Make Every School Bus Better.
Thomas Bus
Steve D Goss
Oct 4, 2011
Sanjay Kumar Jim Lannan
Agenda
1. Update on successes
2. IC Bus ‘Fluid’ Economy Claims
3. Cummins Fuel Economy
4. How to sell Cummins
School Bus Industry Data
 Industry data suggests a 5% gain in Cummins
market share (50% to 55%)
 Recently gained business with largest bus customer
IC Bus ‘Fluid’ Economy Claims
 IC Bus published report of fuel economy testing
stating ‘up to a 4.5%’ advantage vs Cummins
 Cummins responded to claims outlining the points in
question including:
– Transmission shift calibration selections
– Aftertreatment regeneration
‘Fluid Economy’ also ignores the price differential
Avg. Diesel Price
Avg. Bulk DEF Price
$3.80
$2.85
Transmission shift calibrations
 IC Bus did not outline what shift calibrations
were used during testing
 Cummins testing validates that proper selection
can result in significant fuel economy gains
Aftertreatment Regeneration
 Typical regen cycle on MF 7 at approx. 135 miles
– Same distance as test
 More EGR = More Soot Generated = More Regens
 Regenerations require the use of more fuel thus
diminishing overall fuel economy
‘Fluid’ Economy
 IC’s claims of ‘fluid’ economy inaccurately represent
total cost of ownership
 No mention of DEF consumption thus inability to
analyze actual DEF usage for test
 Differences in DEF and diesel fuel pricing vary
significantly so need to be analyzed separately
Cummins Fuel Economy
 ‘Others Test. We Deliver’
 Cummins and Thomas Bus both currently testing
ISB Fuel Economy Tops DTNA Testing
Freightliner M2 106
with Cummins ISB
(EPA 10)
Vs.
International Durastar 4300
with
MaxxForce DT (EPA10)
Result
• 8.5% Better Fuel
Economy
• 2 Regens for ISB Vs 10
for MaxxForce DT in the
14 hour test period
In Cylinder NOx Control Challenges
 Fuel economy significantly compromised
 Increased risk of EGR condensation
 Significant increase in heat rejection
 Complex system integration
 Driver satisfaction significantly compromised
 Power density and torque limitations
In Cylinder NOx Control Challenges
Fuel Economy Significantly Compromised
 5-9% disadvantage
 Combustion efficiency degradation:
– Higher engine pumping losses
– Increased intake & exhaust manifold pressures
– Increased Particulate Filter regenerations
In Cylinder NOx Control Challenges
Increased Risk of EGR Condensation
 Higher EGR flow produces excessive acidic
condensation
 Power cylinder corrosion
– Rapid deterioration of lube oil
 Reliability and durability compromised
In Cylinder NOx Control Challenges
Significant Increase in Heat Rejection
 20% increase
 Higher EGR flow:
– Multiple EGR coolers on & off engine
– Larger vehicle cooling package
– Major redesign of radiator / Charge Air Cooler / Fan
systems
In Cylinder NOx Control Challenges
Complex System Integration
 Higher EGR flow
 Air handling system
 Vehicle cooling system
In Cylinder NOx Control Challenges
Driver Satisfaction Significantly
Compromised
 Higher EGR Flow
– Throttle Response
In Cylinder NOx Control Challenges
Power Density and Torque Limitations
 Deterioration of 50 – 100 hp for same displacement
 Higher EGR flow & EGR controls compromises
engine performance
Bus Owners Have Two Choices for 2010
Advanced EGR
Radiator
Intercooler
Clean Air
DOC
DPF
Higher heat rejection:
Larger Radiator
Larger Charge air cooler
EGR + SCR After-Treatment System Setup
Catalyst
DOC
DPF
AMOX Cat
Doser
Tank
Emissions Control Technology
NOx is converted into N2 and H20
downstream from the engine using
a diesel exhaust fluid catalyst
Exhaust gas is re-circulated
through the cylinders reducing
peak combustion temperature,
lowering NOx emissions
 SCR allows for a lower EGR run rate,
 EGR introduces excessive carbon and
increasing fuel economy and engine life
soot into the cylinder, causing pre-mature
liner and piston wear
 With emission controls moved out of and
away from the engine, power generation is
unhindered
 Higher EGR cooling capacity strains the
cooling system, leading to shorter coolant
change intervals and component failure
The Facts about the Fluid – DEF Properties
 DEF is safe to handle and store
– Non-toxic
– Non-polluting
– Non-flammable
Acidic pH
 DEF freezes at 12° F (-11° C).
However, frozen DEF does not impact
start up and normal operation of the
vehicle
 When stored at extreme
temperatures, neither DEF nor Urea
become toxic
 DEF is slightly alkaline with a pH of
approximately 9
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DEF
DEF - Myths & Facts
 Navistar’s claim of ammonia level being close to 1000
ppm in a near empty DEF tank is a ‘stretch of
imagination’
 DEF, when heated and maintained at a constant
temperature 120 degrees Fahrenheit, will very slowly
start to form small amounts of ammonia
 It would take over two years at this constant temperature
to convert DEF into levels of 1000 ppm of ammonia
 Such a situation can be probably modeled in ‘laboratory
setting’ but not in the real world
Cummins ISB6.7 vs Navistar MaxxForce 7
Competitive Comparison
Cummins ISB6.7 vs. MaxxForce 7
Cummins
Advantage
Feature
Displacement
Configuration
Horsepower
6.7L
Inline 6
200 - 325 HP
6.4L
V-8
200 - 300 HP
Fewer parts /
better reliability
Better power
density
Better power
Torque
520 -750 lb-ft
560 - 660 lb-ft
Aspiration
One - variable
geometry turbo
(2) dual stage
Fewer parts /
turbos
better reliability
Oil change
15,000 mi.
10,000 mi.
interval
(24,000 km)
(16,000 km)
Lower maintenance
cost / better uptime
Engine weight (dry)
1,150 lb (522 kg)
1,225 lb. (556 kg)
Lower weight
density
Competitive Comparison Summary
Feature
Cummins ISB6.7
Advantage
MaxxForce 7
Complexity
Single VG turbo, single
radiator & charge air
cooler
Dual turbos, multiple
charge air coolers and
radiators, large
EGR cooler
Emission
Controls
Diesel Particulate Filter
and Selective Catalytic
Reduction
Diesel Particulate Filter
and Advanced EGR
15,000 mile service
intervals and 3,500
authorized service
locations
10,000 service intervals
and 900 authorized
service locations
Maintenance
and Service
Designing For the School Bus Market
 Reliability
 Total cost of ownership
 Low maintenance
 Safe Operation
 Sociability
 Performance
 Weight/space
 Minimal driver training
 Ease of operation
 Information systems
 Emissions compliance
Cummins Diesel Power
ISB6.7 & ISC8.3 Features
 Improved combustion system
 Advanced VGT Turbocharger
 Improved cooled-EGR
subsystem/cooling circuit
 Fully integrated electronic controls
 New Cummins Aftertreatment System
ISB6.7 & ISC8.3 Customer Benefits
 Best-in-Class Fuel Economy
 Improved Reliability
 Minimal Installation Impact
 Stronger Performance
 Increased Power Density
Cummins Natural Gas Power
ISL G Product Features and Benefits
 8.9L Stoichiometric Cooled EGR engine
with spark ignition
 In production since mid-2007
 Low emissions
 Diesel-‘like’ Performance, Reliability
and Durability
 Over 80% parts commonality with ISL9
 Compatible with CNG, LNG, or Biomethane (RNG)
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2010 ISL G Natural Gas
 Stoichiometric Combustion
Cooled EGR
 Three Way Catalyst
Aftertreatment
– Same rated speed as ISL9
diesel
– Passive device
– 30% more torque at idle
– Maintenance-Free
– 5% better fuel economy
– Packaged as a muffler
Integrating Critical Subsystems
Filtration and
Diesel Exhaust Fluid
Electronic
Controls
Combustion
Technology
Aftertreatment
System
Turbochargers
Fuel
Systems
PowerSpec
 Software Application
– Provide gearing recommendation
– Customize engine ‘specs’
– Collect valuable trip information
– Free to download and use
www.powerspec.cummins.com
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INLINE™ adapter
 Cummins datalink adapter used
in conjunction with PowerSpec
 Allows user to:
– transfer feature parameter settings
– download trip information
 INLINE™ 5 kit (part number: 4918416) includes all
necessary parts to connect the vehicle to a laptop
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Make Every School Bus Better.
TM
 Better Fuel Economy.
– Up to 3% better than our ’07 ISB and ISC
– Joint testing underway on EPA 2010 product
 Better Performance.
– Improved driveability and throttle
response
 Better Reliability.
– Best-in-class durability and dependability
 Better for the Environment.
– Near zero NOx and PM emissions
– Improved MPG results in smaller carbon footprint
Saf-T-Liner EFX
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Common Parts with HDX means
faster design cycle
Sub-system ID (estimated number of parts to be eliminated ~100)
Front Roof Cap
(6)
Destination Sign
(20)
#2 Hood
(2)
Clearance/Marker Lights
(6)
Windshield
(3)
Wipers
(15)
Header Height/Drip Rail
(4)
“A” Mirrors
(8)
Hazard Lights
(4)
“B” Mirrors
(8)
Bumper
(10)
00000-00-Thomas Built Buses Standard Template.ppt
Walk Gate
(8)
Headlight & Bezel
(4)
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Driver Focused Improvements Storage
•
Added driver’s
storage to right
side dash
•
Can be used for
safety equipment
storage or for
personal items
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Driver Focused Improvements Visibility
• Improved
visibility
•
HDX windshield
•
Larger driver’s side
window
•
Argosy headlights
•
Running lights standard
00000-00-Thomas Built Buses Standard Template.ppt
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Driver Focused Improvements Visibility
•
Improved defrost
capability
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Technician Focused
Improvements - Access
•
Headlight doors and
removable grill provide
easy service access
• Lights
• Wiper motors and
linkages
• Washer fluid
• Power steering reservoir
• Defrost heater relays
00000-00-Thomas Built Buses Standard Template.ppt
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Technician Focused
Improvements - Access
•
Lower driver side
access panel for
chassis PDM’s
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Technician Focused
Improvements – Misc.
•
More reliable components
should translate to fewer
replacements
•
Increased parts
commonality means less
parts for technician to
maintain
•
Bus can still be jacked up
by front bumper
00000-00-Thomas Built Buses Standard Template.ppt
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Family Look
HDX
00000-00-Thomas Built Buses Standard Template.ppt
EFX
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EFX Status
Gate 9/8 Status: Passed (May 9th)
Gate 7/6 Status: Passed
Scheduled SOP: Q1 2012
Project Budget approved.
Bus to be showcased at NAPT in October.
Estimated start of production 1Q2012
Pilot/Preseries
 We’ll be soliciting orders within the next month
 Will come with new sales codes – WebEx will be scheduled to assist in ordering
process
 Will come with $300 cost increase
Design Validation
 Cooling passed.
 FEA and fatigue analysis in progress.
 Defrost testing planned for early October
 6000 mile durability to begin mid-September at Bosch Proving Grounds.
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Questions?
Thomas Built Buses Dealer Sales Meeting 2012
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