emp cooling systems solutions ppt 04 10 11

EMP PROPRIETARY INFORMATION

EMP Thermal System Capabilities Thermal System Development and Example Proposal

Prepared By: Mark BaderApril 28, 2011

April 2011 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



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



Historic Perspective: Vehicle Thermal System Programs

OEM Production Electric Cooling System for Transit 2008

20101998



EMP CapabilitiesAnalysis 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



Dedicated Product Launch with 31+ Engineers/Techs

Design & Analysis Prototyping

Performance Testing Validation & Reliability

Vehicle Installs & Testing



EMP COMPONENTS



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



EMP Components: F-11 Fan and controller FEATURES: • Fully controllable or single speed

• High Efficiency



• 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



EMP Components: FiL-11 Fan FEATURES: • Fully controllable or single speed





• 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



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)


• Closed-loop control on 2 different temperature sensors or 1 temp and 1 pressure

• Configurable through CAN or EMP-LINK™ With Service Tool


• 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



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)

Per

cen

t o

f O

per

atio

n

Hours Per Bus

0

500

1000

1500

2000

2500

3000

8512 8514 8515 8516 8517 8518 8519 8520

Bus Number

Ho

urs



EMP Components: Micro Thermal System controller (μTMC)

FEATURES: • Controls slave controllers via; PWM, or EMP-LinkTM

• Capable of controlling as many as 10 components


• Closed-loop control on 2 different temperature sensors or 1 temp and 1 pressure

• Configurable through EMP-LINK™ With Service Tool


• 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



EMP Components: P450 AlternatorFEATURES: • 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)



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.



EMP Components: OP35/45 Oil Pump

FEATURES: • Fully controllable or single speed

• High Efficiency




• Long Life

• Compact

• Customized End Cover For Connections (Flange Mount Shown)

• Customer Specified Lead Lengths

• CAN Capable


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



OP35 Electric Oil Pump: BAE Hybrid Drive



Thermal System Examples



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:



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:



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:



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:



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:



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:



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:



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:

emp cooling systems solutions ppt 04 10 11

Technology

thermal systems

test facility escanaba

c storage range selectable

c glass

c operating range ignition

validation capabilities

amps continuous

precision machining