Rotary e PDF

Press Information October, 1999
P R E F A C E
The rotary engine is the technology that only Mazda owns in the
world's automobile industry. As the sole producer of rotary engine
cars, we would like to further develop this unique internal combustion
engine while introducing to the public its potential and possibility.
The publication of this kind of materials is a part of our
commitment to promoting public understanding of this innovative
technology.
Therefore, we have revised the Rotary Engine
Press Imformation for the first time since 1993.
The past 6 years of research and
development witnessed several new
findings and innovations. Some of
them are already implemented into
production engines.
The first chapter focuses on such
innovations as well as future rotary
engine technology.
Our latest experimental engine, the
RENESIS, is highlighted here and
documented in detail.
The history of the rotary engine is summarized
in the second and third chapters, respectively
addressing engineering development and motor sports
activities.
This booklet also includes a list of Mazda's Series-Production
Rotary Engine Cars and Trucks, in the second chapter, and a
technical document titled "Structure and Working Principles of the
Rotary Engine". Both ar ticles will be of special interest to those
readers who are not very familier with the rotary engine technology.
We hope that the readers will find this booklet interesting and
informative and that it will help them to better understand the
attractions of this unique internal combustion engine.
October 1999
Mazda Motor Corporation
PREFACE 001
●Chapter 1 Rotary Engine Today and Tomorrow 003
Introduction 004
RENESIS−Mazda's Rotary Engine for the Next Millennium 006
13B-REW−Mazda's Latest Production Rotary Engine 010
●Chapter 2 Chronicle of Rotary Engine Development 013
The Birth of Rotary Engine 014
From Cosmo Sport to RX-7 016
Turbo, Multi-Rotor and Advanced Rotary Engine 018
Mazda's Series-Production Rotary Engine Cars & Trucks 020
●Chapter 3 RE Challenges the World 023
Mazda RE Dominates Le Mans 24 Hours Race 024
Mazda RE Competes in Races and Rallies the World Over 026
APPENDIX : Structure and Working Principles of Rotary Engine 029
Mazda Rotary Engine : Chronological Table 032
002
Chapter 1
As the sole automobile manufacturer in the world that produces rotary

engined cars, Mazda assumes full responsibility for the future of
this excellent mechanism. Through 38 years of commitment to the
research of the rotary engine, Mazda has developed its high potential
and created series-production engines with excellent commercial value.
However, our challenge has not yet ceased. This chapter focused on
the latest innovations and future technologies of the Mazda rotary engine.
003
The Rotary Engine: A Technology to
Symbolize Mazda's Brand Personality
In 1961 Mazda focused on the development of
the newly-invented rotary engine and, after
Mazda Rot
overcoming many engineering challenges,
succeeded in making it a viable commercial
proposition.
This engine generated power very smoothly by
rotation alone. Many talented scientists and
researchers from nearly all the major manufacturers
had tried in vain to develop this idea--- but Mazda
persevered with the development and succeeded
in commercializing this unique concept. Through the
development and success of the rotary engine,
Mazda became a household name--- even though
the company was a relative newcomer to the
automobile industry.
But Mazda did not rest on its laurels. Even after
becoming, by the mid-70's, the only company
designing and producing rotary engine cars, Mazda
continued to meet the challenge of improving this
unique engine's technology, fuel efficiency and
emissions. In fact Mazda devoted itself to
developing products that fully expressed the
strength and personality of the remarkable rotary
engine; compact, lightweight, and high performance.
Mazda has introduced dozens of new vehicles
powered by the rotary engine, including the
legendary Cosmo Sport and the highly-praised
RX-7. As of September 1999 the accumulated
total production of our rotary engine vehicles had
reached nearly 1.8 million.
Mazda has participated in motor sports events
around the world to showcase the technological
potential and reliability of the rotary engine. The
highlight came in 1991 when Mazda's rotary engine
car achieved overall victory in the world famous Le
Mans 24 Hours race - the first win for a rotary
engine and the only win ever for a Japanese car.
004
Introduction
The rotary engine is a truly unique asset
possessed exclusively by Mazda, and we regard it
ary Engine
as a technology that symbolizes the personality of
the Mazda brand---a personality which is
Stylish, Insightful and Spirited.
The Potential of
the Rotary Engine
We believe that the rotary engine has enormous
potential for the future. The new experimental
engine, "RENESIS" which powers the "RX-EVOLV"
concept car at the 33rd Tokyo Motor Show,
represents such future potential. Due to its compact
size, the RENESIS engine allows the RX-EVOLV to
accommodate four adults comfor tably in a body size
of the RX-7, while achieving enhanced driving
performance as a true sports car.
The RENESIS is conceived using a side port
layout and lighter rotors. As a result, it boasts 280
PS, the highest output ever achieved by a naturally
aspirated two-rotor rotary engine and has a 10,000
rev limit. The side port layout has also contributed to
improved fuel economy and cleaner exhaust. Such
achievement has been enabled by applying
Mazda's technologies in many fields such as new
materials and combustion.
Mazda awaits with anticipation the reaction of the
public and media to this latest development of
Mazda's unique rotary engine.
Tadahiko Takiguchi
Senior Managing Director
Mazda Motor Corporation
005
Chapter1
Rotary Engine
comfortable accommodation for four people. The
Today&Tomorrow
engine produces 280PS(206kW) at 9,000rpm
(target value) and 23.0kg-m (226Nm) at 8,000rpm
The RENESIS is Mazda's new-generation (target value), the highest power density ever
rotary engine, which will take this extraordinary achieved by a naturally aspirated rotary engine
power unit into the next millennium. Fully for a road-going automobile.
exploiting and enhancing the engine's inherent The RENESIS' fuel efficiency has been further
virtuesーthe compact size, light weight and high improved over its predecessor, the MSP-RE
power density, this latest rotary is also experimental engine, which had already improved
environmentally friendly, Mazda's engineers idling consumption by 20 percent over the 13B-
having made great strides in both efficiency and
low emissions.
RENESIS stands for "the
RE(rotary engine)'s
GENESIS", or the rotary
engine for the new
millenium.
The RENESIS is the
development
and refinement of
the MSP-RE
experimental rotary
engine which
powered the
RX-01 concept
sports car
unveiled at the
1995 Tokyo
Motor Show. The
RX-01 was accepted
with applause by the
public all over the world
while touring a
international motor show
circuit and, after that,
accumulated a good measure
of fast mileage on Mazda's
Global Road Circuit for evaluation. In
the meantime, at the home of Mazda,
the rotary engine development team continued its
work to improve the MSP-RE to an entirely new
level, one that deserves the new name, RENESIS. REW unit powering the current Mazda RX-7. This
gain has now been extended up to 40 percent.
Highest Power Density for Naturally
The RENESIS is designed to qualify for the
Aspirated Rotary Engine
stringent new emission standards, soon to be
The RENESIS propels the RX-EVOLV 4-door implemented in Japan, by greatly reducing all
Sports concept car, an automobile that combines three major pollutants in the exhaust gas(NOx,
exhilarating performance with superbly HC and CO), to very low levels.
006
Side-Exhaust and Side-Intake Ports. many port variations Mazda's design team had
tried in the earliest days of rotary engine
The RENESIS inherits the MSP-RE's port research. It was Mazda's mastery of rotary engine
configuration. MSP stands for Multi Side Ports, gas-and oil-sealing technology that once again
with both intake and exhaust ports in the side directed the designers' attention to the Multi-
housings of each rotor chamber, versus the Side-Port possibility.
successful hallmark design of the series The design's potential, however, far surpassed
production engine which has side intake and Mazda's expectation, proving its worth in three
peripheral exhaust ports. Actually, the side- major areas-- performance, fuel efficiency and
intake, side-exhaust configuration was one of emission characteristics.
The exceptional performance of the RENESIS is
attributable to the following features.
(1) Innovations for Higher Output

-- New Port Profiles
With the adoption of
the side exhaust ports,
port opening overlap
has been eliminated,
enabling port profile
optimization. Intake
ports now open
earlier, close to TDC
(Top Dead Center)
instead of opening
later.
-- Enlarged Port Area
The intake and
exhaust port areas
have been greatly
enlarged, as the result
of the new port
configuration.
The port area is 30
percent larger, as the
Mazda's Rotary Engine intake port begins to open, and the exhaust port
area, two ports per chamber now, is almost twice
for the Next Millennium as large, improving flow characteristics.

-- New Three-Stage Induction System
Max.Output : 280PS (206kw)/9,000rpm This system employs variable induction tracts
Max.Torque : 23.0Kg-m (226Nm)/8,000rpm that feed into six ports (three for each rotor
007
Chapter1
Rotary Engine
Today&Tomorrow overlap and delays exhaust port opening,
increasing the power (expansion) stroke and
chamber), and utilizes the incoming air's dynamic improving thermal efficiency, without exhaust gas
charge effect to improve filling efficiency. A new diluting the incoming charge. The engine runs on
variable port control valve has reduced air leaner mixtures without the need for internal
resistance. exhaust gas recirculation.
-- Lightweight Rotor -- Finer Fuel Atomization
Produced through a precision casting technique, The RENESIS features new small fuel injectors to
which greatly reduces thermal loads, the rotor improve fuel atomization.
employed in the RENESIS is lighter by 14 percent -- Lean Mixture Setting at High Speeds
than that of the series production unit. As a result, The rotary engine's unique combustion
the engine's rev limit becomes 10,000 rpm. characteristics require less enrichment of mixture
--Higher Compression Ratio in a higher speed range than a comparable
Improved combustion of the RENESIS has
The concept car RX-01, powered by the
allowed the compression ratio to be raised. concept rotary engine, MSP-RE, was f irst
unveiled at the 1995 Tokyo Motor Show.
(2) Innovations for

Improved Fuel Efficiency
-- Eliminated Overlap
An improved exhaust port profile eliminates
Figure 1 : Compatibility of Figure 2 : Increased Intake Port Area Figure 3 : 3-stage Intake System
Performance and Fuel Economy
Overlap
;;;
Port Area
BDC TDC BDC 30% Increase
Current Peripheral
Intake Port
; ;;
Exhaust Port
Port Area
BDC TDC BDC
Side Exhaust Peripheral Exhaust

Rotary Engine Rotary Engine
Intake Air
Intake Air Shutter Valve
TECHNICAL HIGHLIGHTS
T
T OF THE RENESIS
L By removing the location of the exhaust ports, from the
L trochoid to the side housings, Mazda engineers
eliminated the overlap of the port timing. As a result, the
Euhaust intake port area has been increased and breathing
Gas eff iciency improved. In addition, the new three-stage
Euhaust Gas induction system maximizes chamber f illing and the
newly-developed lightweight rotors allow a higher rev
limit. Emission of Hydrocarbon has also been reduced
with the adoption of the side exhaust ports.
;
Figure 4 : Reduced Emission of HC Figure 5 : Lightweight Rotor
; ;
Depth of the
; ;
Current Peripheral Exhaust Side Exhaust Combustion Chamber
;; ;;;
Rotor Rotor
Exhaust Exhaust
Port Port
Trochoid Trochoid Rotor Weight

(-14%)
Unburned Gas Unburned Gas
008
reciprocating engine, which relies on strong Cutaway model of the RENESIS. As you can see below, the
exhaust port is located not on the peripheral surface but on
swirl/vortex during low-and mid-speed operation, the side housing. T hree intake ports, located also on the
side housing, are provided for each rotor.
and is thus prone to unstable combustion (richer
mixtures can overcome the condition at a cost of
fuel consumption).
(3) Innovations for Lower Emission Mazda's Rotary Engine

-- Reduced Emission of Hydrocarbon for the Next Millennium
With the adoption of the side-exhaust layout,
unburned hydrocarbons no longer escape into
the exhaust port, and is trapped within the
chamber, carried over and, burnt in the following
cycle.
-- Improvement in the Catalyst System
A double-skin exhaust manifold maintains a high
exhaust gas temperature to improve catalyst
activation. The catalyst itself is now a two-stage
type with manifold and underfloor converters.
(4) Other Innovations

-- Tighter Sealing and New Management System
The gas- and oil-sealing of the RENESIS is
unique and specific to the new port design: it
ensures tight sealing, a major factor in the
engine's performance, fuel efficiency and
reduced emissions. The RENESIS also adopts an
entirely new engine management system, even
more advanced than the state-of-the-art oxygen-
sensor feedback system.
-- New Wet-Sump Lubrication System
A new low-height, lightweight lubrication
system has been developed for the RENESIS.
The oil pan's 40-mm depth is about one-half that
of a conventional oil pan. The rotary engine's
advantage is that the eccentric shaft is positioned
higher than a conventional crankshaft, out of the
sump, and thus free from windage losses. On the
other hand, the engine's lubrication system must
ensure a supply of lubrication under the severest
of lateral acceleration, as high as 1.0G. The
RENESIS system has a widened sump with an
elaborately shaped baffle chamber, as well as a
high-suction strainer. The low-height wet-
sump is about 3 kg lighter than a
comparable dry-sump system which
requires an engine-driven twin-pump
installation and a lubricant reservoir.
009
Chapter1
Rotary Engine
Today&Tomorro
The Latest Version of Mazda's Series Production

Rotary Engine Developing 280 PS, the Highest
Power Available in the Domestic Cars.
The 13B-REW powering the current Mazda RX-7 is
the world's only rotary engine for series production
cars. The latest version of the proven type 13B two
rotor unit, it features Mazda's unique Sequential Twin
Turbo and offers outstanding power and response.
Late last year, the engine was comprehensively
improved and its maximum power increased up to
280PS, the highest mark of any automobile engine
available in Japan. The components then modified
include the turbocharger, lubrication system, exhaust
system and the cooling system. As a result, torque in
the mid speed range (over 2,500 rpm) has been
Ultra-High-Flow Turbine
increased by 2.0 kg-m, contributing to improved
driveability in daily use, while at speeds over 5,000rpm,
output has been increased by 15 to 18 PS for even
more striking performance at the top end.
Improved Efficiency and Ultra-High-Flow Turbine adopted on

Greater Air Flow the latest version of the 13B-REW.
The turbine's outer diameter(50mm)
The Sequential Twin Turbo developed by Mazda has is smaller than the previous design,
but the increased inclined angle and
been praised for its high supercharging efficiency over
extended length of the blade resulted
the whole speed range. To further enhance this in reduced inertia mass and increased
attribute, Mazda engineers incorporated several new air f low.
13B-REW Engine
Adoption of Abradable Seal

Improvement in Compressor Efficiency
The abradable seal is a device which is made of special
resin and minimizes clearance between the turbine blade
and housing of the compressor.
New Design Old Design
Tip Clearance
Turbine Blade
Abradable Seal Compressor Housing
After assembly has been completed, each turbine is spun at high speed and
wears the resin surface to create a custom precision fit to its housing.
Ultra-High-Flow Turbine
Increase in Air Flow Capacity
Extended in
Length
New Design Old Design Turbine Blade
Outer
Diameter
50mm 51mm
Increase in Air Flow Area

The new turbine blade is smaller in diameter but larger in length.
010
mmHg to 560 mmHg, contributing greatly to the
engine's higher output.
Improvements in Lubrication,
Exhaust and Cooling Systems
Mazda's work on the 13B-REW had yielded
impressive results in power and performance due to the
Face-lifted in late 1998, the mazda R X-7 has a turbo changes, therefore lubrication became even more
new front fascia with enlarged air intake areas critical, particularly lubrication of the apex seal. Mazda
for enhanced cooling eff iciency.
therefore decided to redesign the metering oil supply
nozzle located on the torochoid housing to improve the
feeding response of the lubridation. As a result, oil
features. supply to the inner surface of the trochoid housing has
First of all, to minimize clearance between the turbine become quicker and the lubrication of the apex seal
blade and its housing, Mazda introduced the abradable more stable even during sudden accelerations.
seal on the compressor turbine. The seal is made of a On the other hand, improvements of the exhaust
special resin. After assembly has been completed, each system included the use of 0.5~1.0mm thinner sheet
turbine is spun at high speed and wears the resin metal in the front pipe wall, which increased exhaust
surface to create a custom precision fit to its housing. flow area, as well as a change in the interior of the main
This assembly method also minimizes differences in silencer. These two improvements resulted in lowered
clearance among individual units and ensures optimized exhaust backpressure (by 10% or about 100mmHg) for
efficiency. a substantial increase in engine power.
At the same time, the turbine blade itself was In addition, the enlarged air intakes in the car's front
improved, reducing outer diameter from 51mm to end also contributed to the enhanced performance of
50mm and increasing blade's angle of inclination for the 13B-REW. The RX-7's new front fascia design
reduced inertia mass and accelerated air flow. In allowed an increase in cooling air intake area, by 110%
addition, to make maximum use of the rotary engine's for the radiator, by 80% for the intercooler, and by 80%
inherent strong exhaust pulses and further increase air for the oil cooler, respectively. Improved efficiency of
flow, the blade has been extended in length. the intercooler had a direct effect on the engine's
With the adoption of this "Ultra-High-Flow Turbine", performance, while the enhanced cooling capacity of
efficiency of the turbochager has been improved by the radiator, complemented by increased core
10% and the maximum boost pressure raised from 470 thickness, helps improve the engine's reliability.
Improvement in Lubrication System
New Design Old Design

Air Air
（Oil ）
Check Valve Check Valve
Oil Oil
A higher output and higher
rev limit means a greater
load on the rotor's apex （Oil ）
seals. Mazda therefore ○0.8 ○2 Metering
redesigned the nozzles Seal Oil Pump
which lubricate the inner
surface of the rotor
housing and improved
response in oil supply.
Reduced Exhaust Resistance
Increased Exhaust Area by the Reduced Resistance in the Silencer

Reduced Metal Gauge of the Exhaust Pipe
To accommodate the
increased exhaust flow,
caused by the enhanced
power output of the
13B-REW, Mazda modified
the main silencer of the
RX-7 (as shown in the right
f igure) andreduced
exhaust backpressure.
011
Chapter1
Rotary Engine
Today&Tomorro
The Latest Version of Mazda's Series Production
Rotary Engine developing 280PS, the Highest
Power Available in the Domestic Cars
Major Specifications of the 13B-REW Engine

280PS Unit
Tuning Level 280PS 265PS 255PS
30
Model Code 13Ｂ−ＲＥＷ
Torque（kg-m)
32.0kg-m／3000rpm 28
26
Type Gasoline, Rotary Piston 24
280 22
Total Displacement r 0.654×２ 260 20
280PS／8500rpm
240 18
Number of Cylinder Inline 2-rotor Longitudinaly- mounted 220 16
200 14
Valve Mechanism −
Output（PS）
180
160
Bore×St roke mm 240.0×180.0×80.0 (Rotary) 140
120
Compression Ratio 9.0：１ 100
80
Max imum Output (JIS net) PS / rpm 280 / 6,500 265 / 6,500 255 / 6,500 60
40
Maximum Torque (JIS net ) kg-m / rpm 32.0 / 5,000 30.0 / 5,000 30.0 / 5,000 20
0
Intake Opening Primary ー45゜ Secondary ー32゜ＢＴＤＣ
Closing Primary 50゜ Secondary 50゜ＡＢＤＣ 1000 2000 3000 4000 5000 6000 7000
Port Timing
Exhaust Opening Engine Speed （rpm）
75゜ＢＢＤＣ
Closing 48゜ＡＴＤＣ
265PS Unit
Idling Speed rpm 700 700 (in P-position)
30
Type Forced Supply
Torque（kg-m)
30.0kg-m／5000rpm 28
Lubrication 26
Oil Pump Trochoid Type 24
System 280 22
Oil Cooler Independent, Air-cooled 260 265PS／6600rpm 20
240 18
Cooling Type Water-cooled, Electric-powered 220 16
200 14
System Radiator Sealed-type
Output（PS）
180
160
Supercharger Type Turbo 140
120
Intercooler Type Air-cooled 100
80
Type Paper Filters 60
Air Purifier 40
Number １ 20
0
Fuel Pump Electric
Fuel Injection Electronic 1000 2000 3000 4000 5000 6000 7000
Engine Speed（rpm）
Type Pintle-type
Number １
Jet Nozzle Nozzle 255PS Unit
Diameter mm 1.31 (primary) 2.34 (secondary)
2 30
Injection Pressure kg/cm 2.55
Torque（kg-m)
30.0kg-m／5000rpm 28
26
24
280 22
260 20
240 255PS／8500rpm 18
220 16
200 14
Output（PS）
180
160
140
120
100
80
60
40
20
0
1000 2000 3000 4000 5000 6000 7000

Engine Speed（rpm）
012
Chapter 2
When NSU/ Wankel announced the completion of the rotaty engine,

most automobile manufacturers throughout the world scrambled to
propose technical cooperation plans. However, with the exception of
Mazda, no company reached series-production of rotary engine car.
By the mid 70s', Mazda had become the only automobile manufacturer
in the world to develop and market rotary engine cars.
013
The Birth of the Rotary En
Dream of Young Wankel research and development of the rotary

engine and the rotary compressor for
The rotary engine began with an commercial use.
improbable dream one summer in 1919 by a One prominent motorcycle manufacturer,
17-year-old German boy named Felix NSU, showed a strong interest in Wankel's
Wankel. In the dream, he went to a concert research. NSU generated a great deal of
in his own hand-made car. He even enthusiasm among motor-sports fans; they
remembers boasting, in the dream, to his were repeat winners of many World Grand
friends; "my car has a new type of engine: a Prix championships. NSU was also attracted
half-turbine half-reciprocated engine. I by the ideal concept of the rotary engine.
invented it!" When he woke up in the After creating partnership with Wankel,
morning, he was convinced that the dream NSU promoted Wankel's research and
was a premonition of the birth of a new type focused on the rotary engine with trochoid
of gasoline engine. housing as most feasible.
He had at the time no fundamental
knowledge about internal combustion First Wankel Engine
engines, but he intuitively
believed that the engine Before that, however, NSU completed
could achieve four cycles development of the rotary compressor and
--intake, compression, applied it to the Wankel-type supercharger.
combustion, and exhaust-- With this supercharger, an NSU motorcycle
while rotating. This intuition set a new world speed record in the 50cc
actually triggered the birth of class, marking a top speed of 192.5 km/h. In
the rotary engine, which had 1957, Wankel and NSU completed a
been attempted countless prototype of the type DKM rotary engine,
times by people all over the which combined a cocoon-shaped housing
world since the 16th century. with a triangular rotor. The rotary engine was
The rotary engine has an first invented here.
almost perfectly smooth The DKM proved that the rotary engine
operation; it also meets the was not just a dream. The structure,
most stringent technical however, was complicated because the
standards. His dream and trochoid housing itself rotated; that made
intuition had steered his this type of rotary engine impractical. A
entire life. more practical KKM with a fixed housing
was completed a year later, in 1958.
Research Starts Although it had a rather complicated cooling
system that included a water-cooled
In 1924, at the age of 22, trochoid with an oil-cooled rotor, this new
Felix Wankel established a KKM was a prototype of the current Wankel
small laboratory for the rotary engine. Forty-nine years had already
development of the rotary passed since young Felix Wankel dreamed
engine, where he engaged in of the rotary engine.
research and development.
During World War II, he
continued his work with the
support of the German
Felix Wankel Aviation Ministry and large
civil corporations, both of
In 1957, in cooperation with
whom believed that the rotary engine would
NSU, Dr. Wankel completed
the type DKM engine. It serve the national interest once it were fully
was the world's f irst prime developed. They held that the rotary engine,
mover by rotating motion if fully exploited, could move the German
alone. In 1958, he completed
a more practical type KKM
nation and its industries toward greatness.
K K M 400 Rot ar y Eng ine
that became the basis of the After the war, Wankel established the
current rotary engine. Technical Institute of Engineering Study The NUS-built single-rotor prototype
engine sent to Hiroshima f rom Germany
(TES) and continued his work on the with its technical drawings. This had a
chamber volume of 400cc.
014
gine Chapter 2
In search of Ideal Engine the department, 47 engineers in four

sections---investigation, design, testing, and
In November 1959, NSU officially material-research---began exhaustive efforts
announced the completion of the Wankel in research and development. Its main
rotary engine. Approximately 100 companies objective was the practical use of the rotary
throughout the world scrambled to propose engine: namely, mass production and
technical cooperation plans; 34 of them market sales. The most critical engineering
were Japanese companies. issue, the chatter mark problem, had to be
Mazda's president, Mr. Tsuneji Matsuda, solved.
immediately recognized the great potential The chatter marks were made inside the
of the rotary engine, and began direct trochoid housing at the wall, where the apex
negotiations with NSU himself. Those seals on the three vertexes of the triangular
negotiations resulted in the formal signing of rotor glided while juddering.
a contract in July, 1961. The Japanese The apex seal itself caused abrasive
government gave its approval. vibration and the inside wall of the trochoid
Mr. Tsuneji Matsuda
The first technical study group was housing was marked as traces of abnormal
As the President of Mazda, he immediately dispatched to NSU, while an wear. The RE Research Division called them
took the initiat ive in proposing in-house development committee was Devil's Nail Marks and found that they were
a technical cooperation plan
organized in Mazda. The technical study made when the apex seal vibrated at the
with NSU for the development
of the rotary engine and group obtained a prototype of a 400cc inherent natural frequency.
obtained the approval. single-rotor rotary engine and related To eliminate this phenomenon, a
drawings, and saw that the "chatter mark" cross-hollow seal was developed, which
problem---traces of wavy abnormal wear on helped a prototype engine to complete 300
the rotor housing that caused the durability hours of high-speed continuous operation.
of the housing to significantly deteriorate--- This technique, however, was not
was the most critical barrier to full adopted in the mass-produced rotary
development. It remained a problem even engines, but served to promote further
inside NSU. research of the apex seal in the areas of
Mazda, while testing the NSU-built rotary materials and structure.
engine, made its own prototype rotary Moreover, in the initial stage of rotary
engine in November, 1961. The engine was engine development, another problem
independently designed in-house. Both caused thick white smoke to pour out when
Mr. Kenichi Yamamoto engines, however, were adversely affected the engine oil leaked into the combustion
As the chief of the RE
by chatter marks. Practical use of the engine chamber and was burned. This also led to
research department, he was not possible without solving that excessive oil consumption and was
played a key role in problem first. regarded as another barrier against
developing Mazda's rotary
commercialization.
engine. Later served as
President and then Chairman Nail Marks of the Devil The cause of the problem was
of the company. inadequate sealing. With cooperation of the
In April, 1963, Mazda newly organized its Nippon Piston Ring Co. and the Nippon Oil
RE (Rotary Engine) Research Department. Seal Co. Mazda designed a special oil which
Under Mr. Kenichi Yamamoto, chief of proved to be a solution.
RE Research Depart ment
In 1963, Mazda organized a

new department which
Chat ter Marks
specialized in research and
The durability of earl y rotary development of the rotary
engines was severely engine. The Department
affected by these wav y traces Manager, Kenichi Yamamoto
of abnormal wear on the (center) and a total of 47
inside surface of the trochoid engineers undertook exhaustive
housing. work for the commercialization
of the rotary engined car.
015
From Cosmo Sport to RX-7
From Dual-Rotor to Multi-Rotor machine tools, and proceeded with the trial
manufacturing of multi-rotor rotary engines,
In the early 1960s, during the initial including three and four-rotor versions.
development stage of the rotary engine, Those prototypes were installed on a
Mazda designed and investigated three prototype mid-engine sports car, Mazda
types of rotary engine: those with two R16A; test drives began soon afterward.
rotors, three rotors, and four rotors. The Those driving tests were performed on a
First Two-Rotor Engine single-rotor version, prototypes of which high speed test circuit at Miyoshi Proving
In 1967 Mazda announced the
were completed by NSU, could run Ground that was completed in 1965. The
world's first commercialized course was the most advanced in Asia at
two-rotor unit, the type 10A. It that time.
developed 110PS.
World's First Two-Rotor
Rotary Engine
On May 30th, 1967, Mazda began selling
the world's first two-rotor rotary engine car,
the Cosmo Sport.
It featured a 110-horsepower type 10A
engine (491cc unit chamber volume)
equipped with newly developed apex seals
made with pyro-graphite, a high-strength
carbon material, and specially processed
aluminum sintering. This type of apex seal
resulted from Mazda's independent
development work and was proven durable
through 1,000 hours of continuous testing.
Cosmo Spor t (S110)
Even after a 100,000 km test drive, it
showed only slight wear and an absence of
Launched in 1967, the Cosmo chatter marks.
Sport powered by a 10A rotary
engine amazed people with its
For the intake system, the side-port
performance and unique design. configuration, coupled with a two-stage
smoothly at high speeds, but in the low four-barrel carburetor, was adopted to keep
speed range, it tended to be unstable, combustion stable at all speeds. For the
causing vibrations and a lacking of torque. ignition system, each rotor was equipped
This was due to the fundamental with two spark plugs so that stable
characteristics of single-rotor engines, combustion could be maintained in cold and
which had large torque fluctuations. hot weather conditions alike, as well as on
Mazda then decided to develop a two- urban streets and expressways. The Cosmo
rotor engine, in which the torque fluctuations Sport recorded more than 3 million km of
were expected to be at the same level as a 6- test drives in six years. Its futuristic styling
cylinder 4-cycle reciprocating engine. The and superb driving performance delighted
rotary engine could also further enhance the car buffs throughout the world.
smoothness of revolution.
Low-Emission 13B Development of Low-Emission
The first two-rotor test engine, type L8A
Rotary Engines
Type 13B is a two-rotor engine (399cc unit chamber volume), was Mazda's
with a 672cc unit chamber original design, and mounted on a After starting mass-production of its two-
volume. F irst introduced in 1973
prototype sports car (type L402A, early rotor rotary engine, type 10A, in 1967,
with full low-emission packages.
prototype of the Cosmo Sport) Mazda did not limit its application to just the
exclusively designed for the Cosmo Sport (which represented, after all, a
rotary engine. Test drives relatively small market): it expanded its
began soon afterward. installation into other sedan and coupe
In December 1964, models for larger volume production,
another two-rotor acquiring a larger number of customers
test engine, type along the way.
3820 (491cc unit Mazda also planned to export rotary
chamber volume) was engine cars to the world market.
T he Luce A P designed. It soon evolved to In 1970 it star ted export to the United
The second generation Luce made
the mass-production trial-type L10A. States, whose government was actively
its debut in 1973 and, in next year Moreover, in recognition of the large preparing the introduction of Muskie Act, the
the first low emission version w ith potential of the rotary engine, Mazda most stringent automobile emissions
a 13B engine was introduced.
invested heavily in imported and exclusive standards the country had yet devised.
016
Chapter 2
In 1966, Mazda started development for to improve their thermal reactor systems
the reduction of exhaust emissions while and carburetors, the company concluded
continuing early-stage developmental work that fuel economy could be raised by 20
of the rotary engine itself. percent as targeted. Further development,
Compared with the reciprocating engine, including enhancing reaction efficiencies by
the rotary engine tended to emit less NOx incorporating a heat exchanger in the
but more HC (Hydrocarbons). For clearing exhaust system, finally
the automobile emission standards under led to a 40 percent
the Muskie Act, Mazda promoted the rise, the ultimate goal. Lean-Burn Rotary Engine
development of an ideal catalyst system, but The success of the
as a more realistic solution, developed a Phoenix Project was
thermal reactor system that could be soon reflected in the sporty Spark Plug
applied. The thermal reactor was a device Savanna RX-7, IC Ignitor-type
Air Pump
that burned HC in the exhaust gas for launched in 1978, HEI
reducing HC emissions. This thermal reactor which proved once Air-Control Valve
system came equipped in the first U.S.- and for all that the
bound export car with a rotary engine, rotary engine was here Reactive
Model R100 (domestic name: Familia Rotary to stay. Thereafter, the Exhaust
Mainfold
Coupe), which met the U.S. standards of world's first catalytic
that year. Later, while other car converter system for Catalytic converter
manufacturers all over the world expressed the rotary engine was
that early compliance of the Muskie Law successfully
standards was impossible, Mazda reported developed, and fuel
in a public hearing with the U.S. government economy was even
further improved. Soon By introducing a catalytic
that the Mazda rotary engine could meet the
converter as a device to purify
standards. afterward, fundamental exhaust emissions, one could
In February 1973, the Mazda rotary engine improvements achieve leaner mixture settings.
engine cleared the U.S. EPA Muskie Act like the reaction-type
test. In November 1972, in Japan, Mazda exhaust manifold, the Six Port Induction System
launched the first low-emission series- high-energy ignition
production car in the domestic market, system, the split
which came equipped with a Rotary Engine secondary air control, Full-Auto-Choke Carburetor
Acturator for Self-Idle Governer
Anti-Pollution System (REAPS). and the two-stage
EGR Valve
pellet catalyst system,
The Phoenix Project were developed in
Semi-Peripheral type
succession. The Spark Plug
In 1970s, the world went through a manifestation of all
stormy period in international political those developments
Actuator
relations. Many developing nations, was the Lean-Burn
Secondary
however, were gaining stature and power by rotary engine that soon Auxiliary Port
using their oil resources as a political appeared on the
weapon. The "Oil Crisis" was the result of market.
this political wrangling. Monolithic Converter
Most Middle-Eastern oil-producing Six-Port Induction
countries during that time restricted their A variable- intake system which
exports of oil; oil prices on the world market After completing utilized the design features
two key projects---- the development of a inherent to the rotary engine to
soared because of the supply shortage.
enhance power and f uel economy.
Automotive manufacturers, responding to low emission system and fuel economy
those situations, started to develop mass- improvement---- Mazda adopted the six-port
produced cars with dramatically improved induction system and the two-stage
fuel efficiency. Mazda realized that a drastic monolithic catalyst system for its type 12A
reduction in fuel consumption was a engine (573cc unit chamber volume).
decisive factor for the survival of the rotary The six-port induction system had three
engine and initiated the "Phoenix Project" intake ports for one rotor chamber. Through
that targeted a 20 percent rise in fuel controlling the three intake port openings in
economy for the first year of research and three stages, fuel economy could be
development, followed by a 40 percent rise improved without sacrificing performance at
as an ultimate goal. high speeds.
After challenging the engineering This system, coupled with the two-stage
development to improve the fundamentals monolithic catalyst system, would further
of the engines, and, among other measures, advance the rotary engine.
017
Turbo, Multi-Rotor and A
Rotary Engines
Turbo and Dynamic Supercharger the turbo rotary engine, the second
generation Savanna RX-7 adopted the 13B
The Cosmo RE Turbo, which went on engine with a Twin-Scroll Turbo which
sale in 1982, was the world's first rotary would minimize turbo lag. The Twin-Scroll
engine car with a turbocharger. The rotary Turbo divided the exhaust intake scroll of
engine's exhaust system inherently had the turbine into two passages so that
more exhaust energy to drive the exhaust could be supplied step-wise. With
This system used neither turbo turbocharger turbine compared with the this configuration, the single turbocharger
nor supercharger, but f illing reciprocating engine; the rotary engine was acted as a variable turbo and sufficiently
efficiency could be drastically
better suited to the turbocharger. Moreover, covered a wide range of speeds.
increased over the conventional
design, by utilizing pressure the Cosmo RE Turbo was the world's first In 1989, the Twin-Scroll Turbo evolved
waves generated inside the series-production into the Twin-Independent-Scroll Turbo,
intake tracts by the sudden rotary engine car which had a more simplified configuration.
opening and closing of the ports.
equipped with an When this new turbocharger was coupled
electronically controlled with improvements in the engine internals, it
Dynamic Supercharging System
fuel injection system. provided more outstanding low-speed
Dynamic Chamber
The Cosmo RE torque, improved responsiveness, and
Intake Manifold for
Dynamic Supercharging Effect Turbo was the fastest upgraded driving performance.
commercial car in
Pressure Wave by Pressure Wave by
Intake inertia Effect Exhaust Interference Japan at that time. It
clearly demonstrated
the attractiveness of
the rotary engine.
Thereafter, the "Impact-
Turbo", developed
exclusively for the
rotary engine, made its
front rear debut. It was
responsible for even
further improvements in
Twin-Scroll Turbo System
response and output.
Choke Valve The "Dynamic
Three-Directional Intercooler
Supercharging" system
Solenoid
Twin-Scroll
was adopted in 1983
for the naturally
S aspirated (NA) rotary
P engine, type 13B. This
system dynamically
increased the intake air 13B Rotar y Turbo Engine
Switch Waste
Actuator Gate Valve volume without turbo or
The second generation RX-7 made its debut in 1985,
Switch Valve mechanical featuring a 13B rotary engine boosted by a Tw in- Scroll
supercharger, by Turbo. The engine produced a maximum output of 185PS.
utilizing the induction
characteristics peculiar
This system helps reduce the
to the two-rotor rotary Dual Fuel Injector
turbo-lag, a traditional
drawback of the turbo-engine. engine.
The duct leading the exhaust gas With the six-port Since 1983, the electronically controlled
to the turbine was split into two induction system and the dual injector fuel injection system for Mazda rotary
passages, one of which was
system, which had two fuel injectors in the engines has adopted two injectors in each
closed by a valve to accelerate
exhaust gas flow at low speeds. chamber for each rotor, the 13B rotary rotor chamber. Generally speaking, a large
engine came equipped with this dynamic nozzle is most suitable for high-performance
supercharging system and achieved output because it can provide increased
significant output increases regardless of amounts of fuel. For more stable
the speed range. The dynamic combustion at low speeds, however, a small
supercharging system was further improved size nozzle is more suitable because it can
in 1985 through changes in the surge tank atomize the fuel better.
configuration. The dual injector was developed to cover
such requirements in controlling the fuel
Twin-Scroll Turbo injection over a wide range of operations.
The two-rotor 13B-REW and the three-rotor
To improve the driving performance of 20B-REW rotary engines adopted
018
dvanced Chapter 2
air-mixture injectors, underwent further stronger exhaust pulse caused by the

evolution of the dual fuel injectors, and sudden opening of the exhaust port, and a
achieved radical improvements in fuel short and smooth manifold. To fully utilize
atomization. such features, the uniquely shaped Dynamic
Pressure Manifold was adopted to guide the
Type 20B-REW Rotary Engine exhaust gas into the turbocharger in a
minimum distance.
In 1990, the Eunos Cosmo, with its three-
rotor rotary engine 20B-REW, went on sale The World's Only Rotary Engine Plant
after steady continuation of research and
development for a quarter-century that How was Mazda able to pioneer the
passed since the beginning of the rotary development of practical two-rotor rotary
engine project. While the two-rotor rotary engines, and to continue to improve them
engine produced a smooth operation for 32 years? The answer lies in the Production L ine
equivalent to the six-cylinder reciprocating company's superior expertise in production
At Mazda's rotary engine plant in
engine, the three-rotor rotary engine and manufacturing engineering. For mass-
Hiroshima, many innovative
exceeded that of the V8 engine; it even production of the rotary engines, brand-new process and manufacturing
approached the level of the V12 engine. production engineering and production methods were introduced which
However, a difficult engineering barrier facilities were required. Mazda built a includes the plating of the
trochoid surface and precision
existed for manufacturing the multi-rotor manufacturing plant of 34,000 square casting of the rotors.
rotary engines en masse. When the rotary meters, with a production capacity of 15,000
engine was planned with an inline multi-rotor units per month,
configuration, only two choices in designing exclusively for
the eccentric shaft were feasible: coupling it the rotary engine.
through joints, or making one of the fixed This was the only
gears on the rotors split-assembled. Since production plant
the early stages of development, from the for rotary engines
1960s, Mazda had focused on the coupled in the world. It
eccentric shaft layout because the fixed combined
gear split layout was considered too incomparable
complicated for mass production. It then craftsmanship
considered how to design the joints. The evolved through
successful solution discovered in the 1980s decades-long
was to use tapered joints in connecting the rotary engine
shafts. When the three-rotor rotary engine production, with
was developed, extensive driving tests for Mazda's state- Hydrogen Rotar y Engine
performance and durability were carried out, of-the-art The rotary engine has
including participation in international sports production engineering. advanteges in using hydrogen
car racing activities like the famous Le Mans fuel since temperatures around
the intake port are relatively low
24 Hours race. Advanced Rotary Engine and it can induct air and
hydrogen separately.
Sequential Twin-Turbo Mazda announced a hydrogen-fueled
concept rotary engine in 1991 at the Tokyo
The Sequential Twin-Turbo first adopted Motor Show. Hydrogen used as fuel HR-X 2
in type 20B-REW and type 13B-REW rotary produces no carbon dioxide, which has A concept car featuring a
engines in 1990 was developed based on been linked with the global warming Hydrogen rotary engine which
the unique engineering concept of utilizing problem. Mazda continued this line of was f irst inveiled at the 1993
Tokyo Motor Show. This car used
two turbochargers in sequence. At low research and, focusing on applications of
metal-hydride to carry hydrogen
speeds, only the first turbocharger works, hydrogen fuel to the engine under a fuel safely.
but in the high speed range, the second fundamental research project for
turbocharger kicks in. Using both future rotary engines, actually
turbochargers enabled sufficient built some experimental
supercharging capacity and yielded high models powered by a
output. Running two turbochargers hydrogen rotary
simultaneously also had the added benefit engine.
of reducing the exhaust resistance, which in
turn contributed to even higher
performance.
As the base engine to install the
turbocharger, the rotary engine had several
inherent superior characteristics, including a
019
Chapter 2
Chronicle of Rotary
Mazda's Series-Production
Engine Development
Rotary Engine Cars&Trucks
Cosmo Sport / Mazda 110S (1967~1972)
World's first two-rotor rotary engine car was launched in May 1967. The low, streamlined silhouette and futuristic body
styling took advantage of the compact rotary engine. It also defined the start of the rotary engine era, and thrilled
customers everywhere. In July of 1968, the improved version of the Cosmo Sport went on sale, featuring a souped-up
128PS L10B rotary engine and a 150mm extended wheelbase. A maximum speed of 200km/h and acceleration of 0 to
400mm in 15.8sec. excited sports car fans all over the globe. A total of 1,176 units were produced in 5 years.
Major specifications:
Length x Width x Height: 4140 x 1595 x 1165mm; Wheelbase: 2200mm; Track (front/rear): 1250/1240mm; Vehicle
Weight: 940kg; Seating Capacity: 2; Engine Type: 10A; Displacement: 491cc x 2; Maximum Output: 110PS/7000rpm;
Maximum Torque: 13.3kg-m/3500rpm (JIS gross) ; Maximum Speed: 185km/h; Transmission: 4-speed Manual.
Familia Rotary / Mazda R100 (1968~1973)

Developed based on the prototype Mazda RX-85, which was announced in 1967 at the 14th Tokyo Motor Show. It went
on sale in July, 1968. The type 10A rotary engine, proven to be reliable and durable in the Cosmo Sport, was mounted
on a fastback, two-door coupe style body. Designed as a high performance touring car, but had sufficient space to be
used as a family car. In 1969, the sedan version--a high-performance family car, the Familia Rotary SS-- was added to
the lineup. A total of 95,891 units were produced in 5 years.
Major Specifications of the Familia Rotsry Coupe:
Luce Rotary Coupe / Mazda R130 Coupe (1969~1972)

A highly refined personal coupe, developed based on the protot ype Mazda RX-87, was announced in 1968 at the 15th
Tokyo Motor Show. It had a front-engine, front-wheel-drive configuration, and went on sale in October 1969. Its egantly
designed Italian-style body exhibited streamlined curves and shapely sualptured facades without the then-popular front
deflector windows. The type 13A rotary engine, generating 126PS at 6000 rpm, boasted an outstanding performance; it
was extra quiet, and fit right into the trend of high-speed driving that was becoming popular at the time.
Major Specifications:
Length x Width x Height: 4585 x1635 x 1385mm; Wheelbase: 2580mm; Track (front /rear): 1330/1325mm; Vehicle
Capella Rotary / Mazda RX-2 (1970~1978)

Launched as a high-performance model in the series of the mid-sized Capella. Went on sale in May 1970. A newly
designed rotary engine, the 12A, was installed under the hood. The G series---the world's first rotary engine cars with
authentic automatic transmission, was added in 1971. The high-performance model GSII , with its 5-speed manual
transmission, was introduced in 1972, and the AP, with its full anti-pollution package, came out in 1974. Winner of the
1972 Import Car-of-the-Year award from Road Test, a popular car magazine in the U.S. at that time.
Major Specifications of the Capella Rotary Coupe:
Savanna / Mazda RX-3 (1971~1978)

A sport sedan and coupe, launched in September 1971, with the type 10A rotary engine. In 1972 the fully automatic
transmission version, the Sport Wagon, was introduced as the world's first rotary engine wagon. The GT, with its 12A
rotary engine and 5-speed manual transmission, was also added. A variety of sport-kits were prepared and contributed
to many successful races. In 1973, the AP, with its anti-pollution package, was added. In 1975, the REAPS rotary
engine, which achieved lower emissions and better fuel economy, was introduced.
Major Specifications of the Savanna Coupe:
Luce Rotary / Mazda RX-4 (1972~1977)

The second generation Luce, with its 12A rotary engine, was launched in October 1972. It came in three body styles:
hardtop, sedan, and custom. These models led the way for rotary engine cars being positioned in the top sport & luxury
markets. In 1973, the Luce Wagon and the Grand Turismo, which had wood-grain panels on the sides, were added. At
the same time, additional models with low emission AP versions and 13B rotary engines were prepared. They proved that
low emissions and high performance could be compatible.
Length x Width x Height: 4240 x 1670 x 1410mm; Wheelbase: 2510mm; Track (front/rear): 1380/1370mm; Vehicle Weight:
1035kg; Seating Capacity: 5; Engine Type: 12A; Displacement: 573cc x 2; Max. Output: 130PS/7000rpm; Max. Torque:
16.5kg-m/4000rpm (JIS gross) ; Max. Speed: 185km/h; Transmission: 5-speed Manual / 3-speed Automatic.
The specifications are all for the original models.

020
Rotary Pickup (1973~1977)
Marketed exclusively in the North American area, where pick-up trucks were very popular. This was the world's first pick-up truck
and utility vehicle with a rotary engine. The lightweight and compact rotary engine was durable and fit well in this type of vehicle.
Massive front grill, boxy body, large mirror, extruded fenders, and wide tires were well-suited to the tastes of American pickup
buyers. This was a unique rotary engine vehicle, not sold in Japan.
Not available in Japan since this was a product exclusively marketed in North American countries.
Parkway Rotary 26 (1974~1976)

World's first rotary engine bus, launched in July 1974. The 13B rotary engine was installed and yielded 135PS maximum
power and 120km/h cruising speed. Pleasant riding comfort, with low noise and little vibration, was pursued, making full
use of the rotary engine's benefits such as smooth operation. Two models were on sale; 26-passenger Deluxe version with
optional air-conditioning operated by the sub-engine, and the 13-passenger Super-Deluxe version, with full luxury
equipment. This was a unique model that had shown that the rotary engine was not solely for passenger cars.
2885kg; Seating Capacity: 26; Engine Type: 13B; Displacement: 654cc x 2; Maximum Output: 135PS/6500rpm; Maximum
Torque: 18.3kg-m/4000rpm (JIS gross) ; Maximum Speed: 120km/h; Transmission: 4-speed Manual
Roadpacer AP (1975~1977)
A full-size sedan, launched in March 1975. Some of the body parts and mechanical components were supplied by
GM-Holden in Australia; but the engine was Mazda's 13B RE. Anticipating the era of international joint operations, this
project aimed at lowering costs and raising quality through shortened development periods; it saved its tooling
investment for the small-volume, premium market. The Roadpacer AP was mainly sold as a chauffeur-driven saloon for
company executives, but was also attractive as a high-class personal car. 800 units were produced in three years.
Weight: 1575kg; Seating Capacity: 5; Engine Type: 13B; Displacement: 654cc x 2; Maximum Output: 135PS/6000rpm;
Maximum Torque: 19.0kg-m/4000rpm (JIS gross) ; Maximum Speed: 165km/h; Transmission: 3-speed Automatic
Cosmo AP / Mazda RX-5 (1975~1981)

Highly refined specialty car, launched in October 1975. Mazda's full confidence shone through with this model. It was
named after the Cosmo Sport, Mazda's first commercialized rotary engine car. Both the 12A,and 13B rotary engines with
low-emissions package were prepared for the Cosmo AP, and 10 optional variations were offered to customers. In 1977,
Cosmo L, the Japan-first Landau-top model, was added. A commercial film, "Red Cosmo," became wildly popular, and
this model became an image leader for developing the high-performance specialty car market in Japan.
Major Specifications of the Cosmo AP:
Weight: 1220kg; Seating Capacity: 5; Engine Type: 13B; Displacement: 654cc x 2; Maximum Output: 135PS/ 6000rpm;
Maximum Torque: 19.0kg-m/4000rpm (JIS gross) ; Transmission: 5-speed Manual / 3-speed Automatic.
Luce Legato / Mazda 929L (1977~1980)

Launched in October 1977 as the top-of-the-line Luce series. The concept for development was high quality, grace, and
distinctiveness. The two rotary engines --t ype 13B with 135PS and 12A with 125PS--were optional. Two bodylines, the
4-door Pillared Hardtop and the 4-door Sedan, were offered. To meet subdivided market requirements, Mazda offered 3
versions and 10 types for the Pillared Hardtop, 4 versions and 10 types for the Sedan, and 3 types (with manual,
automatic, and column-shift automatic transmission) for the top version, 13B engine-powered Limited.
Major Specifications of the Luce Legato 4-door Hardtop:
Weight: 1225kg; Seating Capacity: 5; Engine Type: 13B; Displacement: 654cc x 2; Maximum Output: 135PS/6000rpm;
Savanna RX-7 / Mazda RX-7 (1978~1985)

The first generation RX-7 was launched in March 1978. 10 years of experience with rotary engine development was
reflected in this model. The concept of development was the pursuit of driving pleasure. The front mid-ship layout of
improved 12A engine and the then-uique retractable headlights helped realized aerodynamic body design. This model
became extremely popular not only in Japan but also in North America. A face -lift was made in 1980, the new 6PI
engine installed in 1981, and the 12A turbo rotary engine, which developed 165PS added in 1983.
Length x Width x Height: 4285 x 1675 x 1260mm, Wheelbase: 2420mm, Track (front/rear): 1420/1400mm, Vehicle
Weight: 1005kg, Seating Capacity: 4, Engine Type: 12A, Displacement: 573cc x 2, Maximum Output: 130PS/7000rpm,
Maximum Torque: 16.5kg-m/4000rpm (JIS gross); Transmission: 5-speed Manual / 3-speed Automatic.

021
Chapter 2
Chronicle of Rotary
Mazda's Series-Production
Engine Development
Rotary Engine Cars&Trucks
Cosmo (1981~1990)
The third-generation Cosmo, launched in October 1980, was developed as a high-end personal car to meet the
requirements of the day. Three body variations were designed: 2-door and 4-door hardtops, and saloon. The 6PI type
12A rotary engine was originally installed; type 13B, with its electronically controlled super-injection system, and type
12A with the Impact-Turbo, the world first turbo rotary engine, were added later. Equipped with four-wheel independent
and electronically controlled suspension, the Cosmo was fast and a pure pleasure to drive.
Major Specifications of the Cosmo 2-door Hardtop:
Luce / Mazda 929 (1981~1986)

The 3rd generation Luce was launched in October 1981, at the same time as the Cosmo. The series included 4-door sedan
and hardtop, powered by a 2.0-liter reciprocating or a 12A rotary engine. Like with the Cosmo, the rotary engine model
employed Mazda's first 4-wheel independent suspension system. Later, the Luce underwent a big face-lift and got an
extensively modified nose and rear end. The new top range models, powered by a turbochaged 12A or dynamic
supercharger-equipped 13B rotary engine, became popular in the market as a luxury car with performance and elegance.
Major Specifications of the Luce 4-door Hardtop:
1165kg; Seating Capacity: 5; Engine Type: 12A; Displacement: 573cc x 2; Maximum Output: 130PS/7000rpm; Maximum
Torque: 16.5kg-m/4000rpm (JIS gross) ; Transmission: 5-speed Manual / 3-speed Automatic.
Savanna RX-7 / Mazda RX-7 (1985~1992)

The second-generation RX-7 was launched in October 1985, with further upgraded styling and dynamic performance.
The 13B rotary engine with Twin-Scroll Turbo and inter-cooler developed a maximum power of 185PS. Mazda's unique
multi-link rear suspension with toe-control capability was also came as standard. The interior was designed with the
perfect blend of harmony, beauty, and sportiness; the result was a "matured" sports car. In 1987, the Cabriolet was
added; in 1989, the engine's maximum output was raised to 205PS.
Weight: 1240kg; Seating Capacity: 4; Engine Type: 13B turbo; Displacement: 654cc x 2; Maximum Output:
185ps/6500rpm; Maximum Torque: 25.0kg-m/3500rpm (JIS net) ; Transmission: 5-speed Manual / 4-speed Automatic.
Luce Rotary (1986~1991)

The fifth-generation Luce, launched in September 1986, was designed to couple the luxury of the top-end sedan with the
sportiness of the rotary engine. The powerful turbocharged 13B rotary engine, with its 180PS maximum power, was
installed. Combined with the newly developed automatic transmission, it realized a smoother and quicker acceleration.
The highly rigid monocoque body featured strut for the front and the Mazda's unique E(Multi)-link suspension for the
rear. It thus resulted in a high level of compatibility between performance and comfort as a luxury saloon.
Weight: 1500kg; Seating Capacity: 5; Engine Type: 13B turbo; Displacement: 654cc x 2; Maximum Output:
180PS/6500rpm; Maximum Torque: 25.0kg-m/3500rpm; Transmission: 4-speed Automatic.
Eunos Cosmo (1990~1995)

The Eunos Cosmo, launched in April 1990, was the world's first series-production car with a 3-rotor rotary engine,
Type 20B-REW, with Sequential Twin Turbo system, developed a maximum power of 280PS in a smooth and
responsive manner. The body was exclusively designed for the "full-size" category in Japan, The cabin was spaced
as a luxury 2 plus 2. The interior materials---leather and wood---were examined from the stage of raw materials. The
engine, suspension automatic transmission, and air-conditioning system were all electronically controlled.
Weight: 1610kg; Seating Capacity: 4; Engine Type: 20B-REW; Displacement: 654cc x 2; Maximum Output:
280PS/6500rpm; Maximum Torque: 41.0kg-m/3000rpm (JIS net) ; Transmission: 4-speed Automatic.
Mazda RX-7 (1991~ )

The third-generation RX-7, launched in December 1991, featured a powerful and responsive 13B-REW rotary engine
with Sequential Twin -Turbo with a naturally harmonized beautiful body silhouette. The all-wheel double-wishbone
suspensions, with newly developed dynamic geometry control mechanism, came standard on all models. Completed as
a true sports car; it pursued ultimate driving pleasure. It was face-lifted in 1996 and in 1998, and the maximum output of
the 13B REW was boosted up to 280PS for enhanced sports-car sansations.
Weight: 1250kg; Seating Capacity: 4; Engine Type: 13B-REW; Displacement: 654cc x 2; Maximum Output:
255PS/6500rpm; Maximum Torque: 30.0kg-m/5000rpm (JIS net) ; Transmission: 5-speed Manual / 4-speed Automatic.

022
Chapter 3
To demonstrate the high performance and reliability of the rotary

engine, Mazda participated in international endurance races with the
Cosmo Sport, Mazda's first series-production rotary engine car, in 1968.
Since then, Mazda continued motor sports activities and, in 1991,
Mazda 787B powered by a four-rotor rotary engine achieved overall
victory in the Le Mans 24 Hours endurance race. It was an historic win
for the rotary engine and the only win ever for a Japanese car.
023
The first Le Mans Challenge the race with a Mazda S124A (Savanna
RX-3), but retired before completing the
At Mazda, participation in motor-sports race. In 1979, the motor sports department
activities is mainly to showcase the of the Mazda Auto Tokyo challenged the
reliability, durability, and high performance IMSA class race with a Silhouette Formula
of the rotary engine. So, winning the world's based on the Savanna RX-7, the so-called
most traditional endurance race ---the Le Mazda RX-7 / 252i, but regrettably retired in
Motor Sports
Mans 24--- was the most inspiring objective. the trial phase of the race. In 1980, an
Activities by The rotary engine car competed in Le American private team entered the race with
Mazda Rotary Engine Mans for the first time in 1970. Mazda a RX-7, and wound up in 21st place overall.
supplied the 10A rotary engine to a private It was the first rotary engine car which
team organized by Belgian drivers, and they finished this historic endurance race.
mounted it in their racing car costructed in In 1981, Mazda Auto Tokyo entered the
the U.K., the Chevron B16, and entered the race again with two Mazda RX-7／253s
race. Regrettably, the car was forced to (modIfIed 252i of 1979), but could not finish
retire because the water cooling hose broke due to the differential and transmission
Mazda RE Dominates
Le Mans 24 Hours Race
The first overall victory by Japanese makes at the Le Mans, it
was achieved by the rotary engine powered Mazda 787B.
down after four hours of operation. In 1973, problems. The following year (1982), two
a Japanese team--- the Sigma Automotive improved RX-7／254s entered in the IMSA-
team--- mounted the rotary engine in their GTX category ; one of them finished the race
car and competed in the race for the first in 14th place overall ( 6th in its category).
time. A 12A rotary engine was supplied to
their car, a modified Sigma MC73 Mazda. Repeated Trials
The car, however, had to retire after 11
hours due to trouble with the electrical From 1983, Mazda Auto Tokyo targeted
system. The following year (1974), a the newly defined Group C Junior category
modified Sigma MC74 Mazda (with type 12A (which changed their name to Group C2 in
rotary engine) received the checkered flag 1984) and developed a mid-ship sports
L e Mans Pit in 1991 after overcoming many troubles, but due to prototype car, the so-called Mazda 717C;
The winner of the 1991 L e Mans 24 Hours a shortage of laps, did not qualify. two of those entered the race. Their strategy
the Mazda 787B, car number 55, was driven
by V. Weidler(Germany), J. Herbert( UK)
In 1975, a French private team entered worked: they came in first and second in the
and B.Gachot( France) C Junior category and won several awards
(12th and 18th overall). In June of that year,
Mazda Auto Tokyo reorganized its motor
sports department into what they called the
Mazda Speed, where the sports prototype
car for Le Mans could be designed and built
on a full scale, and where the Mazda Racing
Team activities were to be developed.
In 1984, a total of four rotary-engine-
equipped cars entered the race. Two were
Model 727C, modified from the 717C, and
the other two were Laura T616 Mazdas (with
13B rotary engines) prepared by the BF
Goodrich team, sponsored by the American
tire manufacturer.
One of the Lauras took first place in the
C2 category (10th place overall), and the
other came in 3rd place in the same
category (12th place overall). The two
Mazda 727Cs took 4th place (15th place
overall) and 6th place (20th overall). All four
rotary cars finished the race, and C2
category was dominated by them for two
consecutive years. Such results were
024
Mazda 787B
The v ictory of Mazda
787B was extremely
valuable because it
defeated the heavily
favored Peugeot 905,
Jaguar XJR12,
Mercedes-Benz C11
and other tough
contenders.
enough to prove the high reliability and consumption and electrical system troubles.
performance of the rotary engines yet again. The 767B completed the race and won the
In 1985, two Mazda 737Cs, modified from IMSA-GTP category but in disappointing 20th
the 727C, entered the race, but ended up in place overall.
disappointing 3rd place (19th place overall)
and 6th place (24th place overall) finishes in Long Awaited Victory Chevron B16 in 1970
C2 category due to transmission and other The first rotary engine car that
competed at the Le Mans, the
troubles. In 1986, two newly developed Mazda The Mazda team challenged the 1991 Le Chevron B16 was powered by a
757s with type 13G three-rotor rotary engines Mans 24 hours race with two further 10A unit.
entered the race in the IMSA-GTP category, strengthened 787Bs and one 787. The R26B
but both were forced to retire due to drive four-rotor unit had greatly improved both
shaft problems. Two 757s, however, repeated power and fuel efficiency on the basis of the
the challenge the next year, and one of them high reliability and durability of the rotary
won the GTP category (7th place overall). engine. The organizer of this historic event
had decided to hold the race next year only
Multi-Rotor Rotary Engine with machines powered by a 3.5-liter Mazda 717C in 1983
reciprocating engine. So this was the last Mazda Speed's first entry, this
car, driven by three Japanese,
In 1988, in a bid to become the overall chance for the four-rotor engine powered won the C Junior class and
champion, two Mazda 767s, with newly 787B and 787. f inished 12th place overall.
developed type 13J-modified four-rotor The three Mazdas competed successfully
engines, along with one proven Mazda 757, from the beginning. At the 12th hour, the787B
entered the race. The two 767s held the lead with car number 55 took 3rd place and fought
over other Japanese entries from the aggressively against Mercedes-Benz, Jaguar
beginning, but due to exhaust manifold and other top contenders. After 21 hours,
breakage, they finished the race in 17th and while a Mercedes-Benz machine had a pit
19th place overall. The 757 also had rotor stop, the 787B got top place. Mazda 767B in 1989
crack problems in the brakes, and finished At just 4 o'clock in the afternoon of June 23, Racing prototype powered by a
four-rotor rotary engine, the
15th overall. They occupied the upper places 1991, the 787B passed the goal line, achieving 767B came in 1st, 2nd, and 3rd
of the IMSA-GTP category, including the top Mazda's long awaited target; two hundred places in the IMSA-GTP class.
position, but could not capture top runners. fifty thousand spectators cheered the car.
In 1989, two 767Bs and one 767 entered
the race. Two of them unfortunately crashed in
the trial run, jeopardizing their entry into the
final race, but the cars were restored by
extraordinary teamwork efforts; all three cars
Mazda 787B in 1991
finished the final. The results were 7th place
Two 787Bs entered the 1991 L e
(won the IMSA-GTP category), 9th place, and
Mans. One of them famously
12th place overall, but still several steps short won the championship, while
of the hoped-for first place overall win. the other f inished 6th place
In 1990, two new cars, Mazda 787s with overall.
their newly developed R26B four-rotor rotary
engines, and one 767B entered the race. The
Mazda 787s were fitted with full-carbon twin-
tube chassis for the enhanced "fighting ability"
T he R26B Eng ine of the 787B
of the car, and were regarded as most
Mazda's four-rotor rotary engine f irst appeared at the Le Mans in
promising for victory. However, the two 787s 1988, powering the 767 and yielding 550PS. But the maximum output
had to retire due to abnormal fuel had been boosted to 700PS in the type R26B unit of the 1991 787Bs.
025
Motor Sports
Activites by
Mazda Rotary Engine
Mazda RE Competes
in Races and Rallies
026
the World Over
Legendary First Race Familia Rotary Coupes registered to compete
in the Spa-Francorchamps 24-hour race;
After announcing the world's first mass- Mazda aimed to dominate the race. In the
produced rotary engine car, Cosmo Sport, race, the Mazda team boldly confronted the
Mazda immediately planned to participate in BMW team, and finished in a dead heat.
motor-sports activities; they believed that Although the Japanese driver pair (Yoshimi Mazda R X-3 (Savanna)
motor sports enthusiasts were highly attracted Katayama and Toshinori Takechi) held the The R X -3 defeated the Nissan
Skyline GT-R and accumulated
to the high performance, reliability, and lead at the 12th hour, the team encountered
100 wins by 1976 in the
durability of rotary engines. some ill-fated trouble and lost three cars. The domestic touring car
But, in the initial stage of development, lone surviving Mazda took 5th place overall, championship.
intensive efforts were focused on research for and the Familia Rotary Coupe earned the
the completion of the rotary engine, and nickname "Small Giant" because of its
participation in motor-sports events was not strenuous efforts.
a priority.
In 1964, however, a small scale Mazda RX-3 Defeats GT-R
racing team was organized, and began to
compete in international races in Southeast While the Familia Rotary Coupe was racing R X-7 in 1979 Dayt ona 24-hr
Asia. Mazda quickly became known as one of all over the world, the first race in Japan for In its first race in the U.S. the
1979 Daytona 24 Hours, the
the more enthusiastic car manufacturers in the the car took place in November 1969. The
R X-7 won the GTU class and
sports. debut race was the All Japan Suzuka demonstrated high potential.
But until Mazda's entry, a rotary-engine car Automobile Grand Cup Race, where the
had never competed in auto races. An Mazda team took first place overall. The
international race held in Europe on August touring car races in Japan at that time,
21, 1968 was selected as the debut race for however, were dominated by the Nissan
the Cosmo Sport. That 84-hour race was Skyline GT-R (powered by a 2.0-liter DOHC
called the Marathon de la Route and was held inline 6-cylinder reciprocating engine).
at Nurburgring Circuit in West Germany, the Although the Mazda racing team continued its
8-Year Consecut ive Wins
home country of the Wankel rotary engine. challenge to the Skyline by switching their
The R X -7 won the IMSA series
The race itself was exceedingly arduous: every entry from the Familia to the more powerful of the U.S. for eight consecut ive
car needed to keep running at full power for Capella Rotary, with its 12A rotary engine, the years, f rom 1980 to 1987, a great
four full days. team couldn't unseat the Skyline's record in IMSA history.
Two Cosmo Sports, modified for the domination. However, the first generation
endurance race, were registered for
entry. The 10A rotary engines there
were modified to enhance reliability and
durability, and maximum power was
limited at a modest 130PS / 7000rpm.
After the race started, two Porsches
and one Lancia formed the top group,
followed by the two Cosmo Sports. The
Mazda racing team boldly fought on,
even though one was forced to retire
during the 81st hour after losing a tire
due to rear axle trouble; the other
completed the 84-hour race, and came
in 4th overall. This result both shocked
and moved racing enthusiasts
throughout the world, and sealed the
reputation of the rotary engine.
Savanna (with its 10A rotary engine), launched Cosmo Sport
R100 : Small Giant in September 1971, was very promising. In In 1968, the year following its
debut, the Cosmo Sport entered
December of that year, three months after it
the Marat hon de la Route, an
As the Familia Rotary Coupe (R100) made went on sale, the Savanna defeated the 84 -hour endurance race held at
its debut in July 1968, Mazda racing team Nissan Skyline GT-R in the Fuji 500-mile Nurburgring i n West Germany,
again started to compete in car races all over Tourist Trophy Race, just in time to prevent and f inished 4th overall.
the globe. The 10A rotary engine mounted on the Skyline's 50th victory.
the Familia Rotary Coupe generated around In the following year, 1972, the Savanna
200PS after special modifications for the race. RX-3 (Savanna GT in the market) with the
In April 1969, the Familia Rotary Coupe long-awaited 12A rotary engine, made its
took first place overall in the Singapore Grand debut, and dominated the Japan Grand Prix
Prix. It then moved on to Europe. In July of TS-b Race by taking the top winning
that year, competing with a Porsche 911 fleet, positions. After some fierce racing battles, the
the team finished 5th and 6th overall at the Savanna finally defeated the Skyline GT-R and
Belgium Spa-Francorchamps 24-hour race. In became the grand champion of racing.
August, the second challenge in the Marathon Thereafter, the Savanna retained its
de-la-route 84-hour race resulted in a finish of champion position, leaving a legacy of
5th place overall. undefeatable race records. Mazda supported
In June of the following year, 1970, the its owners by offering sports kits in the market
team took 8th place overall at the RAC Tourist to meet the requirements of motor-sports fans
Trophy Race in England, followed by a 4th and continued their motor-sports activities.
place showing overall in July at West Germany The Savanna chalked up its 100th victory in
Touring Car Grand Prix. Later that year, four domestic race events when it won the JAF
027
Motor Sports
Activities by
Mazda Rotary Engine
Mazda RX-7:
Unbeatable Champion
R X -7 in 1992 Bathurst
The new R X-7, launched in 1991,
won the famous Bathurst 12-hour
race in Austral ia, for three
straight years from 1992 to 1994
in the World Sports-Car Races

Grand Prix TS/GTS-B Race in 1976. that could not become a reality 11 years
Mazda also manufactured "pure" race earlier--- was finally achieved by the RX-7.
engines based on the 13B rotary engine and
supplied them to racing teams in Japan. The WRC Challanges
13B-powered racing prototypes came to
dominate the Fuji Grand Champion Series. Mazda also challenged the World Rally
Championship to demonstrate the high R X-7 in 1985 Acropolis
RX-7: The Great Winner potential of the RX-7. In 1984, Mazda entered to the
The first full-scale competition was the WRC a special Group -B R X-7
The Mazda RX-7 (Savanna RX-7 in the 1981 RAC Rally, where it finished 11th place w ith larger 13B rotary engine.
It f inished 3rd overall in the
domestic market) made its debut in May 1978. overall. In 1982, the entry in the New Zealand 1985 Acropolis Rally.
It was a high-performance sports car that Rally ended up in 5th place overall.
received a laudatory welcome by racing In 1984, the RX-7 with a 13B rotary engine
enthusiasts all over the world. Rotary engines, was specially developed for the World Rally
with their proven high durability and reliability, Championship, where it was widely believed
were easy to tune and maintain, two attributes that only four-wheel-drive cars could
that made them extremely attractive for motor compete. But the two-wheel-drive RX-7 took
sports enthusiasts. 9th place overall, proving its strong
Mazda's activities in the International Motor capabilities.
Sports Association (IMSA) in the United States Rally activities all over the globe continued, 1990 IMSA GTO Class
were especially extensive. At its debut race in and in 1985 Mazda's entry in the Acropolis In 1990 at the San Antonio GP,a
R X-7 driven by Pete Halsmer
1979, Mazda won the GTU class (5th place Rally resulted in 3rd place overall. Thus, it was took first place in the GTO class,
overall) in the Daytona 24-hour race. They proven that the highly durable rotary engine achieving the 100th win of the
have never lost a race in the GTU class. For could excel not only in races but also in rallies. R X-7 in the IMSA series.
eight consecutive years (from 1980 to1987),
Mazda continued to win the IMSA series Challange Will Continued
championship, a first in IMSA history.
In 1985, the RX-7 marked the IMSA In October 1991, the third-generation
winning record for a single model line, a Mazda RX-7 (with a turbocharged 13B rotary
distinction formerly held by the Porsche engine) was unveiled, and immediately began
Carrera RSR. Thereafter, Mazda continued its competing in motor-sports events in Japan,
activities in `IMSA series and won the the United States, and Australia.
100th Win at IMSA
championship 10 times in the GTU class. Especially in Australia, from 1992 through
Since its f irst race at the
From 1990, the RX-7 powered by a specially 1994, it consecutively won the overall Day tona 24-hour in 1979, the
prepared four-rotor rotary engine officially championship in the most popular touring car R X-7 accumulated victories in
began to compete in the GTO class, and in race, the Bathurst 12-hour Endurance Race. the IMSA series and achieved
its record 100th win in 1990.
1992 in the GTP class. Until 1990, a total of In Japan, many private teams using the
100 victories were accumulated, an IMSA RX-7 actively competed in the All Japan GT
series record. Championship Race and in the Super
The RX-7 also won championships in the Endurance Series.
British Saloon Car Race, the Belgium Touring The Mazda RX-7, with its compact and
Car Race, and the Australia Touring Car high performance rotary engine, will continue
Endurance Race. In 1981, the RX-7 won the to be well received by motor sports fans and
Spa-Francorchamps 24-hour race. First place racing teams throughout the world, and will
overall--- a dream of the Familia Rotary Coupe play very active roles in the circuits.
028
APPENDIX
Structure and Working
possibilities of various types of rotary engines
Principles of Rotary Engine and reached the optimum shape of the trochoid
housing . His working knowledge on the rotary
valves used for the aircraft engines, the airtight
sealing mechanism for the superchargers and
the incorporation of these mechanisms into his
design contributed to practical realization of
Wankel-type rotary engine.
Structure and Operation of the
Rotary Engine :
The rotary engine is composed of a cocoon-
Wankel-type Rotary Engine : shaped housing and a triangular-shaped rotor
inside of it. The space between the rotor and
Over the past 400 years, many inventors and the housing wall provided the chamber for
engineers have pursued the idea of developing internal combustion and the force of the
a continuously rotating internal combustion expansion pressure served to turn the rotor. In
engine. It was hoped that the reciprocating- order to make the rotary engine work as an
piston internal combustion engine using would internal combustion engine, the four processes
be superceded by an elegant prime mover of intake of the mixture, compression,
bearing a closer resemblance to the "wheel", combustion and exhaust had to be performed
one of mankind's greatest inventions. in succession in the working chamber. Let us
It was late in the sixteenth century that the suppose that the triangular-shaped rotor were
phrase,"continuous rotating internal concentrically placed inside a true circular
combustion engine" first appeared in print. housing. In this case, the working chamber
James Watt (1736~1819), the inventor of the would not vary in volume as the rotor turned
connecting rod and crank mechanism, also inside the housing. Even if the fuel-air mixture
took up research on a rotary-type internal were ignited there, the expansion pressure of
combustion engine. For the last 150 years combustion gas would merely work toward the
especially, a number of ideas on the rotary center of the rotor and would not result in
engine design have been set forth by inventors. rotation. That was why the inner periphery of
It was in 1846, that the geometrical structure of the housing was contoured as a trochoid-
the working chamber of current rotary engine shape and assembled with the rotor installed
designs was planned and the concept of the on an eccentric shaft.
first engine using an epitrochoid curve was The working chamber changes in volume
configured. However, none of those ideas had twice per one turn, thus the four processes of
been put to practical use until Dr. Felix Wankel the internal combustion engine could be
developed the Wankel-type rotary engine in achieved. With the Wankel-type rotary engine,
1957. the rotor's apexes follow the oval contour of
Dr. Wankel had researched and analyzed the inner periphery of the engine casing while
Roter Gear
Stationary Gear
Arm
Ignition &
Intake Compressin Exhaust
Expansion
Eccentricity e Generating Radius R
Pr incipl e of Per itrochoid Cur ve : Comparison wit h Reciprocating Engine-1

Dr. Wankel and his colleagues devised how to configure the trochoid With the rotary engine, the inside space of the housing is always divided
curve as follows: First, f ix an outer-toothed gear on a white sheet above into three working chambers and, as the rotor turns, those chambers also
a table and mesh an inner-toothed gear on it. Put a pen attached w ith an moves. Four processes of intake, compression, combustion and exhaust are
arm on the outside of the inner- toothed gear. The gear ratio between executed succesively in a different place of the trochoid housing. This is
both gears is to be set as 2:3. When turning the inner-toothed gear on significantly different from the reciprocat ing engine, where the four
the other gear, the pen w ill generate the cocoon-shape trochoid curve. process are carried out within a cylinder.
029
APPENDIX
remaining in contact with the gear on the which rotates the output shaft.
output shaft which is also in eccentric orbit The inside space of the housing, called (or
around the center point of the engine casing. A the trochoid chamber) is always divided into
phase gear mechanism dictates the orbit of the three working chambers. Due to the turning of
triangular rotor. The phase gear consists of an the rotor, those three working chambers are
inner-toothed gear ring fixed on the inside of always in motion and successively execute the
the rotor and an outer-toothed gear fixed on an four processes of intake, compression, ignition
eccentric shaft. If the rotor gear were to have (combustion) and exhaust inside the trochoid
30 teeth inside it, the shaft gear would have 20 chamber. Each process is carried out in a
teeth on its perimeter so the gear ratio is 3:2. different place in the trochoid chamber. This is
Due to this gear ratio, the rate of turning speed significantly different from the reciprocating
between the rotor and the shaft is defined as engine, where those four processes are carried
1:3. The rotor has a longer rotation period than out within each cylinder.
the eccentric shaft. The rotor rotates one turn The displacement volume of the rotary
while the eccentric shaft rotates three turns. engine is generally expressed by the unit
With the engine running at 3000rpm, the rotor chamber volume and by the number of rotors.
will run at a mere 1000rpm. For example, with the model 13B two-rotor
rotary engine, the displacement volume is
Comparison With the Reciprocating
shown as "654cc x 2".
Engine :
The unit chamber volume means the
In order to get the turning force, both the difference between the maximum volume and
reciprocating engine and the rotary engine rely the minimum volume of a working chamber,
on the expansion pressure created by the while the compression ratio is defined as the
combustion of the fuel-air mixture. The ratio between the maximum volume and the
difference between the mechanisms of the two minimum volume. The same definitions are
Principle of Generat ing Torque
engines is in the way that the expansion used for the reciprocating engine. In the figure
With the reciprocating engine, the expansion
pressure of the combustion gas is changed pressure is used. In the reciprocating engine, shown below, the changes of the working
to the turning motion through the the expansion pressure generated above the chamber volume of the rotary engine and the
connect ing rod and to the crankshaft. piston's top surface forces the piston down four-cycle reciprocating engine are compared.
While, with the rotary engine, through the
effect of the eccentric shaf t, the expansion
and the mechanical force is transferred to the Although, in both engines, the working
force directly turns the rotor and then the connecting rod that causes rotation of the chamber volume varies smoothly in a wave
rotor turns the eccentric shaf t. crankshaft. In the case of the rotary engine, shape, there are two distinctive differences
however, the expansion pressure is applied to between two engines. One difference is the
the flank of the rotor. One of the three sides of turning angle per process. The reciprocating
a triangle is forced oward the center of the engine turns 180 degrees while the rotary
eccentric shaft as a result. (PG in the figure). engine turns 270 degrees, one and half times
This movement consists of two divided that of the reciprocating engine. In other words,
forces. One being the force toward in the reciprocating engine, the crankshaft
the output shaft center (Pb in the figure) (output shaft) makes two turns (720 degrees)
and the other is the tangential force (Ft) during the four processes, while in the rotary
Compar ison w ith

Reciprocating Eng ine -2
The drawing here shows the volume
change of the working chamber along with
the working process, respectively for the
reciprocating engine and the rotary
engine. As seen here, the reciprocating
engine runs two turns while completing
the four processes, on the other hand, the
rotary engine runs three turns. When the
output shaf t speed is the same, the rotary
engine can spend more time for one
process than the reciprocating engine.
030
Structure and Working Principles of Rotary Engine
engine, the eccentric shaft (output shaft) makes exceeds the level of the V8 reciprocating
three turns (1080 degrees) while the rotor engine with three-rotor layout.
makes one turn. In this way, the rotary engine
has a longer process time, causes less torque Less V ibration and Low Noise
fluctuation and results in smooth operation.
Furthermore, even in high speed running, the With the reciprocating engine, piston motion
rotor's rpm is comparatively slower, thus, the itself could be a source of vibration, while the
more relaxed timing constraints of the intake valve acting system generates unwanted
and the exhaust processes facilitate the mechanical noises. The smooth turning
development of systems aimed at attaining motions of the rotary engine generate
higher performance. considerably less vibration and the absence of
a valve acting mechanism contributes to a
Unique Features of the Rotary smooth and quiet operation.
Engine :
Simple Structure
Small Size and Light Weight
As the rotary engine converts the expansion
The rotary engine has several advantages but pressure of the burnt mixture directly into the
the most important ones are reduced size and turning force of the triangular rotor and the
weight. Where the two-rotor layout is eccentric shaft, there is no need for connecting
considered equivalent to the inline six-cylinder rods. The intake and exhaust ports are opened
reciprocating engine in quietness and and closed by the rotor movement itself. The
smoothness of operation, the rotary engine can valve mechanism which include the timing belt,
be designed to be two-thirds of the weight and the camshaft, the rocker arm, the valve, the
size while achieving the same level of output. valve spring, etc. required in the reciprocating
This advantage is very attractive to automobile engine are not required and can therefore be
designers especially in light of the recent trends built with far fewer parts.
toward stricter requirements in crashworthiness
(collision safety), aerodynamics, weight Reliability and Durability
distribution and space utility thus putting the
rotary engine in spotlight once again. As mentioned before, the rotor turns at one-
third of the engine speed. Therefore, when the
Flat Torque Characteristics rotary engine runs at speeds of 7000 or
8000rpm, the rotor is turning one-third that
The rotary engine has rather flat torque curve rate. In addition, since the rotary engine doesn't
throughout the whole speed range and have such high-speed moving parts as rocker
according to the research results, the torque arms and conrods, it is more reliable and
fluctuations during operation are at the same duarable under high load operations. This was
level as the inline six cylinder reciprocating demonstrated by the overall win at the Le Mans
engine even with the two-rotor design and in 1991.
1 2
5 4
3
6
Major Components of the Rotar y Eng ine
The rotary engine need not a valve acting mechanism to
open and close the intake and exhaust port and, compared
12 with the reciprocating engine, is composed of much fewer
7
9 8 parts. The photo on the lef t shows the RX-7's type 13B-
REW twin-rotor unit d isassembled for reference. The
names of major components are: 1 side housing, 2 rotor
housing, 3 rotor, 4 eccentric shaft, 5 stationary gear, 6 f ly
wheel, 7 apex, side and oil seals, 8 intake
11 10 manifold, 9 exhaust manifold, 0 rotor housing assembly
volts, A turbocharger, B sealing rubbers
031
Mazda Rotary Engine: Chronological Table
Felix Wankel collaborated with NSU to promote his rotary engine Mazda's rotary engine car cleared the US 1975 emission
1951 1973.2
research and development standards, and this fact was confirmed by EPA test.
1957 Wankel/NSU built a prototype DKM rotary engine. Accumulative production of rotary engine cars reached
1973.6
500,000 units.
1958 Wankel / NSU built a prototype KKM rotary engine.
The Luce AP Grand Tourismo powered by 13B engine
1 9 7 3 .12
1959 Wankel completed the type KKM250 rotary engine. was introduced.
1960 Wankel / NSU tested their rotary engine in public. 1974.7 The Parkway Rotary 26 was introduced.
1961.7 Mazda made a technical contract with NSU and Wankel. 1975. 3 The Roadpacer was introduced.
1 9 6 1 .11 Mazda completed its own first prototype rotary engine. The Cosmo AP was introduced featuring a low emission
1 9 7 5 .10
rotary engine with 40% improved fuel-efficiency.
1963.4 Mazda organized Rotary Engine Research Department.
1978.3 The Savanna RX-7 was introduced.
A prototype sports car powered by a rotary engine is unveiled at
1964.9
the Tokyo Motor Show. Accumulative production of rotary engine cars reached
1 9 7 8 .11
1,000,000 units.
Mazda announced the completion of the rotary engine.
1967.5
The Cosmo Sport was introduced into the domestic market. 1 9 8 1 .10 The New Cosmo and Luce Rotary were introduced.
1968.7 The Familia Rotary Coupe was intoroduced. The RX-7 was face-lifted and the world-first turbo rotary
1983.9
engine model was added.
Mazda exported rotary engine cars for the first time (to Australia
1969.9
and Thailand). 1 9 8 5 . 10 The RX-7 was entirely redesigned.
The Luce Rotary Coupe (front-wheel-drive) was introduced. Accumulative production of rotary engine cars reached
1986.4
1 9 6 9 .10 Mazda's rotary engine car cleared the emission test by US Federal 1,500,000 units.
Government.
1986.9 The Luce was entirely redesigned.
Mazda was awarded by Japanese Mechanical Engineering Society
1970.4
for the commercialization of the rotary engine. The Eunos Cosmo debuted featuring the world's first
1990.4
three-rotor rotary engine (20B-REW).
Export of rotary engine cars to Europe (Switzerland) started.
1970.5
The Capela Rotary (powered by 12A unit) was introduced. The Mazda 787B achieved overall win at the 59th Le
1991.6
Mans 24 Hours race.
1970.6 Export of rotary engine cars to the United States started.
The RX-7 was completely redesigned (with a 255PS
1 9 9 1 .10
Accumulative production of rotary engine cars reached 13B-REW unit).
1 9 7 0 .12
100,000 units.
The RX-01 concept car (powered by a type MSP-RE
1 9 9 5 .10
1971.9 The Savanna Rotary was introduced. experimental engine) was unveiled at the Tokyo Motor Show.
1 9 7 1 . 10 Accumulative production of rotary engine cars reached 200,000 units. The RX-7 was face-lifted (engine output increased up to
1996.1
265PS).
The Capela Rotary Coupe completed 100,000km endurance run,
1972.1
through eleven European countries and with its engine fully sealed. The RX-7 was face-lifted (engine output increased up to
1 9 9 8 .12
280PS).
The first series production car with full emission control package,
1 9 7 2 .10
the Luce Rotary was introduced. The RX-EVOLV concept car with the RENESIS
1 9 9 9 .10
experimental engine was unveiled at the Tokyo Motor Show.
032

Rotary e PDF

Uploaded by

Copyright:

Available Formats

Rotary e PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Rotary e PDF

Uploaded by

Copyright:

Available Formats

Press Information October, 1999

As the sole automobile manufacturer in the world that produces rotary

(1) Innovations for Higher Output

for the Next Millennium as large, improving flow characteristics.

(2) Innovations for

Side Exhaust Peripheral Exhaust

Intake Air Shutter Valve

Trochoid Trochoid Rotor Weight

(3) Innovations for Lower Emission Mazda's Rotary Engine

(4) Other Innovations

The Latest Version of Mazda's Series Production

Improved Efficiency and Ultra-High-Flow Turbine adopted on

Adoption of Abradable Seal

Abradable Seal Compressor Housing

Increase in Air Flow Area

Improvement in Lubrication System

New Design Old Design

Reduced Exhaust Resistance

Increased Exhaust Area by the Reduced Resistance in the Silencer

Major Specifications of the 13B-REW Engine

1000 2000 3000 4000 5000 6000 7000

When NSU/ Wankel announced the completion of the rotaty engine,

Dream of Young Wankel research and development of the rotary

In search of Ideal Engine the department, 47 engineers in four

RE Research Depart ment

In 1963, Mazda organized a

air-mixture injectors, underwent further stronger exhaust pulse caused by the

Familia Rotary / Mazda R100 (1968~1973)

Luce Rotary Coupe / Mazda R130 Coupe (1969~1972)

Capella Rotary / Mazda RX-2 (1970~1978)

Savanna / Mazda RX-3 (1971~1978)

Luce Rotary / Mazda RX-4 (1972~1977)

The specifications are all for the original models.

Parkway Rotary 26 (1974~1976)

Cosmo AP / Mazda RX-5 (1975~1981)

Luce Legato / Mazda 929L (1977~1980)

Savanna RX-7 / Mazda RX-7 (1978~1985)

The specifications are all for the original models.

Luce / Mazda 929 (1981~1986)

Savanna RX-7 / Mazda RX-7 (1985~1992)

Luce Rotary (1986~1991)

Eunos Cosmo (1990~1995)

Mazda RX-7 (1991~ )

The specifications are all for the original models.

To demonstrate the high performance and reliability of the rotary

in the World Sports-Car Races

Eccentricity e Generating Radius R

Pr incipl e of Per itrochoid Cur ve : Comparison wit h Reciprocating Engine-1

Compar ison w ith

You might also like