Post on 29-Mar-2015
Make Every School Bus Better. Thomas Bus Oct 4, 2011
Steve D Goss 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
Avg. Diesel Price
$3.80Avg. Bulk DEF Price
$2.85
‘Fluid Economy’ also ignores the price differential
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 106with Cummins ISB (EPA 10)
Vs.International Durastar 4300with 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
5-9% disadvantage
Combustion efficiency degradation:– Higher engine pumping losses
– Increased intake & exhaust manifold pressures
– Increased Particulate Filter regenerations
Fuel Economy Significantly Compromised
Increased Risk of EGR Condensation
In Cylinder NOx Control Challenges
Higher EGR flow produces excessive acidic condensation
Power cylinder corrosion– Rapid deterioration of lube oil
Reliability and durability compromised
In Cylinder NOx Control Challenges
20% increase
Higher EGR flow:– Multiple EGR coolers on & off engine
– Larger vehicle cooling package
– Major redesign of radiator / Charge Air Cooler / Fan systems
Significant Increase in Heat Rejection
Complex System Integration
In Cylinder NOx Control Challenges
Higher EGR flow
Air handling system
Vehicle cooling system
In Cylinder NOx Control Challenges
Higher EGR Flow– Throttle Response
Driver Satisfaction Significantly Compromised
In Cylinder NOx Control Challenges
Deterioration of 50 – 100 hp for same displacement
Higher EGR flow & EGR controls compromises engine performance
Power Density and Torque Limitations
Clean Air
DOCDPF
Bus Owners Have Two Choices for 2010
Advanced EGR
EGR + SCR After-Treatment System Setup
Tank
Catalyst
DoserAMOX Cat
DOCDPF
Intercooler
Higher heat rejection:
Larger Radiator
Larger Charge air cooler
Rad
iato
r
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, increasing fuel economy and engine life
With emission controls moved out of and away from the engine, power generation is unhindered
EGR introduces excessive carbon and soot into the cylinder, causing pre-mature liner and piston wear
Higher EGR cooling capacity strains the cooling system, leading to shorter coolant change intervals and component failure
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The Facts about the Fluid – DEF Properties
DEF is safe to handle and store– Non-toxic– Non-polluting– Non-flammable
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
Acidic pH
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
FeatureCummins
Advantage
Displacement 6.7L 6.4L -
Configuration Inline 6 V-8Fewer parts /
better reliability
Horsepower 200 - 325 HP 200 - 300 HPBetter power
density
Torque 520 -750 lb-ft 560 - 660 lb-ftBetter power
density
AspirationOne - variable geometry turbo
(2) dual stage
turbos
Fewer parts /
better reliability
Oil change
interval
15,000 mi.
(24,000 km)
10,000 mi.
(16,000 km)Lower maintenance cost / better uptime
Engine weight (dry) 1,150 lb (522 kg) 1,225 lb. (556 kg) Lower weight
Feature Cummins ISB6.7 Advantage MaxxForce 7
ComplexitySingle 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
Maintenance and Service
15,000 mile service intervals and 3,500 authorized service
locations
10,000 service intervals and 900 authorized
service locations
Competitive Comparison Summary
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
Three Way Catalyst Aftertreatment– Passive device
– Packaged as a muffler
– Maintenance-Free
Stoichiometric Combustion Cooled EGR– Same rated speed as ISL9
diesel
– 30% more torque at idle
– 5% better fuel economy
CombustionTechnology
Filtration and Diesel Exhaust Fluid
Integrating Critical Subsystems
Electronic Controls
Aftertreatment System
Turbochargers
Fuel Systems
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PowerSpec
Software Application– Provide gearing recommendation
– Customize engine ‘specs’
– Collect valuable trip information
– Free to download and use
www.powerspec.cummins.com
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
TM School Bus Better.
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
36
Daimler Trucks
Common Parts with HDX means faster design cycle
00000-00-Thomas Built Buses Standard Template.ppt 37
Bumper(10)
#2 Hood(2)
Front Roof Cap(6) Clearance/Marker Lights
(6)
“A” Mirrors(8)
Walk Gate(8)
Headlight & Bezel(4)
Wipers(15)
Hazard Lights(4)
Header Height/Drip Rail(4)
“B” Mirrors(8)
Destination Sign (20)
Windshield(3)
Sub-system ID (estimated number of parts to be eliminated ~100)
Daimler Trucks
Driver Focused Improvements - Storage
• Added driver’s storage to right side dash
• Can be used for safety equipment storage or for personal items
00000-00-Thomas Built Buses Standard Template.ppt 38
Daimler Trucks
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 39
Daimler Trucks
Driver Focused Improvements - Visibility• Improved defrost capability
00000-00-Thomas Built Buses Standard Template.ppt 40
Daimler Trucks
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 41
Daimler Trucks
Technician Focused Improvements - Access
• Lower driver side access panel for chassis PDM’s
00000-00-Thomas Built Buses Standard Template.ppt 42
Daimler Trucks
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 43
Daimler Trucks
Family Look
HDX EFX
00000-00-Thomas Built Buses Standard Template.ppt 44
Daimler Trucks
EFX Status
00000-00-Thomas Built Buses Standard Template.ppt 45
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.
Questions?
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Thomas Built Buses Dealer Sales Meeting 2012