(continued from above)
"When we decided to work together on the RAV4 EV, President Akio Toyoda
wanted to adopt a new development model that incorporated Tesla's streamlined,
quick-action approach," said Jim Lentz, president and chief operating officer,
TMS. "The result was a hybrid - a new decision and approval process and a
development style that our engineers refer to as "fast and flexible."
Led
by the Toyota Motor Engineering and Manufacturing North America (TEMA) Technical
Center in Michigan, the new development model helped reduce development time
without compromising product quality. The team has accomplished this by
approaching the project as they would a typical mid-cycle "major-minor" product
change. Specifically, midway through a generation, the team began with a fully
engineered current-generation RAV4, to which was added a major powertrain
option, along with minor feature and cosmetic changes.
Tesla was
responsible for building and supplying the battery, as well as other related
parts, that met specific Toyota engineering specifications in performance,
quality and durability. Toyota was responsible for development and manufacturing
leadership and the seamless integration of the powertrain.
A large part
of the team's focus on the customer experience targeted driveability. In this
case, the end goal is a vehicle with driveability characteristics as close to
the conventional RAV4 as possible.
For example, the demonstration
vehicle weighs approximately 220 pounds more than the current RAV4 V6 yet it
will accelerate from zero to sixty nearly as quickly.
This added weight
factor required significant retuning of major components and a prioritized focus
on weight distribution. Not only were suspension and steering modified
significantly, major components needed to be relocated to better balance the
increased mass of the battery pack.
Production Version Expected in
2012
The demonstration vehicle Toyota is currently testing is powered
by a lithium metal oxide battery with useable output rated in the mid-30 kwh
range. However, many decisions regarding both the product, as well as the
business model, have not been finalized. Battery size and final output ratings,
as well as pricing and volume projections of the vehicle Toyota plans to bring
to market in 2012, have not been decided.
As for a final assembly
location, Toyota is considering many options and combinations. The basic vehicle
will continue to be built at its Canadian production facility in Woodstock,
Ontario. Tesla will build the battery and related parts and components at its
new facility in Palo Alto, Calif. The method and installation location of the
Tesla components into the vehicle is being discussed.
Styling Changes
The RAV4 EV received several distinct exterior styling changes including a
new front bumper, grille, fog lamps and head lamps. New EV badging and the
custom "mutually exclusive" paint color, completed the transformation. The
interior received custom seat trim, multimedia dash displays, push-button
shifter and dashboard meters. The RAV4 platform brings a 73-cubic-foot cargo
area with rear seats folded down - no cargo space was lost in the conversion to
an electric powertrain.
