View
1.800
Download
3
Category
Preview:
Citation preview
EMP’s Mini-HybridTM Thermal System for Transit Bus Market
Go Green & Save Money with EMP’s MiniHybrid system
Marcus Jackson West Coast Regional Sales/Service Manager
Established 1981 Current Employment ~400 Precision Machining Facility, Escanaba, MI Robotic Assembly Facility, Greenfield, IN Engineering, Validation, Assembly Facility, Escanaba, MI (Mini-Hybrid Production) TS and Six Sigma certified
Current OEM Customers:
Caterpillar, International, Sauer Danfoss, John Deere, Cummins, DDC/Freightliner, Volvo/Mack, Paccar, Eaton, Newflyer, Gillig, NABI, Orion, El Dorado
Major Markets: Defense, On Highway, Off Road, Hybrid Vehicles, Transit
Key Awards: 2001 Michigan Manufacturer of the Year, 2005 R&D Excellence in Business Award The EMP Mini-Hybrid received the prestigious 2008 "Clean Air Excellence" Award from United States Environmental Protection Agency.
Company Overview
Mini-HybridTM
The Mini-HybridTM is an electric cooling system kit that replaces the standard hydraulic cooling system on transit buses.
Converting to an electric cooling system: • Increases fuel economy • Lowers emissions • Lowers maintenance costs • Increases horsepower • Reduces the risk of hydraulic fires
Over 3,000 Units in Field across North America
• Over 3,000 MINI-HYBRIDTM Electric Cooling Systems in Service. • Serving 70+ Municipal Transits in North America every day. • MH kits on 18 of top 20 transit properties. • Shipping 60+ MINI-HYBRIDTM Thermal Systems week.
Base Kit of the Mini-Hybrid
Fil-11 Electric Fans
Optimized Radiator and CAC
Components included in Mini-Hybrid Base Kit: • (8, 9, or 10) EMP Fil-11 24 Volt Pusher Fans • (1) EMP TMC Master Controller • (1) Aluminum Radiator • (1) Aluminum Charge Air Cooler • (1) Powder coated Steel Frame & Fan Shroud • Jacket Water & Charge Air Temperature Sensors • Wiring Harness • Installation mountings and hardware • P450 Air cooled 450 amp alternator • Power Steering Pump-optional • All metal piping to engine-optional • Downloadable Service Tool • Made in America
TMC Fan Controllers
P-450 Alternator
• Brazed aluminum bar/plate construction on both radiator and CAC is much stronger than conventional tube fin copper/brass heat exchangers
• Cross-flow configuration • Welded tanks eliminate
tank to header leaks • Pressure cycle test
– 200 PSI for 15,000 cycles
Heat Exchangers
Bar & Plate Design
Features the competition doesn’t offer
Integrated Controlled Fans
• Fully controllable or single speed • Locked Rotor Protection
• Sealed & Fully Submersible
• 12 or 24 Volt Models
• Brushless, Sensorless Motor
• Programmable Reversal
• Temperature Switch Input
• Closed Loop Temperature Control
• Pusher or Puller Configurations
• Integrated Controller
• Motor and Controller Diagnostics
• Finger Guard Option Available
• E-Mark Certified
Features:
Features the competition doesn’t offer
Power 450amp Air Cooled Alternator
• EMP’s air cooled, brushless Power 450 comes standard with the min-Hybrid cooling system
• Designed to last: filter-less air cleaning system, oversized bearing design, highest efficient alternator on the market
• Drop in replacement • Keeps your batteries fully
charged at idle and extends life
Brushless Alternator Comparison
150
200
250
300
350
400
450
500
550
1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
Alternator, RPM
Cur
rent
, Am
ps
Power 450
Competitor A
Competitor B
Competitor C
• Most transit buses operated at idle and low speeds
– Power 450 provides Best in Class amperage output in these speed ranges
EMP Components: Testing & Validation
– HALT/FMVT Highly Accelerated Life Testing
Failure Mode Verification Testing – Thermal Fatigue – Thermal Shock – High Pressure Wash – Fluids Compatibility – Salt Spray – Dust – Submersion – Humidity – Vibration – Operational Shock – Transit Drop – Handling Drop – Cycling – EMI/EMF – Durability
In transit applications fans operate at max speed less than
2% of the time
Fans are tested at Max-Speed/ Max-Hi Temp
Competitors have not been
able to pass vibration testing
How it works 4/6 Fan Control
Speed of Top 2 Fans Controlled by CAC or Intake Manifold Temp
Speed of Bottom 4 Fans Controlled by Jacket Water Temp Baffle Locations
2
1 3
4
5
6
7
8
CAC
Radiator
Speed of Shared 2 Fans Controlled by Highest Speed Command (CAC or JW Temp)
• Fans Consume Energy Only if Needed • Variable Speed Fans Run At Low Speed
Coolant Fan Speed Control - Cummins ISB/C/L/X -
Coolant Temperature
Max
Coo
lant
Tem
p
Eng
Dia
gnos
tic T
emp
107 113 91 102 82 93
Goal: Keep engine as warm as possible Constraints:
1. Fans on after thermostat opening 2. Fans full on below engine max 3. Avoid diagnostic fault codes
5000
2500 Curbside
5500
8 fans 6 fans
EM
P C
ritic
al T
emp 99
AE
B M
ax F
an T
emp
EM
P Fa
n O
n Te
mp
2875
750
1813
3938
180 196 199 210 225 235 216 °C °F
CAC Fan Speed Control - Cummins ISB/C/L/X -
CAC Temperature (DegC)
45 69
5000
2500 Curbside
5500
8 fans 4 fans
EM
P C
ritic
al T
emp
65
AE
B M
ax F
an T
emp
EM
P Fa
n O
n Te
mp
2875
750
1813
3938
°C °F 113 156 149
Cummins ISL 280G, , El Paso, TX Summer Fan Operation
0.0%
23.7
% 27.0
%
23.0
%
15.7
%
6.2%
4.4%
0.0%
140
0 3 14
36
80
204
160
0%
5%
10%
15%
20%
25%
30%
Revers
e Off75
018
1228
7539
3850
0055
00
Fan Operating Speed
Perc
ent o
f Ope
ratio
n
0
50
100
150
200
250
Curre
nt C
onsu
mpt
ion
@ 2
8VDC
(A
mps
)
Fan Operation Summer Cooling System Current
Fans Rarely Operate At Maximum Capability
Fan Performance - Program History Data -
Fan Operation Percent of Time at Fan Speeds
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0 1000 2000 3000 4000 5000
RPM
0
20
40
60
80
100
120
140
160
180
Mesa 8-months WMATA - 9 months MARTA - 12 months TriMet - 14 months Amps
System Architecture
Temps
LED & Reverse
Transmission Engine Vehicle J1939
Service Adaptor
J1939
Temps
PWMs EMP-Link™ 2
Transmission Engine Vehicle J1939
Service Adaptor
J1939
EMP-Link™1
Telematics Telematics
LED & Reverse
Original Mini-Hybrid Generation II Mini-Hybrid
Features & Options
Included Features • Curbside Noise Abatement
– 2500 RPM Limit When Vehicle Stopped
– < OSHA 6 hour exposure level
– Will Exit If Necessary to Protect Engine
• Fan Reversal – Pushbutton or Automatic
• Fail Safe (4000 RPM) • Fault Tolerance - Fan
Redundancy • LED Blinks Fault Codes • Clever Devices (Telematics) • ZF Transmission Fan Request • Electrical Load Reduction (AC
Shutdown)
Available Options • Temperature Regulation Set points • Temperature Regulation Source
– EMP Sensors - or - Engine Sensors via. J1939
• Minimum Fan Speed – Engine Compartment Air
Circulation • Fan Reverse Duration • Fire Suppression via. Wakeup Signal • J1939 Addresses • J1939 Diagnostic (DM1) Message
Features the competition doesn’t offer
EMPower Connect™
• Downloadable service tool • Main Features
– Full Diagnostic Readout – Virtual Dashboard – View Calibration – Calibration File Upload
• Other Features – Reflash – Data Plot – Data Logging – Histograms – Download of Controller Data
• Customer Viewable File • Engineering File
• Multi-Level Security • No cost and no license fees • Competition does not offer service tool
Kit Layout & Component Locations
Fault Code Lookup
Fan Speed Readout
Coolant Temp
CAC Temp
Fault Code List
Fuel Savings
Average Fuel Economy ImprovementWith EMP Mini-Hybrid System
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
Winter Summer
7
7%
3%
Fuel Savings
Mini-Hybrid provides more fuel savings throughout the engine rpm range. Typical fuel economy ranges from 3% to 10% based on duty cycle, climate, and engine type.
Model Annual Mileage
Fuel Economy
10% Fuel Savings
Gallons $
New Flyer 10 million 3.27 mpg 305,810 $611,621
Neoplan 2.5 million 3.07 mpg 81,433 $162,866
Total
12.5
million
N/A
387,244
$744,487
Preliminary MTA evaluation of EMP miniHybrid system
demonstrates fuel economy improvement of 7-10%
Fuel Economy Results
MBTA (Boston)Average 10% Improvement
0
0.5
1
1.5
2
2.5
3
3.5
4
Dec-07 Jan-08 Feb-08 Mar-08 Apr-08 May-08
Jun-08 Jul-08 Aug-08 Sep-08
MP
G
EMP Fleet
WMATA (Washington DC)Average 6% Improvement
0
0.5
1
1.5
2
2.5
3
Aug-07
Sep-07
Oct-07
Nov-07
Dec-07
Jan-08
Feb-08
Mar-08
Apr-08
May-08
Jun-08
Jul-08
Aug-08
Sep-08
MP
G
EMP Fleet
g
0
0.5
1
1.5
2
2.5
3
3.5
Oct-07
Nov-07
Dec-07
Jan-08
Feb-08
Mar-08
Apr-08
May-08
Jun-08
Jul-08 Aug-08
Sep-08
MPG
EMP Fleet
Boston 10% D.C. WAMATA 6%
Seattle 4% Oahu 10% Tri-Met 4%
Omni-Trans 7%
Power to Wheels - MARTA Study -
Net Engine Power Relative to Adverised Power CurveShop Air supplied to Bus, No Steering Input, AC Off, Interior Lights Off
0
50
100
150
200
250
300
600 800 1000 1200 1400 1600 1800 2000 2200
Engine Speed (rpm)
Flyw
heel
Hor
sepo
wer
Advertised PowerBase Fan OffBase Fan EngagedEMP 1800EMP 5000
Torque Improvement
Mini-Hybrid reduces thermal events by eliminating the hydraulic fan system and reduces maintenance costs
Safety, Maintenance, Diagnostics
MTA spends an average of $1 million annually on parts and labor to repair hydraulic, radiator, and alternator related failures – $2,740 for each New Flyer – $4,040 for each Neoplan – Total Savings: $1 million
Annual Savings
Before EMP After EMP
Any Questions
For more information please contact: Marcus Jackson
EMP (928) 710-4089
Marcus.Jackson@emp-corp.com
Recommended