1. University of Wisconsin Madison Presented by: Eric Schroeder Adam Schumacher 2005 SAE Clean Snowmobile Challenge Design Presentation

2. Design Considerations: Market Survey  Survey in Fall 2003  75 student riders  Customers Want:  Acceleration  Agility  Historical Best Sellers  Ski-Doo Rev Platform  Polaris 600 XC SP  Top speed not given high priority Fall 2003 Survey (Experienced Riders) 75 Students Surveyed

3. Engine Selection  Engine emissions from 2002 and 2003 CSC and current commercial snowmobile engines  Ski-doo SDI system reduces two stroke emissions by 50% 1  Polaris Liberty engine has lowest emissions of commercially available engines HC g/kW-hr CO g/kW-hr NO x g/kW-hr Two-stroke average (SwRI 2002) 1895170.72 Idaho four-stroke (CSC 2003) 2.123.85.5 Idaho four-stroke (SwRI 2002) 3.5152.90.19 Arctic Cat 660 (4s) (SwRI 2002) 6.279.910.6 Polaris Liberty (4s) (SwRI 2002) 3.279.17.0 1: http://www.ski-doo.com/media/2004_SOTY.pdfhttp://www.ski-doo.com/media/2004_SOTY.pdf * SwRI 2002 (Leda, White) Snowmobile Engine Emissions Testing

4. Powertrain Enhancement Unique Hybrid Electric Design Increases performance without need for larger engine Motor mounts to custom student machined chaincase Measured Performance Increase Improves acceleration from 30- 60 km/hr Does not increase top speed of the snowmobile

5. Hybrid Energy Storage  48 Volt Battery Pack  4 Johnson Controls Inspira Batteries  6.5 Amp-hour capacity  Sufficient for 30 seconds of peak power  Designed to assist the engine during acceleration  Makes the sled “feel more powerful” without added fuel consumption and emissions

6. Emissions Reduction

7. CSC 2004 Emissions Results High CO and HC emissions at WOT Found to be open loop at WOT Single catalyst used in 2004

8. Emissions Reduction Improvements for 2005 Closed loop at WOT Dual Catalyst System Removed Secondary Air Injection

9. Emissions Reduction 2005 Emissions Testing Results 94% reduction from stock 86% reduction from 2004

10. Sound Testing

11. Sound Pass By Testing Contributions of Components to Overall Noise Hood BarrierTrack Skirt

12. Frequency Analysis of Sound Engine 1 st order Track 2 nd order Track

13. Sound Reduction  Two Stage Muffler System  Catalysts  Three Chamber Broadband Muffler Engine Track Tunnel Stiffeners Direct Sound Barrier

14. Resonance of Tunnel

15. Total Sound Reduction  Predict Sound Power Level of 107.5 dBA sound power based on Pass by Testing  43% reduction (2.5 dBA) in sound power level from 2004 Bucky 800 HD

16. Additional Features  Electronic Throttle  Cruise Control  Traction Control During Launch  Evaporative Emissions System  Reduces HC Emissions from thermal cycling of fuel tank

17. Projected Cost ITEM UW-Madison Bucky 800 HD 2003 Polaris Frontier Classic Base sled cost with 784 cc Liberty Four-Stroke $5,899 SLED MODIFICATIONS$60 None Electric Motor and Controller $283None Hybrid Battery and wiring $151None Catalyst$40 None Total:$6,433 $5,899  Only $500 higher cost than stock  Based on 5000 sleds per year  Difference between 700 and 900cc 2 stroke Polaris Snowmobiles  $900 for a 15% increase in power

18. Questions?

19. Hybrid Layout

20. Drivetrain Torques

21. Motor Performance

22. Motor Controller

23. Battery Construction

24. Emissions Testing Modes Engine Speed (rpm)Torque (N-m)Power (kW) Mode 1 (WOT)560046.4317527.229 Mode 2 (85%)476022.4488711.19 Mode 3 (75%)420015.265236.714 Mode 4 (65%)36009.1026023.4316 Mode 5 (idle)11001.0417410.12

25. Emissions

26. Emissions