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Hybrid Technical Overview

Hybrid Technical Overview . This is a big deal! $ 1.45 + fuel & over $128 per barrel of oil US Supreme Court decision on green house gases EPA must now regulate CO2 21 States already with emissions or Green House Gas Legislation Platforms of the Future Must Save Fuel

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Hybrid Technical Overview

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  1. Hybrid Technical Overview

  2. This is a big deal! • $1.45 + fuel & over $128 per barrel of oil • US Supreme Court decision on green house gases • EPA must now regulate CO2 • 21 States already with emissions or Green House Gas Legislation • Platforms of the Future • Must Save Fuel • PLUS: 2010 Emissions Technology

  3. Emissions Reductions SULFUR Content In Fuel ASH/Sulfur Content In Oil 1994 Note: 2007 diesel emissions really does not impact green house gases or CO2 . The reduction is in NOx and PM.  The only way to reduce CO2 emissions in any magnitude is to not to burn the fuel.  5.0 Ash 1.5% 500 PPM (6/93) 1998 Sulfur .8% 4.0 NOx (g/hp-hr) 2002/2004 2.5 2007 Ash 1.0% 1.2 ULSD 15 PPM (6/06) Sulfur .4% 2010 0.2 0.0 PM (g/hp-hr) 0.0 0.01 0.10

  4. Why Hybrid Trucks? Impacts on the future of diesel transportation Environmental issues Energy issues Fuel efficiency Climate change Clean air Up to 60% more fuel economy with e-PTO

  5. What Makes The System Work? Eaton Hybrid Electric Power Train - Hybrid drive system components International® Diamond Logic ® Electrical System - Complete electronic vehicle integration - Optimization body of functions

  6. Fully Integrated Chassis &Body

  7. Standard Controls Controls minimize operational differences for the operator Non- Hybrid Standard Controls Hybrid Standard Controls

  8. Full J-1939 Communications - entire vehicle Full diagnostics & system communication Optimization of e-PTO system w/engine off Fuel economy – system time-outs Chassis body equipment interlocks Protect equipment Protect operators Body equipment customization • Hybrid Chassis and Body Integration Diamond Logic® is the key to body / chassis integration.

  9. Customers • Companies with “green” corporate culture • Food service, beverage, pickup & delivery • Customers impacted by legislation • All Governments, non-attainment cities, Utilities • Early “leading edge” technology adaptors • Change agents (electrification of the reefer)

  10. Utility Truck Emissions Reduced** Over the Road Over the road & Worksite Ops Engine off work-site Fuel Saved – Emissions Reduced On 2006 Emissions Engines Dollars & Gallons of Fuel Saved Annually $690 *1 523 lt 20,000 kms Hybrid Car* ~ 2300 – 3400 lt Saved 6.6 – 9.9 Tons of CO2 Reduced ~ $2,500 to $3,800*2 32,000 kms P&D ~ 3800 – 5700 lt Saved 11 – 16.5 Tons of CO2 Reduced 3 hrs / day Work-site Ops 20,000 kms ~ $5500 to $8300*2,3 ~ 4550 – 7200 lt Saved 13.2 – 21 Tons of CO2 Reduced Utility 6 hrs / day Work-site Ops 15200 kms ~ $6,600 to $10,500*2,3 *1Assume $3.52 gal; 21mpg; 30% improvement *2$1.45 fuel *3 Assume baseline: 7.5 mpg & 1.18 gph idle ** Based on independent 3rd party testing P&D – 30-50% fuel economy improvement Utility – 40-60% fuel consumption reduction

  11. Fuel Economy Improvements • Keys to improvements • Intercity application critical (Duty Cycle) • Regenerative braking • Idle reduction • Expectations • 30 to 60% fuel economy improvement • Reduced emissions • Reduced maintenance • Bio-diesel approved (B-20) The only way you can reduce greenhouse gases is to not burn the fuel!

  12. Application Coverage • 23,500 to 33,000 GVW • Base System • Van applications • Beverage • Armored car • Pickup & delivery • Stake flat • Shuttle bus • e-PTO System • Utility (Aerial / Service) • Tree aerial bucket • Crane • Recovery vehicle

  13. Primary Hybrid Components • Maximize payload weight and space • ~450 lbs. additional weight over a non-hybrid equipped chassis DC/DC Converter Power Electronics Carrier (Battery Box) Motor Inverter/Controller Hybrid Drive Unit (HDU)

  14. Hybrid System Component Location Hybrid Drive Unit 12VBatteries Controller/Inverter & DC/DC Converter Hybrid SystemHeat Exchanger PEC(Hybrid Batteries) Hybrid CoolingReservoir

  15. 52” 13” 20” Temporary Mount Power Electronics Carrier (PEC) Hybrid High Voltage Batteries

  16. Power Electronics Carrier (PEC) Hybrid High Voltage Batteries Chassis(12 volt Batteries)

  17. Traditional Drivetrain ENGINE HP T + Same Vehicle Torque Output kW + kW kW kW Hybrid Drivetrain engine hp T Motor/Generator Mild Parallel Hybrid System Pre-Transmission

  18. 0-60 Acceleration 9 seconds faster to 60 mph at full throttle

  19. System Description andOperating Modes

  20. Hybrid System Diagram DC/DC Converter Motor Controller/Inverter Fuller AutomatedTransmission (AMT) Hybrid Electric Motor Electric Clutch 120AC/60HzPower Panel Auxiliary Power Generator (AGP) Inverter Power Electronics Carrier (PEC) Lithium Ion Batteries Battery Controls

  21. Direct Hybrid – Engine Starting Mode Motor Controller/Inverter Fuller AutomatedTransmission (AMT) Hybrid Electric Motor Auto Clutch Engaged Engine Power Electronics Carrier (PEC) Lithium Ion Batteries Battery Controls

  22. Direct Hybrid – Electric Only Mode Motor Controller/Inverter Fuller AutomatedTransmission (AMT) Hybrid Electric Motor Auto Clutch Engaged Engine (Idle) Drive Torque Discharge Mode Power Electronics Carrier (PEC) Lithium Ion Batteries Battery Controls

  23. Direct Hybrid – Engine & Motor Drive Mode Motor Controller/Inverter Fuller AutomatedTransmission (AMT) Hybrid Electric Motor Auto Clutch Engaged Engine Torque Discharge Mode Power Electronics Carrier (PEC) Lithium Ion Batteries Battery Controls

  24. Direct Hybrid – Engine Only Mode Motor Controller/Inverter Fuller AutomatedTransmission (AMT) Hybrid Electric Motor Auto Clutch Engaged Engine Torque Charging Mode Optional Power Electronics Carrier (PEC) Lithium Ion Batteries Battery Controls

  25. Direct Hybrid – Braking/Regeneration Mode Motor Controller/Inverter Fuller AutomatedTransmission (AMT) Hybrid Electric Motor Auto Clutch Engaged Engine Torque Charging Mode; Regen Braking Power Electronics Carrier (PEC) Lithium Ion Batteries Battery Controls

  26. Auxiliary Power Generation (APG) Update • Drives AC loads from hybrid battery source • 260-434V DC to 120V AC at 5 KW (6KW peak) • 3 x individually GFCI-protected duplex outlets • Two-part design enables flexible mounting • IP67 for chassis mounting • Liquid cooled

  27. Direct Hybrid – Engine off e-PTO & APG Motor Controller/Inverter Fuller AutomatedTransmission (AMT) Hybrid Electric Motor Auto Clutch Engaged Engine Auxiliary Power Generator(APG) Discharge Mode Power Electronics Carrier (PEC) Lithium Ion Batteries Battery Controls

  28. Direct Hybrid – Engine on e-PTO & APG Motor Controller/Inverter Fuller AutomatedTransmission (AMT) Hybrid Electric Motor Auto Clutch Engaged Engine (Idle) Auxiliary Power Generator(APG) Charge Mode Power Electronics Carrier (PEC) Lithium Ion Batteries Battery Controls

  29. Diamond Logic® Builder Equipment up-fitters must be minimum DLB Level 2 certified to further improve HEV efficiency for any hybrid parameter or software modification using International’s DLB. e-PTO System m-PTO System

  30. Hybrid Launch • Completed test validation • Beverage Van unit in service for more than 2 years • 37% improvement in fuel economy with 97% uptime • 24 HTUF units running for better than 3 years • 27 additional units built with 2006 engines • Positive results to date + 1.5 million miles • 49 units built with 2007 engines • Additional orders in-house

  31. Eaton Hybrid Warranty • Standard warranty - 3 years / 240,000 kms • Includes base transmission and Eaton-supplied hybrid system* *Cooling portion of system International Truck & Engine-supplied • 5 year extended warranty coverage - coming

  32. Hybrid Life Cycle Costs 5 Year Projected Maintenance • PEC requires air filter changes every 4-6 months - $15.00 (retail) X 10 = $150.00 • Transmission oil (E500 synthetic lube) - No change required for 800,000 kms* Grease Zerk through inspection cover for upper clutch cross shaft roller bearing *Rugged applications require oil change at 2,000 hours or 5 years.

  33. Battery Life Expectancy • Current life projection 6-8 years • Strongly dependant upon application, duty cycle • Continued focus on • PEC serviceability • Component exchange program • Reman program

  34. Top Ten Reasons To Choose 1. Reduces fuel consumption 2. Reduces emissions and green house gases 3. Assembly line production of HEV System 4. Over 2 years of in-service testing of system across North America 5. Complete HEV vehicle system warranty from one source 6. Improved corporate “green” social image 7. Assistance to body builders to integrate and advantage hybrid system 8. Enhance vehicle performance and productivity 9. Fully integrated engine, transmission and vehicle electronics 10. International dealer service network support

  35. How Do You Identify A Hybrid? • Vehicle displays “Hybrid” on the outside • Dashboard shift label displays “Eaton Hybrid” • Presence of bright orange high voltage cables • Watch for the new TSI-08-10-Hybrid

  36. How Do You Identify A Hybrid?

  37. How Do You Identify A Hybrid? Shift Label on “doghouse” inside cab

  38. How Do You Identify A Hybrid? Orange High Voltage Cables

  39. High Voltage Components Motor/Generator Always located between engine flywheel and transmission

  40. High Voltage Components Inverter located on left side on frame rail

  41. High Voltage Components • Power Electronics Carrier - Standard location on left side on frame rail Can be mounted on body equipment

  42. High Voltage Components DC/DC Converter (e-PTO) - Located on left side on frame rail

  43. Emergency Procedure Shutdown • Preferred Option – Turn off ignition key • High-voltage batteries still alive but isolated in PEC • Option 2 – Disconnect low voltage 12V batteries • High-voltage batteries still alive but isolated in PEC • Option 3 – Push in “Service Switch” on PEC • Shuts down engine • High-voltage batteries still alive but isolated in PEC After the vehicle is disabled, power is maintained up to 5 minutes in the high-voltage electrical system.

  44. Do’s • Always assume vehicle is “live.” • Always perform one of three Emergency Shutdown Procedures. • Before working on the vehicle, allow vehicle to sit for 5 minutes.

  45. Don’ts • Never work on the vehicle if Emergency Shutdown Procedures are not complete. • Never work on vehicle if the vehicle hasn’t set for five minutes. • Never cut orange high-voltage cables. • Never cut into or open • Inverter • PEC • DC/DC Converter

  46. Vehicle towing and jumpstarting

  47. Thank You!

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