Htuf Iea Briefing 02-09-07
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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 Co-Hosts: • Every major 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
Copyright WestStart-CALSTART 2007
ISE hybrid cutaway shuttle bus
First Production
International: First ProductionIntent 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 heavyduty 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 & Outreach
Specification, Commitment & Deployment
Deployment, Testing & Production Ramp-up
WG Application 1 Fleet Characterization Spec Development Enact EPAct tax credits Business Case Indianapolis OEM Negotiations Forum 1 Purchase Agreements Develop additional Target Purchase funds/ Application Develop incentives San Antonio Market EPAct Forum 3 Assessment tax credits Working Recruitment Groups & Info Launched Chattanooga Forum 2 Commercialization Barriers Assessment
2002
Review Phase
Kalamazoo Forum 4
Develop Pre-Production Buy Down Funding
2003
Pre-Production Deployment 15-50 Vehicles per application Toledo Forum 5
Testing Evaluation Validation
Early Production 500+ Units
San Diego Forum 6
Purchase Agreements OEM Negotiations Business Case WG 2+ Spec Development Assist EPA Fleet Characterization Test Protocol Development
2004
Commitment Phase
2005
2006
2007
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 Project Goals: – 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 interest
Copyright WestStart-CALSTART 2007
Other partners: Kalmar, LBCT, EPA
Yard tractors are a common terminal vehicle at ports, distribution and shipping yards
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 operations
65% (2-3h)
21% (1-2 h)
14% (0.5-1 h)
Electric-only driving range
35% (40 mi)
28% (30 mi)
21% (20 mi)
7% (10 mi)
Available time to plug-in
21% (8h)
14% (6 h)
15% (10+)
7% (0.5 - 8 h)
Time of day
71% (5pm 6am)
29% (11pm - 6am)
Weight Penalty
50% (1000 lbs)
50% (500 lbs)
Fuel Displacement
43% (50% fuel)
22% (60% fuel)
14% (40% fuel)
14% (30% fuel)
On-board Power
79% (Y)
21% (N)
Amount of Power
37% (20 kW)
14% (10 kW)
7% (5 kW)
14% (other)
Type of Power
29% (single phase)
14% (3-phase AC)
14% (single & 3-phase)
7% (2 phase)
Tools
57 % (Electric & Hydraulic)
43% (Hydraulic only)
Copyright WestStart-CALSTART 2007
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
Copyright WestStart-CALSTART 2007
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
HTUF Planning Hybrid Truck Introduction Timing 2006 HTUF Working Groups
2007
2008
2009
Utility 24 trucks deploy 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)
Product Release Stages
Allison & BAE Bus Driveline production International/Eaton 1st Production Class 6/7 Freightliner CC/Eaton 1st Production? Azure 1st Production Freightliner Class 7 Prototype – Field Pilot?
Peterbilt/Eaton 1st Production? 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 Form HTUF Utility Working Group FALL 2002
Collect Fleet Data, Duty and Use Cycles
Identify, Select Key Performance Parameters (KPPs) SUMMER 2003
Final KPPs and Additional Functionality FALL 2003
HTUF Develops Buy-Down Funds
First Truck Deliveries 2006
Copyright WestStart-CALSTART 2007
Validator Truck Testing SUMMER 2005
Supplier Team Selected SUMMER/ FALL 2004 Final Fleet Orders WINTER 2005
RFP Sent to Manufacturers SPRING 2004
Fleet Commitment Letters WINTER 2003 Letter of Notice Sent to Manufacturers
Key Performance Requirements and Pre-Production Results • Maintain base vehicle dimensions and core functionality
No change in frame
– 65 mph top speed; Able to merge with freeway 25-30% improvement traffic Small weight gain – No decreased payload capacity – Able to tow trailer Better performance
• Transparent to user from vehicle and lift perspective
No change in user interface
– Hydraulic power for lift/tools
• Reliability equal to or exceeds baseline vehicle – Measured by cost to maintain/mean time to failure Copyright WestStart-CALSTART 2007
Meet or exceed – builds on base of existing components
Key Performance Requirements and Pre-Production Results • Significant increase in fuel Increased economy Increased FE FE – 50% increase desired
• Reduce emissions over diesel – Meet or exceed 2010 requirements
• Overall life-cycle costs less than or equal to diesel • Reduced noise levels compared to diesel – Operate at work sites on stored energy
• Generate field power
Silent Silent Watch Watch
– 25 kW output – Field Field Power Power Copyright WestStart-CALSTART 2007
40-60%+ fuel use reduction expected! To be determined: Up to 50% reduction over current truck expected Meet/exceed Considering fuel savings and benefits Idle reduction – average 2 hours without engine 120 V power, 5 kW and 10 kW
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 Deliveries Winter/ Spring 2006
Training & In-service Winter/ Spring 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
6 (7) Cumulative totals in parentheses
1 (14)
7 (17)
3 (19)
• 24 of 24 delivered by end December
2 (24)
• 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
5
Dec
Field Testing – Data Collection
24 HEV 20+ Baselines 12 Months 14 Fleets
On-board Acquisition AWARE
Data from Fleets
Supplier Reporting
Acceptance Surveys
• 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%
Cumulative Availability (%)
90% 80%
Current HEV Availability is 97.7% 19 trucks in service
First three units placed
70% 60% 50%
Mission Ending Failures (MEFs): 4
40%
Eaton Hybrid MEFs: 08/11/06 - Motor assembly issue (prototype process) 09/04/06 - Failed HCM analog input 10/02/06 - PEC, failed solder joint (prototype process) 10/16/06 - Poor 12V ground in hybrid system
30% 20% 10% 0%
Apr-07
Mar-07
Feb-07
Jan-07
Copyright WestStart-CALSTART 2007
Dec-06
Nov-06
Oct-06
Sep-06
Aug-06
Jul-06
Jun-06
May-06
Month
Courtesy Eaton
User Survey
• Comparative survey • 6 surveys collected • Most ratings better than baseline • Goal was equal to or better than baseline Copyright WestStart-CALSTART 2007
5.0
Noise inside
Mean Value
5 - much better 4 - somewhat better 3 - same 2 - somewhat worse 1 - much worse
4.0 Braking Launch
Decel
Accel Manuv
Boom
Noise outside
Shift quality Tool circuit
3.0 Grade pulling
2.0
1.0
Survey Questions
Survey – Hybrid Features 5.0
5 – excellent 4 - very good 3 - good 2 - poor 1 - very poor
4.0
New Hybrid features rated “very good”
2.0
Engine-off Boom
Engine-on Cab Ergonomics BoomElec-Mech Boom
3.0
1.0 Hybrid Features Copyright WestStart-CALSTART 2007
Early Field Performance Data HEV 1 Fuel, gal
115 gal Operation Hrs 96 h Engine Hrs 70 h Driving Hrs 30 h Boom Hrs 5.8 h Mileage/mo 550 mi Gal/h 1.2 MPG 4.8 Copyright WestStart-CALSTART 2007
HEV 2
470 gal 250 h 203 h 105 h 13 h 3,300 mi 1.9 7.0
HEV 3
240 gal 180 h 154 h 55 h 18 h 1,400 mi 1.3 5.7
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
Driveline Incremental Cost in $
What’s Next? Increase Volumes in Markets With Similar Drivelines to Lower Costs
100,000 75,000 50,000
Target Price Points 25,000 Driveline Volumes Needed for Price Points
15,000
10 Copyright WestStart-CALSTART 2007
100
1000
2,000-3,000
5,000
Yearly Similar Driveline Volumes
10,000
HTUF Targets Increased Volumes Across Multiple Platforms Each Hybrid Driveline Range Supports Multiple Uses
Light Food & Delivery HUMVEE Light Military
10,000 Copyright WestStart-CALSTART 2007
Trouble Heavy Truck Parcel
Cutaway/ Shuttle Van Small Trouble/ Light Service Shuttle/ Parcel & Truck school buses Delivery
Refuse Beverage & Regional Delivery Medium Military FMTV
14,500 17,000 19,000 22,000 GVWR
Transit
26,000
33,000
Heavy Military
40,000
Hybrid Incremental Cost – The “Wedges” Regional/State Incentives
Project "Buy Down"
Rewards high fuel economy Gains: 30-50% Federal Tax Credit
Copyright WestStart-CALSTART 2007
Must work together to get these two Fuel savings, Maintenance savings, Increased productivity – use $2.50-$3.00/gal fuel prices
Business Case
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: • 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 • Key military assessment locations also in NW Copyright WestStart-CALSTART 2007
Fleet supporters include:
Expanded Partnership: Discussing a joint conference in 2007 focused on committing to actions to reduce GHG and petroleum in transportation
HTUF: “Expanding the Funnel” Hybrids, Advanced Capability Trucks First Commercial Volumes
Deployment, Testing & Production Ramp-up
Technology Enhancement
s ynthetic S L T C / L GTL/BT
hybrids Biofuel
Outcomes: 4+ hybrid system suppliers each at min. 2500 system/year volumes
Early Production: Testing 500+ Truck Evaluation Deploy Validation Launches Commercial Phase
Commercial Hybrids
Increased Truck Volume Refuse Hybrid Segment
Increased Truck Volume Shuttle Hybrid Segment
6 truck/ chassis OEMs active Industry volume 20k hybrids/year
Increased Truck Volume Delivery Hybrid Segments Class 8 OTR and Drayage Hybrid
40-50% fuel use reductions per vehicle
Increased Truck Volume Utility 5-7 Hybrid Segment
Increased Truck Volume Industrial Hybrid Segment
Power g eneratio n Energy s torage Electrifie d compo nents
2006
2007
2008
2009
2010
Plug in m
2011
Increased capabilities of silent watch, power gen
odes
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 Advanced Transportation Technologies
SM
SM
www.weststart.org For info contact: Bill Van Amburg (626) 744-5600 [email protected]
www.htuf.org
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 Co-Hosts: • Every major 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
Copyright WestStart-CALSTART 2007
ISE hybrid cutaway shuttle bus
First Production
International: First ProductionIntent 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 heavyduty 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 & Outreach
Specification, Commitment & Deployment
Deployment, Testing & Production Ramp-up
WG Application 1 Fleet Characterization Spec Development Enact EPAct tax credits Business Case Indianapolis OEM Negotiations Forum 1 Purchase Agreements Develop additional Target Purchase funds/ Application Develop incentives San Antonio Market EPAct Forum 3 Assessment tax credits Working Recruitment Groups & Info Launched Chattanooga Forum 2 Commercialization Barriers Assessment
2002
Review Phase
Kalamazoo Forum 4
Develop Pre-Production Buy Down Funding
2003
Pre-Production Deployment 15-50 Vehicles per application Toledo Forum 5
Testing Evaluation Validation
Early Production 500+ Units
San Diego Forum 6
Purchase Agreements OEM Negotiations Business Case WG 2+ Spec Development Assist EPA Fleet Characterization Test Protocol Development
2004
Commitment Phase
2005
2006
2007
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 Project Goals: – 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 interest
Copyright WestStart-CALSTART 2007
Other partners: Kalmar, LBCT, EPA
Yard tractors are a common terminal vehicle at ports, distribution and shipping yards
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 operations
65% (2-3h)
21% (1-2 h)
14% (0.5-1 h)
Electric-only driving range
35% (40 mi)
28% (30 mi)
21% (20 mi)
7% (10 mi)
Available time to plug-in
21% (8h)
14% (6 h)
15% (10+)
7% (0.5 - 8 h)
Time of day
71% (5pm 6am)
29% (11pm - 6am)
Weight Penalty
50% (1000 lbs)
50% (500 lbs)
Fuel Displacement
43% (50% fuel)
22% (60% fuel)
14% (40% fuel)
14% (30% fuel)
On-board Power
79% (Y)
21% (N)
Amount of Power
37% (20 kW)
14% (10 kW)
7% (5 kW)
14% (other)
Type of Power
29% (single phase)
14% (3-phase AC)
14% (single & 3-phase)
7% (2 phase)
Tools
57 % (Electric & Hydraulic)
43% (Hydraulic only)
Copyright WestStart-CALSTART 2007
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
Copyright WestStart-CALSTART 2007
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
HTUF Planning Hybrid Truck Introduction Timing 2006 HTUF Working Groups
2007
2008
2009
Utility 24 trucks deploy 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)
Product Release Stages
Allison & BAE Bus Driveline production International/Eaton 1st Production Class 6/7 Freightliner CC/Eaton 1st Production? Azure 1st Production Freightliner Class 7 Prototype – Field Pilot?
Peterbilt/Eaton 1st Production? 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 Form HTUF Utility Working Group FALL 2002
Collect Fleet Data, Duty and Use Cycles
Identify, Select Key Performance Parameters (KPPs) SUMMER 2003
Final KPPs and Additional Functionality FALL 2003
HTUF Develops Buy-Down Funds
First Truck Deliveries 2006
Copyright WestStart-CALSTART 2007
Validator Truck Testing SUMMER 2005
Supplier Team Selected SUMMER/ FALL 2004 Final Fleet Orders WINTER 2005
RFP Sent to Manufacturers SPRING 2004
Fleet Commitment Letters WINTER 2003 Letter of Notice Sent to Manufacturers
Key Performance Requirements and Pre-Production Results • Maintain base vehicle dimensions and core functionality
No change in frame
– 65 mph top speed; Able to merge with freeway 25-30% improvement traffic Small weight gain – No decreased payload capacity – Able to tow trailer Better performance
• Transparent to user from vehicle and lift perspective
No change in user interface
– Hydraulic power for lift/tools
• Reliability equal to or exceeds baseline vehicle – Measured by cost to maintain/mean time to failure Copyright WestStart-CALSTART 2007
Meet or exceed – builds on base of existing components
Key Performance Requirements and Pre-Production Results • Significant increase in fuel Increased economy Increased FE FE – 50% increase desired
• Reduce emissions over diesel – Meet or exceed 2010 requirements
• Overall life-cycle costs less than or equal to diesel • Reduced noise levels compared to diesel – Operate at work sites on stored energy
• Generate field power
Silent Silent Watch Watch
– 25 kW output – Field Field Power Power Copyright WestStart-CALSTART 2007
40-60%+ fuel use reduction expected! To be determined: Up to 50% reduction over current truck expected Meet/exceed Considering fuel savings and benefits Idle reduction – average 2 hours without engine 120 V power, 5 kW and 10 kW
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 Deliveries Winter/ Spring 2006
Training & In-service Winter/ Spring 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
6 (7) Cumulative totals in parentheses
1 (14)
7 (17)
3 (19)
• 24 of 24 delivered by end December
2 (24)
• 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
5
Dec
Field Testing – Data Collection
24 HEV 20+ Baselines 12 Months 14 Fleets
On-board Acquisition AWARE
Data from Fleets
Supplier Reporting
Acceptance Surveys
• 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%
Cumulative Availability (%)
90% 80%
Current HEV Availability is 97.7% 19 trucks in service
First three units placed
70% 60% 50%
Mission Ending Failures (MEFs): 4
40%
Eaton Hybrid MEFs: 08/11/06 - Motor assembly issue (prototype process) 09/04/06 - Failed HCM analog input 10/02/06 - PEC, failed solder joint (prototype process) 10/16/06 - Poor 12V ground in hybrid system
30% 20% 10% 0%
Apr-07
Mar-07
Feb-07
Jan-07
Copyright WestStart-CALSTART 2007
Dec-06
Nov-06
Oct-06
Sep-06
Aug-06
Jul-06
Jun-06
May-06
Month
Courtesy Eaton
User Survey
• Comparative survey • 6 surveys collected • Most ratings better than baseline • Goal was equal to or better than baseline Copyright WestStart-CALSTART 2007
5.0
Noise inside
Mean Value
5 - much better 4 - somewhat better 3 - same 2 - somewhat worse 1 - much worse
4.0 Braking Launch
Decel
Accel Manuv
Boom
Noise outside
Shift quality Tool circuit
3.0 Grade pulling
2.0
1.0
Survey Questions
Survey – Hybrid Features 5.0
5 – excellent 4 - very good 3 - good 2 - poor 1 - very poor
4.0
New Hybrid features rated “very good”
2.0
Engine-off Boom
Engine-on Cab Ergonomics BoomElec-Mech Boom
3.0
1.0 Hybrid Features Copyright WestStart-CALSTART 2007
Early Field Performance Data HEV 1 Fuel, gal
115 gal Operation Hrs 96 h Engine Hrs 70 h Driving Hrs 30 h Boom Hrs 5.8 h Mileage/mo 550 mi Gal/h 1.2 MPG 4.8 Copyright WestStart-CALSTART 2007
HEV 2
470 gal 250 h 203 h 105 h 13 h 3,300 mi 1.9 7.0
HEV 3
240 gal 180 h 154 h 55 h 18 h 1,400 mi 1.3 5.7
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
Driveline Incremental Cost in $
What’s Next? Increase Volumes in Markets With Similar Drivelines to Lower Costs
100,000 75,000 50,000
Target Price Points 25,000 Driveline Volumes Needed for Price Points
15,000
10 Copyright WestStart-CALSTART 2007
100
1000
2,000-3,000
5,000
Yearly Similar Driveline Volumes
10,000
HTUF Targets Increased Volumes Across Multiple Platforms Each Hybrid Driveline Range Supports Multiple Uses
Light Food & Delivery HUMVEE Light Military
10,000 Copyright WestStart-CALSTART 2007
Trouble Heavy Truck Parcel
Cutaway/ Shuttle Van Small Trouble/ Light Service Shuttle/ Parcel & Truck school buses Delivery
Refuse Beverage & Regional Delivery Medium Military FMTV
14,500 17,000 19,000 22,000 GVWR
Transit
26,000
33,000
Heavy Military
40,000
Hybrid Incremental Cost – The “Wedges” Regional/State Incentives
Project "Buy Down"
Rewards high fuel economy Gains: 30-50% Federal Tax Credit
Copyright WestStart-CALSTART 2007
Must work together to get these two Fuel savings, Maintenance savings, Increased productivity – use $2.50-$3.00/gal fuel prices
Business Case
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: • 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 • Key military assessment locations also in NW Copyright WestStart-CALSTART 2007
Fleet supporters include:
Expanded Partnership: Discussing a joint conference in 2007 focused on committing to actions to reduce GHG and petroleum in transportation
HTUF: “Expanding the Funnel” Hybrids, Advanced Capability Trucks First Commercial Volumes
Deployment, Testing & Production Ramp-up
Technology Enhancement
s ynthetic S L T C / L GTL/BT
hybrids Biofuel
Outcomes: 4+ hybrid system suppliers each at min. 2500 system/year volumes
Early Production: Testing 500+ Truck Evaluation Deploy Validation Launches Commercial Phase
Commercial Hybrids
Increased Truck Volume Refuse Hybrid Segment
Increased Truck Volume Shuttle Hybrid Segment
6 truck/ chassis OEMs active Industry volume 20k hybrids/year
Increased Truck Volume Delivery Hybrid Segments Class 8 OTR and Drayage Hybrid
40-50% fuel use reductions per vehicle
Increased Truck Volume Utility 5-7 Hybrid Segment
Increased Truck Volume Industrial Hybrid Segment
Power g eneratio n Energy s torage Electrifie d compo nents
2006
2007
2008
2009
2010
Plug in m
2011
Increased capabilities of silent watch, power gen
odes
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 Advanced Transportation Technologies
SM
SM
www.weststart.org For info contact: Bill Van Amburg (626) 744-5600 [email protected]
www.htuf.org
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