1. Topic: The Hybrids are here! By: Scott Sine
FALL TRAINING 2006
Topic: The Hybrids are here!
By: Scott Sine

2. What is a Hybrid?
A hybrid vehicle uses more than one source of producing, storing and delivering power to increase overall efficiency.
The “primary” source is the diesel engine, and the “secondary” or “hybrid” source is electrical or hydraulic.
A hybrid can capture and store energy during braking that otherwise would be lost as heat through braking.
It then can reuse this energy for driving demands such as launch and acceleration.
A hybrid might combine the power from the diesel engine with stored energy from a second source and deliver both to the driveline. In this way, the hybrid system can cause both sources to operate most of the time near their optimum conditions rather than pushing either source’s capacity limits during high demand or wasting energy during low-demand excursions.
Courtesy of TMC

3. DIFFERENT TYPES OF HYBRIDS

4. HYBRID DEFINITIONS
Hybrid-Electric - Primary engine is diesel or gas; secondary motor is electric.
Hybrid-Hydraulic - Primary engine is diesel or gas; secondary motor is hydraulic.
AC/DC Inverter - Electrical device that converts AC voltage to DC voltage or DC voltage to AC voltage. The electric motor on a hybrid uses and creates AC voltage. The hybrid batteries store electricity as DC voltage.
DC-DC Converter - Electrical device that converts high voltage DC current to a lower voltage DC current.
APG (Auxiliary Power Generator)- Electrical device that converts high voltage DC current into 120/240 AC current.
High Voltage Cables - Electrical cables that conduct more that 50 AC or DC volts. Industry standard is to wrap the cables in bright orange conduit.
Battery Pack - Batteries that store high DC volts. They are used to store energy from regenerative braking, the diesel engine or provide energy to drive a hybrid electric motor.
Courtesy of TMC

5. HYBRID APPLICATIONS
Dry Van – Stop and go driving & regenerative braking.
Utility trucks – Pto applications & ePto –engine off hydraulic functions.
Bus applications
Example: 24 Hybrid Test Units
4300 Chassis, Altec L42M Body
DT HP, 560 lb-ft Engine
44KW Electric Motor
340V, 50kW Li-lon Battery (4)
Engine On/Off PTO Capable
Auxiliary Power Generation
Telematics Added for Vehicle Performance Monitoring

6. What Makes The System Work?
Diamond Logic Electrical System
Eaton Hybrid Electric Powertrain
Aware® Vehicle Intelligence System
Body Integration

7. DIAMOND LOGIC BUILDER

8. What Makes The System Work?
Diamond Logic Electrical System
Hybrid Electric Powertrain
Aware® Vehicle Intelligence System
Body Integration

10. Direct Hybrid – Engine Starting Mode
AutoClutch
Motor
AutoShift (AMT)
Engine
Torque
Neutral
Gear
Position
Engaged
Discharging
Mode
Battery System

11. Direct Hybrid – Electric Only Mode
Engine
AutoClutch
Motor
AutoShift (AMT)
Motor
Torque
Drive
Torque
Disengaged
where, Drive Torque =
Motor Torque (Tm)
x Gear Ratio
Discharge
Mode
Battery System

12. Direct Hybrid – Engine & Motor Drive Mode
AutoClutch
Motor
AutoShift (AMT)
Engine
Torque
Combined
Torque
Drive
Torque
Engaged
Discharge
Mode
where, Drive Torque =
Engine Torque (Te) +
Motor Torque (Tm)
x Gear Ratio
Battery System

13. Direct Hybrid - Engine Only Mode
AutoClutch
Generator
AutoShift (AMT)
Engine
Torque
Engine
Torque
Drive
Torque
Engaged
Charging
Mode Optional
where, Drive Torque =
Engine Torque (Te)
x Gear Ratio
Battery System

14. Direct Hybrid – Regen Braking Mode
Generator
Engine
AutoClutch
AutoShift (AMT)
Engine
Torque
Regen
Torque
Inertial
Torque
Engaged or
Disengaged
Charging
Mode
where, Regen Torque =
Inertial Torque (T)
x Gear Ratio
Battery System

15. What Makes The System Work?
Diamond Logic Electrical System
Eaton Hybrid Electric Powertrain
Aware® Vehicle Intelligence System
Body Integration

16. Integration of The Three Systems
J1939 Data Link
EATON
Altec
INTERNATIONAL
Auto shift Transmission
Hybrid Controller
Auxiliary Power Generator
Remote Power Modules
Fiber Optic System
Hydraulic System
DT 466 Engine
Electronic System Controller
Center Panel Switches
ABS System
Chassis Wiring
AWARE Telematics
Gauge Cluster
Internet Portal
Geo-Synchronous
GPS
Satellite
1xRTT

17. Benefits Fuel Consumption Quiet Operation 1/3 from Driving
2/3 from Work Site
Quiet Operation
Public
Operators

18. HEV Utility Vehicle Benefits
Noise
Driving: Potential for Quieter Launches
Jobsite: Significant Engine Off Time
Drivability
Equal to or Better Drivability
Engine Downsizing
Future Potential to Downsize Engine and Electrify Accessories
Auxiliary Power Generation
25 KW Exportable Power Available

19. Operators’ & Supplemental Manuals
Eaton Hybrid System Operators’ Manual
International Chassis Operators’ Manual
Altec Operators’ Manual
Supplement

20. HYBRID TECH SUPPORT
International Tech support to take the initial calls.
-Tech support will guide tech through the diagnostic procedures.
-If problem is not found, then the Vehicle Programming Group will take over the call and do more advanced diagnostics.
-If the Vehicle Programming Group is unable to resolve the issues, an Application Engineer will resolve any or all issues.
-Tech support will also have the ability to do remote diagnostics using the web site
Vendor Tech Support
- Eaton & Enova will have tech support for hybrid specific questions.
-International will forward tech support calls to appropriate vendor if the problem is within the hybrid system.
-Hybrid vendors have mobile service technician to travel to dealerships to do diagnostics and repair work until the International tech is trained.

21. HYBRID TRAINING Hybrid System Specific Training -Eaton Hybrid System
-Enova Hybrid System
-High Voltage Training?
-Hybrid Computer Based Training (CBT)
-Diamond Logic Builder Hybrid Specific
-TSI High Voltage Best Practices.

22. Safety Considerations: High Voltage Cables
Bright Orange to Correspond with Established Industry Practices (Prius and Insight)
Orange High Voltage Cable on Eaton Utility truck
Orange High Voltage Cable on underside of Honda Insight

23. Electric Shock Protection
High voltage system, including the motor & battery, is isolated from the vehicle chassis and body.
Contact with the HEV battery or other high voltage components can only occur if the Power Electronics Carrier (PEC) is damaged and the contents are exposed, or the PEC is deliberately opened without authorization.
PPE (Personal Protective Equipment) – gloves, face shield, boots, & insulated tools.
The high voltage cables are protected by bright orange rubber casing and orange plastic conduit.
Additionally, the high voltage AC cables have no current in them after the vehicle has been shut down or disabled for at least one minute.

24. High Voltage Electrical System Disablement
Option 1 (Preferred)
Turn Ignition (Key) off on Dash
Engine will shut down
Dash lights will shut down
HEV system will shut down
HEV batteries are still “live” but are isolated in PEC
Option 2
See hybrid vendors procedures for further maintenance disablement.

25. Eaton System
Eaton System Overview

26. Eaton System

27. Eaton System

28. Eaton System

29. Eaton System

30. Eaton System

31. Eaton System

32. Eaton High Voltage Component Locations on a 4300.
Hybrid Electric Motor
Battery Pack
AC/DC Inverter
DC/DC Converter

33. ENOVA SYSTEM
Enova System Overview

34. ENOVA SYSTEM

35. ENOVA SYSTEM

36. Hybrid documents on ISIS and Sales page
G letter
SFN

37. Emergency Response Procedures
Vendors responsible for emergency response procedures
All emergency response documents found in ISIS
Trucks are labeled as a hybrid and high voltage components are clearly identified
Fleets to Alert Local Emergency Personnel of Hybrid Truck Presence

38. Questions & Answers Q: What is the life of the Eaton HEV battery pack?
A: The life of the battery pack on the Eaton hybrid system is estimated at 6-8 years.
Q: Type of batteries used in the HEVs?
A: The Eaton hybrid system utilizes Lithium Ion batteries.
Q: What is the up-charge for the hybrid feature?
A: Base system will be around $47,000 to $50, The optional ePTO adder will be roughly $15,000. The exportable power option is not yet available. These prices are subject to change.