TOYOTA MOTORSPORT GmbH — THE HOME OF HIGH PERFORMANCE

TOYOTA MOTORSPORT GmbH THE HOME OF HIGH PERFORMANCE TOYOTA MOTORSPORT GmbH — THE HOME OF HIGH PERFORMANCE 3

CONTENT WELCOME CAR DESIGN & DEVELOPMENT 04 - 13 Car Design 06 - 07 CFD and Calculation 08 - 09 Driving Simulator 10 - 11 TO THE HOME OF HIGH PERFORMANCE Chassis Workshop 12 - 13

RESEARCH & DEVELOPMENT 14 - 21 Wind Tunnels 16 - 17 Component Testing 18 - 19 Full Car Testing 20 - 21

ENGINE DESIGN & DEVELOPMENT 22 - 29 Engine Design 24 - 25 TOYOTA Motorsport GmbH (TMG) is a unique Constructed to the highest standards with Engine Dynamometers 26 - 27 high-performance development, testing and no compromise on quality or functionality, Engine Component Testing 28 - 29 manufacturing facility located in Cologne, the spacious 30,000m² facility and its highly- Germany. skilled staff of around 250 offer a remarkable range of machines, facilities and expertise. High performance, precision and diversity ELECTRIC VEHICLE DEVELOPMENT 30 - 35 are core principles at TMG and our technical TMG has developed into a one-stop shop for EV Technology 32 - 33 specialists have in-depth engineering specialised services focusing not only on EV Motorsport 34 - 35 experience across various sectors. automotive clients but also those from other sectors where precision and performance are TMG has honed its competences in top-level essential. competition, from our world championship- MANUFACTURING 36 - 43 winning rally cars to revolutionary Le Mans TMG’s range of services encompasses the prototypes and record-breaking electric complete development cycle, with seamless Rapid Manufacturing 38 - 39 vehicles via the pinnacle of motorsport, interaction between systems and facilities Composites 40 - 41 Formula 1. to ensure speed, efficiency and, most CNC and Fabrication 42 - 43 importantly, quality. Whatever the requirements and however extensive the project, TMG can create a Our complete range of processes and systems tailor-made solution to deliver prototype is far too lengthy to list in detail but one CUSTOMER MOTORSPORT 44 - 49 development, specialist testing or look at the highlights and it is clear that TMG TMG GT86 CS-V3 46 - 47 enhancement of existing components. truly is the home of high performance, with Yaris R1A 48 - 49 everything under one roof. CAR DESIGNCAR DEVELOPMENT & DEVELOPMENT CAR DEVELOPMENT TOYOTA MOTORSPORT GmbH — THE HOME OF HIGH PERFORMANCE 5 INNOVATION

TMG’s state-of-the-art car development facilities are the perfect environment for our skilled engineers to innovate in order to deliver high performance. CAR DESIGN & DEVELOPMENT CAR DEsign TOYOTA MOTORSPORT GmbH — THE HOME OF HIGH PERFORMANCE 7

PERFORMANCE PLANNING CAR DESIGN COMBINES CALCULATION, DESIGN AND EXPERIMENTATION TO DELIVER HIGH PERFORMANCE ACCORDING TO YOUR SPECIFICATIONS.

With a highly-skilled team of designers and structures, with specialised calculation the facilities to back them up, we have all the engineers to ensure appropriate strength and necessary tools to realise your targets, whether weight while various static or dynamic load in complete vehicle design or specialised part cases can be tested in controlled ambient development. conditions.

TMG’s car design department uses Catia TMG is at the cutting edge of gearbox V5 technology and offers part designs for technology, including driveshafts and almost any application, utilising our extensive differentials, and offers a full range of experience in high-performance development developments supported by specific tests. while integrating our established time and cost-saving procedures. We also offer a variety of specialist component solutions from carbon and Our calculation group will confirm structural metallic suspension elements to steering or efficiency through material and geometry brake systems development, supported by a optimisation while experimentation on our full range of calculation techniques, including component testing rigs verifies calculations topology optimisation and on-site testing. or proves prototype parts and systems, validating the achievement of performance Hydraulic system development is another area targets and ensuring effective development. of expertise, with thorough simulation tools and the testing of servo valves and pumps, as Supporting the design and development well as other systems and components. process, our material specialists ensure you select the best solution for your performance Additionally, integration with engine and pricing specifications. and component testing allows unified development of fuel systems and water or We have in-depth knowledge of high- oil coolers, encompassing lay-out, design and performance composite design, including experimentation. structural items and impact absorption CAR DESIGN & DEVELOPMENT CFD and Calculation TOYOTA MOTORSPORT GmbH — THE HOME OF HIGH PERFORMANCE 9

VIRTUAL DEVELOPMENT TOOLS DETAILED UNDERSTANDING OF HOW A COMPONENT OR FULL VEHICLE PERFORMS IS ESSENTIAL IN DEVELOPMENT WHICH IS WHERE OUR CFD AND CALCULATION SPECIALISTS CAN HELP.

At TMG we offer supercomputing power and analytical charts and illustrations exactly incredibly detailed analysis, both in the field matching your requirements. of computational fluid dynamics (CFD) and calculation. Also in the virtual domain, TMG’s chassis calculation experts will deliver a full structural Our CFD experts use powerful software to calculation service to optimise parts – from experimentally improve flow efficiency and cars and boats to domestic appliances – for performance, with up to 80 million hexahedral efficiency and weight reduction. cells making up a complete vehicle model. Our extensive software suite features Tosca, This delivers a full understanding of flow Genesis, ANSA, Abaqus, Nastran, LSDyna dynamics no matter what object requires (crash applications), LMS Virtual.Lab, LMS testing and this process integrates perfectly Imagine.Lab, AMESim and Matlab, working on with our wind tunnel, chassis calculation and a high-capacity hardware cluster. simulator technology to create an efficient development cycle. That enables our experts to run multi-body simulations with rigid and flexible models, All you need is CAD geometry of your with particular attention paid to modelling development item and TMG’s experienced details and ensuring a clear correlation engineers can create a model and begin CFD between simulation results and actual analysis. measurements.

With a typical full-car model of 60 million In addition to standard chassis calculation hexahedral cells, calculation, including procedures, TMG also offers a specialised automatic generation of post-processing carbon composite service, building on our movies, can be performed within 24 experience in top-level motorsport. hours and three cases of this size can run simultaneously. By establishing the optimum carbon fibre lay- up situation, you can reduce weight without An automatic post process suite streamlines endangering your ideal stiffness levels the development process and eliminates the while dedicated composite design software need for complex, time-consuming manual ensures complete production accuracy and analysis, delivering a bespoke selection of repeatability. CAR DESIGN & DEVELOPMENT driving simulator TOYOTA MOTORSPORT GmbH — THE HOME OF HIGH PERFORMANCE 11

SIMULATION AND EVALUATION TAKE ADVANTAGE OF THIS HIGHLY-ACCURATE VIRTUAL DRIVING SIMULATOR FOR DRIVER-IN- THE-LOOP ENGINEERING DEVELOPMENT OR FOR DRIVER ACCLIMATISATION PROGRAMMES.

TRACK LIST: The simulator is a dedicated engineering tool An accurate tyre model includes thermal developed exclusively by TMG, featuring the effects, as well as a choice of weather, to cover • latest technology to accurately reproduce the all scenarios and provide full flexibility for • Autodromo Nazionale Monza driving experience in a virtual environment. repeated tests in identical conditions. • Bahrain International Circuit With extremely detailed models of a variety Developments can be evaluated on a range • Circuit de Catalunya of circuits as well as various vehicles, TMG’s of circuits which have been surveyed using the latest laser-mapping technology with an • simulator is a next-generation tool for car development where completely consistent unprecedented degree of accuracy. • (Le Mans) and repeatable track conditions promote The simulator is a flexible tool, adaptable for • Circuit de reliable evaluation that is directly relevant to your development programme. open or closed cockpit cars and with a fully • Circuit de Spa-Francorchamps parameterisable dynamic vehicle model. • The accuracy of every track is assured thanks to an exhaustive development process In addition to its engineering function, the • Hockenheim featuring driver input and focusing on every simulator is also a valuable tool for driver • detail, from the kerb angles and track surfaces development. Programmes are available to background scenery and other visible to familiarise drivers with different cars or • Interlagos features. circuits in a safe and predictable environment, • Marina Bay Circuit while an interactive pit crew aids the practice A six-degrees-of-freedom electric motion of procedures. • Nürburgring Nordschleife platform simulates driving sensations and • Sepang International Circuit an electric feedback motor creates realistic Realistic conditions also offer a valuable steering torque while TMG’s vehicle model opportunity for drivers and engineers • translates wind tunnel kinematic data to develop efficient communication and • Simulated Vehicle Dynamics Area to simulate the effect of aerodynamic or working practices in a controlled and flexible mechanical changes. environment away from track pressures. • Suzuka Circuit • Valencia CAR DESIGN & DEVELOPMENT chassis workshop TOYOTA MOTORSPORT GmbH — THE HOME OF HIGH PERFORMANCE 13

SPACE AND KNOWLEDGE TMG’S CHASSIS WORKSHOP CAN MANAGE EVERYTHING FROM CONVERSION PROJECTS TO PROTOTYPE OR RACING CAR BUILDS, SUPPORTED BY TOP-LEVEL EXPERTS.

Large, clean-environment chassis workshop hits the road or . facilities, featuring five independent work bays, combine with fully-fitted clean rooms for Our 760m² workshop and 600m² of separate hydraulic and gearbox preparation to provide working space were built from new in 2000 the ideal environment for precision work. and conform to the highest standards of cleanliness and preparation while private TMG’s history as a constructor of rally and bays can be screened off to guarantee prototype racing cars, as well as our long- confidentiality. standing road car tuning business, has created a team of highly-skilled technicians, Facilities include lifting machinery, a flat bed who on average have more than 17 years for validation and direct HGV access. of experience each at the cutting edge of automotive technology. A dedicated team of technicians bring knowledge from various road car and The chassis workshop plays an integral part in motorsport disciplines to deliver the our full-car development process as the place experience necessary to get the most out of where innovation is turned into reality, after any project. comprehensive design, development and production elsewhere in TMG. Our facilities and personnel are perfect for feasibility studies to transform prototype With comprehensive facilities and large projects into designs suitable for repeat capacity, we are perfectly suited to build any production or road-to-racing conversions. kind of low-production- volume vehicle, from touring or rally cars right up to prototype Additionally, why not take advantage of our vehicles. expertise to train your own technicians in the specialised skills required for running and By integrating car build into the development maintaining high-performance or prototype process, which all takes place under one roof, machinery? we can ensure efficiency and ease of handling

for the best possible results when your car RESEARCHCAR DEVELOPMENT & DEVELOPMENT CAR DEVELOPMENT TOYOTA MOTORSPORT GmbH — THE HOME OF HIGH PERFORMANCE 15 ACCURACY

TMG has an unparalleled range of R&D facilities covering everything from full-car testing to individual component analysis, all delivering incredibly detailed and accurate results. RESEARCH & DEVELOPMENT WIND TUNNELS TOYOTA MOTORSPORT GmbH — THE HOME OF HIGH PERFORMANCE 17

THE ULTIMATE AERO EXPERIMENT OUR TWO WIND TUNNELS ARE BASED ON CLASS LEADING TECHNOLOGY AND OFFER UNIQUE INTERACTION WITH TMG’S OTHER SERVICES FOR SPEED, ACCURACY AND MAXIMUM EFFECT.

Both our wind tunnels (WT1 and WT2) use At TMG we are dedicated to efficiency and a continuous steel belt rolling road with a true-to-life accuracy, so High Speed Data maximum speed of 70m/s. Both wind tunnels Acquisition (HSDA) and Continuous Motion are capable of up to 60% model testing whilst Systems (CMS) are available on both tunnels. WT1 is also equipped for full-size cars. In CMS mode, a user-defined programme of Accuracy is the focus of TMG’s wind tunnel ride height, yaw, roll, steer and individual services and our highly-advanced models pre-load changes provides continuous motion include up to 512 pressure measurement on a predefined trajectory while the HSDA channels, accurate to 7Pa, and laser system is continuously acquiring data at high technology to ensure correct positioning to frequency. 0.05mm accuracy. Even tyre deformation and exhaust gases can be simulated. This allows realistic road or track analysis, reducing tunnel time by as much as 70% and Both tunnels also benefit from particle image increasing the amount of useful data from velocimetry (PIV) analysis to visualise flow each individual test compared to standard structures in X, Y and Z planes within the wind motion and acquisition systems. tunnel. A secure exclusive data analysis tool enables Our ‘wheels on’ approach offers fast and reliable interpretation of results representative suspension kinematics, active for efficient development. TMG’s system suspension pre-load with integrated pushrods synergies allow wind tunnel data to be and automatic steering. streamed to the CFD and driving simulator departments. RESEARCH & DEVELOPMENT COMPONENT TESTING TOYOTA MOTORSPORT GmbH — THE HOME OF HIGH PERFORMANCE 19

A UNIQUE TESTING FACILITY WITH A HUGE CHOICE OF TEST RIGS PERMITTING OVER 200 DIFFERENT TESTS, WE WILL DEVELOP AN INDIVIDUAL COMPONENT TESTING SOLUTION JUST FOR YOU.

Welcome to the most extensive and advanced confidentiality, no matter which services you (uprights and hubs) can be analysed for high-performance component testing require. performance and reliability. laboratory on the open market. But it is not simply the choice of machines TMG’s transmission lubrication test system The purpose-built 2,600m² advanced and processes which sets TMG out as a class provides a comprehensive analysis of internal component testing area within TMG offers a leader; our highly-skilled technicians come lubricant flow. comprehensive range of in-house calibration, from a variety of industrial sectors and are customised component rigs, single axis adaptable to meet whatever challenge they The system fixtures include a stationary rigid test rigs, geometric measurement, centre face. base on which are mounted three servo- of gravity and inertia verification, vibration electric motors, drive gears and moveable testing and much more. TRANSMISSION TEST SYSTEMS fixtures for pitch and roll to simulate acceleration, deceleration and centrifugal TMG offers two rare and powerful testing forces. As well as complete-vehicle testing solutions, rigs designed specifically for transmission TMG also offers multiple examples of various durability, reliability and performance This allows a transmission to be mounted and single component rigs, allowing simultaneous investigations. testing to streamline development. exposed to accurate pitch and roll motions while a drive motor delivers rotational input, The transmission test system is a high- recreating the drive normally produced by the With rare commercially-available items such dynamic and high-performance rig which engine. as a transmission test system, seven-post permits real-time simulation of road or track rig, a four-corner full-car road simulator, a conditions. Three electric motors drive the By fully understanding lubricant flow in road/ transmission lubrication test system and gearbox for dynamic response to replicate track conditions, lubrication of all internal rotary damper rigs, TMG has it all. engine stresses. Two hydraulic rear axle road gearbox components can be optimised simulators apply suspension loads. Every square metre of our extensive advanced for performance and total reliability. The system is also perfect for component tests to component testing facility is accessible by The system is perfect for development of road- optimise items such as spray bars, oil pumps overhead crane while a modular lay-out and ready clutch, launch and seamless gear shift or oil coolers. multiple access points allow for complete solutions while inner and outer suspension RESEARCH & DEVELOPMENT FULL-CAR TESTING TOYOTA MOTORSPORT GmbH — THE HOME OF HIGH PERFORMANCE 21

FULL-CAR ROAD SIMULATOR actuators at the front and rear mounted in the vehicle’s centre line. The industry-leading MTS 329 6DOF full-car road simulator creates a real-time simulation Accurate stiffness measurements, friction including a replay of all forces and moments. investigations and pushrod-to-vertical-load ratio checks can be achieved using static body Its six degrees of freedom at vehicle spindle configuration, where a chassis is clamped gives control over vertical, lateral and securely to the floor while wheels are moved longitudinal translation, brake/drive torque, independently by the corner posts. camber moment and steer moment while the 29 channels are accurate to 0.001mm and The versatile and robust seven-post rig also an additional four actuators can simulate carries out full component fatigue or proof downforce. testing of dampers, torsion bars, springs and wishbones, as well as complete car This comprehensive test solution simulates suspension friction measurements and multi-axial inputs to a vehicle to replicate its inerter mass optimisation. true stress state at any given moment and includes ±44° steering simulation and heat COMPONENT TESTING application for unparalleled realism. For an overview of the additional test The full-car road simulator is the ultimate facilities which exemplify TMG’s commitment complete car and component test rig, for to flexibility, performance and accuracy, check front and rear axle fatigue testing, full car out the summary below. For comprehensive stiffness tests and analysis of suspension sub details of all the specialist testing solutions systems. under one roof please contact us directly.

Main Configuration Specifications: • Multiple suspension component rigs • Steering system test rigs Floating body (up to 29 channels) for accurate • Static brake test rig full-vehicle stress distribution analysis of non- • Component testing machines, analysing manoeuvring events force, torque and temperature Fixed body (up to 15 channels) for single • Centre of gravity rig, also for accurate axle suspension tests including braking and three-directional inertia tests cornering simulation • High-performance shaker with climatic conditions for fatigue testing Semi-floating body (up to 14 channels) for • Load frames for damper, side intrusion single axle suspension and partial vehicle panel, material and suspension testing body tests including brake simulation • High-frequency material test rig • Uni-axial damper test system including SEVEN-POST RIG rotary damper capability • Stress test rig for carbon composite parts Our seven-post rig adapts to most vehicles • Driveshaft test rig to pre-stress or rate and is a valuable development and proving driveshafts tool for original equipment manufacturers • Three-dimensional coordinate and high-performance car developers. measurement system • Geometric optical measurement, with Our baseline configuration, featuring one TMG-developed post processing tools such frontal downforce actuator and two at as for complete car stiffness maps the rear, is ideal for optimising the vertical • Scanning of surfaces, such as static tyre dynamics of cars generating large amounts of deformations under load downforce. For vehicles without significant • FIA homologation facilities for all static downforce our four-post configuration, with chassis homologation tests no downforce actuators, is the best solution. • In-house calibration for force, torque, displacement, angle, acceleration, Easily establish the ratio between vertical electrical dimensions and temperature force and pushrod force or check your ride • On-site machine shop for simple height control systems in our alternative adaptations and jig modifications downforce mode, which sees downforce ENGINECAR DESIGN DEVELOPMENT & DEVELOPMENT CAR DEVELOPMENT TOYOTA MOTORSPORT GmbH — THE HOME OF HIGH PERFORMANCE 23 EFFICIENCY

With various distinct types of dynamometer and a unique range of testing systems, TMG is the key to unlock the performance potential of your engine. ENGINE DESIGN & DEVELOPMENT ENGINE DESIGN TOYOTA MOTORSPORT GmbH — THE HOME OF HIGH PERFORMANCE 25

THE POWER BEHIND YOUR PROJECT THE FLEXIBLE APPROACH AND COMPREHENSIVE RANGE OF SOLUTIONS IN ENGINE DESIGN CAN BE TAILORED EXACTLY TO YOUR PROJECT.

Bring the benefit of experience to your performance solutions developed quickly and engine development by utilising TMG’s expert reliably thanks to a culture of rapid problem engineers, who have worked in a variety solving. of different sectors within the automotive industry. All developments can be analysed thoroughly in TMG’s extensive engine and comprehensive With the support of our engine calculation testing suite, where detailed processes verify department, utilising the power of a complete range of specific performance computational fluid dynamics (CFD) and the parameters. finite element method (FEM), you can achieve marked improvements. Utilising bespoke testing systems, we are able to analyse engine behaviour in precise Our integrated development cycle focuses detail, allowing continuous improvement and on more than simply power and efficiency; refinement. drivability, dynamic response and fuel economy as well as gear shift refinement are Our materials department can assist specialities. the process through advanced material development while microscopic analysis The TMG engine design service looks at every accurately determines the cause of any detail of your project, including materials, failure, allowing immediate remedial work. coatings, surface textures, fuel spray velocity, calibration, emissions and much more. Completing our comprehensive engine design and development portfolio, the 1,100m² Heat and friction analysis is carried out to engine workshop features 21 assembly and the highest possible standards, with high- five disassembly workbenches, manned by highly-skilled technicians. ENGINE DESIGN & DEVELOPMENT ENGINE DYNAMOMETERs TOYOTA MOTORSPORT GmbH — THE HOME OF HIGH PERFORMANCE 27

UNDERSTANDING ENGINE PERFORMANCE OUR SUITE OF ENGINE DYNAMOMETERS HAS A PROGRAMME FOR EVERY PROJECT, FROM ROAD CAR TO HIGH-PERFORMANCE AND HYBRID ENGINE ANALYSIS.

TMG’s distinct varieties of dynamometer can single-component and full powertrain test An additional 320km/h, two-axle rolling road meet all your performance testing needs, from benches dedicated to hybrid development. dyno allows in situ testing of a complete car, high-power internal combustion engines to with 550kW power per axle and a maximum smaller electric or hybrid units, so whatever The extremely accurate single-cylinder dyno axle load of 2,400kg. Suitable for manual and engine you are working with, TMG has a testing is designed for minute analysis of single automatic transmissions, this specialist test solution. cylinders from high-performance engines or rig allows evaluation of drivability, reliability complete small capacity engines of around and fuel consumption. The TMG experts have experience of various 100PS. With no neighbouring cylinders, there sectors within the engine development is less outside influence on results while a Fully conditioned air, water, lubricants and and analysis industry while TMG-modified greater variety of tests can be carried out. fuel promote reliable test performance and software gives greater flexibility to our clients. you can be sure of complete confidentiality Our multi-function high-dynamic dyno during your time at TMG, with private Our complex car model allows virtual accurately simulates road or track driving workshops and offices available to allow simulation and hardware-in-the-loop system conditions based on a defined plan, with up discreet development. is customisable to suit virtually any vehicle, to 22,000rpm engine speed, 3,000rpm wheel ensuring entirely repeatable tests linked speed and 800kW engine power. Among its • Endurance testing directly to your specific requirements. various uses, the dynamic dyno is also ideal • Playback of specific scenarios for exhaust reliability studies and launch • Powertrain development With various dynos available, all accurate development. • Gear shift control development to less than 1%, plus certification to utilise • Drivability tuning aviation fuel, TMG has the capacity and The standard dynos monitor behaviour • Fast in-cylinder sampling flexibility to meet the engine or motor at constant speed for endurance and • Exhaust gas analysis analysis requirements of most industries. performance analysis as well as engine • Fuel efficiency tuning calibration. It is the perfect way to confirm • Calibration and mapping We have the capability to test hybrid or engine characteristics at constant speeds. • Lubricant endurance testing electric motor systems, with • ECU development • Pressure indication • Heat and friction analysis ENGINE DESIGN & DEVELOPMENT ENGINE COMPONENT TESTING TOYOTA MOTORSPORT GmbH — THE HOME OF HIGH PERFORMANCE 29

ANALYSIS IN DETAIL UNIQUE ENGINE COMPONENT TESTING RIGS PUT EVERY ELEMENT OF YOUR ENGINE AND COMPONENTS TO THE TEST, SO CHALLENGE US TO DELIVER THE ANALYSIS YOU NEED.

Many of our specialist test rigs have been A unique fuel system testing facility developed in-house and can be adapted exactly incorporates the most comprehensive to your requirements for in-depth analysis analyses available, including a fuel pump test of fuel systems, radiator core performance, rig, fuel rail calibration rig and single injector pneumatic and steel valve spring behaviour or test and development rig. clutch and launch systems. Heat rejection and friction analysis is Our cam rig for air and valve spring a particular speciality while the latest measurement can run up to 22,000rpm technology is utilised to provide incredibly engine speed with an 110Kw electric motor. A detailed data on individual components. 70-channel measurement system, six-channel laser system and high-speed camera provide High-speed cameras and lasers deliver full valve motion analysis. incredible accuracy, as does the military-grade thermal camera on our 10,000rpm clutch The adjustable radiator wind tunnel runs development rig, which requires a specific at realistic air speeds up to a maximum of permit from the authorities. 12m/s for lifelike analysis of radiator core performance. Additionally, we offer Horiba exhaust gas analysers, Malvern laser system for fuel A port development flow bench - a very rare spray characterisation, fast flame ionisation example - provides low pressure exhaust detection and rapid in-cylinder sampling. measurement and valve shape optimisation, complete with Particle Image Velocimetry (PIV) analysis. ELECTRICCAR DEVELOPMENT VEHICLE DEVELOPMENT CAR DEVELOPMENT TOYOTA MOTORSPORT GmbH — THE HOME OF HIGH PERFORMANCE 31 IMAGINATION

To break the mould and set new standards for the industry requires imagination and pioneering spirit; exactly the qualities which make the TMG’s EV Technology Development Centre a sector leader. ELECTRIC VEHICLE DEVELOPMENT EV Technology TOYOTA MOTORSPORT GmbH — THE HOME OF HIGH PERFORMANCE 33

PIONEERING ELECTRIC VEHICLE DEVELOPMENT TMG HAS PROVEN ITS EV TECHNOLOGY IN THE TOUGHEST ENVIRONMENTS, SETTING NEW STANDARDS USING OUR IN-HOUSE DEVELOPED ELECTRIC POWERTRAIN.

EV development began in 2007 for Formula 1 In addition to development of the powertrain projects and since that time, through the use of itself, TMG also offers infrastructure cutting-edge technology, TMG has emerged as integration and innovative charging a leader in the EV field both for motorsport and technology plus the technologies required road vehicles. to utilise renewable energy for mobility and transportation. Thanks to electric records at world-renowned motorsport venues such as the Nürburgring This holistic approach, which also Nordschleife and Pikes Peak International Hill encompasses vehicle-to-x communication and Climb, TMG’s EV technology has established energy transfer, ensures a complete solution itself as the performance leader in this sector. for road or track EV developments.

TMG’s key competences cover the whole TMG’s EV Technology Development Centre has spectrum of EV technology, ranging from a team of experienced professionals and also complete electric powertrain design and provides the latest hardware in a constantly- integration to individual components such evolving field. The facilities are ideal for as battery management, vehicle control and bespoke technology development, prototypes energy management systems. and pre-development projects.

Strong relationships with class-leading As a European hub for EV technology and partners allow TMG to offer proprietary beyond, TMG is the partner of choice for component development for high- TOYOTA companies and third parties, thanks performance batteries and motor/inverter to its core aptitudes and unique vision. technology. ELECTRIC VEHICLE DEVELOPMENT EV MOTORSPORT TOYOTA MOTORSPORT GmbH — THE HOME OF HIGH PERFORMANCE 35

RECORD-BREAKING EV TECHNOLOGY TMG HAS REWRITTEN THE RECORD BOOKS FOR EV MOTORSPORT THANKS TO THE TMG EV P002 RACE CAR, WHICH SHOWCASES OUR HIGH-PERFORMANCE ELECTRIC POWERTRAIN.

In setting a new electric record at the In addition to the vehicle itself, the record Nürburgring Nordschleife of 7mins 22.329secs, achievements confirmed the potential of the TMG EV P002 established itself as one of TMG’s off-grid DC quick charger, a powerful, the fastest road-legal cars ever around this versatile and mobile charging station demanding circuit. Class victory and a new mounted for ease of movement in a van. electric record of 10mins 15.380secs at the Pikes Peak International Hill Climb is further Recharging of this unit can be done from any evidence of this car’s performance prowess. standard power supply and takes seven hours, after which the charger is completely mobile The TMG EV P002 is powered by two axial flux and ready to charge a race car in just 90 electric motors and delivers 350kW of power, minutes or to provide a range-extending boost achieving a top speed of 255km/h and 900Nm in only a few minutes. of maximum torque from its single-reduction gearing. The DC quick charger is an efficient, fast and high-power solution to charge EVs on-event Lithium ceramic battery technology delivers independently of a direct power source, industry-leading performance from a 42kWh making it ideal for use on race tracks, during capacity while TMG’s own inverter technology testing or at exhibitions. No specific or costly is deployed. installation is required. MANUFACTURINGCAR DEVELOPMENT CAR DEVELOPMENT TOYOTA MOTORSPORT GmbH — THE HOME OF HIGH PERFORMANCE 37 Precision

TMG is a leading rapid manufacturing centre and, with precise quality control systems, you can be certain the finished product exceeds your expectations. MANUFACTURING RAPID MANUFACTURING TOYOTA MOTORSPORT GmbH — THE HOME OF HIGH PERFORMANCE 39

SPEED IS OF THE ESSENCE WITH ONE OF THE LARGEST CONCENTRATIONS OF RAPID MANUFACTURING MACHINES UNDER ONE ROOF, TMG IS A CENTRE OF EXCELLENCE FOR THIS CUTTING-EDGE TECHNOLOGY.

Whether for the medical, automotive, items for any industry, no matter whether you architectural or consumer sector, with 10 need small numbers of prototypes or larger stereolithography machines (SLA 5000 and SLA production quantities. 7000 units) and two large-frame laser sinter machines (P700 and P360 units), TMG can meet There is simply no faster or more economical your demands. way to accurately produce precision items to your exact specifications, but the real This flexible and adaptable technique advantage of TMG’s technology is its allows even the most complex objects to be flexibility. produced as single structures whether for use as finished parts or wind tunnel models, using No matter where you are in the world, advanced materials such as nanotool. production can begin on your item at TMG within just a few hours - simply deliver a TMG’s rapid manufacturing systems have suitably-detailed 3D CAD model or STL file been refined in the high-pressure world and we will quickly turn your innovation into of motorsport, where as many as 2,000 reality. unique parts a month were required, but our skilled technicians come from a variety of And you can be sure of a smooth and trouble- backgrounds and have the knowledge to take free process thanks to our modified machines, on any project. which allow round-the-clock supervision and instant reaction to any problems. Utilising Using their expertise and TMG’s state-of- video and internet technology, we can make the-art technology, the rapid manufacturing your production faster and more reliable than department can produce highly-detailed ever before. MANUFACTURING COMPOSITES TOYOTA MOTORSPORT GmbH — THE HOME OF HIGH PERFORMANCE 41

LIGHTWEIGHT BUT HIGH VALUE TMG’S VERSATILE COMPOSITES DEPARTMENT COMBINES EXPERIENCE AND HIGH-QUALITY HARDWARE TO CREATE BESPOKE SOLUTIONS PRECISELY TO YOUR REQUIREMENTS.

Two large autoclaves (with 420 x 160cm curing To meet the extreme demands of prototype platforms) and one smaller unit (with 200 x development, TMG has refined the carbon 80cm platform) provide the capacity to prepare production process for high structural anything from small parts right up to items the integrity and tight tolerances and this size of a complete car. technology is now available to enhance projects of all sizes from all sectors. We offer a full choice of materials to suit the precise needs of your project, from Kevlar Safety critical items can be produced in to glass, carbon or hybrid fibres, with a complete confidence thanks to our thorough filtered, clear-air, positive-pressure lay-up area on-site testing procedures and high-standard eliminating the risk of contamination. quality control systems, while long experience of prototype development has enhanced our Our advanced pre-impregnated (pre-preg) problem-solving capacity. process, utilising Kevlar, glass, carbon or hybrid fibres, is the optimal choice when To complement this top-quality composite you need maximum strength combined with service, TMG also provides pattern, tool and minimum weight. final product machining which is supported by any programming requirements to provide TMG’s aim is to provide a range of options to a comprehensive answer for every composite meet your precise requirements, so for a cost- question. effective yet ultra-reliable product, we also offer a wet carbon fibre lay-up service. MANUFACTURING CNC AND FABRICATION TOYOTA MOTORSPORT GmbH — THE HOME OF HIGH PERFORMANCE 43

PRECISION MILLING AND TURNING OUR CNC AND FABRICATION DEPARTMENTS HAVE THE IDEAL CAPACITY AND EXPERTISE FOR DETAILED MILLING WORK AND TO CATER FOR HIGH-PERFORMANCE FABRICATION NEEDS.

The CNC department has a varied selection of department where the highest standards are 15 five-axis milling machines, two CNC turning used to ensure all approved parts meet our machines and one turn-mill centre ready to clients’ expectations. bring speed, precision and efficiency to your project. Three-dimensional measurement machines examine each item down to a single micron, From incredibly accurate units capable of leaving nothing to chance for performance or machining over an area of up to 1m² to an safety critical parts. accuracy of 4 microns, to large machines for heavy-duty tasks, TMG has a variety of FABRICATING SUCCESS solutions available. From road cars to World Rally cars and motorsport prototypes, TMG’s fabrication Our 3,200m² CNC area has the flexibility specialists have a wealth of experience in to meet requirements big or small and completing demanding and bespoke projects. specialises in extremely complex high- TMG’s skilled fabricators are familiar with performance items, with all parts meeting the a variety of materials, including special strictest quality and reliability checks. materials such as Inconel. In addition, a stringent quality control procedure, Automated machinery gives us the option combined with experience gained at the top of uninterrupted full-capacity production level of motorsport, ensures all projects are around the clock seven days a week while full completed to the highest standards. connectivity means one machine can control all others to bring efficiency and reliability. Facilities includes large angle-forming presses, a welding dome with an Argon environment That streamlined technology also brings to reduce the risk of oxidisation and tube end significant speed advantages, with a forming machines. machining strategy normally defined and ready for production within 30 minutes of 3D A large Kuka laser robot provides laser cutting CAD model delivery. for two-dimensional and three-dimensional components while complex shapes can be Quality control at TMG is a matter of great formed from sheet metal thanks to the Aida pride, nowhere more so than in the CNC 150 tool press. CUSTOMERCAR DEVELOPMENT MOTORSPORT CAR DEVELOPMENT TOYOTA MOTORSPORT GmbH — THE HOME OF HIGH PERFORMANCE 45 PASSION

TMG is passionate about motorsport, whether top-level works projects or exciting and accessible entry-level vehicles. CUSTOMER MOTORSPORT TMG GT86 Cs-V3 TOYOTA MOTORSPORT GmbH — THE HOME OF HIGH PERFORMANCE 47

SPEED, SAFETY AND STUNNING LOOKS THE TMG GT86 CS-V3 IS A WINNER AT THE NÜRBURGRING AND, AS AN AFFORDABLE, RACE- READY AND EASY-TO-MAINTAIN CAR, IT IS IDEAL FOR PRIVATE COMPETITORS.

The exciting rear-wheel-drive, 200hp car has delivers a fun and easily-accessible racing been developed specifically for the V3 class experience. of the Nürburgring-based VLN series and has achieved homologation from the Deutsche Safety is of course a top priority and with a Motor Sport Bund. certified roll cage and racing seat with six- point harness, drivers can feel comfortable A race-ready GT86 CS-V3 is instantly and secure. Electronic fire extinguisher system competitive in a production-based class and and electronic main switch system enhance represents impressive value for money. the car’s safety features.

With a 200hp, four-cylinder boxer engine As well as a race-ready standard race car, TMG delivering maximum torque of 205Nm, the offers a list of optional extras, available upon GT86 CS-V3 can hold its own against other order or as after-sales items exclusively for the production-based competitors while the GT86 CS-V3. highly-praised handling characteristics of the road car are retained and improved. Limited-slip differential (4,1 ratio) and rear lower strut bar, plus racing engine and TMG has stiffened the chassis and optimised differential oil cooler kits, all enhance the weight distribution for motorsport while car’s sporty handling and proven performance. installing racing exhaust, and brakes. Adjustable Öhlins motorsport suspension A data logger, dashboard race display, radio offers a range of set-up options to fine- integration kit and XL driver’s seat are offered tune the car’s behaviour for any circuit or to upgrade the overall racing experience, conditions. while DMSB vehicle certification (Wagenpass) can be pre-ordered to allow immediate racing The result is an eye-catching and competitive upon delivery. race car built to TMG’s high standards which CUSTOMER MOTORSPORT YARIS R1A TOYOTA MOTORSPORT GmbH — THE HOME OF HIGH PERFORMANCE 49

RALLY FUN FOR ALL THE TMG YARIS R1A IS AN ENTRY-LEVEL RALLY CAR WHICH ENABLES DRIVERS OF ALL AGES AND ABILITIES TO EXPERIENCE THE THRILL OF MOTORSPORT.

TMG has developed the Yaris R1A specifically TMG’s upgrade kit includes racing exhaust to provide an affordable, exciting entry into and catalytic converter system, motorsport rallying for competitors young and old. suspension with adapted springs and adjustable ride height. As a first step into rallying, the car provides the reassurance of manufacturer quality and In addition, comprehensive safety equipment safety, while long-term participants can tap features bolt-in roll cage, guards for sump, into the memory of TOYOTA Team Europe, run fuel tank and fuel lines, fire extinguishers, by TMG during the 1980s and 1990s. rally seats and safety harness plus power cut- off switch. During that time, TMG won three manufacturers’ and four drivers’ world The Yaris R1A has already proved itself on the championships and the Yaris R1A is our first big stage, with a successful outing as a course step back into the world of rallying since car in the 2012 ADAC Rallye Deutschland, a those heady days. round of the FIA World Rally Championship.

The FIA’s R1A regulations permit only limited Although developed as a rally car, the TMG performance modifications to the standard Yaris R1A is also suitable for other forms of 1.33l petrol-engined, three-door Yaris. Front automotive recreation such as slalom, driving wheel drive delivers 99PS and a maximum schools or experience days. torque of 125Nm, combining with a shorter final drive to deliver a fun rallying experience. The car is offered as a self-installation package, with donor car and upgrade kit to be This nimble small car is agile around twisty assembled by the buyer in order to ensure the stages but can reach 175km/h top speed, most cost-efficient package. making it the ideal car to learn the rigours of rallying. 51

BY PLANE, TRAIN OR AUTOMOBILE: TMG IS AT THE HEART OF EUROPE

The Home of High Performance is just a short journey away, with TMG’s prime location at the WHAT MORE CAN heart of Europe. WE SAY? CONTACT Cologne lies at a crossroads in Europe, with three major highways passing through the US NOW FOR MORE city and connecting to the main routes in Belgium, France, Holland and beyond to bring cities like Brussels (200km), Amsterdam INFORMATION (270km), Paris (500km) and Zurich (580km) With so many services on offer, a brochure can only give an overview. within easy reach. So for a detailed discussion on how to extract the full potential of your project or product simply call or email for a no-obligation consultation to Even a journey across, or under, the Channel understand exactly what we can offer. from Great Britain to TMG is straightforward, with regular ferry or Eurotunnel crossings As a multi-national company we have representatives speaking all major from Calais just 400km away. European languages and several more besides, so get in touch by phone on +49 2234 1823 0, email [email protected] or check out Cologne Bonn airport, the sixth largest www.toyota-motorsport.com to find out more. passenger hub in Germany and its second biggest air freight terminal, is less than 25km from TMG while Düsseldorf at 65km and Frankfurt at 200km are also within easy reach.

For those who prefer the train, modern high- speed rail links connect Cologne to Brussels, Paris and Frankfurt faster than ever before while connections to most major European stations make a stop in the city. CAR DEVELOPMENT CAR DEVELOPMENT

TOYOTA MOTORSPORT GmbH Toyota Allee 7, 50858 Cologne, Germany

Telephone +49 2234 1823 0 Email [email protected]

www.toyota-motorsport.com