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Toyota Motorsport GMBH - The Home of High Performance

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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 CAR DESIGN & DEVELOPMENT 04 - 13


WELCOME
TO THE HOME OF HIGH PERFORMANCE
Car Design 06 - 07
CFD and Calculation 08 - 09
Driving Simulator 10 - 11
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 interaction between systems and facilities
vehicles via the pinnacle of motorsport,
Composites 40 - 41 to ensure speed, efficiency and, most
Formula 1.
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 look at the highlights and it is clear that TMG
development, specialist testing or
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 DESIGN & DEVELOPMENT
CAR 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
• Albert Park Circuit 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 Developments can be evaluated on a range


With extremely detailed models of a variety
• Circuit de Catalunya of circuits as well as various vehicles, TMG’s of circuits which have been surveyed using
simulator is a next-generation tool for car the latest laser-mapping technology with an
• Circuito de Jerez
development where completely consistent unprecedented degree of accuracy.
• Circuit de la Sarthe (Le Mans) and repeatable track conditions promote
reliable evaluation that is directly relevant to The simulator is a flexible tool, adaptable for
• Circuit de Monaco
your development programme. open or closed cockpit cars and with a fully
• Circuit de Spa-Francorchamps parameterisable dynamic vehicle model.

• Fuji Speedway 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
development. Programmes are available
• Hungaroring detail, from the kerb angles and track surfaces
to background scenery and other visible to familiarise drivers with different cars or
• Interlagos features. circuits in a safe and predictable environment,
while an interactive pit crew aids the practice
• Marina Bay Circuit
A six-degrees-of-freedom electric motion of pit stop procedures.
• Nürburgring Nordschleife platform simulates driving sensations and
Realistic conditions also offer a valuable
• Sepang International Circuit an electric feedback motor creates realistic
steering torque while TMG’s vehicle model opportunity for drivers and engineers
• Silverstone Circuit translates wind tunnel kinematic data to develop efficient communication and
working practices in a controlled and flexible
• Simulated Vehicle Dynamics Area to simulate the effect of aerodynamic or
mechanical changes. environment away from track pressures.
• Suzuka Circuit
• Valencia Street Circuit
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 race track.


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


RESEARCH & DEVELOPMENT
CAR 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
As well as complete-vehicle testing solutions, forces.
rigs designed specifically for transmission
TMG also offers multiple examples of various durability, reliability and performance
single component rigs, allowing simultaneous This allows a transmission to be mounted and
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-
With rare commercially-available items such recreating the drive normally produced by the
dynamic and high-performance rig which
as a transmission test system, seven-post engine.
permits real-time simulation of road or track
rig, a four-corner full-car road simulator, a conditions. Three electric motors drive the
transmission lubrication test system and By fully understanding lubricant flow in road/
gearbox for dynamic response to replicate
rotary damper rigs, TMG has it all. track conditions, lubrication of all internal
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
component testing facility is accessible by system is also perfect for component tests to
The system is perfect for development of road-
overhead crane while a modular lay-out and optimise items such as spray bars, oil pumps
ready clutch, launch and seamless gear shift
multiple access points allow for complete or oil coolers.
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
ENGINE DESIGN & DEVELOPMENT
CAR 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.
ELECTRIC VEHICLE DEVELOPMENT
CAR 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.
MANUFACTURING
CAR 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.
CUSTOMER MOTORSPORT
CAR DEVELOPMENT 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

WHAT MORE CAN


The Home of High Performance is just a short
journey away, with TMG’s prime location at the

WE SAY? CONTACT
heart of Europe.

US NOW FOR MORE


Cologne lies at a crossroads in Europe, with
three major highways passing through the

INFORMATION
city and connecting to the main routes in
Belgium, France, Holland and beyond to
bring cities like Brussels (200km), Amsterdam
(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 contact@toyota-motorsport.com 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 contact@toyota-motorsport.com

www.toyota-motorsport.com

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