reduction technology

(1) Highly efficient engines with a world-beating compression ratio developed in pursuit of ideal combustion

　The development of automotive mechanisms for engines has a history going back more than 120 years. For this reason we tend to find it difficult to think that any further improvement in performance is possible. But the fact remains that 70 to 80 percent of the energy contained in fuel is lost within a vehicle’s powertrain and fails to be transferred as motive power to its wheels.Many of today’s automakers are working on engine refinement by making engines smaller and various other methods. One of Mazda’ s recent developments towards an ideal engine configuration is the Homogenous Charge Compression Ignition (HCCI) engine, which offers the combined advantages of both gasoline and diesel engines. In commercializing the rotary engine and through other remarkable technical achievements, Mazda has a history of making the seemingly impossible possible. Now, we have taken on the challenge of pursuing ideal combustion. As a result, we have attained a world’ s best: a compression ratio of 14.0:1 in both the gasoline and diesel categories. Thanks to a number of technological breakthroughs, we succeeded in dramatically improving fuel efficiency, power, exhaust gas emissions and other attributes. With the diesel engine in particular, we have managed to meet stringent exhaust gas emissions regulations in every country our vehicles are sold without installing expensive aftertreatment devices such as urea selective catalytic reduction (SCR) to counteract NOx emissions.

“Base Technologies” - the cornerstone of the Building Block Strategy -

This section introduces the next-generation base technologies to be progressively equipped in most models as the foundation of SKYACTIV. The following three areas are vital to the dramatic improvements we are striving to simultaneously achieve for driving pleasure, and environmental and safety performance.

(2) Highly efficient transmission developed in pursuit of the 　 ideal transmission

　Vehicle transmissions are not only extremely important for improving fuel economy, they also exert a major influence on driving performance. The performance demands on automatic transmissions




P5

Fig.1-8 SKYACTIV-Drive

Fig.1-9 SKYACTIV-Body

Breakthrough

via technological

innovation

vary greatly depending on the market, and since there is not a single transmission in existence that satisfies all these varied demands, automakers deploy a variety of systems, each matched to a particular market. Employing the world’ s most commonly-used combination - a torque converter and stepped automatic transmission - as the basic structure, and by using technology that substantially reduces slip in starting devices, Mazda has brought together the benefits of each system and developed a highly efficient automatic transmission with a substantially direct drive feel that will be perfectly suited to conditions in numerous global markets.

(3) Highly rigid body and chassis that achieve outstanding crash safety performance through comprehensive weight reduction technology

　Mazda has always put the highest priority on offering driving pleasure, and is therefore strongly focused on weight. Reducing vehicle weight does not simply boost fuel economy; combined with the innovative engines described above, it complements the engine’s performance potential, and vastly improves the vehicle’ s core performance attributes when driving, turning and stopping. To gain maximum benefit from the complete redesign of its base technologies, Mazda also set itself the challenge of reducing the weight of its vehicles by approximately 100 kilograms through a process of “comprehensive weight reduction,” which was focused mainly on the next-generation body and chassis. This all-inclusive process aimed to achieve a lightweight and highly-rigid body with excellent crash safety performance by pursuing an ideal body structure, adopting new production technologies and substituting new materials. For example, by first addressing the issue of the locations for the powertrain, chassis and other components, we were able to design an ideal body structure. The optimization of materials and sheet thicknesses was enabled through the use of computer-aided engineering (CAE). Additionally, new production technologies such as laser welding and weld bonding ultimately helped reduce weight and resulted in better crash safety performance and rigidity. We have also pursued chassis improvements through an optimized suspension structure and mounts.




8000rpm4000rpm2000rpm

8000rpm

4000rpm2000rpm

圧縮比 14

Compression ratio11

P14

Fig.2-21 SKYACTIV-Drive

Fig 2-22. Advantages of Each Transmission Type

+ + o +- + + ++ - + ++ - + +- + o ++ o o +

Technology

GoodFE

FE at low speed

FE at high speed

Easy start up(Launch feel)Easy start up on hill(Creep)

Direct feel

Smooth shifting(Shifting Quality)

Important in Japanese market

Important in European market

Important in NA market

Ideal for global market

CVT DCT Step ATSKYACTIV - Drive

+ : Bettero : Average－ : Worse

(2)Improvement in Fuel Economy and Achievement of Direct Feel with Full Range Lock-Up

The torque converter transfers engine power to the transmission through fluid, making a smooth start-up

and gearshifts possible. The drawback is that fuel economy worsens due to the loss of power transfer

through the fluid, and slippage during rapid acceleration, which causes vehicle speed to lag behind engine

speed. Therefore, a torque converter with a lock-up clutch was developed, which locks the torque

converter’ s turbine to the impeller to improve fuel economy and direct drive feel.

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Mazda - SKYACTIV Technologies