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EMP Thermal System Capabilities Summary
1.
EMP PROPRIETARY INFORMATION EMP
Thermal System Capabilities Thermal System Development and Example Proposal Prepared By: Mark Bader April 28, 2011
2.
April 2011Page 2
EMP PROPRIETARY INFORMATION Copyright © 2009 EMP | 2701 N 30th St. Escanaba, MI 49829 (906)-789-7497 | www.emp-corp.com Company Overview • Established 1981 • Current Employment ~500 • Facilities: • Plant I & II (Escanaba, MI): Precision Machining • Plant III (Greenfield, IN): Assembly • Product Launch Facility (Escanaba, MI): Dev. & Assy. • Test Facility (Escanaba, MI) • Europe Sales Manager & Distributors • TS 16949 and ISO9001:2008 Certified • Current OEM Customers: • Caterpillar, International, Sauer Danfoss, John Deere, Cummins, DDC/Freightliner, Volvo/Mack, Eaton, Borg Warner, NewFlyer, NABI, Gillig, Orion, Misc. • Services: • Thermal Systems, Electrified Components, Precision Machining, Complex Assembly, Development from Concept to Production • Key Awards: • 2001, 03, 04 Design News Award for Electric Pump, Advanced Filter, Electric Thermostat/Valve • 2001 Michigan Manufacturer of the Year, 2005 R&D Excellence in Business Award
3.
April 2011Page 3
EMP PROPRIETARY INFORMATION Copyright © 2009 EMP | 2701 N 30th St. Escanaba, MI 49829 (906)-789-7497 | www.emp-corp.com EMP Manufacturing and Quality Quality Support • Precision Machining – Low & High Volume • State-of-the-Art VMC, HMC & Lathes • 3, 4 and 5 Axis Machining • Robotics for High Volume Production • Dedicated Process Development Area • Complex Assembly – Low & High Volume • State-of-the-art Pokeoke systems • Robotics for High Volume • Quality System • QS9000 Certified since 1998, TS in 2004 • Computer Based SPC • CMM’s with CNC control • Metallurgical Lab
4.
April 2011Page 4
EMP PROPRIETARY INFORMATION Copyright © 2009 EMP | 2701 N 30th St. Escanaba, MI 49829 (906)-789-7497 | www.emp-corp.com Historic Perspective: Vehicle Thermal System Programs OEM Production Electric Cooling System for Transit 2008 20101998
5.
April 2011Page 5
EMP PROPRIETARY INFORMATION Copyright © 2009 EMP | 2701 N 30th St. Escanaba, MI 49829 (906)-789-7497 | www.emp-corp.com EMP Capabilities Analysis Capabilities: Validation Capabilities: • Mechanical/Hydraulic/Electric • Vibration • Primary and Secondary Systems • Thermal Shock • Thermal System Analysis • Pressure Cycling •Computation Fluid Dynamics (CFD) • Corrosion • Pro-E CAD • Software Validation • Thermal System Software Production Capabilities: Prototype Capabilities: • ISO Certified • CNC Machining • Assembly • Sheet Metal Fabrication • CNC Machining • Welding • Inspection • Wiring harness Fabrication Proven Components • Rapid Prototyping (SLS) • Fans Testing Capabilities • Thermal System Controllers • Heat Exchanger Performance • Heat Exchangers • Vehicle Fit-up • Wiring Harnesses • Vehicle Testing and System Calibration • Temp Sensors
6.
April 2011Page 6
EMP PROPRIETARY INFORMATION Copyright © 2009 EMP | 2701 N 30th St. Escanaba, MI 49829 (906)-789-7497 | www.emp-corp.com Dedicated Product Launch with 31+ Engineers/Techs Design & Analysis Prototyping Performance Testing Validation & Reliability Vehicle Installs & Testing
7.
April 2011Page 7
EMP PROPRIETARY INFORMATION Copyright © 2009 EMP | 2701 N 30th St. Escanaba, MI 49829 (906)-789-7497 | www.emp-corp.com EMP COMPONENTS
8.
April 2011Page 8
EMP PROPRIETARY INFORMATION Copyright © 2009 EMP | 2701 N 30th St. Escanaba, MI 49829 (906)-789-7497 | www.emp-corp.com EMP Components: WP29 Water Pump FEATURES: • Fully controllable or single speed • High Efficiency • 12 or 24 Volt Models • Brushless, Sensorless Motor • Corrosion and Water Resistant • Long Life • Compact • Ease of Integration • Quiet • CAN Capable • E-Mark Certified Controller • Current Limit Protection Specifications: • Over Temp Protection • Transients/Short Circuit/Reverse Battery Protection Pump • Ø1” Inlet/Outlet connection • Ignition Enable Specifications: • -40 to 95° C Operating Range • CAN I/O • -50 to 125° C Storage Range • Selectable CAN Address/Thermistor • All Aluminum Outer Housing • 25 Amps Continuous @ 12 V, 95° C • 6.5 Lbs • 20 Amps Continuous @ 24 V, 95° C • Stainless Steel Impeller • 9 – 32 VDC Range • DTP06-4S-E003 Power Connector • DTM06-6S-E007 CAN Connector
9.
April 2011Page 9
EMP PROPRIETARY INFORMATION Copyright © 2009 EMP | 2701 N 30th St. Escanaba, MI 49829 (906)-789-7497 | www.emp-corp.com EMP Components: F-11 Fan and controller FEATURES: • Fully controllable or single speed • High Efficiency • 12 or 24 Volt Models • Brushless, Sensorless Motor • Sealed & Fully Submersible • Long Life • Compact • Pusher or Puller Configurations • Customer Specified Lead Lengths • CAN Capable • Locked Rotor Protection • Finger Guard Option Available Controller • Current Limit Protection Fan Specifications: • Over Temp Protection Specifications: • Ø11” Blade • Transients/Short Circuit/Reverse Battery Protection • -40 to 95° C Operating Range • Ignition Enable • -50 to 125° C Storage Range • CAN I/O • All Aluminum Outer Housings • Selectable CAN Address/Thermistor • 9.0 Lbs (including controller) • 25 Amps Continuous @ 12 V, 95° C • Glass Filled Plastic Blade • 20 Amps Continuous @ 24 V, 95° C • 20,000 Hour Life • 9 – 32 VDC Range • Fully Reversible • DTP06-4S-E003 Power Connector • IP69k Rated • DTM06-6S-E007 CAN Connector
10.
April 2011Page 10
EMP PROPRIETARY INFORMATION Copyright © 2009 EMP | 2701 N 30th St. Escanaba, MI 49829 (906)-789-7497 | www.emp-corp.com EMP Components: FiL-11 Fan FEATURES: • Fully controllable or single speed • Locked Rotor Protection • Sealed & Fully Submersible • 12 or 24 Volt Models • Brushless, Sensorless Motor • Programmable Reversal • Temperature Switch Input • Closed Loop Temperature Control* • Pusher or Puller Configurations • Integrated Controller • Motor and Controller Diagnostics • Finger Guard Option Available • E-Mark Certified Controller • Current Limit Protection Fan Specifications: • Over Temp Protection Specifications: • Ø11” Blade • Transients/Short Circuit/Reverse Battery Protection • -40 to 95° C Operating Range • Ignition Enable • -50 to 125° C Storage Range • EMP-Link™ I/O • All Aluminum Outer Housings • Selectable EMP-Link™ Address • 8.5 Lbs (including controller) • PWM Input with Tach Output • Glass Filled Plastic Blade • 25 Amps Continuous @ 12 V, 95° C • 20,000 Hour Life • 20 Amps Continuous @ 24 V, 95° C • IP69k Rated • 9 – 32 VDC Range * When used with uTMC or TMC • Delphi Mixed MP 480/150 Connector
11.
April 2011Page 11
EMP PROPRIETARY INFORMATION Copyright © 2009 EMP | 2701 N 30th St. Escanaba, MI 49829 (906)-789-7497 | www.emp-corp.com EMP Components: Thermal System Controller (TMC) FEATURES: • Controls slave controllers via; CAN, PWM, or EMP-LinkTM • Capable of controlling as many as 30 components (20 E- Link, 10 CAN) • 12 or 24 Volt Models • Closed-loop control on 2 different temperature sensors or 1 temp and 1 pressure • Configurable through CAN or EMP-LINK™ With Service Tool • Transients/Short Circuit/Reverse Battery Protection • Diagnostic Capable – Fault History Data Storage and Reporting: • 63 Histogram parameters • 16 Events • 16 Time Activities • 8 Accumulators Specifications: • 9 – 32 VDC Range • IP67 Rated • -40 to 95° C Operating Range • 512k Flash, 32k RAM, 32k NVM Processor • -50 to 125° C Storage Range • DTM06-12SA-E007 Connector • Duetsch Box (nylon) • 300 μA Quiescent Current Draw • 7.8 oz. • 250 mA Current Draw
12.
April 2011Page 12
EMP PROPRIETARY INFORMATION Copyright © 2009 EMP | 2701 N 30th St. Escanaba, MI 49829 (906)-789-7497 | www.emp-corp.com EMP Components: Thermal System controller (TMC) • Data Storage and Reporting • 63 Histogram Channels: % time at each increment – Example: fan time at each speed • 16 Events: counts of an event – Example: fan turning on or off • 16 Time Activities: total time for a parameter – Example: how long a fan is on • 8 Accumulators: total of a parameter – Example: total fuel used during life of vehicle Engine Coolant Temp Distribution 0.00% 2.00% 4.00% 6.00% 8.00% 10.00% 12.00% 14.00% 16.00% 18.00% 20.00% 75 77 79 81 83 85 87 89 91 93 95 97 99 101 103 Coolant Temp (C) PercentofOperation Hours Per Bus 0 500 1000 1500 2000 2500 3000 8512 8514 8515 8516 8517 8518 8519 8520 Bus Number Hours
13.
April 2011Page 13
EMP PROPRIETARY INFORMATION Copyright © 2009 EMP | 2701 N 30th St. Escanaba, MI 49829 (906)-789-7497 | www.emp-corp.com EMP Components: Micro Thermal System controller (μTMC) FEATURES: • Controls slave controllers via; PWM, or EMP- LinkTM • Capable of controlling as many as 10 components • 12 or 24 Volt Models • Closed-loop control on 2 different temperature sensors or 1 temp and 1 pressure • Configurable through EMP-LINK™ With Service Tool • Transients/Short Circuit/Reverse Battery Protection • Diagnostic Capable – Fault History Specifications: • 9 – 32 VDC Range • -40 to 95° C Operating Range • -50 to 125° C Storage Range • 62k Flash, 2k RAM • Duetsch Box (nylon) • DTM06-12SA-E007 Connector • 7.8 oz. • 300 μA Quiescent Current Draw • IP67 Rated • 250 mA Current Draw
14.
April 2011Page 14
EMP PROPRIETARY INFORMATION Copyright © 2009 EMP | 2701 N 30th St. Escanaba, MI 49829 (906)-789-7497 | www.emp-corp.com EMP Components: P450 Alternator FEATURES: • Complete Brushless Design • Stationary Field Windings • Aluminum Components are either A356T6 (permanent mold) or 360 (die-cast) - Low Cu Content (corrosion resistant) - Good Strength - Good Thermal Conductivity • Oversized full complement sealed ball bearings • Unique Lamination feature allows improved cooling • Designed for severe applications • Intake air management system requires approval Specifications: • Operational Speed: 1800 to 6500 RPM • Amps: 280A @ idle, 450A @ 5000 RPM •Storage Temperature: -40 to 125C • Turn On Speed: 1250 RPM •Weight: 100 lbs • Rotation: CW or CCW •Dimension: 10.25”D x 16.00” L •Ambient Temperature: -40 to 95C •Mount: Pad •Intake Temperature: -40 to 80C •Negative Ground (not isolated)
15.
April 2011Page 15
EMP PROPRIETARY INFORMATION Copyright © 2009 EMP | 2701 N 30th St. Escanaba, MI 49829 (906)-789-7497 | www.emp-corp.com EMP P450: 12kW Remote Power Pack (RPP) Drive shaft from Vehicle PTO drive Front of Vehicle • Ideal solution for applications that require large electrical power but no room for additional/larger alternator under the hood. • Mounting – Bolts to the vehicle’s frame rail behind PTO drive Assembly or where applicable • Simple and Effective – Drive Power provided by vehicle’s Power Take Off (PTO). • Reliable – Will provide several years of service without maintenance • Corrosion Resistant – Will survive harsh road environments; Magnesium Chloride, Road Salt, ICE-Be-Gone, etc.
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EMP PROPRIETARY INFORMATION Copyright © 2009 EMP | 2701 N 30th St. Escanaba, MI 49829 (906)-789-7497 | www.emp-corp.com EMP Components: OP35/45 Oil Pump FEATURES: • Fully controllable or single speed • High Efficiency • 12 or 24 Volt Models • Brushless, Sensorless Motor • Sealed & Fully Submersible • Long Life • Compact • Customized End Cover For Connections (Flange Mount Shown) • Customer Specified Lead Lengths • CAN Capable • Locked Rotor Protection Controller • Current Limit Protection Specifications: • Over Temp Protection Pump • Gerotor Pumping Technology • Transients/Short Circuit/Reverse Battery Protection Specifications: • 3.5/4.5 Gal/min @ 80 psi • Ignition Enable • -20 to 100° C Operating Range • CAN I/O • -50 to 125° C Storage Range • Selectable CAN Address/Thermistor • All Cast Aluminum Outer Housings • 25 Amps Continuous @ 12 V, 95° C • 6.5 Lbs • 20 Amps Continuous @ 24 V, 95° C • 6.8” x 4.6” x 3.8” • 9 – 32 VDC Range • TBD Hour Life • DTP06-4S-E003 Power Connector • Fluid Type (ATF to SAE15W-40) • DTM06-6S-E007 CAN Connector
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EMP PROPRIETARY INFORMATION Copyright © 2009 EMP | 2701 N 30th St. Escanaba, MI 49829 (906)-789-7497 | www.emp-corp.com OP35 Electric Oil Pump: BAE Hybrid Drive
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EMP PROPRIETARY INFORMATION Copyright © 2009 EMP | 2701 N 30th St. Escanaba, MI 49829 (906)-789-7497 | www.emp-corp.com Thermal System Examples
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EMP PROPRIETARY INFORMATION Copyright © 2009 EMP | 2701 N 30th St. Escanaba, MI 49829 (906)-789-7497 | www.emp-corp.com Mini-Hybrid for Transit Bus Application: Replaces standard hydraulic or mechanical cooling system on Transit bus Hardware: 8 to 10 FiL-11 fans, μTMC system controller, aluminum bar/plate radiator, fabrications, air and coolant temperature sensors and system wire harness. There is a version for diesel, CNG and hybrid drives Functionality: The kit controls fan speeds based on a coolant thermistor CAC air thermistor, CAN communication with vehicle, engine and transmission (or hybrid drive) There is a built in fan reversal and a staggered fan start for improved temperature stability. Diagnostics are output using an LED mounted on the kit. There is a connector for PC service tool interface for diagnostics and calibration Benefits to Customer: Reduced noise because of variable speed, increased fuel economy from eliminating the mechanical fan, ambient temperature control of engine compartment, improved temperature control of coolant increases engine reliability, diagnostics, reduced radiator clogging because of reversal scheme. Summary:
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EMP PROPRIETARY INFORMATION Copyright © 2009 EMP | 2701 N 30th St. Escanaba, MI 49829 (906)-789-7497 | www.emp-corp.com TK3/TK4 for Stationary Industrial Applications Application: General radiator applications ranging from stationary industrial applications to vehicle primary JW cooling Hardware: 3 or 4 FiL-11 fans, μTMC system controller, aluminum bar/plate radiator, fabrications, air and coolant temperature sensors and system wire harness. There is a version w/o the radiator available for retrofit to existing coolers. Functionality: The kit controls fan speeds based on a coolant thermistor and an ambient air thermistor. There is a built in fan reversal and a staggered fan start for improved temperature stability. Diagnostics are output using an LED mounted on the kit. There is a connector for PC service tool interface for diagnostics and calibration Benefits to Customer: Reduced noise because of variable speed, increased fuel economy from eliminating the mechanical fan, ambient temperature control of engine compartment, improved temperature control of coolant increases engine reliability, diagnostics, reduced radiator clogging because of reversal scheme, lever vent radiator cap for safety, air purge safety feature removes any hazardous gases from the shack prior to maintenance Summary:
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EMP PROPRIETARY INFORMATION Copyright © 2009 EMP | 2701 N 30th St. Escanaba, MI 49829 (906)-789-7497 | www.emp-corp.com OK6 Oil Cooler for Hybrid Transit Bus Application: Electronics cooling on Allison Hybrid Transit bus application Hardware: 6 FiL-11 fans, μTMC system controller, aluminum bar/plate oil cooler, fabrications, oil temperature sensor and system wire harness Functionality: The kit controls fan speeds based on an oil thermistor. There is a staggered fan start for improved temperature stability and reduced fan cycling in cold weather. Diagnostics are output using an LED mounted on the dash of the bus. The EMP link from the μTMC is routed to the rear 9 pin connector for PC service tool interface Benefits to Customer: Reduced noise because of variable speed, staggered fan start results in reduced fan cycling and improved temperature control, diagnostic output from LED and PC tool ensures that nobody has to crawl on the roof to check functionality of the kit Summary:
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EMP PROPRIETARY INFORMATION Copyright © 2009 EMP | 2701 N 30th St. Escanaba, MI 49829 (906)-789-7497 | www.emp-corp.com Motor and Electronics Cooling for BAE Transit Bus Hybrid Drive Application: Cooling of electronics and drive system for BAE Series Hybrid Applications Hardware: 2 FiL-11 fans, WP29 water pump (with CM20 board), aluminum bar/plate heat exchanger, degas bottle, coolant temperature sensor, level sense switch and system wire harness Functionality: The kit reads in the coolant temperature via the WP29 pump. This temperature is broadcast via J1939 to the customer who then tells the pump what speed to run via J1939. The customer also controls the fan speed using PWM input and monitors the fan speed using speed feedback output. There is an active degas system contained in the kit and a float switch to tell the customer when the fluid level is low. Benefits to Customer: Precise temperature control using variable speed WP29 and FiL-11, accurate temperature measurement and reporting via J1939, high heat rejection for a small package size, degas loop simplifies filling procedure, 16 psi pressure cap ensures adequate cooling at higher elevations (possible because of fabricated degas bottle) Summary:
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EMP PROPRIETARY INFORMATION Copyright © 2009 EMP | 2701 N 30th St. Escanaba, MI 49829 (906)-789-7497 | www.emp-corp.com OK1/OK2 Oil Coolers for Transmission and Hydraulic Cooling Application: Engine, Transmission and Hydraulic Oil cooling Hardware: F-11 fan(s), aluminum bar/plate heat exchanger, fabricated shroud, coolant temperature sensor, C20/CM20 controller(s) and system wire harness Functionality: The kit reads in the oil temperature via the CM20 controller. This temperature can be broadcast via J1939. The fan speed is controlled based of the oil temperature. There is a reverse at startup and also a timed reversal to prevent clogging Benefits to Customer: Precise temperature control using variable speed fans, accurate temperature measurement and reporting via J1939, high heat rejection for a small package size, built in bypass to protect the core during cold weather, reversal routine has helped reduce downtime for heat exchanger cleaning in forestry equipment Summary:
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EMP PROPRIETARY INFORMATION Copyright © 2009 EMP | 2701 N 30th St. Escanaba, MI 49829 (906)-789-7497 | www.emp-corp.com TK1 for Electronics and Aux Engine Cooling Application: Hybrid electronics cooling, engine auxiliary cooling Hardware: F-11 fan, WP29 pump, high performance aluminum tube/fin heat exchanger, fabricated shroud, coolant temperature sensor, CM20 controller, degas bottle and system wire harness Functionality: The kit reads in the coolant temperature via the CM20 controller. The fans speed is controlled based of the coolant temperature. The WP29 is On/Off. There are some versions of the kit that use SPAL fans for on/off operation Benefits to Customer: Precise temperature control using variable speed fan, high heat rejection for a small package size, high flow in restrictive systems from WP29 pump, options for installation hardware, degas bottles, etc Summary:
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EMP PROPRIETARY INFORMATION Copyright © 2009 EMP | 2701 N 30th St. Escanaba, MI 49829 (906)-789-7497 | www.emp-corp.com Mack/Volvo Refuse Vehicle Auxiliary Cooler Application: Auxiliary JW cooling of high horsepower cab over refuse vehicles Hardware: F-11 fans, fabricated shroud, C20 controllers Functionality: The C20 controllers monitor the engine coolant temperature via J1939. The fans turn on/off based on the J1939 temperature. The 2007 application only turns this cooler on as a last resort when coolant temperature is above a certain temp. For the next generation, variable speed is being considered Benefits to Customer: The customer needed high airflow to provide the auxiliary cooling for 2007 engine. The J1939 communication made a clean install. For the next generation, variable speed is being considered to help keep the main engine fan off for noise reduction and possible slight fuel economy gains. Keeping the main engine fan off will also keep the cabs warmer in the winter because the mechanical fan sucks the heat out of the cab when it runs. The next generation may switch to FiL-11 for cost savings. Summary:
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EMP PROPRIETARY INFORMATION Copyright © 2009 EMP | 2701 N 30th St. Escanaba, MI 49829 (906)-789-7497 | www.emp-corp.com Over the Road Truck Remote AC System Application: Remote AC kit used for over the road trucks with sleeper cabs Hardware: 2 12V FiL-11 fans, 2 AC condensers, fabricated shroud, TMC controller, system wire harness Functionality: The FiL-11 fans are controlled using pressure sensors located on each condenser outlet line. The TMC takes in both pressures and determines which fan runs and the speed the fan runs. Benefits to Customer: Fuel economy is the key driver for this test. PACCAR measured 75% reduction in mechanical fan run time at idle and 23% reduction in mechanical fan run time using the Wal-Mart specific urban drive cycle. The heat rejection of the engine cooling pack was improved by offloading the AC requirements. The reduction in mechanical fan operation reduced the noise produced. The variable speed FiL-11 fans also reduced the noise produced by the APU condenser fan compared to the on/off brushed fan that was previously run full speed whenever the compressor was running. Summary:
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