Hybrid Vehicles – Page 2 – Utility Fleet Professional

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Green News

Written by Seth Skydel on June 4, 2013. Posted in Smart Fleets.

New product introductions played a significant role at The Work Truck Show 2013, produced by NTEA. This year, more than 120 products made their debut at the event, and many fell into the category of green fuel-saving technologies.

The Green Truck Summit, jointly produced by NTEA and CALSTART, was also held in conjunction with The Work Truck Show. The event included a Ride-and-Drive, and attendees were able to visit with exhibitors at the CALSTART Clean Technology and Fuels Pavilion on the show floor. In addition, there were numerous opportunities to learn more about products and programs during a general session on green fleets and in breakout sessions. Topics for the sessions were covered by industry experts and “early adopter” fleet managers who shared their insights, lessons learned and solutions for implementing green technologies.

On its first day, the Green Truck Summit attracted more than 675 attendees. Keynote presenter Lee J. Styslinger III, chairman and CEO of Altec Inc., discussed the future of the green truck industry. Styslinger also reported on Altec’s development of a next generation of hybrid-electric, all-electric and range-extended electric work trucks.

The second day of the Green Truck Summit kicked off with a keynote address by Ron Schoon, executive manager, partnership development at National Renewable Energy Laboratory. Schoon discussed NREL and Clean Cities programs and initiatives, focusing on ongoing outreach to identify the value of clean fuels and technologies in the commercial truck industry. He also shared details about an upcoming national database of duty and drive cycles that all fleets can access to evaluate technologies in real-world applications. Visit www.ntea.com.

Green Truck Association Names 2013 Board of Directors Officers
The Green Truck Association announced its new officers of the board of directors during The Work Truck Show. The affiliate division of NTEA works to improve the efficiency and productivity of work trucks through the development and deployment of strategies to reduce diesel and gasoline consumption and associated environmental impacts.

Elected to one-year terms were:
• Joe Dalum, president and chief executive officer of Odyne Systems LLC, GTA president.
• David Bryant, manager of vocational sales for Freightliner Trucks, GTA vice president.
• Bill Burns, fleet operations manager for the City of Columbus, Ohio, GTA treasurer.

Also now serving on the board for three-year terms are Shawn Brougham, director, marketing and product engineering for Altec Industries, and Rob Stevens, chief nameplate engineer, commercial truck programs for Ford Commercial Truck.

The goal of the GTA is to continue the progression of green work trucks by showcasing green trucks and technology developments, serving as the resource for legislative, regulatory and funding initiatives relevant to green truck development, supplying market data and technical resources relevant to green truck development, and sharing timely news on green truck products and initiatives. Visit www.greentruckassociation.com.

HYBRIDS

Tallahassee Adds Terex HyPower to its Fleet
Terex Utilities has supplied the City of Tallahassee, Fla., with eight new utility trucks equipped with its HyPower Hybrid technology. The sale included four Terex TL41P Hi-Ranger telescopic material-handling aerial devices and four Terex C4045 digger derricks.

According to Buddy Driggers, alternative fuels manager, City of Tallahassee, the city is using its new TL41P HyPower aerial devices as trouble trucks, tasking them to handle everyday utility jobs such as responding to small power outages and removing downed tree limbs from power lines. The Terex C4045 HyPower digger derricks are being used by the city’s line crews.

The new Terex models in the Tallahassee fleet are replacing older utility trucks. In the future and as other units come due for replacement, Driggers noted, the city will evaluate opportunities to add more Terex HyPower trucks to its fleet.

According to Terex, the HyPower Hybrid System significantly reduces fuel consumption, diesel engine exhaust emissions, operating costs and work site noise pollution. The plug-in electric hybrid technology uses stored energy from the system’s rechargeable batteries to power nonpropulsion functions of the vehicle. Operating the utility truck’s boom functions and accessories, the HyPower system can allow crews to work on job sites for hours without starting the engine.

The Terex HyPower Hybrid System can be retrofitted onto existing vehicles. Visit www.terexhypower.com.

Allison Transmission Unveils Fully Automatic Hybrid
Designed for medium- and heavy-duty vehicles, the new Allison H 3000 hybrid-propulsion system is a fully automatic parallel hybrid solution based on the Allison 3000 Series transmission. The H 3000 captures wasted energy during vehicle braking and uses it to assist in propulsion and powering of auxiliary equipment. The design features a torque converter fully automatic transmission and a hybrid motor-generator, power electronics and lithium-ion cell battery packs.

Scalable to each application, the modular lithium-ion battery packs in the H 3000 enable an optimal amount of energy capacity to be tailored to a specific vehicle or duty cycle, Allison noted, allowing for greater flexibility and performance. Depending on vocation and duty cycle, according to the company, the system is designed to offer fuel savings of up to 25 percent.

Production of the H 3000 is expected to begin later this year. Visit www.allisontransmission.com.

Odyne Systems Showcases Walk-In Van Hybrid Power Application
The Odyne Systems plug-in hybrid system that the manufacturer says is capable of reducing diesel fuel consumption up to 50 percent, depending on duty cycles, was recently displayed in a new walk-in van application where it powers climate control and underground tools.

The Odyne plug-in hybrid system interfaces with Allison Transmission’s fully automatic transmissions and uses a Remy electric motor in parallel with the existing drivetrain to provide launch assist and regenerative braking. At the job site, the Odyne hybrid plug-in battery system, featuring Johnson Controls’ lithium-ion battery packs, powers typical applications with the engine off.

Odyne systems are modular and can be applied and retrofitted to a wide range of work truck chassis in various applications. The systems are sold through a distribution network including Altec, DUECO and Terex Utilities. Visit www.odyne.com.

XL Hybrids Expands Product Line
Ford E-Series vans can now be equipped with an XL Hybrids hybrid electric powertrain designed for Class 1 to 3 fleet vehicles. The XL Hybrids technology will initially be available for 2013 model year E-150 and E-250 cargo van and passenger wagon models. The company then plans to release systems for older model year vehicles. The hybrid electric powertrain will be available for retrofit on model year 2013 vans already in fleet service

XL Hybrids also recently announced an installation partnership and distribution agreement with Leggett & Platt Commercial Vehicle Products. Visit www.xlhybrids.com.

Echo Automotive Rolls Out Full-Size Chassis
A 2007 Ford E-250 van with almost 400,000 miles on it was used to demonstrate how the Echo Automotive EchoDrive bolt-on hybrid electric kit for fleet vehicles can be used on multiple model year vehicles within a fleet.

Designed to integrate with existing vehicle architecture, EchoDrive does not replace the existing drivetrain. The system includes a battery, electric motor, inverter and charger that provide additional energy. EchoDrive fits most vehicles with adapter plates and brackets and includes modular battery packs that allow fleets to customize the system. Visit www.echoautomotive.com.

Siemens Moves Hybrid System Production to Georgia
Siemens has brought production of its hybrid traction electric drive systems to its manufacturing plant in Alpharetta, Ga. The move, according to the company, was made to allow for a quicker response to the production and service needs of North American customers.

The company has begun production of inverters, inductors and voltage protection modules at the plant as well as the assembly of electric drive systems within roof rack configurations for transit buses. Visit www.usa.siemens.com/drivetechnologies.

CNG & LPG

Ford Expands CNG-/LPG-Ready Offerings
With sales of Ford vehicles capable of running on CNG or propane autogas reaching record levels, the manufacturer has expanded its line of CNG- and LPG-ready models. Ford will now offer the all-new Ford Transit range of full-size vans, wagons, cutaway and chassis cab models powered by a 3.7-liter V-6 with a CNG/LPG prep kit.

Transit joins the current compact Transit Connect van, wagon and taxi lineup; Ford Super Duty pickups; stripped chassis, E-Series vans, wagons and cutaways; and medium-duty F-450, F-550 and F-650 models being offered with engines prepped for CNG/LPG conversion. In addition, the next generation of the Transit Connect range will add a CNG-ready 2.5-liter four-cylinder engine when it goes on sale later this year.

Each Ford engine that is factory-prepped for gaseous conversion comes equipped with hardened valves and valve seats. Visit http://corporate.ford.com.

Westport Bi-Fuel System Available on Ford Chassis Cab Models
Westport Innovations has announced that its Westport WiNG Power System, a CNG bi-fuel system, is now offered on Ford F-450 and F-550 Super Duty Chassis Cab trucks.

The WiNG Power System is integrated on the 6.8-liter V-10 engine and offers a combined fuel range of approximately 650 miles (at 9 mpg) with maximum CNG capacity (42 gasoline gallon equivalent) and a standard 40-gallon gasoline tank. Once the CNG fuel is depleted, the Super Duty trucks with the Westport system run on conventional gasoline. Visit www.westport.com.

3M and Chesapeake Energy Announce CNG Tank Collaboration
3M has successfully completed the NGV2-2007 certification process for its first CNG tank. The 21.5-x-60-inch tank is designed for light- and medium-duty pickup trucks and corporate fleet vehicles.

The successful certification follows the 2012 announcement by 3M and Chesapeake Energy Corp. that the two companies would collaborate in designing, manufacturing and marketing a broad portfolio of CNG tanks for use in all sectors of the U.S. transportation market.

Chesapeake is slated to become one of the first users of the new 21.5-x-60-inch tank, which it will incorporate in its fleet vehicles. The utility is currently converting its fleet of nearly 5,000 vehicles to run on natural gas. “The fuel tank has been the most expensive single component on a CNG vehicle, causing a bottleneck for the market,” said Nathan Pumphrey, Chesapeake director – fleet operations. “We look forward to incorporating these tanks into our fleet vehicles to save money on our conversions.”

Initially, 3M tanks will be available through five approved upfitters including OEM Systems of Okarche, Okla.; Venchurs Vehicle Systems of Adrian, Mich.; Alternative Fuel Solutions of Mahaffey, Pa.; AVS of Salt Lake City; and World CNG of Kent, Wash. Visit www.3m.com/cng.

Venchurs CNG Announces Collaboration With 3M
Venchurs, a Qualified Vehicle Modifier for Ford Motor Co. with ship-through facilities in Louisville, Ky., and Adrian, Mich., is now utilizing 3M’s newly certified CNG tank.

Companies interested in adding CNG Ford F-250s or F-350s to their fleets are also invited to apply for Venchurs’ short-term loaner program, where they can put the converted trucks to the test. Visit www.venchurscng.com.

ROUSH CleanTech and Green Alternative Systems Unveil New Ford F-550
A Ford F-550 chassis cab powered by propane autogas has been unveiled by ROUSH CleanTech and Green Alternative Systems. The customizable Ford F-550 – for use in passenger vehicles as well as construction, transit and utility applications – is equipped with a 6.8-liter V-10 engine.

Green Alternative Systems, a certified Ford Qualified Vehicle Modifier installer, designs mounting hardware, handles packaging strategy and integrates ROUSH CleanTech propane autogas fuel system technology into the F-550 chassis cab. Visit www.greenalternativesystems.com and www.roushcleantech.com.

DISH Rolls Out Propane-Powered Fleet
Satellite TV company DISH has unveiled the first of 200 ROUSH CleanTech propane autogas-fueled Ford E-250 cargo vans that will enter its fleet in 2013. The company estimates the new propane autogas-powered vehicles will lower carbon dioxide emissions by 12.5 million pounds over the lifetime of the fleet’s operation compared to gas-powered counterparts.

DISH’s new alternative fuel vehicles will support residential and commercial customer service in Atlanta, Chicago, Detroit, Los Angeles and San Francisco. Visit www.roushcleantech.com.

Icom Receives EPA Certifications, Announces Fleet Installation
Icom North America has received 15 new Environmental Protection Agency certifications for its patented JTG II Propane Liquid Injection bi-fuel and dedicated systems. The certifications cover approximately 100 different 2012-2013 General Motors and Ford light-duty trucks and SUV platforms with GM 4.8- and 5.3-liter engines and Ford 3.7-, 4.6- and 5.4-liter engines. Icom’s JTG II system is now available for approximately 600 vehicle platforms.

Icom has also announced an installation program for 140 propane autogas Ford F-150 pickup trucks for use by Menards home improvement stores. The vehicles will serve 36 Menards locations throughout Illinois and at Menards’ Eau Claire West store in Wisconsin. Visit www.icomnorthamerica.com.

HYDROGEN

Fuel Cell-Electric Hybrid Trucks Rolling in Houston
Funding from the Department of Energy and regional stakeholders – including the Houston-Galveston Area Council, Total Transportation Services Inc., Air Products, Vision Industries and the Environmental Defense Fund – is replacing 20 diesel-powered heavy-duty vehicles with zero-emission Tyrano hydrogen fuel cell-electric trucks. The DOE granted HGAC $3.4 million in funding to launch a zero-emission engine technology demonstration project at the Port of Houston Authority where heavy-duty trucks are projected to account for almost half of all port emissions by 2015.

Expected emission reductions from the project include 39 tons of nitrogen oxides and 0.8 tons of particulate matter per year. The trucks are expected to be rolled out later this year and will be fueled with hydrogen locally sourced from natural gas feedstock. Visit www.edf.org.

Real-World Solutions: Green Truck Summit 2013

Written by Seth Skydel on February 15, 2013. Posted in Smart Fleets.

Registration is now open for the work truck industry’s educational forum on clean vehicle technologies – the Green Truck Summit that kicks off The Work Truck Show 2013.

Offering fleet managers practical ideas and solutions for implementing new green practices, the Green Truck Summit 2013’s slate of presenters will cover clean technology and fuel trends, deployment strategies, viable alternative fuels and funding opportunities.

On the summit’s agenda are a range of technical experts and industry leaders, including representatives from truck and engine OEMs, government agencies and fleet operations. The Green Truck Summit features 24 breakout sessions, five general sessions and two keynote addresses.

The Green Truck Summit 2013 will begin with a speech by Lee J. Styslinger III, chairman and chief executive officer of Altec Inc. Altec is developing a next generation of hybrid-electric, all-electric and range-extended electric work trucks. In 2012, the equipment and service provider opened a new green-focused assembly plant.

Dr. Michael Pacheco, associate laboratory director for deployment and market transformation at the U.S. Department of Energy’s National Renewable Energy Laboratory, will address the Green Truck Summit as well, sharing insights into clean energy deployment, including programs that affect commercial vehicles and fleet operations. The focus of NREL is on achieving widespread adoption of more efficient and renewable technology, including alternative fuels and advanced vehicles.

The general session lineup at the Green Truck Summit will include the following sessions:
• Trends in Clean Technologies and Fuels
• OEM Perspectives on the Future of Clean Technologies
• Modeling the Benefits of Deploying Green Technologies
• Optimizing Engines: New Ideas to Be Clean and Efficient
• Compounding the Green: Incremental Measures for Going Green and Sustainable

Breakout sessions scheduled for the summit will cover propane, hydrogen fuel cells, natural gas, hybrid-electric systems, bi-fuel CNG and LPG systems, turbine-electric trucks, truck updates and other fuel-saving advancements. The complete Green Truck Summit schedule is available at www.ntea.com/greentrucksummit/schedule.

Presented by International Truck, the Green Truck Summit is produced jointly by NTEA, the Association for the Work Truck Industry, and CALSTART, a nonprofit organization that works nationally to foster the rapid growth of the clean transportation technology industry. The event precedes The Work Truck Show, which also includes a Green Truck Ride-and-Drive, sponsored by Hino Trucks, where attendees can experience the latest in clean vehicle technology. On the show floor, the CALSTART Clean Technologies and Fuels Pavilion features green equipment that is commercially available today.

The Green Truck Summit runs March 5-6 at the Indiana Convention Center in Indianapolis. Summit registration includes admission to The Work Truck Show. To register, visit www.ntea.com or call 800-441-6832.

HYBRIDS

Eaton Developing Predictive Battery Management Technology
A power control system to reduce the size of hybrid system batteries is under development by Eaton Corp. The goal of the $2.5 million project, funded jointly by Eaton and a grant from the U.S. Department of Energy’s Advanced Research Projects Agency-Energy, is to reduce the size of the battery by 50 percent and improve the performance of the system and its charge rate while maintaining fuel economy and overall vehicle performance.

The development project will be led by Eaton’s Innovation Center team in Southfield, Mich., which will work with a team from the National Renewable Energy Laboratory. Eaton’s engineers and scientists will leverage the company’s expertise in intelligent power management systems and hybrid technology with NREL’s expertise in battery modeling and prognostics.

“This project is a continuation of Eaton’s keen focus on hybrid technology development and our confidence in the value of hybrids for the future,” said Tom Stover, chief technology officer for Eaton’s Vehicle Group. “Eaton is continuing to invest in developing the infrastructure that supports the future of the transportation industry, and this project is an example of how we are working to find safe, efficient and sustainable ways to improve hybrid vehicle performance.” Visit www.roadranger.com.

GE and Ford Collaboration
GE has announced it will purchase 2,000 new Ford C-MAX Energi plug-in hybrids for its fleet. The purchase of Ford C-MAX Energi vehicles is another step in GE’s commitment to convert half of its global fleet to alternative fuel vehicles. The addition of the 2,000 plug-in hybrids brings the number of alternative fuel vehicles in GE’s fleet to more than 5,000. To date, GE employees have driven approximately 18 million miles in alternative fuel vehicles, saving about $2 million in fuel costs and reducing emissions by approximately 12 million pounds.

The Ford C-MAX Energi plug-in hybrid provides a 21-mile electric-only range and a 620-mile single-tank driving range for a city EPA rating of 108 mpg.

As part of the collaboration, Ford will jointly market GE’s WattStation charging station and CNG In A Box natural gas fueling station to its commercial vehicle customers. The OEM will also supply new alternative fuel vehicles for use at GE’s Vehicle Innovation Center.

The two companies will also work with the Georgia Institute of Technology on data collection and analysis to study employee driving and charging habits, with the goal of improving all-electric driving and charging performance. Study findings will be shared with commercial customers to provide insights and help facilitate alternative fuel vehicle deployment across the country. Visit www.ford.com.

Hybrid Bus Team Recognized for ‘Visionary Leadership’
Eaton Corp. was part of the Kentucky Clean Fuels Coalition team, along with the Kentucky Department of Education, that received the first-ever Visionary Leadership Award from the Southeast Diesel Collaborative. SEDC is part of the U.S. Environmental Protection Agency’s National Clean Diesel Campaign to reduce pollution emitted from diesel engines.

The KCFC team provides hybrid-electric school buses to the state of Kentucky under a $12 million grant from the U.S. Department of Energy. Eaton assembles the hybrid system, including the clutch, electric motor, battery and six-speed automated transmission. As part of Kentucky’s hybrid bus program, Eaton offers training for drivers, mechanics and first responders. It also provides a technical overview for local communities.

With 162 buses fitted with Eaton hybrid systems, Kentucky has the largest hybrid school bus fleet in the U.S. On average, the hybrid buses are 34 percent more fuel efficient than traditional diesel-powered models. In some cases fuel consumption has been cut in half, depending on driving cycles and styles. The buses, which are used in a wide range of school districts across Kentucky, are typically driven 10,000 to 15,000 miles per year and have a 14-year life. Visit www.roadranger.com.

ELECTRIC VEHICLES

Chicago Awards Electric Garbage Truck Contract
Chicago is set to become the first U.S. city to deploy all-electric, zero-emissions garbage trucks. The five-year contract issued by the city to Motiv Power Systems will put in service 20 Class 8 EV refuse trucks with a GVWR of 52,000 pounds and a range of 60 miles.

The city of Chicago, which operates 600 garbage trucks, chose to request bids for electric refuse trucks after evaluating hybrid and compressed natural gas options. The city found that its garbage routes did not enable those technologies to be financially viable compared to the all-electric option.

Additionally, it has been validating the Motiv electric Powertrain Control System (ePCS) since March 2012 in an all-electric bus. The pilot program, funded by a grant to Motiv from the California Energy Commission, placed the 20-passenger bus, which can cover more than 120 miles on a single charge, in service.

Motiv’s ePCS uses off-the-shelf batteries and motors, which can be mixed and matched to fit the exact size of medium- to heavy-duty electric vehicles from 15,000 to 52,000 pounds. The Chicago refuse trucks, slated to be the heaviest electric vehicles in the U.S., will have the same ePCS system as the pilot bus, but include a larger motor and 10 battery packs. Motiv will work with Detroit Chassis to install the ePCS on a standard refuse chassis and Loadmaster will provide the truck bodies. Visit www.motivps.com.

GM Sets Sights on Electrification
By 2017, General Motors plans to have up to 500,000 vehicles on the road with some form of electrification. Included is a focus on plug-in systems like those used in the Chevrolet Volt extended-range electric vehicle introduced in 2010. The same technology is planned for the Cadillac ELR and the Chevrolet Spark EV, which will go on sale next year in certain U.S. markets. Additionally, the OEM is on track to sell more than 50,000 vehicles this year with electrification, including Chevrolet and Buick models with its eAssist light electrification technology.

Since 2010, Chevrolet Volt operators, including a number of fleets, have collectively driven more than 100 million all-electric miles. The average Volt travels more than 65 percent of the time in pure electric mode, only using the gasoline-powered generator for longer trips. In total, according to the manufacturer, Volts in service have saved 5 million gallons of fuel, equivalent to $21 million in overall gasoline costs based on $4 per gallon. For the first 38 miles, a Volt can operate using only a full charge of electricity stored in its 16.5-kWh lithium-ion battery. When the Volt’s battery runs low, a gas-powered engine/generator extends the driving range another 344 miles on a full tank.

When it arrives in California next summer, the 2014 Chevrolet Spark EV will have undergone more than 200,000 hours of battery testing. The Spark EV is driven by a coaxial drive unit powered by an oil-cooled, permanent magnet motor that produces at least 100 kW (130 HP) and torque of about 400 pounds per feet. More than 75 percent of the propulsion system components are from the Volt and GM’s hybrid truck programs. The vehicle’s more than 20-kWh lithium-ion battery pack is capable of handling multiple DC Fast Charges of up to 80 percent of battery capacity in approximately 20 minutes. Charging can also be completed in fewer than seven hours using a dedicated 240-volt charge. Visit www.gm.com and www.chevrolet.com.

Protean’s In-Wheel Solution
In multiple demonstration vehicles, including a Ford F-150 pickup truck, the Protean Drive fully integrated, in-wheel motor, direct-drive solution from Protean Electric is showing fuel economy improvements up to 30 percent depending on battery size. Designed to fit within the space of a conventional 18-inch road wheel, the system’s 68-pound motors each produce 81 kW (110 HP) and 590 pounds per feet of torque and, through regenerative braking capabilities, allow up to 85 percent of available kinetic energy to be recovered. Visit www.proteanelectric.com.

Mobile Electric Power Produces Results
In Austin, Texas, Energy Xtreme’s cleantech mobile electric power idle reduction solution has been installed in 33 of the city’s public works trucks and more than 600 Austin Police Department vehicles. Additional units have been retrofitted on Austin Energy and water utility department trucks. The producer of mobile power idle reduction systems has also installed its solution in an Austin EMS ambulance.

The Energy Xtreme mobile power idle reduction system is a smart power management device that provides power, without engine engagement, to vehicles with demanding electrical needs. The system allows a vehicle’s auxiliary electrical systems to operate without having to idle the vehicle’s engine and automatically recharges while the vehicle is being driven. Visit www.energyxtreme.net.

PROPANE & NATURAL GAS

Propane-Powered Buses
CleanFUEL USA and Collins Bus Corp. have delivered 134 propane autogas school buses to First Student Inc., the largest provider of student transportation services in North America. The buses will be used by First Student to provide service to Seattle Public Schools and Portland (Oregon) Public Schools. The purchase of the buses was made possible through grants from the U.S. Department of Energy and the American Recovery and Reinvestment Act.

The Collins propane-powered NEXBUS is built on a dual rear-wheel GM chassis and utilizes a GM 6.0-liter engine. It has an estimated range in excess of 300 miles and is available in capacities up to 32 passengers. The propane autogas fuel system was developed in partnership with CleanFUEL USA and has obtained certification from both the U.S. Environmental Protection Agency and the California Air Resources Board. Propane autogas, the third most widely used transportation fuel after gasoline and diesel, averages 40 to 50 percent fewer emissions per gallon. Visit www.cleanfuelusa.com and www.collinsbuscorp.com.

SuperShuttle Deploys 75th Alternative Fuel Vehicle
An operator of propane autogas vehicles since 2009, SuperShuttle has placed its 75th propane-powered shuttle in service in Phoenix. The alternative-fueled van is equipped with a ROUSH CleanTech propane autogas engine fuel system.

During its life cycle, each SuperShuttle propane autogas shuttle will release 175,000 fewer pounds of carbon dioxide than it would if it were operating on gasoline, the company noted. SuperShuttle franchisees operating these alternatively fueled vehicles are saving an average of $200 per week, or $10,400 per year, based on historically lower propane autogas costs and reduced maintenance. Visit www.roushcleantech.com.

Linde Demonstrates Mobile LNG Fueling
Linde North America has conducted a successful trial of its new LNG mobile fueling unit and plans to expand its use of mobile fuelers to help fleets make the transition to LNG fuel. Linde operates cryogenic plants and makes several million deliveries of cryogenic gases annually. It offers the technologies, equipment, supplies and services for LNG fueling solutions, including producing and servicing mobile and permanent refueling stations. Visit www.lindelng.com.

Alliance AutoGas Adds to Its Clean Fueling and Conversion Network
Alliance AutoGas welcomes new Canadian partner Wilsons Fuel Company Ltd. to its expanding clean vehicle fueling and conversion network. Wilsons brings the Alliance program to Nova Scotia, New Brunswick, Prince Edward Island, and Newfoundland and Labrador for fleets running on propane autogas. The Alliance program guides fleets through every aspect of switching to propane, including vehicle conversions, fueling, on-site fuel station installation, data integration, training and technical support. The Alliance AutoGas partner network now spans 40 states, Washington D.C. and seven Canadian provinces. Visit www.allianceautogas.com.

GAS & CLEAN DIESEL

Clean Diesel Technology Delivering for the Future
Advancements in clean diesel technology over the past decade, in conjunction with new research and development in all types of diesel engines, will play a major role in helping meet the updated Clean Air Act particulate matter (soot) standards announced by the U.S. Environmental Protection Agency.

“For the last decade, diesel technology has undergone a fundamental transformation to near zero emissions, based on ultralow sulfur diesel fuel, advanced clean-burning engines and new emissions control technology,” said Allen Schaeffer, executive director of the Diesel Technology Forum. “These advancements have occurred across the board, from the smallest industrial engine to increasingly popular clean diesel cars, commercial trucks, and off-road machines and equipment. The results of these efforts are clear since today, according to EPA, diesel engines account for only a small portion of the national PM emissions inventory – less than 6 percent.

“These last 10 years truly are the decade of clean diesel and the results are visible today,” Schaeffer continued. “New highway diesel truck engines have near zero emissions of particulate matter and oxides of nitrogen – a remarkable 98 percent less than 1988 models. It is also noteworthy that truck and engine manufacturers are not only producing near zero-level emissions, but these vehicles are also consuming an average of 5 percent less fuel. Just how significant is this accomplishment? Consider that it now takes 60 of today’s clean diesel heavy-duty trucks to equal the particulate emissions of one 1988 truck – a 60-to-1 ratio.”

Similar reductions in emissions of particulates and oxides of nitrogen are well underway and will be completed by 2014 for the wide range of off-road engines found in everything from small construction to large off-road equipment.

“Beyond the new technology advancements in reducing particulate emissions, there are opportunities for modernizing and upgrading existing diesel engines and equipment,” Schaeffer noted. “We are continuing to work with national environmental and health organizations to increase funding for the highly successful voluntary and incentive-based Diesel Emissions Reduction Act, which is helping to modernize and upgrade older diesel engines in school and transit buses, commercial trucks and construction equipment.”

Visit www.dieselforum.org.

Mack and Volvo Receive Greenhouse Gas Certificates
The full lineup of model year 2014 trucks and tractors from Mack Trucks and Volvo Trucks is now certified by the U.S. Environmental Protection Agency and the National Highway Traffic Safety Administration in accordance with 2014 fuel efficiency and greenhouse gas regulations. Visit www.macktrucks.com and www.volvotrucks.us.com.

Navistar Announces Clean Engine Technology Plan
Navistar International Corp. said it will introduce its next generation clean engine solution – In-Cylinder Technology Plus (ICT+) – to meet U.S. Environmental Protection Agency emissions regulations for 2010 and position the company to meet greenhouse gas rules in advance of 2014 and 2017 requirements. The ICT+ technology combines Navistar’s advanced in-cylinder engine solution with urea-based aftertreatment. Visit www.navistar.com.

GMC and Chevrolet Bi-Fuel Pickup Production Begins
Now underway is production of the 2013 Chevrolet Silverado HD and GMC Sierra 2500 HD bi-fuel pickup trucks. Powered by Vortec 6.0-liter V-8 engines, the trucks run on gasoline or compressed natural gas (CNG) and seamlessly switch between the two fuels. CNG and gasoline tanks have a combined range of 650 miles. The Type-3 single-tank CNG system in the Silverado HD and Sierra 2500 HD is designed to retain more bed space. The pickups are available in standard and long-box and two- or four-wheel drive in the extended cab models.

GM and Chevrolet bi-fuel pickups are ordered from the factory, sent to tier-one supplier IMPCO for installation of the CNG bi-fuel delivery and storage system, and then delivered to the dealer or to an upfitter. The vehicles meet all U.S. Environmental Protection Agency and California Air Resources Board emission certification requirements.

“At Chesapeake Energy Corp., we are converting our fleet of more than 5,000 vehicles to run on natural gas, and having options from GMC and Chevy is critical to help us reach our conversion goal,” said Nate Pumphrey, director of fleet operations. “Following our full conversion, we will save $11 million to $12 million annually on fuel costs. As a fleet manager, the stable price of natural gas is another major benefit that helps me budget more accurately, and the fuel’s reduced emissions align with Chesapeake’s commitment to environmental excellence.”

Visit www.gm.com and www.chevrolet.com.

OILS & LUBES

Phillips 66 Offers Natural Gas Engine Oils
To support customers using natural gas-powered vehicles, Phillips 66 Lubricants has introduced natural gas engine oils. The Phillips 66, Conoco and 76 Lubricants and Guardol NG and Kendall Super-D NG products are designed for use in trucks powered by compressed natural gas or liquefied natural gas as well as in other natural gas-powered mobile equipment.

The new oils from Phillips 66 are formulated to meet the enhanced wear protection requirements of diesel-conversion natural gas engines. Lubricants for natural gas engines must protect against a larger range of conditions than diesel engine lubricants. To meet these special requirements for converted diesel engines, the oils offer temperature and oxidation control, balanced ash content to prevent valve stem deposits and reduce valve seat recession, and better shear stability and exhaust aftertreatment protection. The oils are approved for Cummins CES 20074 and Detroit Diesel 93K216 specifications. Visit www.phillips66lubricants.com.

RSC Bio Solutions
A manufacturer of bio-based cleaning, degreasing and lubricating products, RSC Bio Solutions is making available a line of biodegradable and nonhazardous products for fleet applications. Included is the company’s line of EnviroLogic bio-based hydraulic fluids and gear oils and SafeCare cleaners and degreasers. Visit www.rscbio.com.

HTUF Report

Written by Seth Skydel on October 26, 2012. Posted in Smart Fleets.

HTUF REPORT
Held in mid-September in Charlotte, N.C., the 11th Annual High-Efficiency Truck Users Forum served again as an educational and networking event for manufacturers, suppliers, fleets and government officials interested in learning the latest about high-efficiency truck technology.

HTUF has been very successful in helping launch the first production of hybrid trucks and is credited with reducing product development time by up to two years. When the conference was first held, no major truck manufacturer was offering electric or hybrid trucks. Today, there are more than 30 different electric, hybrid electric, hydraulic hybrid and workplace hybrid trucks available.

At this year’s conference, three federal government and private industry representatives took center stage. Heather Zichal, deputy assistant to the president for energy and climate change, discussed policy initiatives to create clean energy jobs, tackle climate change and reduce dependence on oil.

Also on the HTUF agenda was Dr. Dane Boysen, program director at the Advanced Research Projects Agency-Energy, who addressed technology research and development initiatives that ARPA-e is funding and how they are accelerating advanced technology market penetration. ARPA-e has made investments in advanced batteries, electric motors and lightweight materials that could enable fleets to dramatically reduce reliance on oil over the next decade. HTUF also featured David Mohler, senior vice president and chief technology officer at Duke Energy, who covered the increasing connections between vehicles, the grid and saving energy.

“We are very pleased to have secured key leading officials from the federal government and industry at HTUF,” said John Boesel, CALSTART president and CEO. “Clean energy jobs and reducing our dependence on oil are core elements of the president’s energy policy, and the Pentagon continues to focus on energy efficiency as a critical component of the nation’s energy security.

“Beyond conventional clean diesel engines, there are now at least five different advanced propulsion systems for commercial and military trucks,” Boesel continued. “At this year’s conference, fleets learned how each of these new drivetrains can be applied and utilized. Never before have there been such opportunities to cost-effectively transition away from dependence on the highly volatile and unstable world oil market.” Visit www.htuf.org.

Odyne Systems Showcases Plug-In Hybrid Systems
Odyne Systems LLC, a manufacturer of hybrid systems for medium- and heavy-duty work trucks, displayed its hybrid propulsion system on a Ford F-750 chassis at HTUF. Odyne plug-in hybrid systems are designed to interface with a wide variety of truck-mounted equipment. Driven through the Allison 3000 RDS transmission, the system uses a Remy electric motor in parallel with the existing drivetrain to provide launch assist and regenerative braking. At the job site, the Johnson Controls’ lithium-ion battery packs power work site applications. Visit www.odyne.com.

Kenworth Delivers with T440 CNG Truck
Kenworth Truck Co. showcased a Kenworth T440 compressed natural gas (CNG) tractor during HTUF. The T440 CNG is equipped with an 8.9-liter Cummins Westport ISL G engine and a six-speed Allison 3000 HS transmission. The model is available as a straight truck or tractor in a gross vehicle weight ranging from a heavy Class 7 vehicle at 33,000 pounds to a light Class 8 at 68,000 pounds. The ISL G engine uses a maintenance-free, three-way catalyst. Rated at 320 HP and 1,000 pounds per feet of torque, the engine’s torque curve closely matches that of its diesel counterparts. Visit www.kenworth.com.

PG&E REPORTS ON ELECTRIFICATION SAVINGS
The Electrification Coalition, a nonpartisan, not-for-profit group of business leaders committed to promoting policies and actions that facilitate the deployment of electric vehicles on a mass scale, has issued the following report on the electrification of the Pacific Gas & Electric fleet.

In 2011, the Pacific Gas & Electric vehicle fleet racked up 114 million miles of travel, many of them logged servicing lines and other equipment that deliver power to customers. As a critical service provider, PG&E must purchase vehicles capable of supporting its mission in low-probability, high-impact situations like severe unplanned power outages. In these scenarios, vehicles must sometimes travel great distances across the company’s service territory and then operate buckets and other repair equipment once on site. In fact, even routine service calls can vary greatly by distance, necessitating flexibility and putting a premium on range and refueling.

Because its vehicles have a low level of route predictability, PG&E is pursuing an acquisition strategy that prioritizes plug-in hybrid electric vehicles (PHEV) and electric work-site idle management systems (EWIMS), which are plug-in vehicles whose batteries provide power for a range of job site functions, but do not move the wheels. PG&E’s fleet of PHEVs is generally spread throughout its passenger cars and pickup trucks. The passenger cars are typically pool vehicles used by employees for work-related travel. These vehicles tend to travel only short distances. The pickup trucks are primarily work trucks, but are also driven by job site supervisors and foremen. PG&E’s EWIMS are Class 6 trucks and are a mix of bucket trucks and material handlers.

In addition to extended range, PG&E’s emerging fleet of PHEV pickup trucks provides the company with an additional strategic benefit. A typical PHEV relies largely on its onboard battery for power over a given mileage range. When the battery is depleted to specific level, the vehicle then relies on an onboard gasoline-powered generator to provide power to the battery, operating essentially as a gasoline-electric hybrid. PG&E has recently begun deploying a handful of retrofitted PHEV pickup trucks manufactured by companies like Orem, Utah-based VIA Motors. These vehicles currently feature between 15 and 100 kW of exportable power, and there is potential to increase that number. When these vehicles are on a job site, their onboard generator can bypass the battery and export electricity to a different destination like power tools or even a transformer.

Work site management technology is a logical fit for the duty cycle associated with PG&E’s Class 6 bucket trucks. These vehicles, which are typically located at a job site for six to eight hours per day, often consume more diesel fuel idling than driving. This is because work site repair functions – operation of the bucket and associated equipment – normally require the truck to be running, using its engine as a generator. It’s an inefficient use of fuel, but has historically been the only option. Today’s EWIMS technology utilizes an onboard battery to power job site equipment, allowing the engine to be turned off and saving fuel. The battery can be recharged by plugging into the grid or by a secondary onboard alternator that provides electricity to the battery while the vehicle is driving. The savings associated with the technology are substantial: In 2011 alone, PG&E saved more than $700,000 on fuel across its fleet of 178 EWIMS work trucks manufactured by Birmingham, Ala.-based Altec.

Finally, as an electric utility, PG&E arguably has an elevated level of interest in understanding plug-in electric vehicles (PEV) and working to support their commercialization. By the end of 2012, the company will own a total of 400 PEVs, ranking it solidly among the top three U.S. commercial fleets in terms of PEV ownership. Perhaps more interestingly, PG&E’s current fleet of PEVs have been sourced from seven different original equipment manufacturers.

A number of factors were taken into consideration as PG&E explored the possibility of adding PEVs to its fleet. The vehicles carry a great deal of promise due to a number of economic, regulatory and environmental benefits, but there are also a number of important challenges. PG&E offered insight into its decision-making process by ranking various factors and discussing their rationale around each one in detail.

Total Cost of Ownership: A vehicle’s total cost of ownership (TCO) – its upfront capital costs combined with operating costs over a specific number of years or miles traveled – is a standard tool for comparing the economics of various technologies. However, while TCO may provide a useful starting point for comparison in the abstract, a vehicle’s purchase price is a more pressing real-world consideration for many fleet operators, PG&E included. This is particularly the case when it comes to purchasing new technologies like PEVs. Any assessment of TCO will necessarily be based on a series of assumptions about performance, some of which may ultimately be less precise for the first generation of a given technology. This type of uncertainty ultimately increases the level of risk placed on the fleet customer. Utilities like PG&E can be particularly capital constrained, in the sense that budgets are often set several years in advance through regulatory filings. Therefore, the higher capital cost of PEV purchases either has to be justified to the regulator – and ultimately the rate payer – or it has to displace other spending. If a plug-in vehicle carries a cost premium of 25 percent, it means a utility with a fixed budget can only purchase four PEVs for the same cost as five traditional vehicles, leaving one vehicle in need of replacement in the field. This attrition represents an operational risk that no utility would likely take on. Therefore, in evaluating the size and timing of its PEV purchases, PG&E is mostly focused on the impact these acquisitions will have on capital budgets. Whether a fleet manager purchases or leases a vehicle, there is a monthly payment associated with it. For PEVs, this payment is currently higher than the payment for a comparable traditional vehicle. If the net of this capital premium less operational savings (reduced fuel expenditures) results in a higher total monthly outlay, it becomes hard to justify. There is intense competition for capital within PG&E, and the higher payment associated with a PEV purchase is capital that is unavailable to be spent on other projects – or booked as profit.

Access to Competitive Financing: Increasingly, fleet customers are looking to commercial financing entities to help manage the capital cost challenge of PEVs. Of course, financing is not a magic wand that can make something inherently expensive become cheap. So what PG&E is particularly interested in is managing the cost structure of PEV purchases as opposed to managing the actual cost of the vehicles. Actual vehicle costs will decline over time due to some combination of manufacturing scale and technological improvements, but the cost structure – that is, the way customers deal with the price premium on PEVs – could potentially be addressed in the near term. One possible avenue to cost management through competitive financing is an extended term on vehicle useful life. For example, PG&E currently finances its purchases of pickup trucks in line with industry common practice, which typically assumes a six- or seven-year vehicle life. However, publicly available data confirms that the age of the average light-duty truck on the road in the United States has increased every year since 2000 and now stands at more than 10 years. By extending the vehicle useful life assumed in standard financing packages for these trucks by three years, the cost premium would be spread out over a greater term, giving fleet customers more capital flexibility and encouraging more PEV purchases. It’s a challenging proposition for an unproven technology, but it’s one way PG&E is working to manage cost.

Operational Benefits: Another option for managing costs is to make sure you are capturing all the benefits. Generally speaking, in terms of performance, utilities get graded on two things: the number of service outages and the duration of those outages. In measuring the number of outages, there is essentially no discrimination between an outage that affects 10 customers and one that affects 10,000 customers. Moreover, regulators do not discriminate between outages that are unplanned and those that are planned. While unplanned outages arising from weather and other unexpected events account for some of PG&E’s service calls, planned outages to repair lines and upgrade transformers account for a substantial portion of total outages. While VIA Motors’ PHEV pickup trucks currently allow for just 15 kW of exportable power, the company is working to increase that capacity to 50 kW. In larger applications, like a retrofitted Ford F-450 from Electric Vehicles International, PG&E believes it is already possible to get close to 100 kW. Altec’s Class 6 EWIMS truck currently features 3 kW of exportable power. Considering that the power needs of the average home in California today are roughly 5 kilowatts, the possibilities for providing backup power to homes – even whole neighborhoods – during outages could be significant. Put another way, the largest portion of neighborhood transformers in the PG&E service territory are fewer than 100 kW (125 kVA). While reliably exporting this kind of power is still a speculative prospect at this point, PG&E believes it is possible to get there in the near term. If accomplished, it’s a technological milestone that would fundamentally change the utility business, allowing companies like PG&E to virtually eliminate planned outages arising from transformer maintenance and upgrades. In a business built around service reliability, this kind of operational advantage could be a game changer for improving customer relations and strengthening utilities’ standing with regulators.

Vehicle Maintenance Savings: PG&E is realizing real savings on maintenance costs for its fleet of PEVs. Conventional wisdom suggests that the savings on maintenance compared to traditional internal combustion engine (ICE) vehicles will be greatest for battery electric vehicles (EVs). This is because the EV drivetrain has the fewest moving parts relative to internal combustion engine vehicles. PHEVs, which retain the use of an engine and fueling system, still require oil and other fuel changes as well as general engine maintenance. Nonetheless, PG&E reports that spending on these maintenance items for its fleet of Chevy Volt PHEVs is lower than spending on comparable ICE models. PG&E attributes the savings to the relatively high portion of electric miles driven by its Chevy Volts, which have an all-electric range of 30 to 40 miles. Employees’ average trip in San Francisco, where the bulk of PG&E’s Volts are located, is just 11 miles. Two notable categories of maintenance savings being captured by PG&E are reduced spending on brake pads and tires for vehicles in San Francisco. The city’s hilly terrain takes a toll on vehicle brakes, which the company estimates it replaces every six months for traditional ICE vehicles. However, initial experience suggests that the brake pads on PG&E’s fleet of Chevy Volt PHEVs will last as long as two years between replacements under the same conditions due to regenerative braking. By essentially running the vehicle’s electric motor in reverse, regenerative braking slows the Volt as soon as the driver lets off the accelerator, converting this kinetic energy into electricity that helps recharge the battery. During actual braking, the regenerative system augments the conventional braking system, a process that offsets friction that wears on the pads. At the same time, it appears that this process is also reducing wear on tires that occurs normally during harder stopping, leading to less frequent tire replacement.

Electric Vehicle Charging Infrastructure: By focusing on PHEVs and EWIMS work trucks, PG&E’s vehicle electrification strategy fundamentally avoids reliance on public charging infrastructure. However, charging infrastructure located at a vehicle’s overnight parking location is still of high importance for recharging the battery after a typical day’s use. In some cases, PEVs are driven home by employees. But in other cases – such as pool vehicles – a number of units are parked at a central facility. In these cases, PG&E reports that that the cost of installing charging infrastructure can be a significant challenge. In 2011, PG&E installed 35 charging stations for pool vehicles at its downtown San Francisco headquarters. The units were installed in an underground secure parking facility. The hardware cost for individual chargers was extremely manageable at approximately $800 per unit. However, construction costs for running power into the underground facility from the street above are estimated to have been roughly $350,000 – more than 90 percent of the total project cost. PG&E reports that the necessary additional wiring ran only 350 feet, placing the cost at $1,000 per foot. The lesson as always is that cracking concrete for charging infrastructure installation is likely to be expensive in most cases. This is especially true when facilities are being retrofit, particularly in high-cost urban areas. Where companies or government agencies have the opportunity to incorporate charging infrastructure into new construction, costs can be dramatically reduced and better managed.

Sam Ori, director of policy at the Electrification Coalition, recently sat down with Dave Meisel, director of transportation services at PG&E, to get a firsthand understanding of how the company’s electrification strategy is playing out in a real-world project. What follows are highlights from the discussion.

You often talk about the unexpected benefits of PEVs for your broader business. How do EWIMS fit into that?
One of the biggest things that we have seen with our EWIMS is the noise reduction. On our traditional bucket trucks, everything is PTO-driven. A mechanical shaft from the engine runs a pump and that’s what moves the bucket. So to operate the bucket, you have to have the truck running, and it makes a lot of noise. But in residential areas of San Francisco, there are noise restrictions in place that essentially make it impossible for us to do routine work using conventional trucks between 7 p.m. and 7 a.m. That’s no longer an issue with an electric bucket because it’s silent. The engine is off. It’s expanded the workday by 100 percent – from 12 hours to 24 hours. In the past, if a PG&E crew was doing new construction and it got to be 7 p.m., they had to stop. It didn’t matter if there were just two hours of work to go. They had to stop, take the whole site down – which could take about an hour – go home for the night and then come back again in the morning. At that point, they had set everything back up again – which takes another hour – do two hours of work and then take it down again. With an EWIMS bucket truck, they can just work the additional two hours on the first day and be done, avoiding unnecessary time spent getting to and from the job as well as costly setup and takedown hours. The customer is happier and we’re more efficient.

How have the drivers reacted?
I’ll go back to the noise. In the utility business, you often work in pairs. One crew member is up in the bucket and the other is at the ground level. With a traditional bucket, the crew has to communicate over the noise of a running vehicle, which can really be a challenge. But in the case of an EWIMS truck, the engine is off and it’s quiet, so communication is much, much easier. Drivers absolutely love that. I would also add that, especially in our business, an enhanced level of communication actually puts our employees in a much safer situation. When a crew member in the bucket is talking to his colleague on the ground, he is trying to get a handle on critical information that has a material impact on job safety. Making it easier to communicate and have a higher level of confidence in information has been a huge hit with our employees. That enhanced feeling of safety is something that happens every time you go to work. Without question there are other benefits. The work crews certainly appreciate not having to be around the tailpipe emissions of a traditional diesel vehicle idling on a job site over a period of several hours. And the abatement of those emissions is also good for urban air quality. That’s a significant plus for us as a corporation.

The EWIMS technology is really a perfectly customized solution. How did you get there?
The drivers of these vehicles are some of our most highly skilled personnel. They are generally our first responders. What that means operationally is that they do a lot of tickets in a single day – lots of shorter stops to deal with pressing issues. They are at an individual site for an average of maybe two hours. They make a fix and move on to the next job. We wanted a system that would work off the battery and be capable of plugging in to the grid, but that couldn’t be the only way the battery recharged. So we developed the secondary alternator that recharges the battery as the vehicle moves from job to job. We also made sure that the battery was big enough to cover all of the work that would be done in a normal day without running the vehicle at any job site. To get there I would say we worked hand in hand with Altec. They have about 70 percent of the U.S. market for bucket trucks, so they understand our business and have a commitment to customer solutions. Our vehicle design and engineering team at PG&E had an idea for an electric bucket system that we felt would save us money and provide a whole range of operational efficiencies. We sketched out our idea in principle, took it to Altec and six months later the first vehicle rolled off the production line. It has worked out really well.

People often talk about the economics of these technologies in broad generalities. What can you say about your experience?
I can tell you that we are getting about a two-and-a-half-year payback on our Class 6 EWIMS trucks. We make business decisions to make money, plain and simple. So we wouldn’t be doing this if it didn’t work for the company. To me, it all goes back to lining up the right technology with the right application. People think electrification has to be about the propulsion system only. But that isn’t where we are using the most fuel in this particular application. Electrify where it makes sense to electrify. The fleet industry uses PTO shafts in a variety of applications, by the way: dump trucks, refrigerated trucks and more. They’re all shaft-driven, and today they all use a diesel engine to power that shaft. That function could be powered by a battery in all these applications.

I know you spend a lot of time thinking about ways to be creative in terms of integrating these technologies into your business model. What have you learned from your EWIMS deployment?
When we first started looking at these vehicles, we were thinking about them in terms of payback period. So we did a standard analysis comparing current technology costs and fuel consumption to the cost of the new technology and projected fuel savings. But what we have learned is that the operating savings, improved relationship with our customers, the extended work day and the safety improvements dwarf the fuel savings. What we also learned is that, frankly, there is a lot that we as an industry can’t measure when evaluating these technologies with a standard approach to ROI or payback period. So PG&E treats each application as a unique situation and evaluates it individually. Let me also say that the economic impact of these vehicles extends beyond just PG&E. We just had the ribbon-cutting ceremony for a new facility here in Dixon, Calif., where Altec will be expanding its production capacity for these and other advanced vehicles. That’s 150 direct manufacturing jobs in the United States. And when you think about the multiplier for manufacturing jobs, which I think is about five times or six times, you are looking at almost 1,000 new jobs for the local community. That has an impact. Visit www.electrificationcoalition.org.

HYBRID VS. CONVENTIONAL
“There has been no significant change in light-duty vehicles as a percentage of utility fleets,” said Tom Nimmo, a partner with the industry benchmarking firm Utilimarc. “However, we have seen changes within certain light-duty vehicle classes, including an increase in hybrids as a percentage of the fleet. Hybrid data also shows improved mpg and improved operating costs.”

Speaking at the 2012 Electric Utility Fleet Managers Conference (www.eufmc.com), Nimmo covered trends, using 2009, 2010 and 2011 data, at a select group of 41 utilities that field approximately 90,000 utility-specific vehicles. In 2012, the entire Utilimarc database, comprised of state, county, city, utility and private fleets, will track more than 300,000 vehicles. Visit www.utilimarc.com.

RALEIGH POLICE DEPARTMENT SEES SIGNIFICANT FUEL SAVINGS FROM MOBILE POWER IDLE REDUCTION SYSTEMS
Earlier this year, the Raleigh (N.C.) Police Department installed mobile power idle reduction systems in 29 police vehicles. The project was funded by an Energy Efficiency and Conservation Block Grant. Since being installed, the systems have saved Raleigh more than 3,000 gallons of fuel, cut emissions of 59,326 pounds of CO2 and reduced engine use by 107,032 miles. The police department now projects an annual fuel savings from the systems of $63,000.

The Energy Xtreme mobile power idle reduction system is a smart power management device that provides power, without engine engagement, to vehicles with demanding electrical needs. In Raleigh, the system allows police cruiser electrical systems, including lights, onboard cameras, computers and radios, to operate without having to idle the vehicle’s engine for at least four continuous hours. The system automatically recharges while the vehicle is being driven. Visit www.energyxtreme.net.

HYBRID NEWS

Eaton Supports California Hybrid Incentives
The California Hybrid and Zero-Emission Truck and Bus Voucher Incentive Project (HVIP) is getting a boost from Eaton Corporation (www.eaton.com/roadranger). Designed to assist California-based fleets with the purchase of low-emission, fuel-efficient medium- and heavy-duty hybrid vehicles, HVIP aims to help speed the introduction of hybrid trucks with financial incentives ranging from $10,000 to $45,000 for eligible vehicles.

“The Hybrid Truck and Bus Voucher Incentive Project offsets about half of the incremental cost of eligible hybrid vehicles,” said Gerard Devito, engineering director, Eaton hybrid power systems. “The program strongly benefits the public and commercial truck industry by helping interested fleets save money while delivering more sustainable transportation. We applaud the state of California for its pioneering work and many investments to promote and support the use of hybrid vehicles and other clean technology vehicles.”

About 87 truck and bus chassis configurations from a variety of vehicle manufacturers that are equipped with Eaton hybrid systems are eligible for the incentives. Under HVIP, incentives are preset for each qualified vehicle. Eaton hybrid power systems have collectively accumulated more than 300 million miles of service. More than 6,000 of Eaton’s hybrid systems are in use today on trucks and buses. Visit www.californiahvip.com.

ALTE LAUNCHES ELECTRIC VEHICLE FLEET PURCHASING SYSTEM
A Commitment to Action as part of the Clinton Global Initiative America designed to spur adoption of hybrid electric technology in fleets has been announced by ALTe Powertrain Technologies. The developer of a range-extended plug-in electric hybrid powertrain for light commercial fleet vehicles has pledged to develop a first-of-its-kind electric vehicle fleet purchasing system, under which fleet customers can consolidate the entire electric vehicle decision-making process in one web-based interface.

The new website, www.electrifyyourfleet.com, will connect corporate and government vehicle purchasers with electric vehicle stakeholders, including utilities, charging station providers and finance companies, and notify customers of available incentives while offering the benefits of group-rate purchases and simplifying the order-to-delivery process.

“Our commitment to the CGI community is to help solve the greatest roadblocks to commercial adoption of electric and plug-in hybrid vehicles: eliminating the lack of affordability and simplifying the EV and charging station order fulfillment process,” said ALTe chief executive John Thomas. “We intend to take a crowdsourcing approach to generate a new industry buying platform that helps fleets better transition to a cleaner operation, offer financial benefits to customers and grow new jobs for the future of America.”

As an electric powertrain systems provider, ALTe will offer certified full-sized pickups and vans that have been retrofitted with electric or plug-in hybrid powertrains. Designed to replace a V-8 internal combustion engine powertrain, the system’s patented technology improves fuel economy, the company said. Visit www.altept.com.

Right Tool for the Right Job

Written by Seth Skydel on August 16, 2012. Posted in Smart Fleets.

Near-, mid- and long-term alternative fuel technologies are available and under development at Ford Motor Company, reported Jim Michon, truck fleet marketing manager, during a presentation at the 2012 Electric Utility Fleet Managers Conference. “In the near term,” he said, “we are migrating to advanced technology. In the midterm we plan full implementation of known technology, and long term we will continue to leverage hybrid technologies and deploy alternative energy sources.”

Specific technologies Ford is addressing, according to Michon, include advanced gasoline and natural gas engines, hybrids, electrified vehicles, fuel cells and hydrogen-powered engines. The company’s path to sustainability also covers body structures, including high-strength steel and aluminum used presently, and the potential for ultrahigh-strength steel, high-strength aluminum, high-temp and reinforced plastics, magnesium and carbon fiber, and bio-based components.

Ford is also targeting aggressive levels of aerodynamic improvements and working on a variety of technologies, Michon noted. Included are auto start-stop, active transmission warm-up, grille shutter, deceleration fuel shutoff, electric power-assisted steering and battery management systems.

Michon also discussed Ford’s EcoBoost family of turbocharged, direct-injected gasoline engines, which the manufacturer claims can provide up to 20 percent better fuel economy without sacrificing power.

In an EcoBoost engine, energy from the exhaust is used to rotate a turbine coupled to a compressor that pressurizes the incoming air, significantly increasing the engine’s power output. Highly pressurized fuel is injected directly into the combustion chamber of each cylinder rather than mixing with the incoming air in the inlet port. The advantage, according to Ford, includes more precise delivery of fuel for lower emissions, improved efficiency and avoidance of knock.

Visit www.fleet.ford.com for more.

Test Drive: Chevrolet Malibu Eco
Billed as the most fuel-efficient Malibu ever, the 2013 Chevrolet Malibu Eco with eAssist technology lived up to the manufacturer’s estimated 37 mpg on highway in a weeklong test drive. The 2013 Malibu Eco is the first Chevrolet to feature eAssist. Along with specific aerodynamic enhancements, according to the OEM, it achieves 12 percent greater highway fuel economy than current models equipped with the 2.4-liter engine.

“Malibu Eco’s eAssist system integrates regenerative braking with the latest lithium-ion battery technology to give our customers significant fuel-efficiency gains,” said Steve Poulos, global chief engineer of eAssist. “Providing electric boost to the powertrain system during heavy acceleration and grade driving helps the transmission operate more efficiently. The engine’s start-stop and fuel shutoff during deceleration features add to the fuel savings.”

The eAssist system is made up of a 32-cell, 0.5-kW lithium-ion battery, an electric motor-generator and a six-speed transmission. The system’s electric motor-generator is mounted to an Ecotec 2.4-liter, four-cylinder engine, in place of the alternator, to provide both motor assist and electric-generating functions through a revised engine belt-drive system.

“The battery system is designed to provide power assistance to the internal combustion engine, rather than storing energy for all-electric propulsion,” said Poulos. “It’s really an extension of the conventional internal combustion engine, not a replacement for it.”

The motor-generator in the eAssist system is a liquid-cooled induction model that bolsters the engine with approximately 11 kW (15 HP) of electric power assist during heavy acceleration and 15 kW of regenerative braking power. This power capability enables the battery to capture energy during regenerative braking.

The air-cooled 115-V lithium-ion battery in the Malibu Eco is integrated into a power pack located in a compartment between the rear seat and trunk. The power pack is cooled by an electric fan that draws air from a vent located in the package tray, behind the rear seat.

Additional fuel-saving features on the Malibu Eco, according to the manufacturer, include an aerodynamically optimized exterior, underbody panels, and electronically controlled shutters in the lower grille that close at higher speeds to push more air over and around the vehicle. In addition, lightweight components and systems – including an aluminum hood, aluminum rear bumper beam, low-mass carpet and dash mat, and more – save approximately 130 pounds compared to comparably equipped non-Eco models.

An Eco gauge in the Malibu Eco’s instrument cluster continuously responds to driving behavior and encourages fuel-efficient driving. A power flow display in the driver information center indicates if the Malibu Eco is operating in battery-charging, electric-assist or auto-stop mode.

The eAssist system works with Malibu’s 2.4-liter Ecotec four-cylinder engine rated at 182 HP and 170 pounds per feet of torque. The Hydra-Matic 6T40 six-speed transmission in the vehicle features changes to clutch controls and hardware to reduce spin losses while improving shift response. The eAssist system’s electric assistance at cruising speeds allows the driver to accelerate lightly or ascend mild grades without the transmission downshifting, and automatic grade braking keeps the transmission in a lower gear when decelerating or coasting on a downgrade. eAssist technology also allows for a numerically lower 2.64 final drive ratio.

The Malibu Eco in our test drive also lived up to the manufacturer’s claim of achieving up to 580 highway miles between fill-ups despite a smaller fuel tank than other 2013 Malibu models at just 15.8 gallons. “It’s a very integrated powertrain system, with no compromises in driving performance, shift quality, or ride and handling,” said Todd Stone, Malibu lead development engineer. “We believe this combination points to the future of vehicles powered primarily by an internal combustion engine.”

Visit www.gmfleet.com for more.

Eaton Makes Multiple Enhancements to Its Hybrid Power System
To increase the fuel economy, performance and payback of its hybrid power system for commercial vehicles, Eaton Corporation has announced a number of enhancements. Included are a new high-capacity battery, a new single-phase 115-V AC auxiliary power generator (APG), a higher-capacity clutch to expand applications up to 860 pounds per feet of torque and a new remanufactured battery for aftermarket purchase.

At the heart of Eaton’s new high-capacity lithium-ion battery is the latest battery cell architecture. The new design increases the fuel savings of Eaton’s hybrid power system an additional 5 to 10 percent, the company noted, while more than doubling the engine-off capability of the system for job site operations.

Eaton is also introducing a new single-phase, 5-kW APG. The APG option converts high-voltage DC current from the battery to 115-volt AC current that can be used by any number of tools on the job site. The APG unit is more compact and 25 pounds lighter than Eaton’s previous offering, which increases flexibility of installation.

The new high-capacity battery and APG will be rolled out during the fourth quarter of this year for utility vehicle applications. Eaton is also now offering higher-capacity clutches that can handle engines up to 860 pounds per feet of torque and 300 HP. Eaton has begun offering a remanufactured battery.

Eaton hybrid power systems have collectively accumulated more than 300 million miles of service. More than 6,000 of Eaton’s hybrid systems are in use today in trucks and buses in a variety of applications.

Yosemite Turns To Eaton For Cleaner Vehicles
Yosemite National Park now allows visitors to enjoy its pristine surroundings onboard new low-emission vehicles powered by Eaton’s hybrid electric systems. Eaton worked with the U.S. General Services Administration and Delaware North Companies Parks and Resorts, which handles the majority of the park’s transportation needs, to deliver four new Class 8 tractors with the Eaton systems. An additional seven vehicles – 37-passenger shuttle buses – are on order.

“The low-speed, low-mileage and stop-and-go duty cycles at Yosemite provide the perfect operating conditions for a hybrid truck,” said Kevin Snow, chief engineer for hybrid applications at Eaton. “On top of that, the environmental and fuel consumption improvements are going to be quite substantial.”

Dan Anthonijsz, village garage manager at Yosemite for Delaware North Companies, agrees. “We are definitely realizing fuel consumption reductions, currently averaging about 6.7 miles per gallon with the tram tractors,” he noted. “That’s a huge improvement over the one mile to the gallon that we were getting with the propane trucks that the new vehicles replaced.”

In addition, Eaton worked with park officials to install a new engine brake on a tow truck with an Eaton hybrid electric system to ensure the regenerative braking function was operating properly. Regenerative braking allows the hybrid system to recover power normally lost during braking and stores the energy in batteries to provide engine-off power takeoff capabilities.

Visit www.eaton.com/hybrid for more.

Terex Hybrid System Retrofit Program
Terex Utilities now offers customers the option to retrofit utility trucks with the Terex HyPower Hybrid System, a plug-in power takeoff system that uses stored energy from the system’s rechargeable batteries to power the nonpropulsion functions of most utility vehicles.

The Terex HyPower Hybrid Retrofit Program can be applied to any Terex or competitive manufacturer’s aerial devices 5 years old or newer and can be completed at any of 14 Terex Equipment Services locations. For an aerial device to be considered for a HyPower retrofit, it needs to pass an initial inspection, which covers the truck’s available payload capacity, body configuration and cab-to-axle length to accommodate the battery packs. After the inspection, retrofits can be completed in as little as two weeks.

HyPower retrofitted trucks come with the standard one-year warranty from the date of in-service on the system, the same as on new HyPower equipped units.

City of Longmont, Colo., Adds Terex HyPower Trucks
Terex Utilities has sold four trucks equipped with its HyPower Hybrid System – a Terex Commander C4047 digger derrick, a Terex Hi-Ranger TCX55 bucket truck and two competitive bucket trucks retrofitted with the HyPower system – to the City of Longmont, Colo.

“We are constantly looking at the emerging technologies like the Terex HyPower Hybrid System to see what would be a good fit for Longmont,” said Deborah Cameron, customer services and marketing manager for Longmont Power & Communications. “LPC crews like that they do not have to yell over engine noise for material or direction with the Terex trucks. They also appreciate that there is no reduction in the performance of the controls while the trucks are in hybrid mode.”

The service area that LPC covers is compact so city crews do not have long drives to work sites, which, according to Cameron, made the Terex HyPower system, with its separate batteries, a smart choice. One of the retrofitted bucket trucks serves as a service truck, taking care of outages and daily calls. The other is the city’s streetlight truck. The TCX55 bucket truck is primarily used by the city’s maintenance crew.

To offset the expense of the Terex HyPower Hybrid trucks, the City of Longmont received $70,000 through the Regional Air Quality Council. In the future, Cameron noted, the city will evaluate opportunities to add more Terex HyPower trucks to its fleet.

Visit www.terexutilities.com for more.

VIA Motors is demonstrating its extended-range electric pickup truck in a partnership between the manufacturer, the state of Utah and Rocky Mountain Power, a division of PacifiCorp and Utah’s largest electric utility. PacifiCorp is part of a group of utility, government and commercial fleets nationwide participating in an early evaluation of electric work trucks developed by VIA Motors in coordination with the U.S. Department of Energy.

VIA’s VTRUX electric vehicles are equipped with a 402-HP electric motor and will be available with a power export option up to 15 kW. The vehicles can average more than 100 mpg with a daily charge and in zero-emissions mode for a majority of fleet driving, the company said. The manufacturer works with General Motors to incorporate its V-DRIVE powertrain into new GM trucks, vans and SUVs. VIA is planning to sell electrified work trucks to fleets early in 2013.

Visit www.viamotors.com for more.

Allison Transmission Inc. has invested in a noncontrolling equity stake in Odyne Systems LLC. The manufacturer of hybrid control systems designed and developed a plug-in hybrid power system, which interfaces with the Allison family of commercial vehicle transmissions.

Odyne’s proprietary and patented plug-in hybrid drive system, sold through a worldwide distribution network, can be installed on a wide variety of new and existing vehicles. Johnson Controls is the exclusive supplier of lithium-ion batteries for Odyne Hybrid Power systems.

Visit www.odyne.com and www.allisontransmission.com for more.

Quantum Fuel Systems Technologies Worldwide Inc., in association with lithium-ion battery system supplier Dow Kokam, has delivered the first pilot version of its plug-in hybrid electric (PHEV) Ford F-150 pickup truck to Florida Power & Light Company.

The PHEV F-150 is powered by Quantum’s F-Drive parallel plug-in hybrid electric drive system. The F-Drive allows the truck to run the first 35 miles on a zero-emission electric drive and then switch to an efficient hybrid drive mode, achieving more than 100 mpg, according to the manufacturer, depending on the drive cycle and charging frequency.

Visit www.qtww.com for more.

XL Hybrids Inc. has released test results that it said validate a 21.2 percent reduction in fuel consumption with the company’s aftermarket hybrid electric powertrain. XL Hybrids’ powertrain is a bolt-on technology that integrates with an internal combustion engine and transmission.

The tests were conducted on a light-duty chassis dynamometer test cell. The testing process compared fuel economy performance from the vehicle in its original condition with the performance using XL Hybrids’ charge-sustaining hybrid system. The test was completed on a Chevrolet 2500 Express cargo van fitted with the OEM’s 4.8-liter engine and six-speed transmission over a light-duty Urban Dynamometer Driving Schedule test cycle.

Visit www.xlhybrids.com for more.

ALTe Powertrain Technologies, the developer of range-extended plug-in electric hybrid powertrains, has installed its system in the Ford Econoline E-350 platform. ALTe already implemented conversions in Ford F-150 trucks. The manufacturer is delivering an E-350 prototype to a fleet customer for evaluation and plans to build more prototypes for customer evaluations throughout the year, leading to a spring 2013 product launch date for the U.S. market.

ALTe’s road tests revealed that the E-350 cutaway chassis prototype can drive approximately 25 miles in an all-electric mode and then deliver nearly 15 mpg in a charge-sustained mode, the company reported. For a fleet vehicle that drives 45 miles per day, ALTe noted, the combined mode fuel economy would be more than 30 mpg, while a similar Ford E-350 cutaway chassis with a V8 gasoline engine averages fewer than 9 mpg based on data provided by major fleets.

Visit www.altept.com for more.

SCR Engine Update
As a speaker on a “Diesel Engines – Current and Future” panel during the 2012 Electric Utility Fleet Managers Conference, Dave Bryant, vocational sales manager at Freightliner, reported on the performance of 2010 emissions-compliant diesel engines. “There is growing confidence in SCR engine technology,” Bryant said. “Market adoption of SCR engines in six key Class 6-8 vocational applications [refuse, utility, construction, heavy hauling, beverage and municipal] is 39 percent greater than non-SCR engines today compared to 18 percent three years ago.”

Among the findings about SCR engine performance in Bryant’s report were the following:

• Fuel economy in EPA 2010 SCR engines was initially projected to be 3 percent better than 2007 models. Customers in utility truck applications are reporting a 5 percent improvement in actual use.
• In many cases, a three-time reduction in diesel particulate filter (DPF) regeneration cycles between 2007 and 2010 engines is being reported, including Detroit Diesel and Cummins models. DPF regeneration, Bryant noted, requires fuel to clean out unburned fuel, so reducing regeneration frequency also has a fuel economy benefit.
• Better drivability from increased horsepower and better throttle response are evident in 2010 engines, especially in Cummins ISB, ISC and ISL models.
• Durability is improved. Cummins has seen an appreciable reduction in warranty repairs on 2010 engines compared to 2007 models, especially for turbochargers and injectors. Additionally, improved cooling system performance is resulting in reduced heat rejection, causing fewer problems.
• OEMs have addressed packaging and chassis space concerns by providing clear frame rails and back-of-cab surfaces, and by not increasing cab heights.
• DEF infrastructure concerns have turned out to be a nonissue. Meeting fleet needs are bulk DEF, and more than 6,500 DEF retail outlets and 500 pump locations.

“In 2009 we told you that 2010 EPA engines compared to 2007 pre-SCR models would have better fuel economy, improved regeneration frequency, increased power with the same displacement, enhanced drivability and better cooling system performance to reduce heat,” Bryant said. “We also said we would address vehicle packaging concerns and DEF availability issues. All of those challenges have been met.”

Visit www.daimler-trucksnorthamerica.com for more.

Peterbilt Grows Natural Gas Vehicle Market
With a 40 percent market share of the commercial truck natural gas market, including vocational and over-the-road models, Peterbilt Motors Company continues to expand its natural gas-powered vehicle offerings.

Peterbilt currently offers two natural gas engine platforms. The Cummins Westport 8.9-liter ISL G, rated 320 HP at 1,000 pounds per feet of torque, is a spark ignition engine with a three-way catalyst emissions system that can be configured with either LNG or CNG fuel systems. The second platform is the Westport HD 15-liter engine rated 475 HP and 1,750 pounds per feet of torque with diesel pilot ignition configured for LNG fuel systems.

The OEM will also offer the new Cummins Westport ISX12 G in 2013. The engine, rated up to 400 HP and 1,450 pounds per feet of torque, features spark ignition and a three-way catalyst, and can be configured with an LNG or CNG fuel system.

Visit www.peterbilt.com for more.

CARB Retrofit Alternative Fuel System Certification
The California Air Resources Board has approved the ROUSH CleanTech propane autogas fuel system for retrofitting 2010 model year 5.4-liter Ford E-150, E-250 and E-350 cargo vans and wagons. ROUSH CleanTech is also pursuing retrofit certification for 2009, 2011 and 2012 model years of the same Ford models as well as E-450 cutaway vehicle platforms.

The CARB certification is the first awarded since 2000 for a liquefied petroleum gas retrofit system, and the first CARB certification for any alternative fuel system for retrofit installation on 2010 model year vehicles. The number of alternative fuel retrofit certifications awarded has been limited due to stricter regulations implemented in 1994.

ROUSH CleanTech offers a wide range of CARB-certified, dedicated liquid propane autogas fuel systems for pre-title installation, which includes applications for Ford F-250/350 trucks, Ford E-series vans, and Blue Bird Propane-Powered Vision and Micro Bird G5 school buses.

Visit www.roushcleantech.com for more.

Green Facility
Altec Industries has opened a new green-focused facility in Dixon, Calif. The manufacturer is using the 42,400-square-foot assembly plant to expand the development and production of its Green Fleet utility vehicle product line.

Altec received guidance and support on the development of the new green-focused facility from Pacific Gas & Electric Company and Southern California Edison. In addition, PG&E and Altec are partnering to develop Green Fleet utility vehicles, which will be produced at the new plant.

“Altec is committed to sustainable solutions,” said Lee Styslinger III, Altec chairman and CEO. “That commitment to sustainability is reflected not only in the products we build, but also in the facilities where we build them.”

Visit www.altec.com for more.

Advanced Technology

Written by Seth Skydel on June 11, 2012. Posted in Smart Fleets.

It is a case of mutual interests combining resources and expertise, says Matt Gilliland, fleet services manager at Nebraska Public Power District (NPPD). “In 2006 to 2007, when Chevrolet was researching and developing the technology it would eventually use in the Chevrolet Volt,” he explained, “the OEM wanted to partner with utility fleets to deploy vehicles and evaluate their performance and function in actual operations.”

The result was an extensive program managed by the Electric Power Research Institute (EPRI), the nonprofit center for electricity and environmental research, that put demonstration Volt models on the road at 64 U.S. and Canadian utilities. For the three-year demonstration project, which officially began in 2011, NPPD is operating one of those vehicles.

NPPD supplies power in 91 of 93 Nebraska counties to communities as well as rural public power districts and electric cooperatives. Supporting its generation, transmission and distribution businesses is a fleet of 1,150 pieces of equipment ranging in size from ATVs to 140-ton cranes. Included are SUVs, pickups and vans, and a range of medium- and heavy-duty trucks.

The collaborative effort between EPRI, General Motors and NPPD is evaluating a 2011 Chevy Volt. The demonstration project will work to ensure safe and convenient electric vehicle charging, raise public awareness and understanding of plug-in electric vehicles, assist electric utilities in determining the support for charging vehicles and help public policy leaders better understand how electricity can be used as a vehicle fuel source. The program is made possible in part by a $30.5 million grant administered by the U.S. Department of Energy’s Recovery Act Transportation Electrification Initiative.

Equipped with a 120-kW electric motor that is equivalent to a 150-HP engine, the electric-powered, extended-range vehicle can travel approximately 35 miles on a full charge. After the battery is depleted, the onboard 80-HP gasoline engine and generator can power the Volt for an additional 372 miles for a total cruising range of 407 miles.

Working its way across Nebraska as a fleet vehicle, the Volt at NPPD is being used at 42 company locations in a variety of environments and under differing weather conditions. Data on the vehicle being supplied to EPRI will be included in aggregate results from all 64 utilities taking part in the project. In addition to performance information from onboard data capture devices, the utilities are helping determine charging and circuit-loading patterns and electric charging infrastructure readiness.

Behind NPPD’s participation in the demonstration project is the utility’s Domestic Energy Research and Application Initiative, which has funds for developing technologies related to environmental issues. “We’ve funded programs for energy research with the University of Nebraska, wind monitoring and carbon capture,” Gilliland noted, “so it made sense to leverage our resources to look into advanced vehicle technology as well. One of the benefits of this program was that by getting involved, we had access to some of the first Volts to come off the production line.

“One of the biggest benefits of the demonstration project,” Gilliland continued, “was that we formed a strong industry partnership where information flowed both ways. That will help us determine if this technology is right for our operation and our customers at the right cost.”

As for the Chevy Volt, Gilliland says it has done everything it was supposed to do. “It’s a great platform,” he stated. “This is one of the biggest advances in automotive technology in many years.”

HYBRID SOLUTIONS

Terex HyPower
The California Air Resources Board (CARB) has approved the Terex HyPower hybrid system for use in any power takeoff-equipped diesel-powered truck application with a gross vehicle weight rating (GVWR) of more than 10,000 pounds. This means the HyPower hybrid system meets the strict emissions requirements for anti-idling in the state of California, which many other states have adopted for fleets that are bidding on projects or requesting project funding.

CARB’s approval of the Terex HyPower hybrid system allows contractors and fleets to purchase new trucks with the system or retrofit older trucks. The Terex HyPower hybrid system enables job site operations without requiring the engine to be running, reducing harmful exhaust emissions and noise and lowering fuel use. According to Terex, the system can save up to 1,500 gallons of fuel per year based on 7,000 miles per year and 1,250 job site hours per year.

Visit www.terexhypower.com for more.

Altec
CARB has approved the Altec Jobsite Energy Management System (JEMS) when used in any power takeoff (PTO), diesel-fueled truck application with a GVWR of more than 10,000 pounds. Altec JEMS is a product of Altec’s Green Fleet, designed to eliminate engine idle time at the job site and reduce fuel consumption, noise and emissions. JEMS is an integrated plug-in system powered by application-specific battery packs. The system provides power for aerial devices, truck cab heating and air conditioning, and export power for hand tools and other electrical accessories.

Visit www.altec.com/green-fleet.php for more.

Eaton
Eaton Corporation has published a fact sheet on hybrid electric power systems for commercial trucks to help fleets determine whether the technology is the correct platform for their operations. The document covers applications, job site operation time, stop densities, vehicle speeds, driving techniques, warranty information and more. It also lists key specification information. More than 5,500 Eaton hybrid systems are in use today on utility vehicles and other commercial applications, and have collectively accumulated more than 200 million miles of service.

Visit www.roadranger.com for more.

Odyne Systems
Odyne Systems LLC has completed five plug-in hybrid vehicles funded by a U.S. Department of Energy development project and has delivered the vehicles to customers of DUECO Inc., the final stage truck manufacturer. Companies receiving the new technology include:
• Choptank Electric Cooperative, a Touchstone Energy Cooperative, which took delivery of a plug-in hybrid bucket truck with a Terex HR42M aerial device to be used in maintenance of electric lines;
• Consumers Energy, the principal subsidiary of CMS Energy, which took delivery of a plug-in hybrid utility truck with a Terex 5FC55 aerial device;
• NiSource, which took delivery of a plug-in hybrid bucket truck with a Terex TL41 aerial device for use in maintenance and construction of its electrical grid;
• NV Energy, which took delivery of an underground utility vehicle featuring a Vanair underdeck compressor for maintenance of an underground natural gas infrastructure; and
• Pepco Holdings Inc., which took delivery of a plug-in hybrid underground utility vehicle with a Vanair underdeck compressor for underground gas infrastructure maintenance.

Odyne has also delivered seven trucks featuring its plug-in hybrid propulsion system to utilities and municipalities throughout Wisconsin. Communities and utilities receiving the new technology were partially funded under the Wisconsin Clean Transportation Program jointly administered through the Wisconsin State Energy Office and the U.S. Department of Energy Wisconsin Clean Cities Program. The new units are anticipated to deliver 50 percent better fuel efficiency than a conventional truck annually, depending upon use.

Receiving vehicles with the Odyne hybrid systems is Milwaukee County, which took delivery of four work trucks that will be used to maintain traffic signals and street lighting. The vehicles feature the first Odyne hybrid systems installed on Kenworth truck chassis and are the first to power Venturo corner mount cranes. The trucks also have fiberglass bodies and Terex TL60 aerials.

Marshfield Utilities, serving the city of Marshfield, Wis., took delivery of a Navistar truck fitted with the Odyne system and a Terex HRX55 boom for use in construction and maintenance of the Marshfield utility grid. The Richland Center and Lake Mills units of Wisconsin Public Power Inc. will also be putting new Navistar chassis with Terex TCX60 booms and the Odyne hybrid system in service for the construction and maintenance of utility grids.

Odyne’s proprietary hybrid technology combines electric power conversion, power control and energy storage technology with Remy electric propulsion motors, modular Johnson Controls lithium-ion battery systems and other automotive components.

Visit www.odyne.com for more.

BAE Systems
The BAE Systems HybriDrive parallel system for Class 6, 7 and 8 vocational trucks is a scalable design that can be modified for a range of truck platforms, vocations and duty cycles. HybriDrive parallel is based on a motor/generator integrated between the engine and the transmission and an energy storage system, coupled with electronic controls. The system’s battery pack and electronics are sealed for under-vehicle environments.

Visit www.baesystems.com for more.

NATURAL GAS

Venchurs Vehicle Systems
Venchurs Vehicle Systems (VVS) is showcasing its new CNG and bi-fuel conversions for Ford F-250/350 trucks. The Venchurs CNG program includes dedicated CNG and bi-fuel systems that allow for seamless switching of the fuel supply and offer a range of up to 650 miles. VVS has built a CNG Search & Rescue Ford F-250 concept truck with its bi-fuel system for pilot program demonstrations by national park rangers. Each CNG conversion will be performed at the Venchurs’ conversion facility in Adrian, Mich.

Visit www.venchursvehicles.com for more.

Freightliner Custom Chassis
Freightliner Custom Chassis Corporation (FCCC), a subsidiary of Daimler Trucks North America LLC, has introduced its S2G chassis, a factory-installed liquid propane gas engine available in medium-duty trucks. The front-engine chassis utilizes a Freightliner M2 cab and has a GVWR of 33,000 pounds. Standard specs include an Allison 2300 automatic transmission with PTO provision.

The S2G’s 8-liter, 325-HP engine supplied by Powertrain Integration uses General Motors’ long block and other engine components. FCCC partnered with Powertrain Integration and CleanFUEL USA in the development of the S2G. A limited preproduction run of the S2G chassis is expected in the fourth quarter of 2012, with full production slated for the first quarter of 2013.

Visit www.freightlinerchassis.com for more.

Ram Truck
Ram Truck has introduced a factory-built CNG pickup. The Ram 2500 Heavy Duty CNG model is powered by the 5.7-liter Hemi V-8 and is equipped with both compressed natural gas tanks and an 8-gallon gasoline fuel tank. Canadian customers can opt for a 35-gallon gasoline tank. The CNG tanks provide a gasoline gallon equivalent of 18.2 gallons. If the CNG tanks are emptied, the vehicle will automatically switch to gasoline. CNG-only range is estimated to be 255 miles, while the backup supply of gasoline extends the range to 367 total miles.

The Ram 2500 CNG system uses a Hemi engine that has been modified to run on compressed natural gas as well as gasoline. Redesigned cylinder heads with specifically designed CNG-compatible valves and valve-seat materials allow the engine to burn both fuels. The engine also has a second, CNG-specific fuel rail and set of injectors, and a new powertrain control module that allows the Hemi to operate on either of the two fuel sources. In use the system is automatic. A small amount of gasoline is used during engine startup before the Ram CNG runs exclusively on compressed natural gas.

Visit www.ramtrucks.com for more.

General Motors
General Motors has announced details of its 2013 bi-fuel Chevrolet Silverado and GMC Sierra 2500HD extended cab pickup trucks. GM bi-fuel pickups are equipped with a CNG-capable Vortec 6.0L V-8 engine that transitions between CNG and gasoline fuel systems. Combined, the systems offer a range of more than 650 miles. The Silverado and Sierra will be available in standard and long box models, with either two- or four-wheel-drive systems.

Visit www.gmfleet.com for more.

Westport Innovations
Westport Innovations has announced that its Westport LD division’s WiNG Power System is being based on Ford’s new 6.2L hardened engine platform. Ford F-250 and F-350 pickups with the bi-fuel system run on natural gas or gasoline. WiNG Power Systems will be installed at the company’s manufacturing facility adjacent to the Ford Kentucky Truck Plant in Louisville.

Visit www.westport.com for more.

ELECTRIC

Motiv Power Systems
Motiv Power Systems has received a California Energy Commission grant of $1.16 million for an assembly line pilot run of four electric truck chassis in partnership with Detroit Chassis. The Motiv Electric Powertrain Control System (ePCS), which provides a 100-mile range, will be demonstrated in shuttle bus applications.

Motiv’s ePCS works with a wide range of batteries and motors. Through its intelligent software control algorithms, Motiv’s ePCS actively manages power flow between all electrical components in the vehicle. It also captures and wirelessly broadcasts data to the Motiv cloud for monitoring and analysis. Factors such as battery charge and vehicle status provide detailed real-time analytics to support fleet operators in preventive maintenance.

Visit www.motivps.com for more.

ALTe
ALTe Powertrain Technologies has installed its powertrain system in a second line of vehicles, the Ford Econoline E-350 platform. ALTe has already implemented conversions in Ford F-150 trucks. Road tests reveal that the E-350 cutaway chassis prototype can drive approximately 25 miles in an all-electric mode and then deliver nearly 15 mpg in a charge-sustained mode. These performance levels should continue to improve, ALTe noted, as it incorporates production level components and refines engineering algorithms. The company is delivering the E-350 prototype to its first potential fleet customer for evaluation and plans to build more prototypes for customer evaluations throughout the year. The company is targeting a spring 2013 product launch date for the U.S. market.

Visit www.altept.com for more.

Protean
Protean Electric is offering Protean Drive, an electric drive in-wheel motor system for existing light-duty vehicles. According to the company, the system can be easily integrated into a broad range of vehicles and can increase fuel economy by more than 30 percent depending on the size of the battery and the driving cycle.

Protean’s solution uses in-wheel motors that can deliver 81 kW (110 HP) and 590 pounds per feet, yet weigh only 68 pounds and are sized to fit within the space of a conventional 18- to 24-inch road wheel. Protean Drive regenerative braking capabilities allow up to 85 percent of the available kinetic energy to be recovered during braking. The system can be used on front-, rear- or four-wheel-drive vehicles that run on gas, diesel or other gaseous fuels such as CNG.

Visit www.proteanelectric.com for more.

VIA Motors
VIA Motors has announced it will collaborate with telecom provider Verizon to develop plug-in electric work vehicles using VIA’s proprietary extended-range electric vehicle (eREV) technology. eREV vehicles have up to 40 miles of all-electric range using lithium-ion batteries and the capability to drive unlimited additional miles using VIA’s onboard electric generator or range extender. In independent testing, VIA’s eREV pickup trucks have demonstrated up to 100 miles per gallon in typical fleet driving, according to the company. In addition, Verizon anticipates utilizing the onboard generator and power export option to power work tools or even provide power to its network in an emergency.

Visit www.viamotors.com for more.

ENGINES

Daimler Certifies Complete Vehicle Lineup
Daimler Trucks North America (DTNA) has announced that the U.S. Environmental Protection Agency (EPA) has certified its complete portfolio of model year 2013 on-highway, vocational and medium-duty vehicles as fully compliant with the new greenhouse gas 2014 (GHG14) regulations. DTNA’s GHG14 compliance has been achieved one full year ahead of the mandate for certification by the EPA and the U.S. Department of Transportation’s National Highway Traffic Safety Administration’s program to reduce heavy- and medium-duty truck greenhouse gas emissions.

Visit www.daimler-trucksnorthamerica.com for more.

Hino Trucks Honored at National Biodiesel Conference
Hino Trucks has been recognized by the National Biodiesel Board with the 2012 Eye on Biodiesel Impact Award. The company was nominated for the award for supporting the use of B20 biodiesel blends and for becoming the first manufacturer to support the use of B20 biodiesel blends in a hybrid-electric truck, as well as in its complete product line of Class 6 and 7 trucks.

All 2011 and later model conventional trucks powered by Hino’s proprietary J-Series engines are approved to use B20 biodiesel blends that contain biofuel blend stock (B100) compliant to ASTM D6751, and blended fuel compliant to ASTM D975. B20 biodiesel meeting these standards is also approved for use in Hino’s newly announced diesel and diesel-electric hybrid cabovers due to enter the market this summer.

Visit www.hino.com for more.

Growing Interest

Written by Seth Skydel on March 13, 2012. Posted in Smart Fleets.

Featuring a larger expo hall where a wide range of vehicle systems in or nearing production for electric, plug-in hybrid, hybrid electric, hydraulic hybrid and work-site electrification were on display, the newly renamed Hybrid, Electric and Advanced Truck Users Forum (HTUF) held its annual meeting in Baltimore this past fall. The 2011 HTUF conference also had very significant participation from hybrid and electric truck manufacturers and suppliers, as well as fleets.

Utility Working Group
The HTUF Hybrid Utility Truck Working Group, consisting of more than 20 large fleets focusing on platforms for the utility industry and related uses, is now actively working on Class 4 and 5 applications and is reviewing plug-in hybrid requirements. This group is credited with fostering the launch of Class 6 and 7 commercial hybrid trucks from several manufacturers and has as parts of its current focus aerial lift trouble or “bucket” trucks in the medium- and heavy-duty weight range.

For the development of Class 4 and 5 hybrid work trucks, the working group is committed to developing preproduction vehicles for field evaluation. On its list of key performance parameters that will form the basis for vehicle specifications are:

• Reliability and durability that meet or exceed baseline vehicles
• Fuel economy improvement of 50 percent over baseline vehicles
• Payload loss of a maximum 500 pounds
• Engine-off power or idling for two to three hours at work sites
• Acceleration rate of a loaded unit that meets or exceeds baseline vehicles
• Startability of 15 percent at 20 mph
• Body and boom that are interchangeable with baseline trucks
• Gradeability of 15 to 30 percent at GVWR
• Top speed of 65 to 75 mph
• Fuel preference for diesel
• Engine-off electric drive or “Creep Mode” available up to 20 mph
• Variable shift points and RPM settings for different applications
• Exportable power of 3.5 kW single phase that meets industry standards
• Towing ability of 1,000 pounds
• In-cab display for driver feedback

Telecom Working Group
The HTUF Telecom Working Group released a request for information to OEMs and suppliers for Class 2 to 4 hybrid or ePTO trucks used in trouble response, spooling/splicing or light aerial applications. Respondents met with the working group at the recent conference and had the opportunity to ask direct questions of telecom companies. Vehicle specifications and key performance parameters are being refined and plans call for demonstration trucks to be available starting in late 2012.

HTUF is a national user-driven program to speed the commercialization of medium- and heavy-duty hybrid and high-efficiency technologies. It is operated by CALSTART in partnership with the U.S. Army’s National Automotive Center, with project support from the Hewlett Foundation and the Department of Energy. Visit www.htuf.org for more.

Electric Vehicles
CALSTART’s E-Truck Task Force (E-TTF) also met during the HTUF 2011 National Conference. The goal of the E-TTF is to speed and support effective electric truck production. The key recommendations of the task force are as follows:

• Call on industry to institute a battery-leasing model, link sales expansion to adequate parts and support networks, and increase quality control.
• Maintain or increase research and development for these technologies.
• Seek support incentives for incremental costs.
• Encourage fleets to require a service turnaround minimum before purchase.
• Create a commercial electric truck charge rate and eliminate/reduce demand charges.
• Create a clearinghouse for data-sharing on e-trucks.

To address the need for better guidance on building a business case for e-trucks, the task force developed an “E-Truck Business Case Calculator” that illustrates the best applications and ways to use an electric truck to recoup the initial purchase investment.

To help e-truck fleets understand their options, trade-offs and costs when setting up an EV charging infrastructure, the E-TTF created an infrastructure planning template based on fleet size. The template addresses power requirements, cost estimates, site considerations and availability of subsidies.

The E-TTF recommendations are now being used as an action plan for industry, fleet and policy activities. After receiving feedback on the E-TTF’s findings and proposed recommendations, CALSTART will publish this information. Visit www.calstart.org/Projects/E-Truck-Project.aspx for more.

EEI Guidebook
Edison Electric Institute (EEI) has released a guidebook to help utilities prepare for new electric cars and trucks. The report, “The Utility Guide to Plug-In Electric Vehicle Readiness,” acts as a road map for electric utilities to get the most benefit from this innovative technology.

The EEI guide focuses on the four areas that every electric utility will need to address to make sure they are ready for plug-in electric vehicles (PEVs) to plug into their service area:

• Getting the utility up to speed – The structure and organizational changes that a utility will need to address, as well as the value of adding PEVs to their fleets.
• Enhancing the customer experience – The educational topics and communication channels that will help utilities get their PEV-owning customers up to speed.
• Key passengers to include – The guide offers advice on engaging key third parties such as state regulators; federal, state and local governments; and additional stakeholder collaborations.
• Plugging into the grid – This section looks at how much power PEVs use, ensuring grid and distribution system readiness; helping customers plug in; and streamlining the charging station installation process.

To download a copy, visit www.eei.org/newsroom/energynews/Pages/20111115.aspx.

Smith Electric Vehicles Expands Production
Smith Electric Vehicles Corp. has announced it will expand its U.S. operations in 2012 by adding a manufacturing facility in New York to build the zero-emission Newton, its all-electric medium-duty vehicle.

The Newton is offered as a chassis cab that can be configured for use in utility operations. The vehicle is offered in a GVW range from 16,500 to 26,400 pounds and in 154-, 177- and 201-inch wheelbases. The Newton has a range of up to 150 miles.

The new facility, Smith’s second U.S. manufacturing, sales and service center, will join existing operations in Kansas City, Mo. The first Newton vehicles are planned for production in New York in the second half of 2012. Smith’s investment in its new plant is being augmented by city and state incentives of approximately $11 million.

New York Governor Andrew Cuomo has also announced the development of a federally funded, multiyear commercial electric vehicle buyer incentive program to accelerate adoption and allow for fleet conversion throughout New York. The New York State Department of Transportation has committed $10 million in federal Congestion Mitigation and Air Quality funding for the first year, which will be offered in the form of vouchers of up to $20,000 per vehicle. The program will be managed by the New York State Energy Research and Development Authority, and will offer voucher incentives to the purchasers of any qualified all-electric vehicle over 10,000 pounds GVW regardless of manufacturer. Visit www.smithelectric.com for more.

Protean Electric Projects Retrofit Market Growth
An all-new retrofit market will grow to a half-million vehicles by 2020, according to Protean Electric, which has developed an in-wheel motor electric drive system for light-duty vehicles. “Rising operating costs, shrinking budgets and green mandates are hard to balance when your fleet still has a job to do every day,” said Ken Stewart, Protean’s vice president of sales and marketing. “The time is right for a system that can add the benefits of this technology to light-duty vehicles that are already in service.”

The vast majority of this new retrofit market will come from converting light-duty government and commercial fleets. The Protean Drive in-wheel solution, which can be integrated into a broad range of vehicles, uses motors that can be fitted to conventional rear axles and installed in the space behind a wheel to produce up to 110 HP. Each motor has its own self-contained inverter controller. Visit www.proteanelectric.com for more.

PG&E Helps Unveil VIA Motors eREV
Pacific Gas and Electric Company joined VIA Motors in unveiling the first extended-range electric pickup truck for utilities. The utility partnered with VIA in 2008 to develop the trucks, called extended-range electric vehicles or eREVs, and already operates two of the trucks.

The VIA Motors eREV powertrain, powered by Symetron SmartDrive, was designed to work in light-duty trucks from GM, Ford and Dodge. An extended-range electric work truck comes with an optional onboard inverter that can be used in place of a tow-behind generator. The eREV trucks run the first 40 miles solely on electricity before switching to gasoline. For electric utilities, the trucks potentially can provide on-site power using a 15 kW capacity inverter.

In addition to the full-size pickup, VIA will offer a four-wheel drive SUV and a three-quarter-ton cargo van. The company has begun taking orders for its extended range electric pickup. Production is scheduled to begin in 2012. Visit www.viamotors.com for more.

Freightliner Custom Chassis Corporation and Enova Partner to Unveil Green for Free Program
Freightliner Custom Chassis Corporation (FCCC) and Enova, a developer of hybrid-electric and all-electric drive systems and drive system components, have launched a program to make electric vehicles more accessible to fleets.

The Green for Free program allows fleets to purchase all-electric vehicles for the cost of a diesel-powered commercial vehicle. The savings fleets incur from the reduced maintenance and fuel savings of the electric vehicles are then used over a period of time to cover the incremental expense of the technology. FCCC and Enova plan to deploy a total of 3,000 alternative-fuel vehicles within a two-year time frame beginning no later than the third quarter of 2012 as a result of the Green for Free program.

The Green for Free program will utilize the FCCC All-Electric Walk-in Van chassis powered by the Enova drive system. Enova and FCCC developed an integration method for both new and retrofit applications. FCCC’s all-electric chassis is built upon the FCCC MT-45 chassis with a GVWR of 14,000 to 19,500 pounds. Visit www.freightlinerchassis.com and www.enovasystems.com for more.

Propane
Trucks fueled by propane autogas, coupled with the cleaner-burning properties of propane, can decrease maintenance costs and extend engine life, according to the Propane Education & Research Council. Vehicles fueled by propane autogas, the most widely used alternative fuel, emit up to 12 percent less carbon dioxide, about 20 percent less nitrogen oxide and up to 60 percent less carbon monoxide than gasoline‐powered vehicles. More than 270,000 vehicles in the United States run on propane autogas, according to the U.S. Department of Energy.

Light- and medium-duty trucks fueled by propane autogas are available from industry-leading manufacturers, including Ford Motor Company, through collaboration with ROUSH CleanTech and General Motors, and through collaboration with CleanFUEL USA. The North American market for vehicles fueled by propane autogas is gaining momentum as more fleet managers become aware of the environmental and economic advantages.

Southern California’s City of Cypress is using ROUSH CleanTech propane autogas vehicles. The city added two Ford F-250 pickups fueled by the alternative fuel. “The City of Cypress is always looking for opportunities to put green vehicles in our fleet, and it’s important to move toward greener fleets when possible,” said Doug Dancs, the city’s director of public works. “Plus, the choice for propane was an easy one since we have had a propane fueling station in place since the early 1980s.”

King County, Wash., is also using vehicles that operate on propane autogas. Its fleet now includes seven Ford F-250s, one Ford F-350 extended cab pickup and one Ford E-250 cargo van with ROUSH CleanTech systems. “Public fleets in particular have a responsibility to take the lead and take steps to achieve significant greenhouse gas reductions within their own fleets,” said Robert Toppen, King County Department of Transportation equipment supervisor.

Visit www.autogasusa.org, www.roushcleantech.com and www.cleanfuelusa.com for more.

Compressed Natural Gas
Compressed natural gas (CNG) is an abundant domestic alternative fuel that offers significant advantages over gasoline. CNG’s per-gallon equivalent is 30 percent less expensive. In many areas of the country there is already infrastructure in place to effectively operate natural gas vehicles and more public-access fueling stations are becoming available. Another major advantage of CNG is 25 percent fewer CO2 emissions than standard gasoline-powered engines.

Strategic Partnership to Produce Natural Gas Vehicles
Leggett & Platt Commercial Vehicle Products (L&P CVP) has partnered with Landi Renzo USA to implement alternative fuel systems using CNG. L&P CVP will install Landi Renzo’s CNG fuel system at its Ford ship-thru facility in Elyria, Ohio, and will offer three- and four-tank options for installation on Ford’s E-250 and E-350 Cargo and Passenger vans. The 21 and 27 gasoline-gallon-equivalent tanks are part of a system that complies with Federal Motor Vehicles Safety Standards and Regulations, is certified by the EPA and is 50-state compliant through CARB. Visit www.leggettcvp.com and www.landiusa.com for more.

IMPCO Receives CARB Certification
IMPCO Automotive, a business unit of Fuel System Solutions Inc., has received certification by the California Air Resources Board (CARB) for its CNG fuel systems on several Ford and General Motors vehicles. Included are:

• Ford E-150/250 and 250 Econoline vans with the 5.4-liter V8 engines
• Ford E-450 Econoline cutaway cab chassis with the 6.8-liter 2v V8 engines
• Ford F-450/550 Super Duty trucks with the 6.8-liter 3v V8 engines
• General Motors 2500/3500 Express/Savana vans with the 4.8-liter and 6.0-liter V8 engines
• General Motors 4.8-liter V8 engine for heavy-duty applications – 10,001 to 14,000 pounds GVW
• General Motors 6.0-liter V8 engine for heavy-duty applications over 14,000 pounds GVW

Achieving CARB certification is especially important because several states have either adopted or are in the process of adopting California’s strict emissions standards. These states include New York, New Jersey, Massachusetts, Maine, Connecticut, Rhode Island, Pennsylvania, Vermont, New Mexico, Oregon, Washington, Maryland and Florida. IMPCO previously received certification from the U.S. Environmental Protection Agency (EPA) for these vehicles.

Now fielding IMPCO-powered vehicles is the City of Chicago, which has ordered up to 40 CNG-powered Chevrolet Express vans and as many as 40 CNG-powered Chevrolet Silverado pickup trucks. The dedicated CNG fuel systems will be installed on the Chevrolet Express vans at IMPCO Automotive’s alternative fuels conversion plant in Union City, Ind. The fuel systems for the trucks will be installed by IMPCO Automotive’s certified installation partner, Auto Truck Group, in Bartlett, Ill. Visit www.impcoautomotive.com for more.

Daimler Trucks North America Produces 1,000th Natural Gas Truck
Daimler Trucks North America, parent company of Freightliner Trucks, turned over the key to its 1,000th natural gas truck. Freightliner’s natural gas vehicles, including the M2 112 and 114SD, are powered by the Cummins Westport ISL G 8.9-liter engine, the only factory-built, dedicated natural gas engine available in the commercial vehicle market. These factory-installed and warranty-covered CNG tanks come in 60 diesel gallon equivalent (DGE) and 75 DGE configurations.

Freightliner Trucks has also announced that DeKalb County, Ga., has ordered 24 Freightliner Business Class M2 112 CNG trucks. DeKalb County will power the new trucks using its methane gas-to-energy process. The program, which was launched in 2011, converts landfill waste to useable natural gas. By converting the waste to energy, DeKalb County produces enough electricity to run 2,500 homes and will produce enough natural gas to run 600 trucks. To support the gas-to-energy program, DeKalb County is also building two fueling stations. Visit www.freightlinertrucks.com for more.

Hybrids

Hybrid Systems Achieve 200 Million Miles of Service
Eaton Corporation has announced that that customers of its hybrid systems have collectively accumulated more than 200 million miles of service, reducing diesel fuel consumption by 8 million gallons and harmful emissions by 80,000 metric tons. More than 5,500 of Eaton’s hybrid systems are in use today worldwide on trucks and buses. In addition to hybrid electric systems, Eaton began commercial production of its hybrid hydraulic system known as Eaton Hydraulic Launch Assist or Eaton HLA in the fall of 2010.

Eaton has also announced a program that lowers the service replacement cost for its hybrid power systems electronics carriers (PECs) and said it will offer two auxiliary power generator (APG) options for its hybrid electric power systems.

“We are now entering the period when the early adopters of hybrid technology are beginning to require service of the hybrid power batteries outside the factory warranty period,” said Gerard Devito, director of engineering, Eaton Hybrid Power Systems Division. “We are committed to helping fleets receive real value in running cleaner, greener fleets by continuing to lower the overall cost of ownership for hybrid systems and provide a positive return on investment.”

The new program significantly lowers the purchase price of PECs by up to half for utility applications. A standard aftermarket warranty of one year on parts and labor applies, with a two-year extended protection plan available at an additional cost. Starting in October 2011, the program became available through dealerships that elect to participate in this program and are authorized to service Eaton Hybrid Power Systems.

In addition to the PEC service replacement program, Eaton has announced it will offer two APG options in 2012 that will allow fleets to run vital equipment from the vehicle without requiring the engine to idle for power generation. The APG options will meet the power needs for customers using 115-volt single-phase tools and 208-volt three-phase loads. Visit www.eaton.com/hybrid for more.

BAE Unveils Scalable Hybrid Solution
The new BAE Systems HybriDrive family of heavy-duty hybrid electric propulsion systems is scalable to meet a wide range of truck platforms, vocations and duty cycles, including those for hybrid utility trucks. HybriDrive Parallel is based on a single electric machine integrated with the engine and the transmission on medium- to heavy-duty trucks.
www.baesystems.com

International DuraStar
The International DuraStar Hybrid, a diesel hybrid electric medium-duty truck is available with a choice of engines. Included are the MaxxForce 7 in ratings from 220 to 300 HP and 560 to 660 lbs./ft. of torque; the MaxxForce DT with automatic and manual driveline options and eight ratings from 215 to 300 HP and 560 to 860 lbs./ft. of torque; and the MaxxForce 9, also with a full range of automatic and manual driveline options and ratings up to 350 HP.

International’s hybrid vehicle is also equipped with the company’s Diamond Logic Electrical System, which integrates body equipment and the hybrid powertrain as a single piece of equipment. The programmable system features self-calibrating gauges that provide an audible alarm and visible LED indication when displaying a value out of normal operating range. Onboard diagnostics monitor electrical modules and capture diagnostic faults, and trouble codes are stored and displayed on the instrument panel’s built-in LCD screen. The International DuraStar Hybrid can also be equipped with the OEM’s AWARE vehicle intelligence system to allow for real-time data collection, reporting and analysis. Visit www.internationaltrucks.com for more.

XL Hybrids Conversion Systems
A hybrid conversion that transforms new or existing Class 1 through 3 vehicles into hybrid electric units is being readied for sale in 2012 by XL Hybrids. Designed for cargo, utility and shuttle vans and pickup trucks, the system has been undergoing pilot trials with select customers. XL Hybrids adds an electric motor, a lithium-ion battery pack and control software to the vehicle without making significant modifications to the engine or transmission. The parallel hybrid system can be installed as a retrofit on existing vehicles through a network of installation partners or as an upfit onto a new vehicle before delivery from a dealer. Visit www.xlhybrids.com for more.

Green Fleet Technologies

Written by Seth Skydel on October 24, 2011. Posted in Smart Fleets.

Eaton
The developer and manufacturer of hybrid power systems for commercial vehicles, Eaton’s parallel hybrid systems are already in use in many utility fleets. Available through truck manufacturers, the systems include the electric hybrid solution featuring an engine-off power-takeoff (ePTO), and an optional auxiliary power generator and AC power panel for utility, telecom and municipal operations using medium-duty bucket trucks.

The Eaton electric hybrid power system maintains the vehicle’s conventional drivetrain and blends engine torque with electric torque. The system recovers power normally lost during braking and stores the energy in batteries. It can provide ePTO and work site capability for operations needing hydraulic and electric power on job sites. The system is coupled with the vehicle’s engine and Eaton’s UltraShift automated manual transmission and clutch. Between the output side of the clutch and the transmission, the system includes an electric motor/generator that is connected to a power inverter and lithium-ion batteries, and is controlled with an electronic control module.

Eaton also offers its Hydraulic Launch Assist (HLA) hydraulic hybrid system. During regeneration with the HLA system, the vehicle’s kinetic energy that is normally lost during braking is captured and used to drive a pump, which transfers hydraulic fluid from a low-pressure reservoir to a high-pressure accumulator.

As the fluid pumps into the accumulator, it compresses nitrogen gas and pressurizes the system. The regenerative braking captures about 70 percent of the kinetic energy produced during braking. For acceleration, the fluid in the high-pressure accumulator is released to drive the system’s motor, which propels the vehicle by transmitting torque to the driveshaft.

The Eaton HLA system has two different operating modes: economy and performance. In economy mode, the energy stored in the accumulator during braking is used to initially accelerate the vehicle. Once the accumulator has emptied, the engine will begin to perform the acceleration. In performance mode, acceleration is created by both the energy stored in the accumulator and the engine. Once the accumulator has emptied, the engine is completely responsible for acceleration.

Visit www.eaton.com for more information.

Allison
Working with Delphi Automotive and Remy International, Allison has developed a hybrid propulsion system for medium-duty trucks. The new technology combines an Allison 3000 Series automatic transmission, Remy International’s High Voltage Hairpin (HVH) electric motor-generator, and Delphi Automotive’s lithium-ion energy storage system and transmission control module.

The Allison Hybrid, according to the company, combines the benefits of the three suppliers’ systems to offer better fuel economy. Among the fuel-saving features of the Allison automatic is the manufacturer’s torque converter technology that is designed to provide for full power shifts, using engine power more efficiently and consuming less fuel. The Remy HVH electric motor-generator, Allison also notes, is a compact design that captures more braking energy while using less energy to generate propulsion power and torque.

Tailored to meet the specific needs of any medium-duty truck application, the Allison Hybrid utilizes Delphi’s scalable lithium-ion energy storage system. The Delphi modular design also includes a transmission control module with the computing capability, memory and processing speed to control the entire hybrid system.

Visit www.allisontransmission.com for more information.

ALTe Powertrain Technologies
Range-extended electric powertrains for light- and medium-duty vehicles up to 26,000 pounds GVW will be available from ALTe initially through a nationwide network of conversion facilities. Eventually, ALTe expects to sell and license its technology to OEMs.

The major components of the ALTe powertrain include a 20 kWh lithium-ion battery pack, a four-cylinder engine, electric drive motors, a generator, a proprietary hybrid controller unit and HVAC modules. The powertrain is projected to provide an initial 30 miles of driving in an all-electric mode, powered directly from the lithium-ion battery pack. The vehicle can then drive an estimated additional 275 miles in a charge-sustained mode before the vehicle would need to be either plugged in or refueled. The battery pack can be charged within an eight-hour time frame from a 110-volt outlet or in about four hours from a 220-volt outlet.

ALTe, a shortened version of the words “alternative energy,” recently announced a contract with Remy to supply HVH 250 electric motors that will act as onboard generators to recharge batteries and deliver electric drivetrain traction power for ALTe’s powertrain conversions. A joint venture with Inmatech Inc. will produce hybrid electric storage devices composed of batteries, supercapacitors and control electronics. An agreement between ALTe and Manheim will provide installation of its powertrains in vehicles at Manheim locations.

Visit www.altellc.com for more information.

Azure Dynamics
The Balance Hybrid Electric vehicle from Azure Dynamics is built on a Ford E-450 commercial stripped or cutaway chassis with a modified drivetrain and electronic controls system. The system’s traction motor, in parallel with the unit’s Ford 5.4-liter EFI FFV gasoline V8 engine and automatic transmission, propels the vehicle. The traction motor assists acceleration and captures energy during regenerative braking events. This energy is stored in the energy storage system (ESS). When the vehicle comes to a stop, the engine will shut off and the electric power assist system is enabled to maintain power steering, power brakes and 12-volt charging.

The Azure system also has an integrated starter generator mounted to the front of the engine, which is used to provide quick restarts of the engine when accelerating from a stop. It also generates power to charge the ESS. The high-voltage system is self-contained and does not have to be plugged in to an external power source for charging.

Visit www.azuredynamics.com for more information.

Odyne Systems, LLC
The Odyne hybrid propulsion system for medium- and heavy-duty work trucks with extended stationary PTO job site functions – such as bucket trucks, digger derricks and cranes – can be applied to most new chassis or as a retrofit. The Odyne plug-in hybrid drive system uses a Remy HVH 250 electric motor, and provides 50-HP launch assist capability, regenerative braking or plug-in charging, and electrical energy storage to power air conditioning and cab heaters while the engine is off. Exportable power up to 7000W is available from the system’s 14 kWh or 28 kWh lithium-ion battery pack.

The Odyne hybrid system is compatible with most chassis over 14,000 pounds GVW and does not require drivetrain modifications. The system’s integration is simplified through the power takeoff (PTO) and propulsion components are placed within chassis frame rails for ease of installation. Battery packs can be placed in a variety of locations

Visit www.odyne.com for more information.

Quantum Fuel Systems Technologies Worldwide Inc.
Quantum Fuel Systems Technologies offers a plug-in hybrid electric (PHEV) conversion for Ford F-150 model pickup trucks. Pilot vehicles will be available for fleet testing in the fourth quarter of 2011. Production at the manufacturer’s Lake Forest, Calif., facility is scheduled to begin in the third quarter of 2012. Base vehicles shipped to the facility are partially disassembled, the new drive system is installed and tested, and the vehicle is reassembled and shipped to the customer.

The Quantum PHEV is powered by the company’s F-Drive hybrid drive system, developed specifically for Ford F-150 4×4 Regular and SuperCab models with a 145-inch wheelbase. The system provides a 35-mile electric-only range, shifting to hybrid electric mode for a total range of more than 400 miles. The F-Drive has been integrated in the F-150 pickup truck to ensure there is no loss of cab or cargo space, and to maintain full ground clearance. F-150 models with the Quantum system have a payload capacity up to 900 pounds and towing capacity up to 5,800 pounds. The 150 kW parallel hybrid drive system can be recharged using 110- or 220-volt power.

Quantum provides a five-year/75,000-mile limited warranty on the drive system. The company also trains fleet maintenance personnel on servicing the system and has an on-call team available to support customer fleet maintenance departments.

Visit www.qtww.com for more information.

Changing Landscape

Written by Seth Skydel on October 24, 2011. Posted in Smart Fleets.

The landscape for utility fleets is changing again. Earlier this year, the first-ever fuel efficiency and carbon rules for trucks were put in place. Following the process used for light-duty vehicles, the new rules set standards for all on-highway vehicles with GVW ratings above 8,500 pounds. The new rules that will take effect include U.S. Environmental Protection Agency greenhouse gas regulations beginning with 2014 model year vehicles and National Highway Traffic Safety Administration fuel consumption regulations that begin with the 2016 model year.

Under these new regulations, fuel efficiency will rise and carbon emissions will go down for all vehicle classes, including tractors, Class 3 to 8 vocational work trucks, and heavy-duty pickups and vans. Manufacturers are expected to meet the new regulations with both engine and full vehicle technology approaches.

The 2011 Electric Utility Fleet Managers Conference, held in Williamsburg, Va., featured a series of presentations on “Focused Strategies for Future Success” by industry experts, manufacturers and fleets. Of interest to the fleet managers in attendance were several presentations on green fleet issues by industry and government stakeholders.

Status and Trends of Green Tech and Fuels in Commercial Vehicles
Bill Van Amburg
Senior Vice President, CALSTART

“Nearly 70 percent of oil used in the U.S. goes to transportation,” Van Amburg said. “To address energy security, transportation must be a top focus. There are two main ways to achieve reductions in imported oil, and we need both. We have to use less fuel to do the same work and switch to nonpetroleum sources.”

To make a business case for alternative fuel-powered commercial vehicles, Van Amburg said, fuel cost issues need to be addressed. “The medium- and heavy-duty hybrid business case improves substantially for fuel prices above $3 per gallon,” he said. “Natural gas already has a substantial price advantage, while other alternative fuels show benefits. In addition, electric trucks are gaining interest as a hedge against fuel price fluctuations because electricity prices are much more stable.”

Commercial plug-in hybrid electric vehicle (PHEV) work trucks show potential because their extra energy storage boosts idle time reduction during work site engine-off operations, Van Amburg noted. “Diesel fuel costs are causing a rapid review of the potential business case for these vehicles,” he said, “but energy storage costs are still high. Still, there is growing interest from fleets if fuel savings are not derived entirely from driving cycles.”

Van Amburg was referring to plug-in body systems from various manufacturers that allow stored energy to be used to operate aerials and tools at the work site. These solutions are generally separate from and do not change conventional drivelines, but still offer potential fuel saving and idle reduction benefits.

Dual-mode hybrids, which are already in use in transit operations, are one technology under development for trucks. In particular, Van Amburg pointed out that Meritor and Navistar are testing an advanced dual-mode hybrid design that provides electric drive capability at lower speeds and a blended power mode at higher speeds. Eaton is also testing a dual-mode hybrid that offers a zero emissions short-range, low-speed driving capability.

Also noted in Van Amburg’s presentation were the expanding choices for natural gas engines in medium- and heavy-duty trucks that showcase the re-emergence of natural gas as a viable fuel option.

“Electric trucks are a key emerging segment,” Van Amburg pointed out. As a result, CALSTART has created an e-truck task force of users and manufacturers to identify market and technology barriers, such as charging issues. Fleet needs are also on the group’s agenda, including determining best duty cycles such as those for high-idle work site applications of PTO-driven components and aerial devices, and quantifying benefits to support and validate a business case for this technology.

“The foundation has been set,” Van Amburg stated. “Advanced low-emitting, high-efficiency technologies are now emerging and are in early production. We are entering a 20-year period of significant technology and fuel change and pressures for greater efficiency and reduced emissions, but a support framework is needed to help industry meet challenges.”

Plug-In Hybrid Electric Vehicles
Mark Kosowski
Program Manager, PHEV Medium-Duty Truck, Electric Power Research Institute (EPRI)

A PHEV, Kosowski explained, is similar to a hybrid truck except that it incorporates an extra 10- to 30-kWh battery that can be charged through an interface to the electrical grid. This stored energy improves fuel economy and reduces emissions by powering functions normally handled by the engine.

Kosowski defined three typical parallel hybrid architectures that can be used in PHEVs:

Pre-transmission hybrids include a pump, battery, inverter and charger. “This is the most capable architecture because the motor and engine can drive the wheels through the transmission, and the motor can drive the PTO without using the engine by opening the clutch,” Kosowski said. “This is a higher cost solution because the transmission needs to be modified.”

Post-transmission hybrids use a battery. “This is a less expensive solution because the transmission does not need to be modified,” Kosowski said. “While the motor in this architecture can drive the PTO without using the engine, the motor can only be operated at transmission output speed.”

PTO-driven hybrids incorporate a pump, battery, inverter and charger. “In this architecture the motor can drive wheels through the transmission and can drive the PTO without the engine,” Kosowski said. “This is also less expensive because the transmission does not need to be modified; however, the motor and engine torque operate in parallel in this solution.”

Fleet readiness for a PHEV charging infrastructure was also on Kosowski’s agenda. For fleets developing charging solutions, he referenced the National Electrical Code (NEC) Article 625, which describes charging safety issues, and Society of Automotive Engineers (SAE) Recommended Practice J1772 for charging systems.

PHEV charging systems were detailed by Kosowski as well. A Level 1 AC 120-volt charging system uses a cord set with one end that has a standard plug arrangement that can interface to any electric vehicle as defined by SAE J1772 . The other end is plugged into a typical 120-volt AC outlet. The cord set is usually stored in the vehicle. Charge time is dependent on the vehicle’s battery size and can range from eight to 20 hours.

Level 2 AC 208/240V charging systems also use a cord set with one end that has a standard plug arrangement that can interface to any electric vehicle as defined by SAE J1772, the same as the 120V interface. The other end is permanently connected to the electrical grid.

“It is recommended that Level 1 charging have a dedicated circuit as chargers are sized to use the maximum capacity of the circuit [80 percent of breaker rating],” Kosowski explained. “In particular, a Level 1, 15-amp charger loads the circuit at 12 amps and a Level 1, 20-amp charger loads the circuit at 16 amps. Breaker tripping is likely if other loads share the circuit. Level 2 chargers require a dedicated circuit [per NEC] with controlled connect/disconnect [high current/voltage] capability, and for safety the connection to the premise wiring is not cycled, meaning the connection is made and broken at the vehicle.”

Kosowski also discussed the EPRI/TVA Smart Station project located at EPRI’s Knoxville lab. The facility, he related, is helping develop best practices and provide public education, and will expand on lessons learned in future site designs.

EPRI serves as the hub of collaboration in this effort through its Infrastructure Working Council, which brings stakeholders together four times a year and works to bridge the gap between utilities, connector and charging system manufacturers, and automakers, among others.

“Our vision,” Kosowski concluded, “is that by 2015 all plug-in vehicles can communicate to the smart grid where charging is intelligently controlled. Smart charging is lower in cost and more convenient for vehicle operators, and can minimize the impact on the electric infrastructure.”

Acquisition and Funding Strategies
Mark Smith
Vehicle Technologies Deployment Manager, National Clean Cities Program, U.S. Department of Energy

“The primary focus of DOE’s Clean Cities Vehicle Technology Program is to achieve petroleum reduction by implementing programs that follow research and development,” Smith stated. “Since 1993, we have helped cut petroleum use by nearly 3 billion gallons annually. Currently, there are over 700,000 alternative fuel vehicles on the road and 7,000 alternative fueling stations, more than 70 percent of them influenced by Clean Cities programs.”

Clean Cities includes more than 100 coalitions serving 78 percent of the U.S. population. The coalitions involve thousands of stakeholders from businesses, city and state governments, transportation industry, community organizations and fuel providers.

Deployment efforts that Smith outlined include local community and coalition partnerships with direct support for Clean Cities activities, public events, training for coalitions and community leaders, local project coordination and strategic planning assistance. In addition, the DOE program provides consumer information, outreach and education in the form of fuel economy guides, the Alternative Fuels and Advanced Vehicles Data Center, other Web-based consumer tools, publications, workshops, and targeted workforce and end-user education.

Technical and problem-solving assistance is available from Clean Cities as well, covering things such as addressing market barriers, safety issues and technology shortfalls. The program also offers financial assistance by providing funding in the form of competitive awards to facilitate infrastructure development and vehicle deployment projects.

Clean Cities, Smith pointed out, is working with the National Clean Fleets Partnership “to deploy over 10,000 alternative fuel and advanced technology vehicles. Also,” he added, “over 1,250 alternative fuel and electric vehicle charging stations will be built or upgraded. An enhanced locator and mapping service for more than 500 new electric vehicle charging locations is planned, and we are working on funding opportunities for all of our programs.

“The goal,” Smith concluded, “is to reduce petroleum use by 40 million gallons per year in the near term and by 2.5 billion gallons annually by 2020.”

Resources
Clean Cities: www.cleancities.energy.gov
Federal Grants: www.grants.gov
Alternative Fuels and Advanced Vehicles Data Center: www.afdc.energy.gov
Fuel Economy Guide: www.fueleconomy.gov
Clean Cities Coalition Contacts: www.afdc.energy.gov/cleancities/progs/coordinators.php
Electric Power Research Institute: www.epri.com
CALSTART (including the Hybrid Truck Users Forum): www.calstart.org

Fleet Reports
During the 2011 Electric Utility Fleet Managers Conference, fleet managers related their experience with hybrid vehicles.

Mike Allison
Director, Fleet Design and Technical Support
Duke Energy

Duke Energy’s 2009 Freightliner hybrid trucks are still receiving good acceptance reports from operators, Allison noted. “Savings are still driven by application and job needs,” he said. “After approximately 40,000 miles of service, the most closely matched hybrids compared to baseline units have exhibited 25 percent better fuel economy, 23 percent less overall engine run time and 41 percent less overall engine idle time. For the hybrids, ePTO use is 76 percent of overall PTO operation time.”

Glenn Martin, CAFM
Fleet Maintenance Manager
Florida Power & Light

The hybrid portion of the Florida Power & Light fleet has increased from 24 units in 2006 to 364 units in 2010, Martin related. “Overall, the data indicates that hybrid vehicles are meeting or exceeding expectations on all fronts,” he said.

“With the hybrids in our fleet, fuel used from 2006 to 2010 decreased by 10 percent while our vehicle count increased by 136 units or 6 percent,” Martin reported. “In the same time period, annual miles driven increased by 2.3 percent and average MPG increased by 14 percent. In addition, maintenance costs for the hybrid fleet are trending significantly under the nonhybrid portion of the fleet and hybrid vehicle availability is trending above the nonhybrids.”

Dave Meisel
Director, Transportation Services
Pacific Gas and Electric Company (PG&E)

With more than 2,600 alternative fuel vehicles, PG&E operates one of the largest high-efficiency vehicle utility fleets in the nation. Included are natural gas (CNG or LNG), biodiesel (B-20), electric (on- and off-road) and hybrid (HEV and PHEV) units.

Challenges do remain on several fronts, however. “Employee familiarity with the operation of and acceptance of the equipment are concerns,” Meisel said, “along with the availability of qualified technicians. For electric vehicles in particular, the charging infrastructure, including the speed of charging and the volume and location of charging stations, is still a challenge.

“The return on investment for some of these technologies is better than for others,” Meisel continued, “and performance varies significantly based on make, model and manufacturer, even among like technologies. Parts and service availability is also an ongoing challenge.”

Meisel noted that in some cases technology development is moving so fast that some regulatory agencies are behind, especially when it comes to incentives. “Government incentives are nice,” he stated, “but they haven’t changed the way we buy vehicles. Financing also continues to be a challenge.

“Fleets need to create a self-sustaining model,” Meisel added. “They need to understand the technology and its application, and conduct a full cost-benefit analysis. Determining accurate costs, useful service life and residual values are among the open issues.

“Greening the fleet makes sense from an environmental and economic standpoint,” Meisel concluded, “but there will not be any one fuel or technology that meets all of our needs. At PG&E we will be evaluating all the technology options as they become available.”

About the Electric Utility Fleet Managers Conference
Organized and produced by a highly dedicated group of fleet managers, the Electric Utility Fleet Managers Conference (EUFMC) features technical and management presentations, and an equipment exhibit built on the guidance of fleet professionals.

“This group of volunteers works for many months to determine what subjects will have the greatest interest to the fleet and supplier community,” said George Survant, director of fleet services at Florida Power & Light and the current EUFMC president. “Utility fleet managers have had to address a greater rate of change in the past decade than in the previous 40 years. EUFMC sorts through this large array of issues to help the fleet community and the entire industry focus on critical items, and make a difference by driving costs in a direction that is acceptable to customers and shareholders.”

The 59th EUFMC will be held June 3-6, 2012, at the Williamsburg Lodge and Conference Center in Williamsburg, Va. For more information, visit www.eufmc.com.

Green-Focused Facility
Altec Industries has announced plans for a green-focused facility in Dixon, Calif. The new plant will feature sustainable construction and exceed Title 24 energy and lighting codes. In addition, Altec plans to use the facility to expand the development and production of its Green Fleet utility vehicle product line.

Altec received guidance and support on the development of the new green-focused facility from two of its customers – Pacific Gas and Electric Company (PG&E) and Southern California Edison. In addition, PG&E and Altec are partnering to develop innovative, technologically advanced Green Fleet utility vehicles, which will be produced at the new facility.

Visit www.altec.com for more information.

Green Fleets

Written by UFP Staff on June 6, 2011. Posted in Smart Fleets.

Around the Industry
The National Clean Fleets Partnership, a Department of Energy (DOE) initiative, has set its sights on helping companies reduce diesel and gasoline use in their fleets by incorporating electric vehicles, alternative fuels and other fuel-saving measures into their daily operations. Through the partnership, the DOE will assist in efforts to reduce fuel use and achieve greater efficiency and cost savings by offering specialized resources, technical expertise and support.

Part of the DOE Vehicle Technology Program’s “Clean Cities” initiative, the National Clean Fleets Partnership includes opportunities for technical assistance and collaboration, such as peer-to-peer information exchange, and access to expertise at DOE and national laboratories where related research and development initiatives are underway. Also possible is assistance in pursuing group purchasing so smaller companies realize the benefits of purchasing advanced technology vehicles.

The DOE has developed a wide range of technical tools to help companies navigate the world of alternative fuels and advanced vehicles. The collection includes cost calculators, interactive maps, customizable database searches, mobile applications and other vital information.

Utilimarc and CALSTART have joined forces to provide fleets with a range of valuable resources and experience about light- and medium-duty vehicles powered by alternative fuel. CALSTART, which is known for its Hybrid Truck Users Forum (HTUF), brings to bear its expertise to guide fleets in selecting and implementing new technology and measuring its benefits. Utilimarc’s benchmarking data plays a critical role in assessment, monitoring and ROI calculation, ensuring a reliable comparison of industry-specific metrics with an emphasis on tracking alternative fuel vehicles.

Regulations mandating environmental protection practices are requiring fleet managers to implement new programs. These rules, which cover a wide variety of topics, include the following:
• U.S. Environmental Protection Agency (EPA) rules covering hazardous wastes defined and regulated by the Resource Conservation and Recovery Act, known as RCRA (“Rick-Rah”), including recycling and pollution prevention options
• Federal underground storage tank (UST) regulations and state UST programs approved by the EPA that are allowed to operate in lieu of the federal program and may have more stringent regulations than the federal requirements
• Safe fuel-handling regulations designed to prevent accidental spills and overfills
• RCRA, Clean Water Act and Clean Air Act requirements that may pertain to vehicle painting
• Refrigeration service activities regulated under the Clean Air Act
• Regulatory requirements for pollutant discharge and storm water runoff systems
• Requirements for hazmat incident reporting

GreenTruck (www.greentruck.com), a consolidated source of information about environmental regulations, is provided by American Trucking Associations and the Transportation Environmental Resource Center. The site details EPA programs for oil spill prevention and response, and hazmat incident reporting. Also covered are federal and state underground storage tank (UST) regulations, safe fuel-handling regulations, hazardous waste definitions, refrigeration service activities regulated under the Clean Air Act and requirements that may pertain to vehicle painting. GreenTruck also provides details on the EPA’s National Environmental Performance Track program, which rewards companies that exceed minimum regulatory requirements and take extra steps to reduce and prevent pollution.

On the Road
Fleet managers continue to learn more about alternative fuel-powered vehicles. During the 2010 Electric Utility Fleet Managers Conference (EUFMC), three executives described their experiences.

Duke Energy has been operating groups of 2006- and 2009-model hybrid trucks, reported Mike Allison, director of fleet design and technical support. The hybrids and baseline vehicles in the fleet were fitted with data capture systems to compare operating information. “For the most closely matched vehicles, both driven approximately 22,000 miles,” he said, “we learned that the hybrid unit used 25 percent less fuel and accumulated 800 fewer engine hours. Overall, fuel economy was 6.83 mpg for the hybrid versus 5.60 mpg for the diesel-powered model.

“Initial acceptance by operators was also good,” Allison added, “and we found that savings were application-driven. Also, while we did have some performance complaints, those were corrected through software changes.”

Florida Power & Light also reported “strong user acceptance” for the initial 24 Class 6-7 hybrid trucks in its operation. At the time, the fleet had 36 months of service on its first hybrid units and more than 1 million miles of combined road service on the group of trucks. “At over 99 percent, availability of the hybrid trucks has been high,” said Claude Masters, manager, vehicle acquisition and fuel. “In addition, the hybrid trucks showed fuel savings of 32 to 47 percent [measured in gallons per hour].

“Factors affecting fuel economy include highway driving conditions and engine-off PTO operation,” Masters also reported. “Realizing efficiencies with hybrid vehicles comes from matching the equipment to the mission.”

Pacific Gas and Electric Company is also a user of alternative power trucks. “Making effective choices,” noted Dave Meisel, director, transportation services, “is about looking at the highest value proposition elements, and because fuel savings are very duty-cycle dependent, no one type of alternative fuel vehicle fits all applications. In addition, there are price and return-on-investment questions that need to be asked and answered because performance varies significantly between makes, models and manufacturers.”

Meisel also defined two other issues to address when considering alternative vehicles. Included were employee challenges, such as familiarity with the operation of the equipment and the availability of qualified technicians. Also to be considered are parts availability
and technical issues related to batteries and charging systems.

Today’s natural gas trucks are ready to handle utility tasks, said Dave Bryant, manager, vocational sales at Daimler Trucks North America (DTNA), during the 2010 EUFMC. DTNA, he noted, has put more than 2,000 natural gas units into service in a range of applications, including utility, municipal and construction fleets.

DTNA’s factory-installed natural gas solution for the Freightliner M2 112 platform features the Cummins Westport ISL G 8 engine. The five models offered in liquefied natural gas (LNG) or compressed natural gas (CNG) versions include 250, 260, 280, 300 and 320 HP options with peak torque from 660 to 1,000 lbs./ft. at 1,300 rpm. For its M2 natural gas models, the OEM offers CNG tanks in 60 diesel gallon equivalent (DGE) and 75 DGE configurations. Factory-installed LNG options include 119- and 147-gallon tanks, which equate to 65 and 86 DGE, respectively.

All Freightliner natural gas vehicles include a standard methane detection system. The system encompasses sensors mounted in the cab, engine compartment and outside the cab near the fuel tank to provide visual and audible warnings of fuel leaks. Freightliner and Cummins Westport also provide on-site fleet customer training, as well as engine and fuel system maintenance and troubleshooting services.

Bryant pointed out several benefits of natural gas engines beyond lower operating costs than diesel. “With the same rated speed as an ISL diesel, the ISL G provides 30 percent more torque at idle, and it is quieter,” he said. “Other advantages include a maintenance-free three-way catalyst and no need for additional emissions control devices, diesel particulate filter regeneration or ash cleaning.

“When you look at fuel choices, natural gas is a great choice to meet short-haul and vocational needs,” Bryant said. “It is less expensive than diesel fuel, and NG-powered engines have a lower cost of operation than their diesel counterparts.”

Liquid propane autogas, another viable alternative for fleet vehicles, took center stage at the 2011 National Truck Equipment Association’s Work Truck Show. There, ROUSH CleanTech announced its new 6.8-liter V10 propane autogas-powered Ford F-550 super duty chassis cab. The propane autogas fuel system will be available for 2012 and later models of the Ford F-450 and F-550 truck series, and is expected to ship beginning in October 2011.

The fuel system is currently in development and will be EPA and California Air Resources
Board (CARB) certified at launch. The system will be available as a Ford ship-through option for installation on new vehicles, or as a retrofit option for vehicles already in service.

While ROUSH CleanTech is still finalizing the details on tank capacity and options, the plan is to offer up to three tank configurations for the Ford F-450 and F-550 propane autogas fuel system – an in-bed tank and two under-bed tanks. The fuel tank choices will be able to be combined to conform to various body configurations and to meet the range requirements of customers. The system, equipped with a five-speed automatic transmission, will work on all cab and wheelbase configurations, as well as 4×2 or 4×4 vehicles.

“Going green is not just for light-duty vehicles anymore,” said Joe Thompson, president of ROUSH CleanTech. “Propane autogas offers so many benefits to fleets in terms of safety, economics, environmental soundness and convenience. There are thousands of refueling stations across the U.S., and many fleets are installing low-cost on-site refueling infrastructure to eliminate the need for off-site stations.”

Propane autogas burns cleaner than gasoline or diesel, with 20 percent less nitrogen oxide, up to 60 percent less carbon monoxide, 17 to 24 percent fewer greenhouse gas emissions and fewer particulate emissions when compared to gasoline. When compared to diesel fuel, the emissions reductions are even greater. Propane autogas also offers up to 40 percent reduction in fuel costs when compared to gasoline.

In the Shop
Southern California Edison (SCE) has been honored for green shop efforts at its Wildomar, Calif. facility, achieving Platinum certification under the Leadership in Energy and Environmental Design (LEED) program sponsored by the U.S. Green Building Council (USGBC). The USGBC process includes a green building rating system covering Sustainable Sites, Water Efficiency, Energy & Atmosphere, Materials & Resources, Indoor Environmental Quality and Innovation in Design.

During the 2010 EUFMC, James Kennedy, manager, presented details on SCE’s Greening Utility Fleet Garage Facilities activities. The Wildomar service center site is home to a
21,116-square-foot, two-story garage with six truck bays, a welding bay and a wash bay, along with an office building, an assembly space and a yard management warehouse.

“In the shop we focused on environmentally-sensitive planning, design and construction,”
Kennedy said. “For example, skylights and glass bay doors in the garage were placed to optimize the use of natural light. Also used were low volatile organic compound-emitting, nontoxic paints, coatings, adhesives, carpets and floor coverings to promote high indoor air quality. In addition, the building has an HVAC system with CO2 monitoring devices and HEPA filters to regulate fresh-air ventilation when indoor CO2 levels reach a predetermined threshold.”

Kennedy went on to say that the Wildomar service center is a model for new building construction at SCE. “We’re committed to environmental protection,” he stated. “Beyond meeting regulatory requirements, we’re developing and implementing programs and practices that improve air and water quality, reduce solid waste and conserve natural resources. In addition, we’re benefiting by reducing operating costs and by providing a healthier, more comfortable work environment for our employees.”

SCE also earned LEED credits for its green building education practices by providing public information on the sustainable features of the Wildomar facility. The utility has also been awarded credits for its green housekeeping program that promotes the use of nontoxic cleaning supplies, for achieving water savings through the use of high-efficiency plumbing and landscaping fixtures, and for the purchase of renewable energy credits to offset the facility’s energy usage.

SCE, one of the nation’s largest electric utilities, operates 1,900 medium-duty trucks and 3,000 passenger and light-duty vehicles, along with 1,000 heavy-duty units and 1,100 pieces of equipment. The fleet is maintained in 44 shops staffed by 246 technicians.

Tag: Hybrid Vehicles