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
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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
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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
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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
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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
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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
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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
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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)
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Allison Transmission, Inc. Confidential
Service Network
BAE Service Network
Allison Service Network
Summary
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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
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