Eaton UltraShift Plus. Eaton Hybrid Electrical. Eaton Hybrid Hydraulic

Eaton UltraShift Plus Eaton Hybrid Electrical Eaton Hybrid Hydraulic

A rich history of Fuller Automation Experience AutoSelect AMT CEEMAT 1985 1989 1991 AutoShift 16 1993 1994 AutoShift 10 AutoShift 18 AutoShift 6 UltraShift HP 1997 UltraShift LST 1998 1999 2000 2001 UltraShift HV UltraShift LHP UltraShift Plus 2002 2003 2004 2005 2006 2010

Eaton AMT Roadmap Explained AutoShift (3-pedal) AS-10 AutoShift 10-Speed (RT-10B/C) AS-18 AutoShift 18-Speed (RT-18A) UltraShift (2-pedal, DM Clutch) LST Line Haul Standard (RT-10B) LHP Line Haul Performance (RT-13A) LEP Line Haul Efficient Performance (RT-13A) UltraShift Plus (2-pedal, ECA) MHP Multipurpose High Performance (RTLO-13B) MXP Multipurpose Xtreme Performance (RTLO-18B) VXP Vocational Xtreme Performance (RTLO-18B) VCS Vocational Construction Series (RTO-8LL) VMS Vocational Multipurpose Series (RTO-9ALL) LAS Line Haul Active Shifting (RTO-10B/C) Feb2007

Eaton UltraShift Plus

New Linehaul Models Overdrive FO-14/16/18E310C-LAS FOM-14/15/16E310C-LAS Direct-Drive FM-14/15E310B-LAS M = Multi-torque, +200 lb ft in top 2 gears

UltraShift M Series Two automated transmission models have been developed for Highway / Multipurpose Applications UltraShift MHP UltraShift MXP Multipurpose Highway Multipurpose Extreme Performance Performance FO- 14/16/18/20/E313A-MHP Overall ration coverage of 17:1 FO-14/16/18/20/22/E318B-MXP Overall ratio coverage of 20:1 Ratings up to 2250lbft

UltraShift V Series Three automated transmission models have been developed for Vocational Applications UltraShift VMS Vocational Multipurpose Series UltraShift VCS Vocational Construction Series UltraShift VXP Vocational Extreme Performance On/Off Highway FO- 14/16/E309ALL-VMS Overall ration coverage of 36:1 Front or Rear Discharge Mixer FO- 14/16/E308LL-VCS Overall ratio coverage of 20:1 (with Wide Reverse Ratios) Dump Truck/Roll-Off Refuse FO-14/16/18/20/22/E318B-VXP Overall ratio coverage of 20:1 Ratings up to 2250lbft High Performance/ Steep Grades/Heavy Loads

Nomenclature UltraShift Vocational Construction Series (VCS) sharing ratios with an 8LL FO-14E308LL-VCS FO-16E308LL-VCS UltraShift Vocational Multipurpose Series (VMS) sharing ratios with a 9ALL FO-14E309ALL-VMS FO-16E309ALL-VMS UltraShift Vocational Extreme Performance (VXP) sharing ratios with an 18B FO-14E318B-VXP FO-16E318B-VXP FO-18E318B-VXP FO-20E318B-VXP FO-22E318B-VXP UltraShift Multipurpose Extreme Performance (MXP) sharing ratios with an 18B FO-14E318B-MXP FO-16E318B-MXP FO-18E318B-MXP FO-20E318B-MXP FO-22E318B-MXP UltraShift Multipurpose High Performance (MHP) sharing ratios with a 13 FO-14E313B-MHP FO-16E313B-MHP FO-18E313B-MHP FO-20E313B-MHP

Safety All the benefits of a manual transmission plus Hill Start Aid Auto Neutral Auto-engage on downgrades Creep mode No urge to move Fuel Savings

ECA Technology Maximum Grade to Launch and Shift:

What is ECA? Electronic Clutch Actuation Using electronics vs. electro-pneumatic or mechanical to manage clutch engagement and disengagement improves transmission performance in a number of areas: Clutch engagement and consequential shifts are rapid ECA facilitates superior transmission performance in on-highway environments Enables technologies such grade sensing, weight computation and driver throttle commands to allow the transmission to make intelligent shift decisions to meet performance, reliability & safety requirements

ECA Design LCIB Low Capacity Inertia Brake Coaxial about the Transmission Input Shaft No Additional Exterior Space Claim 2500 rpm/sec decal rate

ECA-Clutch Design (15.5, 2 plate, ceramic) Backer plate to actuate LCIB Sealed release bearing Solo adjustment system Strap-drive IP

Vehicle Installation / Integration Installation - Same as G3 UltraShift Except: Solo-Clutch ECA space-claim Oil-fill Site-glass Engine Speed Sensor Grade Sensor Overall length 4-Chl ABS with ATC & HSA

What a Fleet wants Maneuverability Warranty Skip Shifting Intelligent Shifting Engine Braking Creep Mode Hill Start Aid Auto Neutral Fuel Saving Ease of Operation Meeting & Exceeding Customer Expectations

Driveline Protection Driveline Protection Features Stall prevention Engine Over-speed Protection Clutch Abuse Protection Auto gear select Skip shifting where appropriate

Safety Auto Engage on down grades Auto Neutral Creep feature (no urge to move ) Hill Start Aid

Serviceability & Repairability Many similar components between manual platforms, other Ultrashift platforms: OEM dealer, fleet familiarity Parts and service widely available Does not require service by a dedicated service network Modular design minimizes cost and time of service Roadranger field service force provides training at dealership and fleet level Advanced Gen 3 diagnostic capabilities

What is HYBRID? (EATON HYBRID TECHNOLOGY NO COMPROMISE) Traditional Drivetrain ENGINE HP T + kw Hybrid Drivetrain + kw kw kw Same Vehicle Torque Output engine hp T Motor/Generator

History Hybrid Definition: "A vehicle with more than one power source such as a small internal combustion engine and an electric motor In 1899 Dr Ferdinand Porsche, then a young engineer at Jacob Lohner & Co, built the first Hybrid Vehicle Data Source: www.hybrid-vehicle.org

Eaton HEV History & Progress

City Delivery HEV System Diagram

Utility HEV System Diagram

Primary Hybrid Components DC/DC Converter Power Electronics Carrier (Battery Box) Motor Inverter/Controller Hybrid Drive Unit (HDU)

120VAC/60Hz Power Panel DC/DC Converter Motor Controller/Inverter Fuller Automated Transmission (AMT) Electric Clutch Hybrid Electric Motor Auxiliary Power Generator (AGP) Inverter Power Electronics Carrier (PEC) Lithium Ion Batteries and Battery Controls

Engine Start (Start-Stop) Mode Direct Hybrid - Engine Starting Mode Engine (on) AutoClutch (engaged) Motor (on) AutoShift (AMT) (in neutral) Engine Torque Discharging Mode PTO Inverter & Power Panel (off) Battery System (discharging mode) Pump (off) Utility Tools (off)

Driving ---- Electric only (EV) mode Direct Hybrid - Electric Only Mode Engine (Idle) AutoClutch (disengaged) Motor (on) AutoShift (AMT) (in gear) Motor Torque Drive Torque PTO Drive Trq = Motor Trq x Gear Ratio Inverter & Power Panel (off) Battery System (discharging mode) Pump (off) Utility Tools (off)

Driving ---- Parallel Hybrid (motor boost) Mode Direct Hybrid - Engine & Electric Motor Drive Mode Engine (on) AutoClutch (engaged) Motor (on) AutoShift (AMT) (in gear) Drive Torque Engine Torque Combined Torque Drive Trq = (Engine Trq + Motor Trq ) x Gear Ratio PTO Inverter & Power Panel (off) Battery System (discharging mode) Pump (off) Utility Tools (off)

Driving ---- Conventional (back-up) Mode Direct Hybrid - Engine Only Mode Engine (on) AutoClutch (engaged) Motor (on/off optional) AutoShift (AMT) (in gear) Drive Torque Engine Torque Engine Torque Trq = Engine Trq x Gear Ratio PTO Inverter & Power Panel (off) Battery System (charging mode optional) Pump (off) Utility Tools (off)

Driving --- Maximum Regenerative Braking Mode Direct Hybrid - Regenerative Braking Mode Engine (on) AutoClutch (engaged or disengaged) Motor (on) AutoShift (AMT) (in gear) Inertial Torque Engine Torque Regenerative Torque PTO Regen Trq = Inertial Trq x Gear Ratio Inverter & Power Panel (off) Battery System (charging mode) Pump (off) Utility Tools (off)

Utility ---- Engine Off Electric PTO Mode Direct Hybrid - Engine Off epto Mode & APG Engine (off) AutoClutch (disengaged) Motor (on) AutoShift (AMT) (in neutral) No Drive Torque PTO Auxiliary Power Generator (APG) Inverter & Power Panel (optional on - 5-10kW) Battery System (discharging mode) Pump (on) Utility Tools (on)

Utility ---- Engine On Mechanical PTO Mode Direct Hybrid - Engine On Mechanical PTO Mode Engine (on) AutoClutch (engaged) Motor (off) AutoShift (AMT) (in neutral) No Drive Torque Engine Torque PTO Inverter & Power Panel (off) Battery System (charging mode optional) Pump (on) Utility Tools (on)

Utility ---- 5 kw Engine Off Power Generation Direct Hybrid - Engine Off Power Generation Mode Engine (off) AutoClutch (disengaged) Motor (on/off optional) AutoShift (AMT) (in neutral) No Drive Torque PTO Inverter & Power Panel (on ---- up to 5kW AC output) Battery System (discharging mode) Pump (on/off optional) Utility Tools (on/off optional)

HEV and HHV Comparison Hybrid hydraulic systems have much higher power capabilities, for a shorter length of time. In addition, they typically regenerate more braking energy than hybrid electric systems.

Hybrid Drive Technology Hydraulic Hybrids: What are they?? Parallel Hybrid (HLA system) Attaches to existing driveline Enhances engine power availability Energy Regeneration features 20-30% fuel economy improvement+ Increases vehicle brake life by >50% Significant productivity increase possible Production start with Peterbilt: Sept. 2009 Suited to heavy start-stop drive cycle Distinct HLA market segments e.g. refuse Retro-fit opportunities Series Hybrid Replaces entire existing transmission. Applicable to broad variety of duty cycles Energy Regeneration, CVT, Engine off 50%+ fuel economy improvement Increases vehicle brake life by >70% Reduced emissions for NO x & CO 2 through optimizing engine loading and RPM. Commercialization planned : 2011 Apply in Package delivery, tow-trucks, wide variety of bus types. Has to be installed at chassis build time only. Fluid Reservoir Low-pressure Energy Storage N 2 High-pressure Accumulator Hydraulic Pump/Motor = Energy Flow Hydraulic Pump/Motor N 2 High-pressure Accumulator Hydraulic Pump = Energy Flow

Parallel Hydraulic Hybrid Architecture Fluid Reservoir N 2 High-pressure Accumulator Hydraulic Pump/Motor = Energy Flow HLA System for Heavy Duty Trucks In a parallel hydraulic hybrid, the conventional vehicle driveline is supplemented by the addition of the hybrid system. The system is best suited for vehicles that operate in stop and go duty cycles. (examples include refuse trucks) The value proposition is provided by: Improved fuel economy achieved through regeneration of braking energy Lower maintenance costs. Brake life is increased 3-4 times. Improved productivity (e.g., more refuse pickups per day). Engine downsizing potential to further reduce fuel consumption w/out losing power Fuel economy and emissions improvements of 20-30% and payback periods of 3 years or less are possible in vehicles that last 10 years.

The HLA System The system is a parallel hydraulic regenerative braking system. The system uses fluid force to brake by charging a high pressure accumulator. Energy recovered is normally wasted as heat during braking. Recovered energy is efficiently stored and used to supplement the engine s power during acceleration, on-demand. The system provides the greatest benefit when the vehicle s driving cycle involves stop and go driving.

It s all about the brakes! Refuse is a great application Braking Aero Drag The objective of a Hybrid System is to store and re-use as much as possible of this wasted energy Rolling Resistance

How does the HLA System work? Regeneration Mode During braking, the vehicle s kinetic energy drives the pump/motor as a pump, transferring hydraulic fluid from the low pressure reservoir to the high pressure accumulator. The fluid compresses nitrogen gas in the accumulator and pressurizes the system. Launch Assist Mode During acceleration, fluid in the high pressure accumulator is metered out to drive the pump/motor as a motor. The system propels the vehicle by transmitting torque to the driveshaft.

Class 8 Refuse Truck Test Data 28.5 Tonne ( 63,000lb ) GVW 315 hp engine 5-speed automatic transmission 30 metres ( 100ft ) between stops

System Specifications 10-year design life Ambient operating temperature ranges Full function range: -30 C to 50 C Annual service: Oil and filter (reservoir, transfer case) Nitrogen level check and top-off as required Maximum rated pressure 345 Bar 5000 psi System Oil Volume 79.8 L 21 gal Typical peak power per cycle 130 kw 175 HP Displacement: 15 in 3 Maximum Flow: 130 gpm Maximum Power: 380 hp Maximum Pump Torque: 1000 lb-ft Peak torque to driveline: 2550 lb-ft Transfer Case Ratio: 2.55:1 Transfer Case Through-Torque: 16,000 lb-ft System pressure: 5000 psi max HLA speed limit: 3000 rpm System weight 1300 lbs CAN Communications SAE J1939

Hydraulic Energy Storage STORED ENERGY Accumulator FILLS KINETIC ENERGY (Speed) STOP Hybrid Power Systems Pumping mode HYDRAULIC BRAKING 2007 Eaton Corporation. All rights reserved. Maximum energy recovered

In-Cab Information. Fault Code: State of Charge: Service lights: Service Level LED Light Result Operator Actions Stop Blinking Yellow HLA system is functioning improperly Stop vehicle and do not drive. Record fault number. Call for Service Service Continuous Yellow HLA system disabled The vehicle may be used. Record fault number. Notify service. Operate No Service light, No Stop light Normal System Ready 2007 Eaton Corporation. All rights reserved.

Current Status: Eaton began delivering a fleet of refuse trucks with preproduction HLA systems to end users in December 2007. These vehicles are used in refuse collection service for for a one year test period. Eaton is releasing the HLA system for use in Peterbilt 320 refuse chassis in Sept. 2009.