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Make Every School Bus Better. Thomas Bus Oct 4, 2011 Steve D Goss Sanjay Kumar Jim Lannan. Agenda. Update on successes IC Bus ‘Fluid’ Economy Claims Cummins Fuel Economy How to sell Cummins. School Bus Industry Data.

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Make every school bus better

Make Every School Bus Better.

Thomas Bus Oct 4, 2011

Steve D Goss Sanjay Kumar Jim Lannan


Agenda
Agenda

  • Update on successes

  • IC Bus ‘Fluid’ Economy Claims

  • Cummins Fuel Economy

  • How to sell Cummins


School bus industry data
School Bus Industry Data

  • Industry data suggests a 5% gain in Cummins market share (50% to 55%)

  • Recently gained business with largest bus customer


Ic bus fluid economy claims
IC Bus ‘Fluid’ Economy Claims

  • IC Bus published report of fuel economy testing stating ‘up to a 4.5%’ advantage vs Cummins

  • Cummins responded to claims outlining the points in question including:

    • Transmission shift calibration selections

    • Aftertreatment regeneration

‘Fluid Economy’ also ignores the price differential

Avg. Diesel Price

$3.80

Avg. Bulk DEF Price

$2.85


Transmission shift calibrations
Transmission shift calibrations

  • IC Bus did not outline what shift calibrations were used during testing

  • Cummins testing validates that proper selection can result in significant fuel economy gains


Aftertreatment regeneration
Aftertreatment Regeneration

  • Typical regen cycle on MF 7 at approx. 135 miles

    • Same distance as test

  • More EGR = More Soot Generated = More Regens

  • Regenerations require the use of more fuel thus diminishing overall fuel economy


Fluid economy
‘Fluid’ Economy

  • IC’s claims of ‘fluid’ economy inaccurately represent total cost of ownership

  • No mention of DEF consumption thus inability to analyze actual DEF usage for test

  • Differences in DEF and diesel fuel pricing vary significantly so need to be analyzed separately


Cummins fuel economy
Cummins Fuel Economy

  • ‘Others Test. We Deliver’

  • Cummins and Thomas Bus both currently testing


Isb fuel economy tops dtna testing
ISB Fuel Economy Tops DTNA Testing

Freightliner M2 106

with Cummins ISB

(EPA 10)

Vs.

International Durastar 4300

with

MaxxForce DT (EPA10)

Result

  • 8.5% Better Fuel

    Economy

  • 2 Regens for ISB Vs 10 for MaxxForce DT in the 14 hour test period


In cylinder nox control challenges
In Cylinder NOx Control Challenges

  • Fuel economy significantly compromised

  • Increased risk of EGR condensation

  • Significant increase in heat rejection

  • Complex system integration

  • Driver satisfaction significantly compromised

  • Power density and torque limitations


In cylinder nox control challenges1
In Cylinder NOx Control Challenges

  • 5-9% disadvantage

  • Combustion efficiency degradation:

    • Higher engine pumping losses

    • Increased intake & exhaust manifold pressures

    • Increased Particulate Filter regenerations

Fuel Economy Significantly Compromised


In cylinder nox control challenges2
In Cylinder NOx Control Challenges

  • Higher EGR flow produces excessive acidic condensation

  • Power cylinder corrosion

    • Rapid deterioration of lube oil

  • Reliability and durability compromised

Increased Risk of EGR Condensation


In cylinder nox control challenges3
In Cylinder NOx Control Challenges

  • 20% increase

  • Higher EGR flow:

    • Multiple EGR coolers on & off engine

    • Larger vehicle cooling package

    • Major redesign of radiator / Charge Air Cooler / Fan systems

Significant Increase in Heat Rejection


In cylinder nox control challenges4
In Cylinder NOx Control Challenges

  • Higher EGR flow

  • Air handling system

  • Vehicle cooling system

Complex System Integration


In cylinder nox control challenges5
In Cylinder NOx Control Challenges

  • Higher EGR Flow

    • Throttle Response

Driver Satisfaction Significantly Compromised


In cylinder nox control challenges6
In Cylinder NOx Control Challenges

  • Deterioration of 50 – 100 hp for same displacement

  • Higher EGR flow & EGR controls compromises engine performance

Power Density and Torque Limitations


Bus owners have two choices for 2010
Bus Owners Have Two Choices for 2010

Clean Air

DPF

DOC

Catalyst

AMOX Cat

DPF

Doser

Tank

DOC

Advanced EGR

Intercooler

Radiator

Higher heat rejection:

Larger Radiator

Larger Charge air cooler

EGR + SCR After-Treatment System Setup



The facts about the fluid def properties

Acidic pH

The Facts about the Fluid – DEF Properties

  • DEF is safe to handle and store

    • Non-toxic

    • Non-polluting

    • Non-flammable

  • DEF freezes at 12° F (-11° C). However, frozen DEF does not impact start up and normal operation of the vehicle

  • When stored at extreme temperatures, neither DEF nor Urea become toxic

  • DEF is slightly alkaline with a pH of approximately 9

DEF


Def myths facts
DEF - Myths & Facts

  • Navistar’s claim of ammonia level being close to 1000 ppm in a near empty DEF tank is a ‘stretch of imagination’

  • DEF, when heated and maintained at a constant temperature 120 degrees Fahrenheit, will very slowly start to form small amounts of ammonia

  • It would take over two years at this constant temperature to convert DEF into levels of 1000 ppm of ammonia

  • Such a situation can be probably modeled in ‘laboratory setting’ but not in the real world





Designing for the school bus market
Designing For the School Bus Market

  • Reliability

  • Total cost of ownership

  • Low maintenance

  • Safe Operation

  • Sociability

  • Performance

  • Weight/space

  • Minimal driver training

  • Ease of operation

  • Information systems

  • Emissions compliance



Isb6 7 isc8 3 features
ISB6.7 & ISC8.3 Features

  • Improved combustion system

  • Advanced VGT Turbocharger

  • Improved cooled-EGR subsystem/cooling circuit

  • Fully integrated electronic controls

  • New Cummins Aftertreatment System


Isb6 7 isc8 3 customer benefits
ISB6.7 & ISC8.3 Customer Benefits

  • Best-in-Class Fuel Economy

  • Improved Reliability

  • Minimal Installation Impact

  • Stronger Performance

  • Increased Power Density



Isl g product features and benefits
ISL G Product Features and Benefits

  • 8.9L Stoichiometric Cooled EGR engine with spark ignition

  • In production since mid-2007

  • Low emissions

  • Diesel-‘like’ Performance, Reliability and Durability

  • Over 80% parts commonality with ISL9

  • Compatible with CNG, LNG, or Biomethane (RNG)


2010 isl g natural gas

Three Way Catalyst Aftertreatment

Passive device

Packaged as a muffler

Maintenance-Free

Stoichiometric Combustion Cooled EGR

Same rated speed as ISL9 diesel

30% more torque at idle

5% better fuel economy

2010 ISL G Natural Gas


Integrating Critical Subsystems

Filtration and

Diesel Exhaust Fluid

Electronic Controls

Aftertreatment System

Fuel Systems

Turbochargers

Combustion

Technology


Powerspec
PowerSpec

  • Software Application

    • Provide gearing recommendation

    • Customize engine ‘specs’

    • Collect valuable trip information

    • Free to download and use

www.powerspec.cummins.com


Inline adapter
INLINE™ adapter

  • Cummins datalink adapter used in conjunction with PowerSpec

  • Allows user to:

    • transfer feature parameter settings

    • download trip information

  • INLINE™ 5 kit (part number: 4918416) includes all necessary parts to connect the vehicle to a laptop


Make every tm school bus better
Make EveryTM School Bus Better.

  • Better Fuel Economy.

    • Up to 3% better than our ’07 ISB and ISC

    • Joint testing underway on EPA 2010 product

  • Better Performance.

    • Improved driveability and throttle response

  • Better Reliability.

    • Best-in-class durability and dependability

  • Better for the Environment.

    • Near zero NOx and PM emissions

    • Improved MPG results in smaller carbon footprint



Common parts with hdx means faster design cycle
Common Parts with HDX means faster design cycle

Sub-system ID (estimated number of parts to be eliminated ~100)

Destination Sign

(20)

Front Roof Cap

(6)

#2 Hood

(2)

Clearance/Marker Lights

(6)

Windshield

(3)

Wipers

(15)

Header Height/Drip Rail

(4)

“A” Mirrors

(8)

Hazard Lights

(4)

“B” Mirrors

(8)

Headlight & Bezel

(4)

Bumper

(10)

WalkGate

(8)

00000-00-Thomas Built Buses Standard Template.ppt


Driver focused improvements storage
Driver Focused Improvements - Storage

  • Added driver’s storage to right side dash

    • Can be used for safety equipment storage or for personal items

00000-00-Thomas Built Buses Standard Template.ppt


Driver focused improvements visibility
Driver Focused Improvements - Visibility

  • Improved visibility

    • HDX windshield

    • Larger driver’s side window

    • Argosy headlights

    • Running lights standard

00000-00-Thomas Built Buses Standard Template.ppt


Driver focused improvements visibility1
Driver Focused Improvements - Visibility

  • Improved defrost capability

00000-00-Thomas Built Buses Standard Template.ppt


Technician focused improvements access
Technician Focused Improvements - Access

  • Headlight doors and removable grill provide easy service access

    • Lights

    • Wiper motors and linkages

    • Washer fluid

    • Power steering reservoir

    • Defrost heater relays

00000-00-Thomas Built Buses Standard Template.ppt


Technician focused improvements access1
Technician Focused Improvements - Access

  • Lower driver side access panel for chassis PDM’s

00000-00-Thomas Built Buses Standard Template.ppt


Technician focused improvements misc
Technician Focused Improvements – Misc.

  • More reliable components should translate to fewer replacements

  • Increased parts commonality means less parts for technician to maintain

  • Bus can still be jacked up by front bumper

00000-00-Thomas Built Buses Standard Template.ppt


Family look
Family Look

HDX

EFX

00000-00-Thomas Built Buses Standard Template.ppt


Efx status
EFX Status

Gate 9/8 Status: Passed (May 9th)

Gate 7/6 Status: Passed

Scheduled SOP: Q1 2012

Project Budget approved.

Bus to be showcased at NAPT in October.

Estimated start of production 1Q2012

Pilot/Preseries

  • We’ll be soliciting orders within the next month

  • Will come with new sales codes – WebEx will be scheduled to assist in ordering process

  • Will come with $300 cost increase

    Design Validation

  • Cooling passed.

  • FEA and fatigue analysis in progress.

  • Defrost testing planned for early October

  • 6000 mile durability to begin mid-September at Bosch Proving Grounds.

00000-00-Thomas Built Buses Standard Template.ppt


Questions

Questions?

Thomas Built Buses Dealer Sales Meeting 2012


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