Work Package 2 – Deliverable 1

Delivery of first 5 hybrid FC taxisWith approval for passenger service operation

during London Olympics(Month 12)

Work Package 2 – Deliverable 1

ID Task Name Duration Start Finish

1 Pre Build 165 days Tue 06/09/... Mon 23/04/122 Supplier selection 8 wks Tue 06/09/... Mon 31/10/113 Part Procurement 25 wks Tue 01/11/... Mon 23/04/124 Design review & Update 13 wks Thu 01/12/... Wed 29/02/125 Fuel Cell Systems 119 days Thu 01/12/... Wed 16/05/126 Fuel Cell System Build 22 wks Thu 01/12/... Wed 02/05/127 FCS Commission 41 days Tue 20/03/... Wed 16/05/128 FCS 1 0 days Tue 20/03/... Tue 20/03/129 FCS 2 0 days Tue 10/04/... Tue 10/04/12

10 FCS 3 0 days Thu 19/04/... Thu 19/04/1211 FCS4 0 days Wed 02/05... Wed 02/05/1212 FCS5 0 days Wed 16/05... Wed 16/05/1213 Vehicle Build 115 days Wed 11/01... Tue 19/06/1214 Taxi Strip 7 wks Wed 11/01... Tue 28/02/1215 Vehicle Build 23 wks Wed 11/01... Tue 19/06/1216 Vehicle Commission 43 days Wed 25/04... Mon 25/06/1217 Taxi 1 0 days Wed 25/04... Wed 25/04/1218 Taxi 2 0 days Mon 30/04... Mon 30/04/1219 Taxi 3 0 days Mon 28/05... Mon 28/05/1220 Taxi 4 0 days Mon 11/06... Mon 11/06/1221 Taxi 5 0 days Mon 25/06... Mon 25/06/12

20/0310/04

19/0402/05

16/05

25/0430/04

28/0511/06

25/06

Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug SepQtr 3, 2011 Qtr 4, 2011 Qtr 1, 2012 Qtr 2, 2012 Qtr 3, 2012

FC taxi preparation activities commenced on 6th September 2011

Work Package 2 – Deliverable 1

Fuel cell system definition (Nov 11)

•First system platform engineered (Feb 12)• Further commissioning process defined• Factory Acceptance Test Defined• Internal gateway (Mar 12)• Fuel cell systems commissioned

for vehicle installation April and May 2012

Work Package 2 – Deliverable 1Taxi preparation 2011-2012

• Lotus selected as vehicle builder (Nov 11) after RFQ, Supplier Quotations & Reviews• BOM created, lead times reviewed (Nov 11), IE to procure all items over £1000• Weekly telephone review & progress tracker• LTI base vehicles and all vehicle conversion parts at Lotus (March-April 12)• H2 fueller sited at Lotus• Lotus Gantt for build• Commissioning plan in place

Base taxi units having completed teardown at the Lotus (Norwich) facility

Work Package 2 – Deliverable 1Taxi preparation 2012

• First 2 vehicles completed April• 3rd taxi = commission 28th May• 4th taxi = commission 11th June• 5th taxi = commission 25th June• TRW brake test work 15th June

DRs Released PO Placed DRs Released PO Placed DRs Remaining PO Remaining

Driveline 0 0 18 18 0 0

Fuel Cell 0 0 59 59 0 0

HEV & Electrical 0 0 441 433 0 8

Controls 0 0 181 181 0 0

Body & Chassis 0 0 681 637 0 44

Cooling System 0 0 203 200 0 3

Total 0 0 1583 1528 0 55

This Week To-Date Remaining

Work Package 2 – Deliverable 1FC taxi – FC system configuration

ContentTwin stack Fuel Cell moduleInduction package• Filter• Compressor• Air flow sensingHeat Exchanger unitFC Coolant and Exhaust system

ChallengesNo loss of luggage capacityMinimal BIW changesMinimise chassis frame changes

FC Coolantreservoir

HEX unit

FC fuses,contactors,& ControlFuel Cell

Module

Work Package 2 – Deliverable 1FC taxi preparation – H2 storage

Tank3.7kg hydrogen capacity from Dynatek (Canada)35MPa operating pressure, package protect for70MPa tankTank – seamless aluminum, over-wrapped withcarbon fibre / KevlarOff the shelf system to minimise cost and matchcertification needs (designed to EC-98)

Work Package 2 – Deliverable 1FC taxi preparation – hybrid powertrain arrangement

Specification14kWh total energy70 kW nominal power at 5CMass 170kgDesign7 battery modules to packageNo major chassis frame changesBattery AssemblyBuilt upside down on a turnover framePlaced on an installation fixturePlace casing over assembly and install

Satellitemodules

Mainmodule

Work Package 2 – Deliverable 1FC taxi – final layout

HVManagement• Inverter

• Converters

• Battery Charger

Powertrain• Motor

• Transfer Gearbox

• Sub-frameTraction Battery• Battery Modules

• BatteryManagement

Fuel Cell System• Fuel Cell Stack

• HEX Modules

• Compressor

• Air Filter

• FCS Controller

Hydrogen Storage• Hydrogen Tank

• First Stage Regulator

• Safety Devices

Work Package 2 – Deliverable 1Taxi delivery and certification 2012

• Initial intention to certify under EuropeanCommunity Whole Vehicle Type Approval(ECWVTA) - provides for the approval of wholevehicles, in addition to vehicle systems andseparate components

• The base taxi has ECWVTA• Due to recent definitional changes, approval of

the fuel cell hybrid taxi would be treated as a‘new vehicle’ and require multiplemodifications and additional features,together with separate acceptance tests, thatwere not available within the time available

• Individual Vehicle Approval, a UK nationalscheme, was the certification format followedand is based on inspection of the vehicle bythe UK Vehicle Certification Authority - VCA

Work Package 2 – Deliverable 1

Taxi delivery and certification 2012

• Certification from VCA achieved over the period 18-06-12 to 26-06-12• Public Carriage Office – taxis acceptance as a London Hackney Carriage – 25-06-12• Safety Case sign off 23-07-12• Shakedown of taxis at Bruntingthorpe test track facility completed 24-07-12• Registration of 5 taxis with DVLA complete 25-07-12• Tax discs issued and number plates fitted

HY02 TAX to HY06 TAX series licenceplates authorised by DVLA

Taxi road licence tax discissued by DVLA

London Hackney Carriage plates authorised andissued by London Public Carriage Office

Work Package 2 – Deliverable 1FC taxi road testing pre-Olympics

Work Package 2 – Deliverable 1Taxi operations

• Taxis transferred to London 25-07-12 ready for Olympics period operations• Taxis based at LTI Mann & Overton London• IE Service Engineers on site with dedicated IE office• Dedicated 4 post ramp.• On site stores for taxi components

LTI’s Brewery Road taxi salesand service site

Dedicated fuel cell taxi area on theupper floor of Brewery Road site

Work Package 2 – Deliverable 1

Taxi Operation – Olympics period

• Taxi used for VIP journeys during theOlympic & Paralympic Games

• Total mileage = 2,500 miles / 4,000kmsin heavy traffic conditions

• 81 journeys during Olympics & 30 duringParalympics

• VIP passengers carried for the LondonMayors Office and included VIPs fromBusiness, Media, Industry, Politics &Show-business

• All scheduled journeys were pre-arranged with the GLA

• IE personnel supporting VIP journeyarrangements (and to gain feedback andresponses to the taxi for HyTECpurposes)

Arnold Shwarzenegger - a VIP taxipassenger for the Olympics

Work Package 2 – Deliverable 1

Work Package 2 – Deliverable 1Summary and Conclusions

• Fuel cell taxi preparation work commenced 06-09-11• Fuel cell system work commenced 1-12-11, followed by vehicle preparation as of 11-

01-12 with the first fuel cell taxi completed 25-04-12 and final taxi on 25-6-12• Certification from VCA achieved during 18-06-12 to 26-06-12• Public Carriage Office – taxis acceptance as a London Hackney Carriage – 25-06-12

for use to carry non fare paying passengers• Registration of 5 taxis complete 25-07-12• Tax discs issued and number plates fitted• Fleet of 5 taxis transferred to London 25-07-12 ready for Olympics period operations• The taxis ran 4,000kms over 81 VIP passenger journeys during the Olympics & 30

VIP passenger journeys during the Paralympics with re-fuelling at the Heathrow site• All taxi drivers and passengers impressed, particularly by the ‘ease, smoothness and

comfort of the ride’ delivered by the fuel cell hybrid powertrain• The taxis delivered against technology, certification performance, passenger and

driver expectations• Mileage accumulation subsequently affected by the VLA mandated removal of taxis

from road operation (steering column) and LTI being put into Administration thensold