Transportation Case Studies and Grants

Optimization and Certification of Hydrous-Ethanol Fumigation System

Driver Max | Conclusion

Major Milestones

Kansas City Metro - AlliedSignal Aerospace

Sept. 6, 1996: First field test of FMD’s new electronic controller [Driver-Max]. This new unit was perfected as an advanced programmable model by AlliedSignal. The first test trials of this new model were conducted on a 1989 RTS 40 ft. Kansas City Metro bus powered by a Detroit Diesel 6V-92 DDEC engine. It was decided field testing would be done at the Arrowhead Stadium in Kansas City because of its convenient location for AlliedSignal electronic engineers participation and the open uncongested parking area. Several acceleration tests were conducted to determine if the Driver-Max would respond fast enough to safely handle steep grades and driver demands. The tests confirmed that the engine power would respond to steep grades safely and smoothly and maximum engine power would reduce as programmed into the Driver-Max control for level and downhill grades. Tests were also conducted to determine the complexity of making Driver-Max program changes using a lap top computer. It was determined program changes in acceleration of mile per hour per second would only require about 1.5 minutes. The speed for reprogramming new or updated acceleration maps into the Driver-Max unit, installed on the vehicle, is a convenient feature for large fleets.

After the first day of shakedown testing it was decided by AlliedSignal personnel to drive the bus back to the AlliedSignal laboratory to test the 12- volt bus supply voltage for the amount and extent of electrical noises created by the alternator, heater fan and other bus electronic equipment. Using AlliedSignal test equipment it was determined that there was indeed a lot of unwanted noise in the bus 12 volt electrical system. AlliedSignal decided to increase Driver-Max electronic filtering to avoid any problems that could develop in the future if the Driver-Max was used on buses with extreme electrical noise. September 16-17, 1996: Test equipment consisting of an exhaust opacity monitor, fuel beakers and exhaust temperature transducer were installed on a Kansas City Metro bus. Several trial runs were made and several acceleration profiles were tested that resulted in reduced smoke and improved fuel mileage. September 24, 1996: Testing of began at 8:00 AM on a 1993 RTS metro bus number 9332. This test included runs with the alcohol fumigation system and Driver-Max. Two days were spent testing the various acceleration programs for optimum fuel savings and reduction of visible smoke. Testing concluded with an acceleration program loaded into Driver-Max that improved fuel mileage by approximately 8% and reduced opacity in excess of 25%. This would calculate to around $800 savings per year in fuel cost reduction plus substantial reduction in the bus maintenance cost. November 20, 1996: Dwayne Fosseen and Dick Evans attended a training session at AlliedSignal Technology Transfer Center. Driver-Max software was programmed into FMD’s laptop computer. AlliedSignal personnel (Mike Carr, Duane Talbott and Mike Todd) explained the simplicity of how to operate the programming feature of our new Driver-Max system. We also received from AlliedSignal the first demo Driver-Max unit, the schematics for reproduction plus Driver-Max software. December 12, 1996: Testing was performed with our first demonstration Driver-Max unit by Dwayne Fosseen and Bruce Bergeson with supervision from AlliedSignal engineers. Testing confirmed the 8% fuel savings and that the portable demonstration Driver-Max unit can be installed on the bus throttle system in less than 30 minutes. The official DMACC monitored demonstration at the Kansas City Metro is tentatively scheduled for the early part of February, 1997. This of course will be determined by weather conditions.

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Driver-Max:
December 16, 1996: Schematics have been shipped out for bids to build the Driver-Max in volume. The Driver-Max unit will be ready to begin a full-scale marketing effort in early 1997.

Grand Canyon AZ. Demonstration:
Sept. 30 - Oct. 3, 1996 Fred Harvey Transportation & National Park Service. Three days were spent setting up the demonstration bus at Grand Canyon. The official DMACC monitored test runs were taken Oct. 3, 1996. The results were outstanding and showed smoke reduction of over 69% using the FMD system. A 15% reduction in diesel fuel used was also shown. (The reason for such large improvement in fuel mileage and smoke reduction can be attributed to the 7,000 foot altitude at the Grand Canyon park. We expect less improvement in normal altitude applications.) It is expected that the Fred Harvey Transportation will sign a purchase order for a minimum of 37 units early in 1997.

Cedar Rapids Five Seasons Transportation & Parking Demonstration:
Nov. 14, 1996: DMACC monitored demonstration of a Five Seasons Transportation & Parking bus at the Hawkeye Downs Raceway track. Tests using Driver-Max and Hydrofire alcohol injection resulted with a 7.5 - 8% displacement of diesel fuel, a significant gain in mpg, and over 25% decrease in visible smoke.

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Conclusions:
The DMACC monitored demonstrations are still to be completed at Kansas City and at Minneapolis Transit. It is our current feeling both Kansas City and Minneapolis will place an order for 20 units each that will be tested on a 60-90 day trial. This test will compare the results of the Driver-Max equipped buses with 20 similar non-equipped buses. (These two fleets alone can result in Driver-Max sales of 1.6 million dollars and the cost payback for the metros is less than 18 months). The results of our fleet field testing consistently coincides with the information in the October 1995 Battelle Report for the Minneapolis Transit Authority, stating the transit saved $700-800 in fuel and $1,300 in wear and tear on the drivetrain totaling $2,100 annually. The PC laptop software programming for the new Driver-Max can be demonstrated on fleet management’s desk top and immediately installed to a Driver-Max equipped transit bus for street demonstration. This will be a very conclusive factor in proving that we do indeed have a product, a product designed by AlliedSignal Aerospace, an organization associated with the U.S. Department of Energy. Driver-Max software and the data compiled by DMACC will give FMD the credibility needed to sell this new energy saving product.

Most of this would not have been possible without the support from Iowa Energy Center and FMD is extremely appreciative of this fact.

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