hybrid chassis overview - the national center for …€¦ · · 2010-12-01hybrid chassis...
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Hybrid Chassis OverviewHybrid Chassis Overview
October 7, 2010October 7, 2010
Jim Pare’Jim Pare’Vocational Sales ManagerVocational Sales Manager-- Product IntegrationProduct Integration
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Corporate Responsibility
•Reduced dependence on fossil fuels
•Reduction in green house gases
–CO2 Emissions–CO2 Emissions
•Use of alternative fuels
•International’s® Green Diesel Hybrid Technology
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4.04.0
5.05.0
1998
2002/2004(g/hp
(g/hp--h
r)
hr)
500 PPM500 PPM(6/93)
SULFURSULFURContentContentIn FuelIn Fuel
1994
ASH/SulfurASH/SulfurContentContentIn OilIn Oil
AshAsh1.5%1.5%
SulfurSulfur.8%.8%
Emissions Reductions
0.010.01 0.100.10
0.20.2
1.21.2
2.52.5 2002/2004
2007
20100.00.0
0.00.0
NOx
NOx (g/hp
(g/hp
PM PM (g/hp(g/hp--hr)hr)
ULSDULSD15 PPM15 PPM(6/06)
AshAsh1.0%1.0%
SulfurSulfur.4%.4%
The only way to reduce CO2 emissions Green House Gases in any
magnitude is to not to burn the fuel.
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Fuel Economy Improvements
• Keys to improvements
– Intercity application critical (Duty Cycle)
– Regenerative braking
– Idle reduction
• Expectations• 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!
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• Three day total fuel economy
improvement over the base is 40%.
Real World Customer Fuel Economy
improvement over the base is 40%.
• The expected fuel economy percent
improvement to fall between 25%
and 45% over all duty cycles on
any given day.
• The overall Average FE% will be
about 35%.
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Primary Hybrid Components
• Maximize payload weight and space
– Additional weight of hybrid related components is ~450 lbs.
– 300 lbs. to the front axle
DC/DC Converter liquid
cooledPower Electronics
Carrier (Battery Box) air
cooled
Motor Inverter/Controller liquid
cooledHybrid Drive Unit (HDU)
liquid cooled
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Traditional Drivetrain
ENGINE
HPT
kW+
kWkWkW
+Same Vehicle
Motor/Generator
Tengine
hp
kWkW+
Hybrid Drivetrain
Same Vehicle
Torque Output
Mild Parallel Hybrid System PreMild Parallel Hybrid System Pre--Transmission Transmission
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0-60 Acceleration
40
50
60
70
Speed, mph
Baseline A
HEV
0
10
20
30
40
0 10 20 30 40 50 60
Time, s
Speed, mph
9 seconds faster to 60 mph at full throttle
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Hybrid Maintenance • PEC requires air filter inspection every 4-6 months
• Transmission oil is E500 synthetic lube, 500,000 miles or five years recommended
Remove the four cover bolts to
inspect the Air Filter
• Transmission oil is E500 synthetic lube, 500,000 miles or five years recommended
service interval
Add a couple of pumps of Grease for upper
clutch cross shaft roller bearing through
the Grease Zert located at the clutch
inspection cover during routine
maintenance inspections
Verify transmission oil level during normal
maintenance inspections
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Eaton Hybrid Warranty• Standard warranty - 3 years / 150,000 miles
– Includes base transmission and Eaton supplied Hybrid system*
*Cooling portion of system International Truck & Engine supplied
• Extended Warranty Coverage additional 2 years / 50,000 miles
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Battery Life Expectancy
• Current life projection 6-8 years
• Strongly dependant upon application, duty cycle
– Continued focus on
• PEC serviceability
• Component exchange program
• Re-man program under consideration by Eaton
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Hybrid Operating Modes
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Fuller Automated
Transmission (AMT)
Hybrid Electric
Motor
Electric Clutch
Motor Controller/Inverter
DC/DC Converter
Hybrid System Diagram
120AC/60Hz
Power Panel
Auxiliary Power Generator
(AGP) Inverter
Power Electronics Carrier (PEC)
Lithium Ion Batteries
Battery Controls
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Fuller Automated
Transmission (AMT)
Hybrid Electric
Motor
Auto Clutch
Engaged
Motor Controller/Inverter
Direct Hybrid – Engine Starting Mode
Power Electronics Carrier (PEC)
Lithium Ion Batteries
Battery Controls
Engine
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Fuller Automated
Transmission (AMT)
Hybrid Electric
Motor
Auto Clutch
Engaged
Motor Controller/Inverter
Direct Hybrid – Electric Only Mode
Power Electronics Carrier (PEC)
Lithium Ion Batteries
Battery Controls
Engine
(Idle)
Drive Torque
Discharge Mode
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Fuller Automated
Transmission (AMT)
Hybrid Electric
Motor
Auto Clutch
Engaged
Motor Controller/Inverter
Direct Hybrid – Engine & Motor Drive Mode
Power Electronics Carrier (PEC)
Lithium Ion Batteries
Battery Controls
Engine
Torque
Discharge Mode
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Fuller Automated
Transmission (AMT)
Hybrid Electric
Motor
Auto Clutch
Engaged
Motor Controller/Inverter
Direct Hybrid – Engine Only Mode
Power Electronics Carrier (PEC)
Lithium Ion Batteries
Battery Controls
Engine
Torque
Charging Mode Optional
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Fuller Automated
Transmission (AMT)
Hybrid Electric
Motor
Auto Clutch
Engaged
Motor Controller/Inverter
Direct Hybrid – Braking/Regeneration Mode
Power Electronics Carrier (PEC)
Lithium Ion Batteries
Battery Controls
Engine
Torque
Charging Mode; Regen Braking
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Optional Onboard APG(Auxiliary Power Generation)
Drives AC loads from hybrid battery source
Confidential Business Information
Outside the Frame RailInside the Frame Rail
60AKD Inside Rail 60AKE Outside Railliquid cooled
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Optional Onboard A/C Power
• 60AKD Inside
– Liquid Cooled
– With GCFI Plugs
• 60AKE Outside Rail
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Fuller Automated
Transmission (AMT)
Hybrid Electric
Motor
Auto Clutch
Engaged
Motor Controller/Inverter
Direct Hybrid – Engine off e-PTO & APG
Power Electronics Carrier (PEC)
Lithium Ion Batteries
Battery Controls
Engine
Discharge Mode
Auxiliary Power Generator
(APG)
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Fuller Automated
Transmission (AMT)
Hybrid Electric
Motor
Auto Clutch
Engaged
Motor Controller/Inverter
Direct Hybrid – Engine on e-PTO & APG
Power Electronics Carrier (PEC)
Lithium Ion Batteries
Battery Controls
Engine
(Idle)
Auxiliary Power Generator
(APG)
Charge Mode
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Exhaust after treatment options:
�RH horz/horz,
�RH under cab horz,
�RH horz./vertical tailpipe
Cruise control availability
Vanity covers the PEC Hybrid Batteries
Production Released
Vanity covers the PEC Hybrid Batteries
Vehicle feature requirements:
�Air brakes
�22.5” Wheels
�On/off fan drive
�Up to 39,000 GCWR
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Application Coverage23,500# to 39,000# GVW
• Base System
�Pickup & Delivery
�Landscape Dump
�Shuttle Bus
�Beverage
�Stake Flat
�Armored Car�Armored Car
�Expediter�Tractor (55,000# GCW)
• ePTO System
�Utility/Aerial Bucket
�Tree Trimmer / Crane /Grapple
�Recovery Vehicle
�Road Patch Truck
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Dump – Spreader
•33,000 GVWR
2
Travel Crew Cab
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Wrecker Roll-Off
•Engine-Off operation with ePTO
2
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Grapple Loader•Waste Collection
•With ePTO
2
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Crane Truck Application
•With ePTO
3
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• Remote Mount PEC
– Temporary Mount
– 10 foot Power Cable
– Clean CA
Expanded Chassis Options
3
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• Beverage Body
– Drop Frame
– Vertical Exhaust
– Air Dryer
– Remote Mount PEC
– Air Ride Cab
Expanded Chassis Options
3
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• Travel Crew Cab
– Cab Air Ride Suspension
Expanded Chassis Options
3
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WorkStar 4x4
•Meritor AWD System
•Limited Release
• Utility
3
• Utility
• Standard Cab Only
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Beverage Tractor•Now available
•255 HP / 660 lb. ft.
•Tractor packaging
•395 mm clutch
Expanded Chassis Options
3
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Expanded Chassis Options
• Auto Therm 60ADA– Engine “off” heating
• DLB template added to hybrid chassis for a true off signal
– 70° F cab heat for 11/2 hours with 32° F outside ambient temperature with
MaxxForce DT
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2010 Hybrid Engine Ratings
215HP/560ft-lb215HP/560ft-lb
230HP/620ft-lb
250HP/620ft-lb
260HP/660ft-lb
SCR
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Hybrid Product Enhancements - Update•Driver’s Display
•Prototype software complete
•Production targeted for late summer 2009
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Future Opportunities •Electrification of Reefer
•Hybrid Route Max “H” w/Johnson
Truck Bodies Cold Plate
•Thermo King
•Carrier with the Oasis System
• Expanding Application Integration
with the Hybrid
• Higher GVWR / GCWR’s
• Electric HVAC Systems
• Hydraulic Brakes
•Higher Engine Horsepower
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40Thank You Thank You