Eaton Corporation, a diversified industrial product manufacturer, announced a number of improvements to improve the fuel economy, power and return on investment of its commercial vehicle hybrid systems. These improvements include the use of new high-capacity batteries, new single-phase 115 volt AC auxiliary generators (AGP), high-performance clutches that extend torque to 1165 Nm, and new regenerative batteries for the aftermarket. The core of the new high-capacity lithium battery is the latest battery cell structure design. The new design will once again increase the fuel economy of the Eaton hybrid system by 5-10%, while also improving the dynamic performance of the vehicle. In addition, the new battery more than doubled the operating capacity of the engine when it was off and extended the life of the battery.
Eaton plans to introduce a new single-phase 5-kilowatt auxiliary generator (APG) this fall. The APG is free to convert the high voltage DC power of the battery to 115 volts AC, which can power a large number of tools in the work site. The new APG is more compact, 11 kg lighter than the original product, effectively increasing the flexibility of the installation. It also provides a soft-start function that comfortably handles the high-load demands that require a rapid increase in power. The new APG is a system completely independent of high-voltage batteries, eliminating the need for using other independent transformer products, not only further reducing weight, but also saving costs.
Kevin Beaty, Product Strategy, Operations and Strategic Purchasing Manager for Eaton Hybrid Power Systems, said: "Not only will the fleet recognize a significant increase in fuel savings and CO2 emissions reduction, but drivers will also appreciate that the updated hybrid system will allow faster vehicle acceleration. The new battery has been designed with simplified internal components in mind, making it easier to maintain."
City transporters and beverage trucks equipped with high-performance batteries were introduced in the third quarter of 2012. Devices incorporating new high-performance batteries and APGs will be used in utility facilities in the fourth quarter of this year.
In addition to the new battery and APG, Eaton also introduced a higher-performance clutch that can be used to load engines with up to 300 HP and 165 Nm. The increase in torque greatly increases the dynamic performance of heavy-duty vehicles, including selective traction axis configurations. Eaton also plans to launch a new battery remanufacturing project in July this year, which will provide the fleet with more affordable battery options.
Beaty said: “Now, fleets need only pay a fraction of the cost of new services, which can significantly extend the useful life of their hybrid systems. Our goal is to build sustainable fleets for those who want to build sustainable vehicles at the right cost. Hybrid users provide the highest value."
The Eaton hybrid system uses a parallel hybrid oil-electric/gas-electric hybrid structure and integrates a motor/generator between the automatic clutch and the transmission. The system is mainly to recover the energy of braking and store it in the battery. The combination of motor torque and engine torque will be used to improve fuel economy and vehicle power performance, as well as enable engine idle start and stop functions.
By the end of May this year, the Eaton hybrid system has accumulated more than 480 million kilometers of operating mileage worldwide, reduced fuel consumption by 30 million liters, and reduced CO2 emissions by more than 80,000 tons. More than 6,000 Eaton hybrid systems serve city buses, school buses, package transportation, beverage transportation, refrigeration, waste removal, municipal and other commercial vehicles in countries around the world.
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