8/9/2012 Allison Conventional Bus 05-June-2012 CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 1 AGENDA • Product Overview – Product ratings – Product design • New Features – – – – Upgrades 4th GEN/MY09 Diagnostics/Prognostics Special features • Maintenance CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 2 1 8/9/2012 AGENDA • Product Overview – Product ratings – Product design • New Features – – – – Upgrades 4th GEN/MY09 Diagnostics/Prognostics Special features • Maintenance CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 3 Product Overview Transmission Designations B400R Retarder Major Revisions 0 = Close Ratio 5 = Wide Ratio 3/4/5 Transmission Series Bus Model CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 4 2 8/9/2012 Product Overview B300/400/500 Product Ratings • B300(R) – – – – • B 500(R) – Bus Up to 280 HP (gross) Up to 735 lb ft Torque (gross) Dry Weight basic 535 lbs (243 Kg) Dry Weight with (R) 615 lbs (279 Kg) • B400(R) – – – – Up to 420 HP (gross) Up to 1300 lb ft Torque (gross) Dry Weight basic 831 lbs (377 Kg) Dry Weight with (R) 906 lbs (411 Kg) • B 500(R) – Coach Up to 300 HP (gross) Up to 925 lb ft Torque (gross) Dry Weight basic 535 lbs (243 Kg) Dry Weight with (R) 615 lbs (279 Kg) CHATO PATTERSON – – – – – – – – Up to 550 HP (gross) Up to 1700 lb ft Torque (gross) Dry Weight basic 831 lbs (377 Kg) Dry Weight with (R) 906 lbs (411 Kg) ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 5 Product Overview Transmission Design • • • • • CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL Torque Converter Connects To and Rotates With the Engine Torque Converter Transmits Power to Transmission Input (Turbine) Shaft Other Shafts, Components, Clutches Transmit Power to Planetary Gear Sets Planetary Gear Sets Create Necessary Ratio and Transfer That Power To Transmission Output Shaft Output Shaft Connects to Driveline Which Connects To Axle/Final Drive SLIDE 6 3 8/9/2012 Product Overview Retarder Models B 3/400R 1000 – 1600 lb ft Absorbs 400 - 600 HP B 500R 1300 – 2000 lbs ft Absorbs 500 - 600 HP Reduces Service Brake Wear Allison B 3/4 and 500 are Output Retarders No Power Interrupts during downshifts No Restrictions on use due to local noise ordnances CHATO PATTERSON Reduces Potential for Brake Fade on Steep Grades Quiet operation ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 7 Product Overview Cooling System • Reference Allison Technical Document (TD 157) for details • The bus/coach must pass the minimum cooling validation tests per ATD Tech Data • 80% Converter Efficiency • Idle in Range Test • 0-30-0 mph Test • 0-40-0 mph Test • Downgrade Test (Coaches) or 1000 Btu sump cooler • Limiting Ambient Temperature (LAT) for Testing • Extenuating Duty Cycle Conditions Acknowledged by OEM – Includes route “down grade” test on city bus where applicable CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 8 4 8/9/2012 Product Overview Integral Cooler CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 9 Product Overview Remote Cooler CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 10 5 8/9/2012 Product Overview Transmission Controls Shift Selector SHIFT SELECTOR FEATURES Range Commanded Old Gen 4 Range Attained Oil Level Diagnostic Codes New Gen 4 New MY 2009 Gen 4 with Prognostics Oil Life Filter Life Service Indicator Wrench Clutch Life Communication with Transmission TCM by J 1939 Communication link CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 11 Product Overview Retarder Controls Hand Lever …Off + 6 Step On Brake Pressure Switch Module 7 psi Pressure Switch 2 psi Pressure Switch 4 psi Pressure Switch Connection to Main Transmission Control Harness if Lever is not used Hand Lever Module Connection to Main Transmission Control Harness “Y” Harness When Hand Lever is used CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 12 6 8/9/2012 Product Overview Control Schematic Layout Multiplex PLC Normal “Hardwire” System Shift Selector Dash This is a typical representation Brake Pressure Switches Coach Manufacturers may differ sometimes dependant upon the number of I/O’s commanded on the J 1939 system. e.g…..The retarder switching may be by way of a combined pressure transducer with integrated J 1939 output signal on TSC 1 CHATO PATTERSON Retarder Module ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 13 AGENDA • Product Overview – Product ratings – Product design • New Features – – – – Upgrades 4th GEN/MY09 Diagnostics/Prognostics Special features • Maintenance CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 14 7 8/9/2012 New Features Allison’s Philosophy on Product Enhancements • Continuous improvement to support the Allison vision of being the world leader of commercial heavy duty automatic transmissions • Allison desires to take advantage of newer technology to provide our customers with additional product features and enhanced value CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 15 New Features B 3/400R Major Upgrades Input Bushing Material Rotating Cl Hsg Weld C1 Back Plate stronger & Snap ring trapped P1,2,3 Index Plates tighter Trimmed Lip Output Seal Double lip input seal Single Output Bolt Oil Pump Gear Bushing Other changes: - Sump cooling provision - TranSyndTM factory fill - Dynax clutch material - Long Life Filters (125 k) -Gen 4 Controls -Prognostics CHATO PATTERSON Filter cover thread inserts Dust slinger and third axial lip to protect seal; Revised output nut and added Belleville spring to reduce output motion ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 16 8 8/9/2012 New Features B 500(R) Major Upgrades Input seal Double Lip Input Bushing Material Stronger C1 hub material C1/C2 C3/C4 Tapered Apply Plate Hub Spline Reduced Temperature Increased Fillet radius Output seal with Slinger (3/03) and Belleville Washer Rotating Cl Hsg Weld Single Output Bolt Hardened Main Shaft – P2 Spline wear reduction Oil Pump Gear Bushing Other changes: - Sump cooling provision - TranSyndTM factory fill -Dynax clutch material -Long Life Filters (125km) -Gen 4 Controls -Prognostics P1,2,3 Index Plates tighter Filter cover thread inserts CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 17 CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 18 9 8/9/2012 New Features Prognostics • Prognostic features – packaged for TES295 fluids ONLY – Oil Life Monitor: • Monitors various transmission operating parameters to determine fluid life remaining • Calendar based fluid change requirements still apply and not part of prognostic operation – Transmission Health Monitor: • Monitors most clutches to determine when clutch maintenance is required. – Filter Life Monitor: • Determines when fluid filter(s) need to be replaced through a pressure switch that monitors main filter pressure CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 19 New Features Prognostics-Oil Life Monitor • Function Description – Operating parameters such as operating time, output revolutions, shift density, retarder usage, etc. are monitored and fluid life is adjusted accordingly. Output is displayed as a percent of fluid life remaining from 100% to 0% • Triggering Event – % life remaining reaches an Allison cal set value (expect 1-2%) • Service Indicator – When maintenance is required, at key on, the light will come on steady and remain on steady for 2 minutes after DRIVE has been selected • Failure to perform maintenance and reset after a cal defined period will result in diagnostic code being set and the CHECK TRANS light being lit. CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 20 10 8/9/2012 New Features Prognostics - Trans Health Monitor • Function Description – Monitors C1 through C5 clutches and evaluates remaining useful life through changes in calculated running clearance. • Triggering event – The change in calculated running clearance reaches an Allison cal set value (expect ~10% life remaining) –OR – value exceeds a max value • Service Indicator – At key on, light will come on steady and remain on steady at all times • Manual reset possible only through service tool • Failure to perform maintenance after a cal defined number of warnings will result in a diagnostic code being set and the CHECK TRANS light being lit. CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 21 New Features Prognostics - Filter Life Monitor • Function Description – Use a delta-p switch to evaluate pressure change across the main filter. Function does not operate below 40 deg C sump temperature • Triggering event – Filter delta pressure reaches 25psi • Service Indicator – At key on, light will flash and remain flashing for 2 minutes after DRIVE has been selected • Reset possible via service tool • Failure to perform maintenance after a cal defined number of warnings will result in a diagnostic code being set and the CHECK TRANS light being lit CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 22 11 8/9/2012 New Features Prognostics and Your Bottom Line • Real-world savings for transit fleets – Improved Lifecycle Costs • Large Transit Fleet testing revealed an annual maintenance cost savings of approximately $60 per vehicle – Conservative cost savings estimates for out of warranty, clutch related repairs are approximately 20% CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 23 New Features Load Based Shift Schedule • Summary – Electronic feature that automatically selects between two pre-determined shift schedules to maximize fuel economy and maintain vehicle performance • Highly integrated feature requiring SEM/LRTP • Benefit – Fuel economy impact • 2% to 5% based on preliminary on-road test results – LBSS will allow short shifting when productivity will not be impacted (i.e. light load or downhill acceleration) – Productivity advantage and fuel savings CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 24 12 8/9/2012 New Features Reduced Engine Load at Stop • Load on the engine is reduced when vehicle is stopped, therefore reducing fuel consumption • Useful for city traffic; frequent stops with engine idling at traffic lights • At a stop in drive, engine must provide fuel to overcome resistance of stalled torque converter – Engine torque absorbed by torque converter CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 25 New Features Park Brake Auto-Neutral • Vehicle which is left in Drive will burn more fuel than vehicle left in Neutral – Approximately 50% fuel savings in Neutral vs. Drive • Feature will automatically shift transmission to Neutral when park brake is applied • Operator must manually re-select range CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 26 13 8/9/2012 New Features Product Design Improvements • Hardware – TCM – Shift Selectors – Valve body module • • • • Pressure sensor Filter pressure valve body Internal harness Control valve body • Software and calibrations CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 27 New Features Product Design Improvements - (TCM) • Memory upgrades required for prognostics – 4MB Flash – 128kB External RAM • EMI improvements – Radiated emissions improved from current controller – Conformance to European standard 2006/28/EC as now recommended by APTA • Continuous Improvement/Obsolescence Items – Improved radiated emissions performance – Improved integrated circuit design – End of life components replacement – Improved supplier reliability CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 28 14 8/9/2012 New Features Product Design Improvements - (TCM) CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 29 New Features Product Design Improvements - Shift Selectors • “Service” indicator symbol added between digits • Service indicator will light for all applications as part of bulb check • Service indicator will light for 3 additional seconds after bulb check if prognostics enabled • Pushbutton and lever selectors included • No changes for all existing shift selector installations (backwards compatible) CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 30 15 8/9/2012 New Features Product Design Improvements - Shift Selectors Similar to today’s oil level readout, depressing up/down arrows or diagnostic button enters user into Diagnostic Mode “Service” NOTE: Information also on J1939 datalink 3/4000 Shift Selector Diagnostic or Up/Down Button Press (Example) Index and Indication Indicator Icon Added Readout 1st press Oil Level – “OL” “OL LO 02”, “OL HI 01”, … 2nd press Oil Life Monitor – “OM” “OM 88”, “OM 25”, … 3rd press Filter Life Monitor – “FM” “FM OK” or “FM LO” 4th press Trans Health Monitor – “TM” “TM OK”, “TM LO” 5th Diag Trouble Code – “d#” press Press and Hold Mode Button CHATO PATTERSON “d1 P 07 22”, “d2 P 13 12”… Clear current displayed monitor (Oil Life) ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 31 AGENDA • Product Overview – Product ratings – Product design • New Features – – – – Upgrades 4th GEN/MY09 Diagnostics/Prognostics Special features • Maintenance CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 32 16 8/9/2012 Maintenance Allison Service Tools • Earlier Prolink Devices had problems reading WTEC3 TCMs • Updated Prolink Can Read pre 4th Gen (built before 2006) • Allison PC based DOC – – – – Allison DOC™ For PC-Service Tool-Allison’s Essential Tool Allison DOC™ For PC (AED) Allison DOC ™ For Fleets-1000/2000 Allison DOC™ For Fleets-3000/4000 • TranshealthTM - Feb2006 Software update – Clutch Life Indicator – Results: Green, Red, or Gray CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 33 Maintenance Allison Service Tools Contact local distributor for purchase of equipment CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 34 17 8/9/2012 Maintenance Preventative Maintenance • Proper Oil/Filter Changes – TranSyndTM or TES295 Approved Fluid – Allison High Capacity Filters • Proper Engine Cooling System Maintenance • Check Fluid Levels – Dipstick – Oil Level Sensor CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 35 Maintenance Oil & Filter Change Interval Calculator • www.allisontransmission.com • Service • Fluid/Filter Change Intervals • Fluid and Filter Change Interval Calculator • See SIL 10-TR-99 for recommended intervals CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 36 18 8/9/2012 Maintenance Transmission Fluid and Filter Changes Interval 130 CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 37 Maintenance Reference Literature • General Fluid Recommendations – Service Tip #1390E • Fluid / Filter Change Intervals – Service Tip #1099F and SA5429EN • Schedule 1 TES 389 Fluids - WATCH 360 • High Capacity Filters – WATCH 359 • Mechanic’s Tips – MT3004EN • Operator’s Tips – OM3749EN • Shift Selector Code and Operation Manual – SA3360EN • Literature available through local distributor and at www.allisontransmission.com CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 38 19 8/9/2012 Maintenance Conventional Transmission ETC • Allison Transmission will provide for repairs or replacement, at its option, during the warranty period of each new B3/4/500R that is installed in a Transit Bus in accordance with the following terms, conditions, and limitations. – What is Covered • • • • • 24 Months standard (Extended coverage available for 5-years total coverage) No mileage limit Warranty period begins on date delivered to property Repairs and replacement Towing – To nearest Allison Transmission Distributor / authorized Dealer – What is Not Covered • • • • • • Damage due to accident, misuse, or alteration Chassis, Body, and Components Damaged caused by lack of maintenance / None approved fluids Repairs by unauthorized dealers Non-Genuine Allison Transmission parts use Extra expenses – Price • • • B300R = $1,400 B400R = $2,160 B500R = $2,350 CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 39 END CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 40 20 8/9/2012 BACKUP CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 41 Title of First Slide Would Be Here • First main bullet – Sub-bullet • Second main bullet • Third main bullet – Sub-bullet – Sub-bullet – Sub-bullet CHATO PATTERSON ALLISON TRANSMISSION, INC. CONFIDENTIAL SLIDE 42 21 7/2/2012 Product Review Allison Transmission, Inc. Confidential Why Allison Hybrid? • • • • • • • • Proven reliability, durability and performance Fuel and emissions reduced Regenerative braking and savings Fast, smooth acceleration Quiet operation Easy installation, easy maintenance Smart electrification Comprehensive coverage 1 7/2/2012 Allison Transmission, Inc. Confidential Allison System Architectures • Allison began with a series hybrid system – Series is much easier to develop but has limitations – Studies of two concepts showed parallel (Allison EVT Based Parallel Hybrid) is superior to series concept – Allison Series ES40 deployed at OCTA and Portland in 2001 • Allison selected a parallel system – Superiority during engineering studies and investigations – Field experience with early Es40 units at OCTA & Portland – H 40/50 EP was chosen due to better fuel economy and better system performance than series hybrid Allison Transmission, Inc. Confidential Series Hybrid Calculation Electrical path Only Engine Generator Motor Vehicle Energy Storage Mechanical to Electrical HP X 91% Inverter X 96% Inverter Electrical to Mechanical X 96% X 91% = HP X 80% No Mechanical Path!! Low Efficiency!!! 2 7/2/2012 Allison Transmission, Inc. Confidential Allison Parallel Hybrid Calculation Two-Mode Compound Split Parallel Hybrid Architecture Electrical path Engine “A” Motor/ Generator “B” Motor/ Generator Vehicle Energy Storage Mechanical path Nearly 100% Efficient Mechanical Path Over 90% Efficiency over 70% of the time!!! Allison Transmission, Inc. Confidential Series Hybrid vs. Parallel Losses 40 Series Hybrid System Energy Losses 35 30 25 Parallel Hybrid 20 15 Series system efficiency goes down as speed increases and as temperature increases 10 5 Allison Parallel Hybrid has less Energy Losses = Less Emissions, Fuel and Noise 0 0 10 20 30 40 50 60 Miles Per Hour 3 7/2/2012 Allison Transmission, Inc. Confidential Selection Decision Result Matrix ES40 Series Weight Volume 965 lbs (ET40 9721 in3 and Generator) (ET40 and Generator) EP40 and EP50 Parallel 900 lbs 6214 in3 Length 35.8 in 33.7 in Architecture Complex interface with vehicle hydraulic, mechanical and electrical systems. Enables simpler hydraulic, mechanical and electrical interface. Product Performance Fuel Economy 5.0 mpg 5.5 mpg NOx Emissions 14.2 g/mile 13.4 g/mile PM Emissions 0.02 g/mile 0.01 g/mile Top Speed 65 mph 65 mph Starting Gradeability 18% 26% Speed on Grade 16% @ 8 mph 16% @ 10 mph System Architecture, Ratings and Components 4 7/2/2012 Allison Transmission, Inc. Confidential Ratings and System Components H 40/50 EP Drive Unit • Same proven form, fit and function • Two-mode parallel hybrid operates automatically as a parallel hybrid or series hybrid • Continuously variable drive with an infinite number of ratios • Automatically adjusts ratios to operate at optimum power curves to attain best performance and fuel economy Allison Transmission, Inc. Confidential H 40/50 EP Drive Unit 5 7/2/2012 Allison Transmission, Inc. Confidential Ratings and System Components Allison Hybrid Bus Ratings Allison H 40 EP Drive Unit - Transit Bus Continuous: Weight: 919 lbs (417 Kg) Dry, 944 lbs (428 Kg) Wet 280 hp (209 kW) Size: 32 (813) L X 17 (432) W X 12 (305) H* in (mm) Rated Input Torque: *Height measured from centerline to sump 910 lb-ft (1234 N•m) Rated Input Speed: 2300 RPM Allison H 50 EP Drive Unit - Suburban Coach / Articulated Bus Continuous: Weight: 919 lbs (417 Kg) Dry, 944 lbs (428 Kg) Wet 330 hp (246 kW) Size: 32 (813) L X 17 (432) W X 12 (305) H* in (mm) Rated Input Torque: *Height measured from centerline to sump 1050 lb-ft (1424 N•m) Rated Input Speed: 2300 RPM Allison Transmission, Inc. Confidential Ratings and System Components Computer Controllers (TCM/HCM) • New 4th Gen H 40/50 EP Controllers – Greater processing power and memory capability – Memory expansion allows for further technology evolution – Fewer electrical connections for greater system durability and reliability – Full optimization with latest engines – Allison HyValue™ performance features HyGain™, HyIdle™ and HyTraction™ 6 7/2/2012 Allison Transmission, Inc. Confidential Ratings and System Components Dual Power Inverter Module 2 (DPIM2) • Specifically designed by Allison to meet customer needs • One DPIM includes two inverters • 600 Volts nominal DC • 150 kW continuous 3-phase AC output • Simply cooled by Drive Unit cooling circuit • Mass: 165 lb (75 kg) • SAE J1939 Control Communications Allison Transmission, Inc. Confidential Allison Energy Storage System • Allison ESS has demonstrated acceptable life for transit application • Continuous improvements are made including Gen 2.0 battery module and control system improvements • Utilizes the second generation Nickel Metal Hydride battery cell technology from Primearth (PEVE) • Common high capacity hardware handles full range of bus sizes 7 7/2/2012 Allison Transmission, Inc. Confidential ESS Refresh Service Kit P/N 29551338 • • • • • • • • • • Same for H 40 EP or H 50 EP Six sub-packs Gen2.0 NiMH cells 240 cell and all matched in production by PEVE Six fan relays Miscellaneous parts Services ESS1* or ESS2 16-week lead-time 6-month parts warranty List price: $31,450 USD for 2011 * Note if you have older ESS1 (prior to ESS2) then you also need Conversion Kit P/N 29551897 ($1,186 list) Allison Transmission, Inc. Confidential H 40/50 EP Warranty and Extended Coverage ; ESS longevity is dependent upon many factors and can vary. 8 7/2/2012 Related Components Allison Transmission, Inc. Confidential 2010 North American Hybrid Engines • • • • Smaller displacement Drive unit commands engine Optimized for H 40/50 EP Validated 2010 EPA engines – ISB-280 hp (209 kW) – ISL-280 hp (limit 330 hp to 280 hp) – ISL-330 hp (246 kW) 9 7/2/2012 Allison Transmission, Inc. Confidential DC-DC Converter “Beltless Alternator” Allison 2011 H 40 EP and H 50 EP Hybrid Software Release (Jan. 31, 2011) Supports DC-DC Converters (Beltless Alternators) Hi Voltage AC llison A Dual ower P Inverter Module 2 (DPIM2) Allison Hybrid Drive nit U == 24 24 olts V Volts DC DC Supplies additional 12/24 Volt electrical system and eliminates belt driven alternators Vanner DC-DC onverter C “Hybrid Beltless Alternator” Allison Transmission, Inc. Confidential DC-DC Converter “Beltless Alternator” • Reduces parasitic loads on engine to save fuel and reduces emissions • Increases safety and reliability • Eliminates hardware – – – – Alternator Regulator Belts Pulleys / Idlers • Eliminates concerns and cost – Routine maintenance – no belt, idler, voltage regulator – Transient power spikes – longer life for on-board electronics – Alternator safety concerns – no moving parts to fail unsafely 10 7/2/2012 Allison Transmission, Inc. Confidential DC-DC Converter “Beltless Alternator” • Software supports two converter models – 250 amp-at-idle (Vanner HBA400-H40EP) – 300 amp-at-idle (Vanner HBA500-H40EP or HBA500-H50EP) • Full power at curb idle and high temperatures – 250 amp model equivalent to 350A-400A alternator – 300 amp model equivalent to 450A-500A alternator Allison Transmission, Inc. Confidential DC-DC Converter “Beltless Alternator” • 25% lighter than traditional alternators (75 lbs) – Saves hundreds of gallons of fuel on weight alone over buses life • Extensive lab and in-service testing • No charge for software – Converter purchased separately via Vanner • Work underway on additional electrification capability – Capability up to 30+ KW (electric AC and other systems) – See next slide 11 7/2/2012 Allison Transmission, Inc. Confidential DC-DC Converter “Beltless Alternator” Fuel Economy 12 7/2/2012 Allison Transmission, Inc. Confidential HyGain™ Hybrid Technology 0.200 g acceleration HyPerformance 0.115 g acceleration Performance 0.100 g acceleration Higher Acceleration HyStandard * 0.090 g acceleration Economy HyEconomy 0.080 g acceleration Higher Fuel Economy * HyStandard is the default setting Allison Transmission, Inc. Confidential HyGain™ Hybrid Technology 13 7/2/2012 Allison Transmission, Inc. Confidential H 40/50 EP Fuel Economy Chassis Dyne Testing – EPA 2010 Engines Testing completed in Q3/Q4 2010 at Environmental Research Management Division of Canada 8 7 Fuel Economy (MPG) 6 5 Conventional 4 ISL H40 EMP ISB H40 Hydraulic 3 2 1 0 CBD UDDS MAN OCTA 29% to 47% Improvement Depending on Configuration and Cycle Allison Transmission, Inc. Confidential Liberty Lines Fuel Economy Calculated MPG 5.6 5.4 Miles per Gallon 5.2 5.0 4.8 4.6 4.4 236 239 244 249 252 256 257 264 283 293 Bus Number 14 7/2/2012 HUSH Mode Allison Transmission, Inc. Confidential HUSH Mode – Future Projects • Temporary state where vehicle is driven solely by hybrid motor and engine remains at idle • Quiet operation used for specific operational environments – Tunnels, enclosed terminals, etc. • Standardized software capability planned for MY2013 release 15 7/2/2012 Allison Transmission, Inc. Confidential HUSH Mode Examples – Future Projects HUSH Mode Expanded HUSH Mode • Developed specifically for Tunnel in Seattle (KCM) • Allison is planning to develop “modified” HUSH modes • Decreased noise and reduced emissions • Provide opportunity for duty cycles such as mall areas, inside bus garages and other locations • No significant impact on ESS life • Potential to use GPS and other external inputs to activate this mode (project in process with KCM) Engine On/Off is next step Market Presence 16 7/2/2012 Allison Transmission, Inc. Confidential All N.A. OEMs Offering Allison Hybrids OEM Gillig Daimler Bus NA (Orion) New Flyer Volvo (Nova) Alexander Dennis* North American Bus Ind. Motor Coach Industries Eldorado-National Engine Option ISB ISB ISB and ISL ISB and ISL ISL ISB and ISL ISL ISB * Tandem Axle Double Deck for North America Allison Transmission, Inc. Confidential Allison Hybrid Releases International OEMs Offering • • • • • Solaris – Poland APTS – Netherlands Volgren/Iveco – Australia SOR – Czech Republic Optare – UK 17 7/2/2012 Allison Transmission, Inc. Confidential Allison H 40/50 EP Bus Statistics Buses Worldwide • H 40/50 EP 2-mode hybrids as of July 2011 – – – – – – – Buses delivered Cities worldwide U.S. states Countries worldwide Accumulated miles Fuel saved CO2 eliminated 4,616 216 39 of 50 13 374,842,625 mi 603,234,236 km 19,925,189 gal 75,416,842 liters 197,185 metric tons • World’s largest producer of HD transit hybrids • Offered by all N.A. bus manufacturers Allison Transmission, Inc. Confidential Hybrid Fleet Deliveries and Orders • Recent competitor press release states that 3,500 units have been delivered or ordered worldwide • Almost half of this volume is one customer • Allison – As of July 2011, 4,616 units have been delivered 18 7/2/2012 Allison Transmission, Inc. Confidential Allison H 40/50 EP Hybrid Deliveries in North American Transit Buses (July 2011) Allison Transmission, Inc. Confidential Allison H 40/50 EP Hybrid Deliveries in North American Transit Buses (July 2011) 19 7/2/2012 Allison Transmission, Inc. Confidential Service Network BAE Service Network Allison Service Network Summary 20 7/2/2012 Allison Transmission, Inc. Confidential Summary • Released in all N.A. OEMs with various engine configuration • Sold more than 5,000 units in Worldwide • Full application coverage • Efficient system architecture and drive unit design • Real-world fuel economy gains • HUSH Mode, electrification, Engine on/off and ESS advances • Extensive service network Allison Transmission, Inc. Confidential Summary • Allison hybrids proven to be most dependable and efficient hybrid systems at work anywhere in the world 21 7/2/2012 22