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HEAVY DUTY GREEN TRUCKS

HEAVY DUTY GREEN TRUCKS. TRIAD MOBILE CARE TRIAD AIR AWARENESS 10-15-2009. DAVE NAVEY GREEN TRUCK SPECIALIST CHARLOTTE TRUCK CENTER 704-968-0145. POINTS OF INTEREST. ELECTRIC HYBRIDS HYDRAULIC LAUNCH ASSIST (HLA) HYBRIDS. ELECTRIC HYBRID. Fleets Reduce operating (fuel) cost

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HEAVY DUTY GREEN TRUCKS

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  1. HEAVY DUTYGREEN TRUCKS TRIAD MOBILE CARE TRIAD AIR AWARENESS 10-15-2009 DAVE NAVEY GREEN TRUCK SPECIALIST CHARLOTTE TRUCK CENTER 704-968-0145

  2. POINTS OF INTEREST • ELECTRIC HYBRIDS • HYDRAULIC LAUNCH ASSIST (HLA) HYBRIDS

  3. ELECTRIC HYBRID Fleets • Reduce operating (fuel) cost • Green image • Improve operating environment (i.e. quieter, lower emissions) • Reduce carbon footprint (if mandated) Government • Improve air quality • Reduce GHG emissions (Global Warming) • Reduce dependence on foreign oil Manufacturer • Competitive product offering to maintain and grow market share • Environmental stewardship and industry leadership

  4. HYBRID APPLICATIONS

  5. CONCEPT Series / Parallel system allows engine only, motor only or engine-motor combination operation During “motor only” operation diesel engine is at idle with clutch depressed. Engine powers the ancillary systems & motor is used to move truck. Engine does not shut off when stopped as hybrid autos do.

  6. CONCEPT During deceleration, the clutch disengages the engine & the motor becomes a Generator. The inertia of the moving truck is turned into electrons and is stored in the battery. “Plug-In” option is available.

  7. MAJOR COMPONENTS POWER ELECTRONICS CARRIER (PEC) DIESEL ENGINE HYBRID DRIVE UNIT AC/DC INVERTER HYBRID COOLING SYSTEM DC/DC CONVERTER ePTO ONLY 5 kW APG (OPTIONAL)

  8. EPA 07 CUMMINS ISB ENGINE Power 200 to 300 hp + 60 hp hybrid peak vs 260 to 330 hp for ISC Torque 520 to 660 ft-lb + 310 ft-lb hybrid peak vs 660/800/860/1000 for ISC Weight 500 lbs lighter, offsets hybrid weight Biodiesel compatible up to 20%

  9. HYBRID DRIVE UNIT (HDU) • Includes electric generator/motor and Ultra-shift transmission • Rated for 35 continuous hp, 60hp and 310ft-lb peak • Liquid cooled on separate circuit • Supplies regenerative power (under braking) to PEC • Provides power for vehicle launch/driving • Primary engine starter • Provides ePTO power with engine off (for ePTO option) • Factory installation similar to normal powertrain

  10. MOTOR / GENERATORTRANSMISSION MOUNTING LOCATION

  11. HOUSING WITH MOTOR REMOVED

  12. STATOR / ROTOR ASEM3 PHASE A/C MOTOR GENERATOR

  13. A/C POWER CABLE CONNECTIONDATA BUS CONNECTION

  14. Power Electronics Carrier (PEC) The PEC is a two-piece plastic shell, with reinforced steel frame. Air-cooled unit with replaceable air filter. Contains two 170-volt lithium ion batteries connected in series, operating at 340-volts DC . PEC weight is approximately 220lbs. Mounting location can vary depending on application and body builder.

  15. Cooler DC/DC Converter Inverter M2e Hybrid - Cooler/Inverter • Hybrid system uses separate liquid cooling system for the high power electronics • Inverter controls the entire high-voltage system and converts 340V power between AC (motor) and DC (battery) • Location Under cab • Inside frame rail LH side • Benefits • Clear back of cab • No wheelbase impact • Supports duel fuel tank options • Day, Extended, and Crew Cab • Works with 2010 engines • RH PTO open

  16. DC/DC Converter Utility truck applications only. Converts Hybrid DC high-voltage to maintain vehicle 12-volt system in ePTO mode DC converter function is controlled by Hybrid Control Module. Unit is liquid cooled.

  17. GEAR SELECTOR Gear displays are located in the dash of the vehicle and are supplied by Freightliner. “Check Hybrid” and “Stop Hybrid” warning lights are also supplied by Freightliner and notify the driver of problems with the Hybrid system. The Push Button Shift Control unit is supplied by Eaton and is available in two different configurations: City Delivery and Utility (pictured).

  18. DUKE ENERGY • M2-106 straight truck • GVW – up to 40K • Cummins ISB – 200 to 300hp / 520 to 660 ft-lb • Eaton Parallel Electric Hybrid Drive – 60hp/310 lb-ft peak • 6 speed Ultrashift transmission • Air Brakes • Performance (dependent on stationary PTO usage) • Fuel Economy Improved 40% - 60% • Idle Time Reduced by 4 / 5 Hours per Day • CO2 Output Reduced 13 to 17 Tons/Year • Financial: • Federal Tax Credit • Class 6 = $6K • Class 7 = $12K • Annual savings $4,500 to $6,000

  19. Electric Refrigerated Van Freightliner M2e Hybrid Eaton Hybrid 5kW APG • Reduce • Fuel Consumption • Maintenance • Noise • Weight • Emissions Aura Systems Oasis Electric

  20. SUMMARY • Works best with stationary, PTO operation, applications • Series / Parallel system allows engine only, motor only & engine / motor combination operation • 20% - 60% better fuel economy • Reduces emissions of NOx, particulates, & CO2 • Provides more torque for quicker acceleration & more pulling power • Greatly increases brake life & extends engine life

  21. Hydraulic Hybrid (HLA) Hydraulic Launch Assist

  22. HLA OPERATION KINETIC: WORKING, MOVING ENERGY

  23. HLA OPERATION POTENTIAL: STORED, NON MOVING

  24. HLA OPERATION MOVEMENT OF ENERGY CAPTURE RELEASE

  25. HLA COMPONENTS PUMP/MOTOR RESERVIOR TRANSFER CASE DRIVE SHAFT COUPLING RADIATOR HIGH-PRESSURE ACCUMULATOR

  26. ENERGY CONSUMPTION BY TRUCKS STARTING NEUTRAL STOPPING

  27. BRAKING During braking, the trucks momentum drives the pump/motor as a pump, transferring hydraulic fluid from the low-pressure reservoir to the high-pressure accumulator.

  28. PRESSURAZITION The hydraulic fluid compresses nitrogen gas in the accumulator and pressurizes the system to a maximum pressure of 5,000 PSI. The regenerative braking captures about 70% of the KINETIC energy produced during braking & turns it into POTENTIAL energy.

  29. REDUCED BRAKE WEAR Capturing 70% of the braking energy with the hydraulic fluid can reduce brake wear by more than 50%. The HLA system prevents service brake application till just before a complete stop. Heavy refuse trucks may need 2 or more brake jobs per year. This system could stretch the life of one brake job to well over 1 year. An average brake job may cost $3500.00 x twice per year X 8 years service life = $56,000.00 One brake job every year x 8 years service life = $28,000.00 $28,000.00 savings through reduced brake wear over 8 years

  30. LAUNCH ASSIST During acceleration, fluid in the high-pressure accumulator is metered out to drive the pump/motor as a motor. The system propels the vehicle by transmitting torque to the driveshaft. 2 LAUNCH MODES AVAILABLE

  31. ECONOMY MODE When the Hydraulic Launch Assist System is operating in Economy Mode, the energy stored in the accumulator during braking is used alone to initially accelerate the vehicle. Once the accumulator has emptied, the engine will begin to perform the acceleration. This process results in increased fuel economy. Economy Mode Savings Increased fuel economy of 30% Increased acceleration of 2% Economy mode allows for maximum fuel savings & Maximum exhaust emission reductions of 20% to 30%

  32. PERFORMANCE MODE In Performance Mode, acceleration is created by both the energy stored in the accumulator and the engine. Once the accumulator has emptied, the engine is completely responsible for acceleration. While fuel economy improvements are seen in Performance Mode, the greatest benefit is increased productivity Performance Mode Savings Increased fuel economy of 17% Increased acceleration of 26% Performance mode allows for faster cycle times, More stops per day, & greater productivity

  33. SPECIFICATIONS • Mass of HLA System 1250 lb • Max Pressure 5000 psi • Total System Oil Volume 21 gallons • Torque 2550 ft-lb • Active Speed Range Up to 25 mph • Minimum Wheelbase 191” (single) 215” (tandem)

  34. SUMMARY • Works best with high stop & go duty cycle applications • Parallel system allows normal vehicle function when HLA is offline • 15-30% better fuel economy • Reduces emissions of NOx, particulates, & CO2 • Provides more torque for quicker acceleration & shorter cycle times • Greatly increases brake life, More than double the life • Extends service intervals for engine & transmission.

  35. NATURAL GAS (another day)

  36. THE FUTURE IS NOW

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