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Heavy Hybrid Vehicle

Commercialization Progress and


Directions
The HTUF Process
Advanced Transportation
Technologies
Clean Transportation
Solutions SM

Bill Van Amburg


Senior Vice President
Jasna Tomic
Senior Consultant
IEA Annex XII Expert Meeting
San Diego
February 9, 2007
Agenda

• Drivers and Context: The World is Changing


• The Truck World Is Changing: Hybrid
Momentum
• HTUF Process
• First Tangible Results
• Next Steps

Copyright WestStart-CALSTART 2007


New Requirements for
Transport

• Need for greater transportation energy efficiency


increasing significantly
• Technologies that reduce fuel use and provide
other benefits (electrical production, silent
watch/idle reduction) have much stronger
business case
• Energy security as big a driver as emissions /
climate change

Copyright WestStart-CALSTART 2007


Truck World is Changing:
Hybrid Momentum

Copyright WestStart-CALSTART 2007


Recent Hybrid News –
Momentum Growing
– ArvinMeritor signs WalMart agreement for Class 8 hybrids
– Oshkosh unveils hybrid refuse truck at HTUF meeting
– Peterbilt introduces Class 7 hybrid truck for customer trials
– International builds its first production-line hybrids in Nov 06
– Freightliner unveils Class 7 utility hybrid truck on M2 chassis
– IC/Enova roll out hybrid electric shuttle bus
– Azure agreement with StarTrans on producing hybrid shuttles
– Eaton developing hybrid system for Class 8 OTR trucks
– UPS testing advanced series hydraulic hybrid prototype
– Bosch-Rexroth buys Dana hydraulic hybrid drive unit
– Misubishi-Fuso Unveil Hybrid work truck (Class 4-5 delivery
cube)
– Wright Group, ISE building 50 advanced hybrid buses for Las
Vegas (62-foot articulated series drive)
– Volvo announces hybrid heavy trucks for 2009 production
– Peterbilt (Paccar) completes second hydraulic hybrid refuse
truck
– FedEx adding hybrid delivery vans; UPS buying 50; Purolator
orders 115 Azure hybrid delivery vans
Copyright WestStart-CALSTART 2007
HTUF National Meeting 2006
• 330+ attendees
(20% increase from
2005)
– One quarter
fleet operators
• 14 med. &
heavy hybrid
vehicles
• 3 Working
Group
meetings and 1
PHEV Task
Force meeting
• Every major Co-Hosts:
truck maker
and supplier in
attendance Co-Sponsors:
Copyright WestStart-CALSTART 2007
Newest Introductions
Oshkosh
hybrid refuse
truck

Peterbilt Class
7 hybrid utility
truck

IC/Enova
hybrid shuttle
bus
Freightliner
Class 6/7
hybrid utility
truck ISE hybrid
cutaway
shuttle bus
Copyright WestStart-CALSTART 2007
First Production

International: First Production-


Intent Volume Fall 2006;
delivery 2007
– Building ~100 Class 6/7
hybrids
– HTUF assisting fleet
commitment orders
– HTUF to assist fleets
finding funding
International 4300 Series Hybrid

Copyright WestStart-CALSTART 2007


FedEx Parcel Delivery Hybrids:
More Than 90 On Road

Diesel-Electric Hybrid System for FedEx W700s

Built by Freightliner Custom Chassis and Eaton


Copyright WestStart-CALSTART 2007
Eaton Hydraulic Hybrid

• Eaton receives $2.15 million from


DoD to accelerate commercial
development of its energy-saving
Hydraulic Launch Assist™
(HLA®) system technology
• Working under a program with the
US Army National Automotive Center
and Impact Engineering
• Eaton will focus on designing third
generation HLA system and
optimizing for specific vehicle
applications
• Eaton’s HLA regenerative braking
system has demonstrated significant
fuel economy, reduction in
emissions, brake wear in stop and go
driving applications

Copyright WestStart-CALSTART 2007


Why Hybrids Are
Gaining Traction with Fleets

• Rising fuel costs: Optimizing urban truck drivelines


is becoming critical for fuel efficiency, emissions
• Major engine changes – and increased
cost/complexity – coming in 2007-2010 to comply
with EPA emissions requirements
• Trend toward integrated engine/drivelines in trucks
• Increasing electrical power needs in heavy vehicles
and equipment
• Idle Management is a growing issue
• Productivity/performance complaints from cleaner
engines

Copyright WestStart-CALSTART 2007


HTUF Role:
A Process for Commercialization

Copyright WestStart-CALSTART 2007


Hybrid Truck
Users Forum (HTUF)
• User-driven process to
commercialize medium- and heavy-
duty hybrid trucks in the U.S.
• Joint WestStart-U.S. Army program
(RDECOM-TARDEC-NAC)
– Also supported by Hewlett Foundation
• HTUF focuses on commercializing
hybrid trucks with dual-use benefits
– Speed commercialization and reduce
overall costs by creating common fleet
requirements, joint purchase
commitments
• Army benefits:
– Commercial volumes = lower unit costs
for military; Military requirements
inserted early in development process
Copyright WestStart-CALSTART 2007
Focus Area for HTUF:
Top Early Hybrid Applications
“Beach Head” Markets Show Best First Promise
Class 7/8 Refuse trucks

Class 3-6 Urban delivery trucks


-package delivery
-beverage delivery

Specialty Truck Applications (Class 4-7)


-Utility “Bucket” trucks
-Telecom/cable trucks

Class 6-8 Heavy Urban delivery trucks


-regional heavy distribution (beverage, grocery, postal)
Copyright WestStart-CALSTART 2007
HTUF Working Groups
• 4 Core Working Groups of fleet truck
users now operating;
• 1 additional in partnership with NTEA
(light truck)
• 2 new groups forming (OTR and
construction equipment)
– Utility/Specialty trucks – George
Survant, Florida Power & Light, lead
– Parcel Delivery trucks – Sid Gooch, Fed
Ex Express; Bob Dengler, FedEx Ground;
Robert Hall, UPS – user leads
– Refuse Truck Working Group – Matt
Stewart, City of Chicago Sanitation, lead
– Bus Working Group – launched with
support of Federal Transit Administration
Copyright WestStart-CALSTART 2007
HTUF Has Proven an Effective
Commercialization Model

Proven process to build HD hybrid volumes


Four fleet Working Groups active, more
forming (one in partnership with NTEA)
First 24 utility Pre-Production Trucks in
final deployment for assessment
Two additional deployments ready
Parcel hybrid RFP on street Aug 2006
Refuse hybrid RFP by early 2007
Over 80 national fleets, including DOD,
involved in process
Six National Meetings of top truck OEMs,
suppliers, fleets (attendance up 60% in 2 yrs)
Military receiving first in-use hybrid field
data from geographically dispersed
nationwide deployment

Copyright WestStart-CALSTART 2007


HTUF “Commercialization Funnel”
Familiarization Specification, Commitment & Deployment, Testing
& Outreach Deployment & Production Ramp-up
WG Application 1
Fleet Characterization
Spec Development
Indianapolis Business Case Enact EPAct tax credits
Forum 1 OEM Negotiations
Purchase Agreements
Target Develop additional
Application Develop Purchase funds/
Market San Antonio EPAct incentives
Assessment Forum 3 tax credits

Working Pre-Production
Deployment Testing Early
Recruitment Groups
Kalamazoo 15-50 Vehicles Evaluation Production
& Info Launched Forum 4 per application Validation 500+ Units
Chattanooga San Diego
Develop Toledo Forum 6
Forum 2
Pre-Production Forum 5
Commercialization Buy Down
Barriers Funding
Purchase Agreements
Assessment OEM Negotiations
Business Case
WG 2+ Spec Development Assist EPA
Fleet Characterization Test Protocol Development
2002 2003 2004 2005 2006 2007
Review Phase Commitment Phase Early Market Phase
First HTUF Commitment:
Hybrid Electric Utility Truck
All 24 Pre-production Trucks Now Deployed
Similar Driveline to Class 5-7 truck,shuttle bus markets

Class 6/7
Hybrid Electric
40-60% Fuel Economy Improvement
Greatly Improved Total Emissions
Idle Reduction (shuts off at work site)
25 kW power export
Meets or exceeds driving performance requirements
24 pre-production trucks to be assessed in 14 fleets
Copyright WestStart-CALSTART 2007
Parcel, Refuse & Shuttle
Working Group Activities
• Parcel/Delivery Working Group - Involvement
from key national fleets
– (FedEx Ground; UPS; USPS; FedEx
Express; Purolator)
• Joint purchase RFP for preproduction
hydraulic hybrid in Class 4 (14,000 lb GVWR)
and Class 6 (22,000 lb GVWR) – on street now

• Refuse Working Group


• 8 major fleets to date including private and
municipal players
– (Waste Management; Onyx; Cities of New
York, Houston and Chicago)
• Joint purchase RFP to be sent Spring 07

• Shuttle Working Group


• Kick off meeting Feb 2007
• Early targets: shuttles under 35-feet;
paratransit; circulator bus
• Most of these buses built on truck chassis
Copyright WestStart-CALSTART 2007
Bus Working Group

• Urban heavy transit hybrid bus


market growing: 1000-2000 on
road/in delivery
• Formed WG to assist faster
growth of hybrid transit bus and
supporting markets
• Have drafted a hybrid business
case for urban transit users to
share with policy leaders
• Now focusing on shuttle and
paratransit buses that use truck
chassis

Copyright WestStart-CALSTART 2007


Ports of Long Beach/LA
Hybrid Yard Hostler Demo

• Project kicks off with port tenant in


2006 Other partners:
• Project Goals: Kalmar, LBCT, EPA
– Establish requirements for a hybrid in
yard hostler duty cycle
– Seek commercial industry proposals to
meet requirements
– Build and test proof of concept
prototype
– Evaluate and analyze hybrid truck
business case and commercialization
potential and barriers
– Considering linking HTUF WG to this
effort to expand fleet involvement,
explore military non-tactical truck Yard tractors are a common terminal
interest vehicle at ports, distribution and
shipping yards

Copyright WestStart-CALSTART 2007


PHET Workshop – Feb 13

• HTUF Workshop to explore PHET market


potential, barriers, user needs and
possible introduction strategies
• Workshop comes day before national
Clean Heavy-Duty Vehicle Conference in
LA
• Users, manufacturers, suppliers, funders

Copyright WestStart-CALSTART 2007


Plug-in Hybrid Truck (PHET)
Fleet Survey Results
Engine-off 65% (2-3h) 21% (1-2 h) 14% (0.5-1 h)
operations
Electric-only 35% (40 mi) 28% (30 mi) 21% (20 mi) 7% (10 mi)
driving range
Available time 21% (8h) 14% (6 h) 15% (10+) 7% (0.5 - 8 h)
to plug-in
Time of day 71% (5pm - 29% (11pm - 6am)
6am)
Weight Penalty 50% (1000 lbs) 50% (500 lbs)
Fuel 43% (50% fuel) 22% (60% fuel) 14% (40% fuel) 14% (30% fuel)
Displacement
On-board 79% (Y) 21% (N)
Power
Amount of 37% (20 kW) 14% (10 kW) 7% (5 kW) 14% (other)
Power
Type of Power 29% (single 14% (3-phase AC) 14% (single & 7% (2 phase)
phase) 3-phase)
Tools 57 % (Electric 43% (Hydraulic
Copyright WestStart-CALSTART 2007
& Hydraulic) only)
PHET over HEV Benefits Expected

PHET Benefits
• Quiet work at night
• Use of company power
• Extended engine-off time
• Increase run time on full electric
• Improve fuel economy, lower maintenance
• Increased electric driving range, reduced emissions
• Less maintenance costs
• Peak savings, electricity savings and fuel economy
Fuel cost savings and extras to offset added cost of
• PHET

Copyright WestStart-CALSTART 2007


Early Performance Parameters

New Ranking of Performance Parameters


1 Fuel Displacement in %
2 Eliminate engine idling
3 Emission reductions better than HEV
4 No mobility compromise at end of workday
5 Required length of time operating from battery only
6 Weight penalty of battery and HEV system limit
7 On-board power generation
8 Payload capacity loss limit
9 Charging Infrastructure Modifications
10 Grid Recharge Time
11 Drivetrain/mounted equipment performance
Copyright WestStart-CALSTART 2007
HTUF Planning
Hybrid Truck Introduction Timing
2006 2007 2008 2009
HTUF
Utility 24 trucks deploy
Working
Groups Delivery WG Pre-Production (15-30)
Refuse WG Pre-Production (15-30)

Utility Truck First Production (100)

Utility/Class 5-7 Truck Next Phase (500+)

Class 5 (15-50)

Shuttle/Paratransit (15-50)
Industry
Launches FedEx II (75)

FedEx III (75)

Purolator II (115)

UPS I (50)

Allison & BAE Bus Driveline production


Product
Release International/Eaton 1st Production Class 6/7
Stages Freightliner CC/Eaton 1st Production?

Azure 1st Production Peterbilt/Eaton 1st Production?

Freightliner Class 7 Prototype – Field Pilot? Volvo 1st Production


Peterbilt - KenworthClass 7 Prototype – Field Pilot
Peterbilt Class 8 Concept
© WestStart 2006
First Tangible Results

Copyright WestStart-CALSTART 2007


North American Deployment & Assessment
Data Will Assist Commercial & Military Hybrid Decisions

HTUF Utility Hybrid Working Group

24 Truck
Deployment
Locations
Supplier Team Building Additional 100 Trucks
Utility Hybrid Truck:
The 3-Year Process
Identify,
Collect Fleet
Data, Duty and Select
Form HTUF Key
Utility Use Cycles
Performance
Working Parameters
Group Final KPPs
(KPPs)
FALL 2002 and Additional
SUMMER
Functionality
2003
FALL 2003
HTUF Develops Buy-Down Funds

Supplier RFP Sent to


Team Manufacturers
Fleet
Selected SPRING 2004
Commitment
First Truck SUMMER/
Validator Letters
Deliveries FALL 2004
Truck WINTER 2003
2006
Testing Letter of
SUMMER Notice Sent to
Final Fleet
2005 Manufacturers
Orders
WINTER
Copyright WestStart-CALSTART 2007 2005
Key Performance Requirements
and Pre-Production Results

• Maintain base vehicle dimensions No change in frame


and core functionality
– 65 mph top speed; Able to merge with freeway 25-30% improvement
traffic
– No decreased payload capacity Small weight gain
– Able to tow trailer Better performance
• Transparent to user from vehicle No change in user
and lift perspective interface
– Hydraulic power for lift/tools
• Reliability equal to or exceeds Meet or exceed –
builds on base of
baseline vehicle existing components
– Measured by cost to maintain/mean time to
failure
Copyright WestStart-CALSTART 2007
Key Performance Requirements
and Pre-Production Results
40-60%+ fuel use
• Significant increase in fuel reduction expected!
economy Increased
Increased FE
FE
– 50% increase desired To be determined: Up
• Reduce emissions over diesel to 50% reduction over
– Meet or exceed 2010 requirements current truck expected
• Overall life-cycle costs less than Meet/exceed
or equal to diesel Considering fuel
• Reduced noise levels compared savings and benefits
to diesel Idle reduction –
– Operate at work sites on stored energy average 2 hours
• Generate field power Silent
Silent Watch
Watch without engine
– 25 kW output –
Field 120 V power, 5 kW and
Field Power
Power
10 kW
Copyright WestStart-CALSTART 2007
Fuel Use by Mission from
Independent Testing

Fuel Use Reduction Over Baseline (revised):


• Mission A – 32% reduction in fuel use
• Mission B – 35% reduction in fuel use
• Mission C – 46% reduction in fuel use
• Mission D – 48% reduction in fuel use

Copyright WestStart-CALSTART 2007


Emissions Reductions by Mission

Reductions
just from
hybrid
system, no
additional
after
treatment

CO2
reductions
closely
tracked fuel
reduction
percentages
Copyright WestStart-CALSTART 2007
Field Deployment Status

Start Field
Deployments
Summer
2006
First Truck Training &
Deliveries In-service
Winter/ Winter/
Spring Spring
2006 2006

• 18 of 24 trucks delivered to fleets by Fall (end Sept)


• 23 of 24 delivered end November: all 24 delivered end 2006
• Standard comparison units in same locations
• 25 kW APG – delayed, but field installation now underway
Copyright WestStart-CALSTART 2007
Staggered Deployment

May June July Aug Sept Oct Nov Dec


6
(7) 1
Cumulative
totals in (14) 7
parentheses
(17) 3
(19) 2
• 24 of 24 delivered by end December (24) 5
• Deployment took longer than expected
- Supply chain component delays
- Training and agreement scheduling
- APG design changes
- Time gap between delivery and in field service
Copyright WestStart-CALSTART 2007
Field Testing – Data Collection

On-board
Acquisition Data from
AWARE Fleets
24 HEV
20+ Baselines
12 Months
14 Fleets

Acceptance Supplier
Surveys Reporting

• Reliability/Availability
• User acceptance
• Performance data
• Maintenance data
Copyright WestStart-CALSTART 2007
Truck Availability
Based on Eaton tracking:
• 19 trucks
• 70 truck months
• Availability based on hybrid drive is 97 %
• 21 Total number of hybrid issues logged
• 4 Mission-ending failures

• Fleets experienced delays due to other service


issues as well
• 70 truck/months – Total 65 Field Issues
Copyright WestStart-CALSTART 2007
Availability – Hybrid System

100%

90%
Cumulative Availability (%)

80%
Current HEV Availability is 97.7%
First three units placed 19 trucks in service
70%

60%

50%
Mission Ending Failures (MEFs): 4
40%
Eaton Hybrid MEFs:
30% 08/11/06 - Motor assembly issue (prototype process)
09/04/06 - Failed HCM analog input
20% 10/02/06 - PEC, failed solder joint (prototype process)
10/16/06 - Poor 12V ground in hybrid system
10%

0%
Aug-06
May-06

Nov-06

Dec-06
Jun-06

Sep-06

Oct-06

Jan-07

Feb-07
Jul-06

Apr-07
Mar-07
Month
Courtesy Eaton
Copyright WestStart-CALSTART 2007
User Survey

5 - much better 5.0


4 - somewhat better
3 - same
Noise inside
2 - somewhat worse 4.0
1 - much worse Mean Value Braking
Decel
Boom
Noise outside
Accel
Launch Manuv Shift quality
• Comparative survey 3.0
Tool circuit

• 6 surveys collected
Grade pulling
• Most ratings better
2.0
than baseline
• Goal was equal to
or better than 1.0
baseline Survey Questions
Copyright WestStart-CALSTART 2007
Survey – Hybrid Features

5.0

5 – excellent
Engine-off Engine-on Cab Ergonomics
4 - very good Boom Boom BoomElec-Mech
4.0
3 - good
2 - poor
1 - very poor
3.0

New Hybrid features


2.0
rated “very good”

1.0
Hybrid Features

Copyright WestStart-CALSTART 2007


Early Field Performance Data

HEV 1 HEV 2 HEV 3


Fuel, gal 115 gal 470 gal 240 gal
Operation Hrs 96 h 250 h 180 h
Engine Hrs 70 h 203 h 154 h
Driving Hrs 30 h 105 h 55 h
Boom Hrs 5.8 h 13 h 18 h
Mileage/mo 550 mi 3,300 mi 1,400 mi
Gal/h 1.2 1.9 1.3
MPG 4.8 7.0 5.7
Copyright WestStart-CALSTART 2007
Early Lessons

• Deployment took longer than expected


– Supply chain component delays
– Training and agreement scheduling
– APG design changes
• Truck fault diagnostic capability had steep learning
curve
– Vehicles are more complex systems than traditional trucks
– Interaction of body, chassis and hybrid system
– Has led to on-going improvements for these trucks and
production intent design
• Data collection not able to start until trucks in full
operation; some challenges with electronic data
collection

Copyright WestStart-CALSTART 2007


Next Steps

Copyright WestStart-CALSTART 2007


What’s Next?

Increase Volumes in Markets


100,000
Driveline Incremental Cost in $

With Similar Drivelines to Lower Costs


75,000

50,000
Target Price Points
25,000

15,000 Driveline Volumes


Needed for Price
Points

10 100 1000 2,000-3,000 5,000 10,000


Copyright WestStart-CALSTART 2007 Yearly Similar Driveline Volumes
HTUF Targets Increased Volumes
Across Multiple Platforms
Each Hybrid Driveline Range
Supports Multiple Uses

Trouble Transit
Cutaway/ Heavy Truck
Shuttle Van
Small Parcel
Light Food Trouble/ Refuse
& Delivery Beverage &
Light Service Shuttle/
Regional
HUMVEE Parcel & Truck school Heavy
buses Delivery
Light Delivery Medium Military
Military Military
FMTV

10,000 14,500 17,000 19,000 22,000 26,000 33,000 40,000


Copyright WestStart-CALSTART 2007 GVWR
Hybrid Incremental Cost –
The “Wedges”

Regional/State Must work together to get these two


Incentives

Project "Buy Fuel savings,


Down" Maintenance savings,
Increased productivity –
use $2.50-$3.00/gal fuel
prices
Rewards high
fuel economy Business
Gains: 30-50% Case
Federal Tax
Credit

Copyright WestStart-CALSTART 2007


In Next 2 Years, Need
Additional Incentives
Developing Regional Hybrid Incentives

Canadian Hybrid Truck Initiative


NW Hybrid
Consortium

NY

Texas
NTRD

Air Districts; Clean Cities; State Energy


Offices; CMAQ Funds; Others
Copyright WestStart-CALSTART 2007
NW Hybrid Consortium

Good Example of Success: Fleet supporters include:


• Public agency and private
fleets in NW/Puget Sound
region organized commitment
to hybrid deployments with
HTUF
• 14-plus fleets currently
supporting in region
• Just have received $250,000
from EPA (announced Nov
15) for 10 trucks, and
additional $150,000 from
regional agencies to expand Expanded Partnership: Discussing a
• Key military assessment joint conference in 2007 focused on
locations also in NW committing to actions to reduce GHG
Copyright WestStart-CALSTART 2007
and petroleum in transportation
HTUF: “Expanding the Funnel”
Hybrids, Advanced Capability Trucks
Deployment, Testing First Commercial Volumes Technology Enhancement
& Production Ramp-up
s
TL S ynthetic
hybrids GTL/BT
L/ C
Outcomes:
Biofuel
4+ hybrid system
suppliers each at
Increased Truck Volume Refuse Hybrid Segment min. 2500
system/year
Commercial Hybrids

volumes
Early Increased Truck Volume Shuttle Hybrid Segment
6 truck/ chassis
Production:
Testing OEMs active
500+ Truck Industry volume
Evaluation Deploy Increased Truck Volume Delivery Hybrid Segments 20k hybrids/year
Validation Launches
Class 8 OTR and Drayage Hybrid 40-50% fuel use
Commercial
reductions per
Phase Increased Truck Volume Utility 5-7 Hybrid Segment vehicle

Increased
Increased Truck Volume Industrial Hybrid Segment capabilities of
Power g silent watch,
eneratio
n power gen
Energy s
torage
Electrifie Plug in m
d compo odes
nents

2006 2007 2008 2009 2010 2011 2012 2013 2014


Capabilities Enhancement
Conclusion:
Status of Hybrid Truck Development

• Not Yet at “Tipping Point” for hybrid commercialization –


but making strong progress
– Have sped commercialization process by 1-2 years
• Two truck makers entering production-intent manufacturing process
– Need assistance to cross cost gap to first production
– Must increase early volumes, justify commercial investments from
manufacturers
• 500+ truck deployment is goal for next push of HTUF effort
– Need regional incentives and “aligned” incentives across regions
• Next deployments will be highly leveraged risk-share
– Partnership of fleets, manufacturers and government
– Deployment stages go from pre-production (15-50 vehicles) to
production intent (100+ vehicles) to early production (500+
vehicles) in each application/Working Group

Copyright WestStart-CALSTART 2007


Clean Transportation Solutions SM

Advanced Transportation Technologies SM

www.weststart.org

For info contact:

Bill Van Amburg


(626) 744-5600
bvanamburg@weststart.org

www.htuf.org

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