Engineering R&D Expertise

Experience:25+ years experience in developing innovative technologies in multiple industries. Particular expertise in automotive and hydraulic power systems including engine and transmissions, hybrids, fuel systems.

Proven track record of rapid design and development of new technologies with the intent of taking it to large scale production.

Expertise:- Mechanical design, solid modeling, GD&T- High bandwidth hydraulic system analysis and design- Dynamic modeling- FEA, CFD, Magnetic modeling- Dynamometer and test facility design & operation - Electronic controls- Powertrain testing- Testing and development- Systems engineering- Program management

Core Strength:Core strength is rapidly developing new technology using a combination of sophisticated analysis tools, creativity, experience and hard work.

Simulation and other virtual prototyping tools allow us to quickly and inexpensively iterate through many different designs to understand how they will function before they are built saving our clients time and money.

Multiple Industries, Same expertise: Concept to hardware

Automotive/Hydraulics O&G CleanTech Fuel injectors & systems: Diesel, NG & gasoline

High bandwidth hydraulics/solenoids

Transmission/hybridAnalysis & Design

Custom head design

Turbocharger test/development

Custom valvetrains(camless and cam based)

Actuators

Offshore drilling equipment

Natural gas gensets

Natural gas fueling skids

Self refueling engine

Anchoring system for semisubmersibles

Support equipment for land base casing operations

Algae based biodiesel

CO2 based cleaning machines

Molten salt test skids

Tidal energy harvesting

Vertical axis wind turbines

Compressed air energy storage

Clients range from start-ups to fortune 50, universities, non-profits, DOE & DOD

Czero engineers have worked on a wide range of innovative products:

Czero Projects:- High speed, low leakage valve designs- Natural gas genset skid design- Natural gas regulator skid design- Automotive engine (head, valves, piston, etc. design)- Offshore drilling equipment- Fuel injector and systems design- Bioreactor design for biodiesel feedstock from algae- Vertical axis wind turbines- Hydraulic hybrid vehicles- Outboard motors- Engine dynamometer and test facility design- Diesel and gasoline generator systems- CO2 based industrial cleaning machines- Solenoid design- Compressed Air Energy Storage- Automatic transmission valve body analysis- Advanced expander design and analysis

We have been fortunate to have some great success…..

Dr. Ellen Williams – Director of ARPAe, with Onboard Dynamics VP Jeff Witwer and CEO Rita Hansen. (2015)3 of the organizations highlighted in the display are Czero clients

2015 Awardee

2015 Awardee

2010 Awardee

Senior Staff

University of Wisconsin – Madison, Ph.D. Mechanical EngineeringUniversity of Wisconsin – Madison, M.S. Electrical EngineeringTechnische Universität Berlin – Mechanical Engineering CourseworkUniversity of Michigan – Ann Arbor, M.S. Mechanical EngineeringUniversity of Vermont – B.S. Mechanical Engineering

Guy Babbitt, PhD

Experience (28 years)- Czero, Inc – CEO; Co-Founder- Sturman Industries – Variable Valvetrain Group Leader- University of Wisconsin Engine Research Center/Powertrain Control Research Laboratory - Laboratory Manager- University of Wisconsin Fluid Power Laboratory – Research Assistant- General Motors/Saturn Corp – Project/Test engineer for automatic transmission group- University of Michigan – Lay Automotive Laboratory – Research Assistant

Expertise- Leading innovation projects- Dynamic modeling/controls

Colorado State University – B.S. Mechanical Engineering; Summa Cum Laude

Chris Turner

Experience (18 years)- Czero, Inc – VP Engineering; Co-Founder. - Sturman Industries – Lead design engineer

Expertise- CAD design- GD&T ASME Y14.5- Structural Finite Element Analysis- Electromechanical/Electrohydraulic actuation

Michigan Technological University – M.S. Mechanical EngineeringMichigan Technological University – B.S. Mechanical Engineering

Dan Pedersen, MS

Experience (23 years)- Czero, Inc.- Westport Innovations – Senior Engine Development Engineer - Combustion, Performance and Emissions- National Renewable Energy Laboratory – Task Leader ReFUEL Laboratory – Engine and Heavy Duty Chassis Dyno- Oshkosh Truck Corporation – Senior Project Engineer - Advanced Products Group- Sturman Industries – Project Leader and Development Engineer - Variable Valvetrain- Diesel Technology Co. – Performance Development Engineer – Team Lead, Development Test Lab- Cummins Engine Co. – Senior Engineer – Midrange Product and Fuel Systems Development

Expertise- Leading innovation projects- System Testing and Development

University of Michigan – Ann Arbor, M.S. Mechanical EngineeringUniversity of Michigan – Ann Arbor, B.S. Mechanical Engineering

Jeff Rogers

Experience (26 years)- Czero, Inc – Senior Mechanical Engineer- Sturman Industries – Analysis Engineer- Babcock and Wilcox Research and Development Center/McDermott Technology Inc. – Senior Engineer- University of Michigan – Thermal Fluids Laboratory – Research Assistant

Expertise- Hydraulic Modeling- Thermal/Fluid Analysis- Computational Fluid Dynamics (CFD)- Dynamic modeling- Combustion Modeling- Magnetic Modeling

University of Colorado – Colorado Springs, M.S. Mechanical EngineeringKansas State University – B.S. Electrical Engineering

Travis Johnson

Experience (16 years)- Czero, Inc. – Senior Controls Engineer- Exostrategies, Inc. – Continuous Integration Environment and Automated System Testing Lead- Sturman Industries – Senior Controls Engineer

Expertise- Automotive Controls and Communications- Embedded Development- Industrial Controls

Michigan Technological University – Houghton, MSME-EM Mechanical EngineeringUniversity of North Dakota – Grand Forks, B.S. Mechanical EngineeringUniversity of Michigan – Ann Arbor, Executive Marketing Program

Lyle Shuey, MSME

Experience (32 years)- Czero, Inc – Business Development Director- Jet Engineering – Vice President Business Development; Engineering, Corporate Strategy, Partner Management- LHP Software – Vice President Business Development and Marketing- Bright Automotive – Vice President Marketing and Sales; Founding Consultant- Maybee Associates – Partner; Marketing and Business Development consulting (included 2 year Sturman engagement)- Delphi / GM – Various Management, Engineering, Marketing, Sales Assignments (17 years)- Michigan Technological Univ. – Research Assistant; Dynamic Systems Modeling, Development, Testing

Expertise- Commercial strategy, business development, marketing and sales process execution- Breakthrough customer solution creation

Software Tools

Solid Modeling/Design

SolidWorks Premium

Autodesk Inventor

Pro/ENGINEER (PTC Creo)

AutoCAD

PhotoView 360 - Solidworks

Showcase - Autodesk Inventor

Microsoft Visio

AutoCAD P&ID

GD&T per ASME Y14.5

Analysis

Finite Element Analysis

• SolidWorks Simulation

• Autodesk A360

Czero has expertise in the following Software and tools:

Analysis (cont’d)

Computational Fluid Dynamics

• Star CD/CCM+

• Fluent

• Converge

• Autodesk A360

• Floworks

Magnetic Modeling

• Maxwell

• FEMM

Dynamic modeling

• MATLAB/Simulink/SimScape

• SolidWorks Motion Study

• PLECS

Analysis (cont’d)

Hydraulic Simulation

• MATLAB/Simulink/SimScape

• HYSAN

• GT Suite – Flow Library; Hydraulic

Amesim

GT Suite – GTPower (developing expertise)

Dymola – Modelica

Thermodynamic Analysis

• MATLAB/Simulink/SimScape

• GT Suite (developing expertise)

• EES

• Refprop (NIST)

Embedded Systems

Rapid prototyping of real time controls systems

• Simulink/Stateflow/Real Time Workshop

Embedded Systems (cont’d)

• dSPACE

• Woodward/Mototron/GAP

• National Instruments/LabVIEW

• Custom systems using Freescale MPC family microprocessors and Siemens C series microprocessors

Programming

• C, C++, C #, Silverlight, Visual Basic, FORTRAN

• MATLAB Coder/Simulink Coder

Communication Protocols

• J1939,J1857,Modbus, XCP,CCP

Instrumentation and data acquisition systems

• National Instruments/LabVIEW

• Measurement Computing

• Custom designed systems

Embedded Systems (cont’d)

SCADA

• Allen Bradley AC800M PLC

• Woodward Micronet and Atlas

Data processing and presentation

MATLAB

JMP

National Instruments DIAdem

Excel

Mathcad

PowerPoint

Project and Program Management

Microsoft Project

Asana

Fuel Injection

High pressure intensified

Unit pumps

Common rail

Accumulator Pump Systems

Gasoline port injection

Gasoline direct injection

Multiple fuel systems

Medium pressure natural gas

Variable Valve Actuation

Electrohydraulic based camless

Electromechanical based camless

Cam based variable valve actuation

Valve deactivation

Related automotive experience

Hydraulics

Steering Systems

Lubrication systems

Mobile hydraulics

Industrial hydraulics

Digital pump controls

High speed valves

Vehicle Technology

Hydraulic hybrids

Vehicle drive cycle analysis

Electric vehicle simulation

Engine / Vehicle testing

Automatic transmissions

Example Projects

Solenoid Valve Design & Analysis (Czero semi automated optimization)

Data imported into

magnetic analysis

software. Force

maps created for

each case

Performance metrics automatically

plotted and rated allowing various

trades to be quickly identified

Magnetic data files used in

simulation for each case to

see how the actuator AND

system perform

Detail CAD DesignGenerate large number

of solid models from file

of parameters

automatically

Fluid Forces and

Internal LossesStructural AnalysisIteration as

needed to get

final design

Test

500-1000 design iterations day.

Optimal designs arrived at very quickly saving time and money

Natural Gas Genset – Cleansheet Design- Cummins QSK60 (1.45 MW)

- Runs off bottled gas

- 30’ ISO container, fully contained

- Czero designed, Cummins built and

qualified.

- Currently being tested by Bright Rail

Energy

Czero worked with Cummins and did

design of container and all support

systems except controls (cooling,

exhaust, etc).

Czero’s work with Bright Rail Energy and Bright Storage Technologies

Bright Energy Storage Technologies & Bright Rail Energy

- Started by augmenting their small engineering team (2011)

- Czero still doing work for both companies and is currently on projects with them

- Czero acted as virtual engineering team at first, and worked with them as they brought majority of work in house

- Multiple patent applications filed

Picture of the genset being tested.

Natural Gas Fuel Skid

Fuel Inlet Conditions:- Gas temperature: -30°C to 40°C

- Gas pressure: 300psi to 3,250psi

Fuel Outlet Requirement:- Fuel Flow: 2,210SCFH to 14,500SCFH

(idle to full load)

- Fuel Pressure: 4.8psi to 6psi

- Fuel temperature: 5°C to 50°C

Clean sheet design by Czero.

Currently being tested with

good success

CO2 Nexus

- Designed and built first double door commercial laundry system (2011)

- CO2Nexus successfully tested with Aramark at their facility

- Patagonia now funding CO2Nexus

- Czero still doing work for CO2Nexus and currently on project for them

- Czero acted as virtual engineering team at first, they are bringing more in house

- Multiple patent applications filed

CO2 Based Cleaning Machines

Czero concepted and

designed the first barrier

system for CO2Nexus. Have

done several more designs for

them.

Custom system Drive Assembly for CO2Nexus

Czero designed a lower cost, higher

reliability drive system for their dry

cleaning machines.

Dual mode engine – for onboard natural gas refueling

Engine operates normally or can be reconfigured on

fly to have some cylinders act as compressor to allow

onboard refueling

Phase one tested successfully, now working on phase

two with DOE.

Custom Valve Deactivation System for ARAPe

Custom valve deactivation system designed and built by

Czero. Parts now being tested.

0 10 20 30 40 50-7

-6

-5

-4

-3

-2

-1

0

1

Positio

n (

mm

)

Time (ms)

Valve Position, Stage 1 Intake: Vary Orifice

0.5 mm2

1 mm2

1.5 mm2

2 mm2

2.5 mm2

3 mm2

3.5 mm2

4 mm2

4.5 mm2

5 mm2

5.5 mm2

6 mm2

10 15 20 25 30 35 40

-1.5

-1

-0.5

0

0.5

1

Velo

city (

m/s

)

Time (ms)

Valve Velocity, Stage 1 Intake: Vary Orifice

0.5 mm2

1 mm2

1.5 mm2

2 mm2

2.5 mm2

3 mm2

3.5 mm2

4 mm2

4.5 mm2

5 mm2

5.5 mm2

6 mm2

Phase II of dual mode required novel check valve/actuator

365 366 367 368 369 370 371 372

0

0.2

0.4

0.6

0.8

1

Pla

te P

ositio

n (

mm

)

Time (ms)

Plate Position

0.5N/mm

1N/mm

3N/mm

5N/mm

Traditional check

Czero does dynamic modeling, CFD, FEA,

etc. to ensure design will work as intended.

Custom head with valve deactivation for dual mode engine

New head to interface with existing Ford hardware

design by Czero. Currently being tested with good

success

Component Mass (g)Quantity/

Dynamic FactorMoving Mass

Valve 22.0 1 22.0

Snubber Piston 3.8 1 3.8

Top Washer 0.8 1 0.8

Bottom Washer 0.8 1 0.8

Top Sleeve 1.0 1 1.0

Bottom Sleeve 2.7 1 2.7

Spring 1.0 0.33 0.3

Spring Perch 3.7 1 3.7

Set Screw 0.3 1 0.3

35.4TOTAL

Length of contact for stem top (for viscous friction and annular leakage) = 4.89mm (‘B’)

Length of contact for stem bottom, through hard stop (for viscous friction and annular leakage) = 10.51mm (‘A’)

Length of contact for hard stop (for annular leakage) = 6.14mm (‘D’)

Length of contact for stem, through guide (for viscous friction) = 8.59mm (‘G’)

Total Moving Mass

Clearances

4 locations of annular leakage accounted for in model:• Top hydraulic volume to ambient (clearance ‘B’)

• Bottom hydraulic volume to ambient (clearance ‘D’)

• Bottom hydraulic volume to ambient (clearance ‘A’)

• Top and bottom volume to flow passage volume while damping (clearance ‘C’)

4 locations of viscous friction, and 1 location of coulomb friction:

• Coulomb: Stem seal

• Viscous: stem top (‘B’)

• Viscous: stem to guide (‘D’)

• Viscous: stem to hardstop (‘A’)

• Viscous: piston (‘C’)

Dual mode engine (cont’d)Geometric Tolerance

Sensitivity

Czero performs extensive stack calculations to ensure that

the product will work under all conditions.

Onboard Dynamics

- Did design and analysis of first system for OSU (2012)

- DOE increased funding from $700k to $1M based on progress

- DOE awarded follow on funding of $3.8M, just delivered second prototype system. Continue to work on project

- Czero acting as virtual engineering team

- Multiple patent applications filed

The ARPAe Project Goes to the White House

Dr. Ellen Williams – Director of ARPAe, with Onboard Dynamics VP Jeff Witwer and CEO Rita Hansen. (2015)

Alage bioreactors for Solix Biofuels / Solix Biosystems

Czero work with Solix Biosystems

- Started by augmenting their small engineering team (2007)

- Took on Engineering Director role and helped fill out engineering team

- Executed on project and helped secure A and B series funding

- Czero still doing work for Solix Biosystems and is currently on project

- Czero acted as virtual engineering team at first, they are bringing more in house

- Multiple patent applications filed

Pilot scale bioreactor designed by Czero

Solix AGS 4000 portable

bioreactor and support

equipment designed by Czero

(Formerly Solix)

Hydraulic Hybrid – Gen III (Czero internal project)Complete design by Czero:

- ~5 months concept to operational

- Leveraged existing components

- Tested in class 6 truck

- 2 years operation with only minor seal leak

- Excellent condition on teardown

Hydraulic Hybrid – Gen III

Pictures of the GEN III installed into truck and tested

Hydraulic Hybrid - GEN II: Drop in Replacement

GEN II designed to address the high cost of installation in retrofit cases.

Hydraulic Hybrid - Gen II

Modification to Allison transmission only required new case and

oil pump housing. Other custom made components resulted in

elimination of the torque converter and split torque hybrid

operation. (only design work done to prints, not manufactured)

(Patented)

Test Rig for 800C Molten SaltsCzero designed a test skid for 800C molten salts for

NREL as a subcontractor to SpringsFab.

Malt processing skidCzero designed a skid for

processing malt for K-malt. The

skid is now in use.

Compressed Air Energy Storage (CAES)– Analysis for Client

Crankshaft Torque Analysis

PV diagram for all four stages

0 30 60 90 120 150 180 210 240 270 300 330 3600

2000

4000

6000

Forc

e, (N

)

Force Cam to Pushrod

0 30 60 90 120 150 180 210 240 270 300 330 3600

500

1000

1500

Forc

e, (N

)

Force Bridge to Valve - must stay positive

0 30 60 90 120 150 180 210 240 270 300 330 3600

2

4

6

Cylin

de

rP

ressu

re (

bar)

0 30 60 90 120 150 180 210 240 270 300 330 3600

5

10

15

Crank Angle (deg)

Pop

pe

t F

low

Are

a (

cm

2)

LP

HP

Valvetrain forces

Czero performed thermodynamic

simulations with mechanical

simulations to ensure that the cycle

was going to achieve the required

round trip efficiency and that the

stresses would be within allowable

limits

We found it was not possible to produce the valve lift with the exact duration required (very short duration, with high lift), so performed trade studies to assess the thermodynamic efficiency with various valve profile traces, comparing both lift and duration for different profiles shapes.

CAES Trade study AnalysisDouble-harmonic

durations

lift 70 75 80 85 90 95 100

8 85.4 87.7 88.1 87.5 86.0 83.7 81.0

9 86.7 88.7 88.9 88.1 86.5 84.2 81.4

10 87.7 89.4 89.4 88.5 86.7 84.3 81.4

11 88.5 89.8 89.7 88.6 86.7 84.2 81.2

12 89.0 90.1 89.9 88.6 86.6 84.0 80.9

6th order polynomial

durations

lift 70 75 80 85 90 95 100

8 87.4 89.3 89.5 88.7 87.0 84.7 81.9

9 88.6 90.2 90.2 89.2 87.4 85.0 82.1

10 89.5 90.8 90.6 89.4 87.6 85.1 82.1

11 90.1 91.2 90.8 89.5 87.5 84.9 81.8

12 90.6 91.4 90.9 89.5 87.3 84.6 81.4

Double-dwell, mod sine, dwell = 10

durations

lift 70 75 80 85 90 95 100

8 90.1 91.3 91.0 89.8 87.9 85.4 82.4

9 91.0 91.9 91.4 90.1 88.1 85.4 82.4

10 91.6 92.2 91.7 90.2 88.0 85.3 82.1

11 91.9 92.4 91.7 90.1 87.8 85.0 81.7

12 92.2 92.5 91.6 89.9 87.5 84.6 81.1

Compressor Efficiency

Poppet Valve Flow Study for compressor – Lift Optimization

Czero performs detailed trade studies enabling data driven

selection of architectures and operating parameters within

complex design space. This gets you to the best solution quickly

saving time and money

CAES Analysis – Iterating/optimization via modelingMultiple iterations were performed to hone in on an optimized solution

Final cam traces provided lower thermodynamic efficiency than hoped for, but favored a design with high confidence of durability

Efficiency sweep

CAES test system

Fuel injection design/analysis/modeling – SAE Paper

Czero engineers do high fidelity hydraulic modeling such as this injector model

Off shore oil drilling/production

Simple hydraulic test skid for O&G

customer designed and built by Czero.

Czero is developing large skids and system for

use in offshore oil drilling for O&G customer