e-traction briefing 11-07-07

FRICTION…..FRICTION…..TransmissionTransmission: kW in – not kW out: kW in – not kW out

InIn OutOutlarge energy loss at nominal speeds

OuOutt

InIn

FRICTION… FRICTION… Rear Axle/DifferentialRear Axle/Differential: kW in - not kW out: kW in - not kW out

large energy loss at nominal speeds

A typical drive train at top speed is claimed to produce an energy-loss of about

15%15%

At nominal speed, however, it produces an energy-loss of about 50%50%

and.. and.. nominal speed is dominantnominal speed is dominant in cities! in cities!

+

e-Tractione-Traction®® System added 1,000 kg System added 1,000 kgin weight of the original VDL Ambassador 200 city busin weight of the original VDL Ambassador 200 city bus

Nevertheless,Nevertheless, rolling resistance declined by 47%rolling resistance declined by 47% fromfrom1515 kg/ton in original diesel configuration, to only kg/ton in original diesel configuration, to only 88 kg/ton. kg/ton.

If ever necessary, the direct-drive wheel hub system can be replaced in about two hours.

Transit buses: large contributors to inner-city Transit buses: large contributors to inner-city pollution:pollution:

Fuel consumptionFuel consumption and air pollutionair pollution: closely correlated

Noise pollutionNoise pollution of common city bus: around 80 Decibels

NeitherNeither of these environmental of these environmental burdensburdens

need to be need to be thatthat high! high!

Transit buses: contributors to inner-city Transit buses: contributors to inner-city pollution:pollution:

Public Transit bus fuel consumption of the largest cities in the Netherlands average*:

50 liters per 100 kilometers 2 kilometers per liter

4.7 miles per (U.S.) gallonPublic Transit bus fuel consumption of the largest cities in the United States average**:

67 liters per 100 kilometers1.5 kilometers per liter

3.5 miles per (U.S.) gallon

* Source: Transit companies of Amsterdam, Rotterdam, the Hague, and Utrecht in the Netherlands

** Source: General Motors (US) and APTA

Transit buses: contributors to inner-city Transit buses: contributors to inner-city pollution:pollution:

In the Netherlands*: 4.7 miles per (U.S.) gallonIn the United States**: 3.5 miles per (U.S.) gallon

* Source: Transit companies of Amsterdam, Rotterdam, the Hague, and Utrecht in the Netherlands

** Source: General Motors (US) and APTA

Reduced Environmental Burden Public Transit Reduced Environmental Burden Public Transit within reachwithin reach

Two e-Traction® powered buses are proving daily that fuel consumption, air and noise pollution can be drastically reduced without any reduction in on-time performance, comfort and safety.

While the environmental benefits are instantaneous, the reduced fuel consumption will quickly recover the initially higher incremental acquisition cost.

The Dutch Government has become well aware of the financial and ecological potential embedded in the e-Traction technology:

The Prime Minister, the Secretary of Transportation, and the Secretary The Prime Minister, the Secretary of Transportation, and the Secretary of Environmental Affairs have all and/or driven in the e-Traction-Bus or of Environmental Affairs have all and/or driven in the e-Traction-Bus or Whisper™Whisper™


Light weight composite e-TractionLight weight composite e-Traction®® BusBus

Fuel consumption certified by TNOFuel consumption certified by TNO


The, 11 metric ton empty-weight, Whisper™ on average uses:

650 Wh650 Wh (Watt hour) per km in city operation (avg. 20km/h)

600 Wh600 Wh per km at a steady 85 km/h on the highway


City bus energy derived solely from diesel fuel (generator @ 3.8 kW per liter)*

miles per (US) gallon

City 85 km/h

e-Traction® powered (Whisper™) city bus 13.9 14.8

Best conventional diesel city bus (NL) 6.3 7.3

Average conventional diesel city bus (NL) 4.7 5.5

Conventional diesel city bus (US) 3.5 4.1

• The Whisper can go 2.2 times further on the same amount of fuel compared to the most efficient city bus in NL.• Its fuel consumption is about one third of that of the average city bus fleet in NL,• Its fuel consumption is about one quarter of that used by an average US city bus, and • Produces no more than 62 decibels or less, a very substantial reduction from the normal 80 decibels.

* Alternatively, at the end of a duty cycle more than 30 kW could instead be derived from the power grid reducing consumption by 8+ liters.

Emissions are to a large extend a function of fuel consumption, thus Annual Fuel Savings: (annual mileage ÷ current MPG) - (annual mileage ÷ Whisper MPG)

for example: (50,000 miles ÷ 3.5 MPG) - (50,000 ÷ 13.9) = 10,689 gallons per year

Annual CO2 emission reduction: @ 10 kg per U.S. gallon of diesel

107 metric tons per year

AnnualAnnual CO CO22 Emission Reduction Emission ReductionWhisperWhisper Bus compared to U.S. equivalent Bus compared to U.S. equivalent

Noise Reduction of e-TractionNoise Reduction of e-Traction®® powered Buspowered Bus

((60 Decibels60 Decibels measured on the measured on the Whisper™ Whisper™ compared to compared to 80 DB80 DB for its conventional for its conventional equivalent)equivalent)

SourceIntensity

Level

# Times Greater than

Threshold of Hearing

Threshold of Hearing (TOH)

0 dB 100

Rustling Leaves 10 dB 101

Whisper 20 dB 102

Normal Conversation

60 dB 106

Busy Street Traffic 70 dB 107

Vacuum Cleaner 80 dB 108

Large Orchestra 98 dB 109.8

Walkman at Maximum Level

100 dB 1010

Front Rows of Rock Concert

110 dB 1011

Threshold of Pain 130 dB 1013

Military Jet Takeoff 140 dB 1014

Instant Perforation of Eardrum

160 dB 1016

100 times quieter

What does a Whisper™ cost?What does a Whisper™ cost? (In Europe)(In Europe)

To Buy: Currently € 325,000 expected to drop to € 250,000

(assumes cost of the body excluding drive train € 100,000)

To Operate: Maintenance expense is comparableDepreciation higher due to purchase price

KM's liters Total Fuel Cost Reduction at average Price per Liter of Diesel in 13 years

year year € 0.75 € 1.00 € 1.25 € 1.50 € 1.75 € 2.00

60,000 10,000 -€ 195,000 -€ 260,000 -€ 325,000 -€ 390,000 -€ 455,000 -€ 520,000

90,000 15,000 -€ 292,500 -€ 390,000 -€ 487,500 -€ 585,000 -€ 682,500 -€ 780,000

120,000 20,000 -€ 390,000 -€ 520,000 -€ 650,000 -€ 780,000 -€ 910,000 -€ 1,040,000

150,000 25,000 -€ 487,500 -€ 650,000 -€ 812,500 -€ 975,000 -€ 1,137,500 -€ 1,300,000

A newly delivered bus, regardless of its energy efficiency and A newly delivered bus, regardless of its energy efficiency and environmental impact, will likely be environmental impact, will likely be still in operation around 2020still in operation around 2020 unless unless environmental regulations or economic reasons force a premature environmental regulations or economic reasons force a premature replacement.replacement.

Current exchange rate: € = US$ 1.47Current exchange rate: € = US$ 1.47

Annual Fuel Savings: (annual mileage ÷ current MPG) - (annual mileage ÷ Whisper MPG)

for example: (50,000 miles ÷ 3.5 MPG) - (50,000 ÷ 13.9) = 10,689 gallons 10,689 gallons per yearper year

AnnualAnnual Fuel Expense Reduction Fuel Expense ReductionWhisperWhisper Bus compared to U.S. equivalent Bus compared to U.S. equivalent

Break-even point depends on incremental cost as a result of:

Vehicle Specifications,Conversion versus new construction,

and…Production location & volume.

Why does Whisper™ Why does Whisper™ succeed where others succeed where others

failed?failed?Because Because “Proven (Hybrid) Technology” “Proven (Hybrid) Technology” applications,applications, more often than not, do not address more often than not, do not address weightweight and and frictionfriction problems, they invariably produce only problems, they invariably produce onlymarginal improvements in energy efficiency.marginal improvements in energy efficiency.

e-Traction® System Design Objective:e-Traction® System Design Objective:

Reduce weight, friction and optimize Reduce weight, friction and optimize Energy Energy Management Management (Consumption, Recovery and Generation) (Consumption, Recovery and Generation) in in combination with ease of application and combination with ease of application and maintenance.maintenance.

e-Tractione-Traction®® System Innovations: System Innovations:

APU (generator)

Traction System and low-floor Axle

Pollution control

Batteries

ComputerizedEnergy Mgt.

The The WhisperWhisper‘s modularmodular e-Traction e-Traction®® System System components:components:

Two TheWheel™ SM500/2FE direct drive propulsion systems recover 70% of theenergy needed to reach a given speed under braking.

e-Traction® universal extreme low floor rear axle

Energy storage, in two air-conditioned containers, each holding 14 Lithium-ionbatteries allow operation for one full hour as a ZERO EMISSION vehicle, whilecombined weighing only 280 kg.

Variable speed, variable VDC output diesel powered generator

CANopen programmable logic computer forms the link between all componentsand are jointly governed by the e-Traction® Energy Management System software.

Electric Direct-Drive Wheel-hub TractionElectric Direct-Drive Wheel-hub Traction®® SystemSystem

(The primary Source of Energy Conservation)(The primary Source of Energy Conservation)

The only moving part!The only moving part!

TireRim

Energy Output @ Contact Patch

VDC Energy Input

∆ 90+%

Electric Direct-Drive Wheel-hub TractionElectric Direct-Drive Wheel-hub Traction®® SystemSystem

(Input & Output Quick-connects for easy Assembly)(Input & Output Quick-connects for easy Assembly)

Cooling Liquid SupplyCooling Liquid Supply

Cooling Liquid ReturnCooling Liquid Return

Liquid Cooling Loop Connection Liquid Cooling Loop Connection

± 400 VDC Power Supply & Return± 400 VDC Power Supply & Return

Data Supply & ReturnData Supply & Return

Rotating splined axle slides in and out of brake rotor

e-Tractione-Traction®® Low-Floor Rear Low-Floor Rear AxleAxleCompatible with commonly used designsCompatible with commonly used designs

100 cm wide aisle, 50 cm above surface @ 15 cm ground clearance

TheWheel SM500/2FEor SM500/1FE or AL

e-Tractione-Traction®® Low-Floor Front Low-Floor Front AxleAxleLow-floor FWD and 4WD Buses finally possible

e-Traction® Suspension Armallows 180° steering movement

e-Tractione-Traction®® Direct-Drive Product Direct-Drive Product RangeRange

SM450/1

SM500/1

SM500/2

SM500/3

SM700/3

SM350/1 SM350/2

e-Tractione-Traction®® Direct-Drive Product Range Direct-Drive Product Range

Brushless VDC Permanent Magnet Brushless VDC Permanent Magnet MotorsMotorsA continuous supply of ± 380 VDC, roughly equal to the

energy storage, is brought to each wheel-hub unit.

Based on operator input, the built-in controller board in each wheel-hub unit receives instructions from the vehicle CPU.

The controller board instructs the built-in inverters in which direction and to what degree energy should be supplied to the AC motor section.

The performance data of each wheel-hub unit is fed back to the CPU for comparison given it built-in traction control and ABS.

e-Tractione-Traction®® Direct-Drive Product Range Direct-Drive Product Range

Brushless VDC Permanent Magnet MotorsBrushless VDC Permanent Magnet Motors

RPM and torque are continuously managed between the different wheel-hub systems. A wheel that spins faster than the computer predicts could be getting a flat tire, or is on a slippery surface. If a wheel under braking stops while the other still moves at the predicted speed must have lost traction.

When the operator makes a steering input, the wheel-hub unit on the inside of the turn will be throttled back, forcing the vehicle to make a turn. The ability to differentially power the wheels greatly reduces tire wear and relieves the powers steering system.

Individual direct-drive unit(s) can be shut down and will simply roll along as any other unpowered wheel. Assuming proper system sizing, the vehicle should still be able to perform most mission tasks.

e-Tractione-Traction®® System Performance System Performance(kW)(kW)

Volts

e-Tractione-Traction®® System System PerformancePerformance

Torque in NmTorque in Nm

Whisper™ – Lessons learnedWhisper™ – Lessons learnedThe initial version of the Whisper™ performed quite well. It used SM700/3AL systems, which were in many ways excessive as they were:

Too big,Too powerful,

Too heavy, and…Absorbed 8 revenue

seats.They have been replaced in 2005 with the SM500/2FE on the Whisper II. The SM500/2FE will soon be replaced with the SM500/3FE to allow for a greater range of operations.

Acceleration from stand-still (beyond that it will outperform all others)

Obstacles (curbs, potholes etc)

Inclines (accelerating uphill with a full load from stand-still)

Regenerative energy storage (sufficient absorption capacity)

The Whisper™ needs about 2,000 Nm for normal operations, but may briefly need as much as 15,000 Nm to overcome minor obstacles.


The key challenge for a direct-drive system:The key challenge for a direct-drive system:


Torque in Nm of Torque in Nm of twotwo Direct-Drive Systems per Vehicle Direct-Drive Systems per Vehicle

TheWheel™ SM500/2FETheWheel™ SM500/2FE(custom designed for the Whisper II)(custom designed for the Whisper II)

Designed for the intended task in the Netherlands:Designed for the intended task in the Netherlands:

At 360 VDC TheWheel™ SM500/2FE with the precisely chosen windings of its current configuration (without the use of field-weakening) will reach a maximum of 520 RPM.

The currently used super-single tire by Michelin, model XDU 455/45 R22.5, has a diameter of 100 cm.

That results in a maximum speed 98 km/h, without field-weakening, which is about 10 km/h above the legal limit in the Netherlands for a bus.

TheWheel™ SM500/2FETheWheel™ SM500/2FE(custom designed for the Whisper II)(custom designed for the Whisper II)

Heat, Heat, and Heat,

produced in challenging situations, such as rapid acceleration and deceleration or overcoming

obstacles.

The e-Traction direct-drives systems have built-in liquid cooling which is connected to use a dedicated radiator(s).

The greater the ambient temperature the greater the need for specialized cooling techniques.

The greater the “reserve power” the lower the need for intricate liquid cooling systems.



The energy consumption of an oversized system is by and large the same as that of a properly sized system, except:

It weighs more,It costs more to make,

It takes more space, and..It has a lower maximum RPM (ex equo).




RPM at different Voltages*RPM at different Voltages*

Volts

* In AC motor star configuration – for triangle configuration multiply by 1.73

Modular Approach:Modular Approach:Affords Infinite AdaptabilityAffords Infinite Adaptability

The Whisper™ is the result of a conversion of a brand new conventional VDL Ambassador 200 diesel bus by e-Traction.

Conversions would appear to be the most logical initial application of the technology as bus manufacturers have been shown to be most reluctant to lead the way in innovation.

The Whisper in its current form is equipped with SM500/2FE wheel-hub systems, Lithium-ion batteries, a diesel motor attached to a e-Traction SM350/2AL as generator, and the e-Mission® Particle Eliminator.

Not only can these components be easily exchanged with spares, with little effort they can also be replaced with alternatives.

* Currently in testing – already achieving a greater than 80% reduction

The Whisper produces only (100% - 66.7%) * 0.8 = 6.7% of the PM2.5 particles of an average Dutch city bus.

Particle Reduction of e-TractionParticle Reduction of e-Traction®® powered powered BusBus

(with 66.7% reduction in fuel-consumption and (with 66.7% reduction in fuel-consumption and e-Mission™ Particle Eliminatore-Mission™ Particle Eliminator*)*)

Roof-mounted container with cyclones, muffler and electronic controls

Receptacles collect carbon deposits that only needto be emptied periodically


e-Mission™Particle Eliminator*

(-24%)

e-Traction®

System (- 67%)

Remainder (7%)

Particle Reduction of e-TractionParticle Reduction of e-Traction®® powered powered BusBus



The TNT truck minimally produces 80% less PM2.5 particles than its conventional equivalent.

Particle Reduction of e-TractionParticle Reduction of e-Traction®® powered powered TruckTruck


Chassis-mounted container with cyclones, muffler and electronic controls

Receptacles collect carbon deposits that only needto be emptied periodically

e-Tractione-Traction®® System System relies onrelies on

Lithium-ion batteriesLithium-ion batteries• The Whisper’s 28 (130 Ah 12VDC) Lithium-ion batteries, in two easily exchangeable air-conditioned containers, only weigh 300 kg.

• These individually CANopen controlled batteries function primarily as the buffer between demand and supply.

• They are also the storage device for the regenerative braking energy.

• They also enable the Whisper to be operate for one full hour as a ZERO operate for one full hour as a ZERO EMISSION vehicleEMISSION vehicle.

• The GPS can inhibit the diesel generator to operate in environmentally challenged zones.

Modular e-TractionModular e-Traction®® Auxiliary Power UnitAuxiliary Power Unit exchanged in about one hour – could also operate on fuel other than diesel exchanged in about one hour – could also operate on fuel other than diesel

Housing the diesel motor driving a variable speed & variable output e-Traction SM350/2ALgenerator producing 60 kW @ 2,500 RPM, but also the air-compressor and power steering pump.

Modular Auxiliary Power Unit offers ChoiceModular Auxiliary Power Unit offers Choice

The container could also house a The container could also house a fuel cellfuel cell..

The generator, located in the silent container also housing the auxiliaries, could be propelled by a combustion motor running on diesel, bio-diesel, ethanol, methane, natural gas, LPG or hydrogen and is quickly adaptable to whatever appears optimum from an environmental perspective or is dictated by changing fuel prices and/or availability.

e-Tractione-Traction®® System Performance System Performance(kW)(kW)

Toyota Prius:Gas: 1.5 L 57 kW (76 hp) @ 5000 rpmElectric: 500 V, 50 kW (67 hp) @ 1200 rpm

The e-Traction SM350/2 can produce 60 kW at 2,500 RPM with a 3 liter (85 hp) VMI diesel motor.

Whisper uses 57 kW @ 80 km/h

e-Tractione-Traction®® System: System:enabling Technology for other enabling Technology for other

Initiatives;Initiatives;improves Viability of Fuel Cellimproves Viability of Fuel Cell..

CUTE fuel-cell bus of the Public Transit Company (GVB) of the City of Amsterdam

e-Tractione-Traction®® System System quadruplesquadruples Range of Fuel Cell BusRange of Fuel Cell Bus

GVB Fuel Cell BusMercedes Citaro-

E

e-Traction®Fuel Cell Bus

Standard Diesel Bus GVB

Amsterdam

Fuel consumption

0.205 kg/km 0.05 kg/km 0.5 l/km

Range

Half a Day Two Days One Day

Fuel Energy density

Hydrogen =120 MJ/kg

Hydrogen =120MJ/kg

Diesel =36 MJ/l

Energy consumption

0.205*120 =24.6 MJ/km

0.05*120 =6 MJ/km

0.5*36 =18.0 MJ/km

Aside from the purchase price and cost of maintenance, insufficient storage capacity of hydrogen is the largest operational handicap experienced by Amsterdam’s Public Transit company (GVB) with the three CUTE buses it currently operates.

The Hytruck was introduced on October 25th 2007. It has received the TERTS innovation Award 2007.

The Hytruck city delivery vehicle uses a 16 kW The Hytruck city delivery vehicle uses a 16 kW fuel cell and 25 kWh Lithium-ion battery fuel cell and 25 kWh Lithium-ion battery storage to power two TheWheel SM500/1FE storage to power two TheWheel SM500/1FE wheel hub systems.wheel hub systems.

EEnabling Technology for other nabling Technology for other Initiatives;Initiatives;

The Hytruck was introduced on October 25th 2007. It has received the TERTS innovation Award 2007.

e-Tractione-Traction®® System for smaller System for smaller VehiclesVehicles

The “Car in the Future”, a project of students of the University of Eindhoven (NL) proposes the use of four e-Traction® SM450/1AL systems.

Same benefits can be achieved

e-Tractione-Traction®® System for smaller System for smaller VehiclesVehicles

Four e-Traction® SM350/1AL units can be placed in an SUV’s where normally the differential is located, leaving the original 4WD concept, suspension and steering and intact. This system is also suited for large or small delivery vehicles.

Same benefits can be achieved

EcologicEcologic && EconomicEconomic Benefits Benefitsrarely ever seen to go hand in hand!rarely ever seen to go hand in hand!

In conclusion, the e-Traction® System:

1.1. Reduces harmful air and noise Reduces harmful air and noise pollutionpollution,

2.2. Reduces the need for (imported) Reduces the need for (imported) energy,energy, and…

3.3. Lowers the cost of mobilityLowers the cost of mobility.

Why is has the e-TractionWhy is has the e-Traction®® System not System not yet become the most sought after yet become the most sought after

technology?technology?The proposed change is revolutionary:

1.1. There is more than 100 years of There is more than 100 years of experience with the current experience with the current technologytechnology,

2.2. The initial cost remains high, at The initial cost remains high, at least until mass production occurs,least until mass production occurs, and…

3.3. Who would want to risk his/her Who would want to risk his/her career with a limited proven career with a limited proven concept?concept?

Goals and/or NeedsGoals and/or Needs

Clean & QuietEnvironment

TransportationCost

Containment

Public and/or Passenger

Urgent need toreduce air & noise

Pollution

Alternative toPrivate Vehicles

LimitTicket Price

National Government

Regional Government

Local Government

Regulations Concession Subsidy

OperatorWhatever thecustomer is

willing to pay

Reliable Equipment

(Penalty Clause)

ProfitMaximization

Bus ManufacturerFollow (not lead)

Customer Demand

Rely on"Proven Technology"

Minimize RiskMaximize Profit

Component SupplierInnovativeSolutions

Same Reliability& Performance

Unable to fundPilot Project withlimited financial

Resources

Goals and/or NeedsGoals and/or Needs

Clean & QuietEnvironment

TransportationCost

Containment

Public and/or Passenger

Urgent need toreduce air & noise

Pollution

Alternative toPrivate Vehicles

LimitTicket Price

National Government

Regional Government

Local Government

Regulations Concession Subsidy

OperatorWhatever thecustomer is

willing to pay

Reliable Equipment

(Penalty Clause)

ProfitMaximization

Bus ManufacturerFollow (not lead)

Customer Demand

Rely on"Proven Technology"

Minimize RiskMaximize Profit

Component SupplierInnovativeSolutions

Same Reliability& Performance

Unable to fundPilot Project withlimited financial

Resources

Every 6 to 8 years

e-traction briefing 11-07-07

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