Cummins

1
Kansas State University Idle Management
Seminar

• Cummins
• Idle Management Strategy

May 15, 2007 Jeffrey P. Seger Shawn Wasson L K
Hwang
2
Background

• Due to rising costs of fuel and environmental
  concerns, the industry is interested in
  anti-idling techniques.
• Cummins has developed a broad set of solutions to
  fit all fleets needs.

3
Purpose Overview

• This presentation will address the following
• Regulatory Requirements
• Cummins Solutions for Anti-Idle
• Icon
• Comfortguard
• 30g NOx exemption
• Future trends and techniques

4
2008 Emissions Hurdle - CARB Regulation

• CARB regulation is effective Jan 2008
• Limit idling of trucks to 5 minutes in California
• If the engine can be certified to 30 g/hr NOx at
  idle, a Certified Clean Idle label can be
  placed on vehicle hood and it is exempt from the
  5 minute idling limit
• All APUs used with 2007 and later engines will
  need to meet one of the following
• An 85 reduction in PM OR
• PM level less than or equal to 0.01 g/bhp-hr OR
• Have exhaust plumbed into engine exhaust system
  upstream of the engines PM aftertreatment device
• All 2007 trucks required to retro-fitted APU in
  2008
• Summary
• Beginning 2008, HD trucks in CA will be required
  to shut-off after 5-minutes, sleeper-berths
  included. The way to be exempt from that
  requirement is if the engine is certified as a
  clean-idle meeting the 30g/hr NOx limit and has a
  "certified clean idle" label on the truck's hood.

5
2007 Idle Management Product Offering

• ICON Monitors the battery voltage, engine block
  and cab temperature. When it drops below a preset
  level, ICON tells the Electronic Control Module
  (ECM) to start the engine. Once the condition(s)
  have been met, then ICON will automatically shut
  the engine off.
• ComfortGuard - A vehicle mounted small diesel
  Auxiliary Power Unit (APU) and integrated HVAC
  system which eliminates the need to idle the main
  vehicle engine, significantly reducing fuel
  costs, emissions, and noise.

6
ICON
2007
COMFORTGUARD

• Engine Mode - When ICON is activated, engine mode
  monitors engine block temperature and battery
  voltage.
• Cab Comfort Mode - Cab comfort mode maintains the
  temperature in the sleeper bunk during rest
  periods.  The driver can set the desired
  temperature on a thermostat control located in
  the sleeper.
• 2 year/250k warranty
• Reduces idle fuel consumption by up to 50

• Engine driven generator / Integrated or stand
  alone cooling
• 2-cylinder water cooled Kubota diesel engine /
  Cummins built alternator
• 120v AC power output 4 kW at 60 Hz
• 12v DC power output 40 amps
• Dimensions 21 L x 24.5 D x 28 H
• Weight 375 lbs
• 500 hour oil change interval (matching truck)
• Reduces idle fuel consumption up to 80 while
  providing power for any hotel load
• Payback period of 1-2 years
• Self Diagnostics
• 2 year/4,000 hour warranty

7
Integrated Exhaust Concerns and Validation Work
8
2008 Heavy Duty On-Highway Engines

• If the engine can be certified to 30 g/hr NOx at
  idle, a Certified Clean Idle label can be
  placed on vehicle hood
• Cummins is working to meet this
• 1100 rpm is a challenge
• Need to assess reliability impact as well
• Impact of 30 g/hr NOx at idle to engine
  performance and cost implications will be
  identified from the assessment work
• Value in other states is also a question

9
CEMS
Future
COMFORTGUARD

• Cummins Energy Management System (CEMS) will
  replace the ICON in mid-2008.
• Functionality of CEMS is much greater than ICON,
  there will be a base and optimized version.
• Energy source, vehicle battery
• Simplified installation requirements
• Expanded control of auxiliary HVAC devices
• Advanced user interface and diagnostics
• Optimized Components
• 12V AGM Batteries, Qty (4)
• Alternator upgrade, 200A
• An integrated low voltage Disconnect (LVD)
  capability
• Fuel fired heater
• Electric A/C or Inverter
• Fuel fired block heater

• In order to meet the CARB 5 minute idling
  regulation Cummins will have two available
  solutions for ComfortGuard.
• Stand Alone Particulate Trap for APU
• Integrated Exhaust, APU exhaust plumbed into
  engine exhaust system
• Overall APU technology is unchanged from 2007

10
CEMS Overview
Cummins Energy Management System (CEMS)
Increased Fleet Savings
Fleet Information
Battery Life Improvement
Improved Idle Efficiency
Energy Management
Engine
Engine Readiness
Thermoelectric Generator
CEMS
Engine Idle Management
Fuel Cells
Vehicle Power Distribution
Auxiliary Power Units
Cab Climate Control
Batteries
Advanced Diagnostics
Predictive Maintenance
Battery Prognostics
Reduced Downtime
11
Current ICON II System Review
Engine Start
Alarm ICON ECM ECM
Sleeper
Thermostat
Ambient Air Temperature Sensor
Hood Tilt Switch
Battery
Key Switch Starter Button Neutral Position
Switch Ignition Bus Relay Parking Brake
Switch ICON Lamp
Battery Starter Relay
12
Standard Idle Reduction Diagram for CEMS
Engine
Starter
135A Alt
ECU
Current ICON II
CEMS
Standard Wet Cell Batteries
Thermostat
Monitor
13
Optimum Idle Reduction Diagram for CEMS
Engine
Starter
135A Alt
200A Alt
ECU
Coolant Heater 17,000BTU/hr
13.6KBTU/hr Air Heater
CEMS
7.5KBTU/hr Air Conditioner
Vehicle Load 12VDC Wiring
Standard Wet Cell Batteries
AGM/Gel Batteries
Monitor
14
Impact of CEMS on OEMs
Engine Start
Alarm New ICON ECM 200A Alternator ECM
Current Sensors
Sleeper
Thermostat
Monitor
Ambient Air Temperature Sensor
Hood Tilt Switch
AGM Battery
Key Switch Starter Button Neutral Position
Switch Ignition Bus Relay Parking Brake
Switch CEMS Lamp
AGM Battery Starter Relay
15
COMFORTGUARD Overview
16
2010 and Beyond
COMFORTGUARD
CEMS
Shared Technology

• CEMS base model will continue to monitor battery
  voltage, engine block and cab temperature. When
  it drops below a preset level, staring the engine
  when necessary and shutting off once conditions
  have been met.
• As technology evolves and Hybrid Battery Systems
  and Fuel Cells become commercially viable, the
  ComfortGuard will move to the right technology to
  deliver optimal idle management results.
• Cummins Power Generation is already involved in
  development of both technologies, through long
  range product planning and engineering groups.
• CEMS Controls will be capable of managing all
  related systems

17
Idle Reduction Systems
System Comparisons (2007- 2008)

• ICON CEMS CEMS
• Current Base System Optimized APU
• Relative Cost Index over the current ICON System
  1 1.00 0.95 4.3 8.0
• Engine Idle Time in Cold Moderate Climate 2
  lt50 lt45 0 0
• Engine Idle Time in Hot Climate 3
  lt40 lt36 lt7 0
• Approximate number of engine starts per night
  4 15 14 1 0
• System Weight (including batteries) 263lbs 262
  lbs 427 lbs 375 lbs
• Fuel savings per year 5 gt1,623 gt1,803 gt3,728 gt
  4,000
• State/Local Law Compliance to Cold Moderate
  Climate 78 78 100 100
• State/Local Law Compliance to Hot Climate 78
  78 95 100
• Approximate Emissions Reduction for NOx and
  PM 57 60 87 80
• Reduction of Idle Fuel Consumption 50 55 80 gt8
  0
• Battery Technology Wet Cell 12 AGV 12 AGV N/A
• Note 1 Cost of an ICON or a CEMS Base System
  includes switches sensors
• Note 2 Considering 25A _at_ 3 hr (wake) and 10A _at_ 7
  hr (sleep) for a total of 10 hrs.
• Note 3 Considering 45A _at_ 3 hr (wake) and 30A _at_ 7
  hr (sleep) for a total of 10 hrs.

18
State Idling Laws
19
Cummins N.A. Idling Regulations Guide
20

• CFI/UPS Status
• Competitive Benchmark
• Alternatives
• Pros/cons

21
Summary Conclusions

• Rising costs of fuel and environmental concerns
  are driving needs for anti-idling solutions
• Cummins has a wide variety of solutions

22
Integrated Exhaust Concerns and Validation Work