Patch Box for Diesel Natural Gas Dual Fuel Kits Achieving Real Fuel Cost Savings by Improving Dual Fuel Blend Algorithm and Incorporating Vehicle Network Data

Penn State Hybrid and Hydrogen Vehicle Research Lab Problem Statement Ten million Diesel trucks in existing fleets Long expected useful life High and rising Diesel fuel costs Cost of natural gas about half Diesel fuel Bolt on “dual fuel kits” add natural gas to Diesel engines Kits simply add natural gas on top of stock Diesel fuel Creates more power but minimal fuel savings realized Factory emissions are effected Need optimal control of Diesel/NG blend 11/14/2018 Penn State Hybrid and Hydrogen Vehicle Research Lab

Penn State Hybrid and Hydrogen Vehicle Research Lab Solution Diesel/NG engine tests determine best blend Patch Box reads digital network truck data Patch Box alters truck and kit fuel signals: Calculates best blend to save fuel and lower emissions Intercepts and changes gas pedal signal Lowers signal for Diesel flow to engine Lowers signal for gas flow through kit Altered blend retains stock engine power curve, feel Retrofitted Diesel truck fleets can then reduce fuel costs and utilize natural gas 11/14/2018 Penn State Hybrid and Hydrogen Vehicle Research Lab

Steps to Conversion 1: Engine Mapping Dyno test engine at constant speed and load Engine installed on an engine dynamometer Vehicle on chassis dynamometer Vary Diesel natural gas blend ratio Measure emissions and efficiency points Build a map of best operating points Load operating map into Patch Box software Develop algorithm using map and vehicle CAN data Calibrate engine throttle signal to map algorithm 11/14/2018 Penn State Hybrid and Hydrogen Vehicle Research Lab

Steps to Conversion 2: Install Kit, Fuel System, and Patch Box Lower Diesel Flow Map and Algorithm Reduce Diesel throttle signal TPS Throttle Signal TPS Truck Network Data 11/14/2018 Penn State Hybrid and Hydrogen Vehicle Research Lab

Penn State Hybrid and Hydrogen Vehicle Research Lab Patch Box Development In-house electronics design Microprocessor Power supply Signal input and outputs Controller Area Network CAN channels Market survey of commercial electronics Compare performance, features, cost Leverage engine data from current Ben Franklin funded Hawbaker CNG project 11/14/2018 Penn State Hybrid and Hydrogen Vehicle Research Lab

PATCH BOX Business Model Products and services to be provided: Engineering services Non-recoverable engineering fees to add new models/years Partner with truck manufacturers and engine test labs Use existing engine test data where available Patch Box electronics package Market electronics and installation kit to large fleets Customer installed Provide diagnostics , service, and repair 11/14/2018 Penn State Hybrid and Hydrogen Vehicle Research Lab

PATCH BOX Business Model (cont.) Annual truck fuel costs and potential savings Typical 300 miles per day 4 mpg Diesel at $4 per gallon is $300/day $78,214 per year Replace 25% at $2 per gallon 12.5% savings on fuel or $9777/year Total payback less than two years Savings could reach 30-40% with refinement of engine map Truck life 10+ years Pricing Dual fuel conversion kits $3000-$5000 Natural gas tanks $5000-$10,000 Installation ~$3000~$5000 Patch Box target price would be ~$1000-$2000 11/14/2018 Penn State Hybrid and Hydrogen Vehicle Research Lab

Penn State Hybrid and Hydrogen Vehicle Research Lab Team and Partners Joel Anstrom, PhD Penn State Larson Institute Electronics packaging, product development experience with IBM Timothy Cleary, Penn State Larson Institute Vehicle control systems experience with GM Penn State Bus Research Center Penn State Energy Institute 11/14/2018 Penn State Hybrid and Hydrogen Vehicle Research Lab

Commercialization Path Forward Complete testing current system Finalize features and design Optimize design for cost and features Engage technical and business partners Finalize business model 11/14/2018 Penn State Hybrid and Hydrogen Vehicle Research Lab

Penn State Hybrid and Hydrogen Vehicle Research Lab Summary Slide Very large built Diesel Truck fleets Truck service life typically 10-20 years Potential savings 12.5% ~ 30% Two year payback per vehicle Significant increase in natural gas utilization in Pennsylvania Significant reduction in foreign imports of petroleum 11/14/2018 Penn State Hybrid and Hydrogen Vehicle Research Lab

Penn State Hybrid and Hydrogen Vehicle Research Lab Contact Joel Anstrom 205 Transportation Research University Park, PA 16802 814 863-8904 jra2@psu.edu 11/14/2018 Penn State Hybrid and Hydrogen Vehicle Research Lab