Best ebus Climate. Entelligence makes the distance. Bus Competence for. Spheros Products for Best ebus Climate

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1 you Bus Competence for Spheros Products for Best ebus Climate Entelligence makes the distance A newly-developed control software interlinks and controls the Spheros components and increases mileage performance. Depending on ambient conditions (primarily temperature), battery charge status and geographical position the control system always selects the component with maximum efficiency. Best ebus Climate

2 Editorial Dear Readers, E-mobility and the electrification of auxiliary equipment pose one of the most exciting challenges of our time. Although many problems have yet to be solved, we know that electrobuses will help to shape the image of the modern metropolises of tomorrow. The principle is simple yet diverse: they produce less greenhouse gases, pollutants and noise and the bottom line is a better quality of life. We are convinced that the future, particularly of public transport, lies in electromobility. But we cannot ignore the discussion about the limited supply of useable waste heat available for heating hybrid and electric buses, and the low energy density of today s traction batteries. We may talk about electric booster heaters for bringing the temperature in the passenger compartment up to a comfortable level without causing emissions, but we are unable to fully dispense with fossil fuels. We have as yet to find a substitute that offers similar advantages and a comparable mode of action. It s something like the Stone Age versus the future, the invention of fire versus new energy resources which perhaps still have to be discovered. For us as bus climate specialists there is no single optimum climate control concept. The key lies in a holistic approach the interplay of vehicle concepts, ambient situations and air conditioning components that have been thought through, right down to the last detail. Our assignment is to optimally use the energy available in the bus and, in addition, exploit all possibilities of energy recovery. To achieve this we must add Intelligence to the E. The latter comprises an innovative higher-level control system, consistent lightweight construction of air conditioning components and advanced power electronics. Entelligence helps to economise, i.e. by reducing energy consumption with a clever climate control strategy and extending the range of all bus systems. Dr. Robert Basile Director Engineering HVAC Products & Systems Entelligence makes the distance Due to the low energy density of today s traction batteries and the limited supply of useable waste heat in hybrid and electrobuses, the energy supply to the vehicle s air conditioning continues to present a key challenge. Depending on the required power requirements of the respective HVAC components and ambient temperatures, a reduction of more than 50% in range must be expected. Compensating for this energy deficit calls for innovative air conditioning and heating solutions which make best use of the limited energy resources. This results in a sustained improvement in efficiency, an increase in the available range and last but not least the more ecological and economical operation of buses. The main prerequisite is the use of highly innovative climate control components (air conditioning systems, heat pumps and heaters) which satisfy the most stringent requirements for energy efficiency and lightweight construction. If we also consider the specific requirements for hybrid or electrobuses, it is possible to develop heating and cooling strategies which can be operated with a high level of efficiency in the overall system by means of superordinate, highly intelligent control technology. Holistic air conditioning at the highest level of technology That s what Spheros Entelligence stands for: a holistic approach to the ecological and economical air conditioning of hybrid and electrobuses at the highest level. Different air conditioning components are interlinked and activated for the first time by means of a newly-developed control software. Depending on the ambient conditions (primarily temperature), battery level and geographic position, the control system always selects the Spheros component offering maximum efficiency. Behind this name is an intelligent air conditioning strategy for buses. The energy requirement for the respective air conditioning task is estimated in advance and the components selected with the aid of an optimization process. Accordingly, the most efficient component for the respective task can be selected from the available air conditioning components (e.g. fossil or electrically powered heater, heat pump) to suit the current heating power requirement, existing restrictions (driving in a zero-emission zone) or remaining electrical sources (traction battery charging status, SOC). If required, a number of different heat sources can be operated parallel in boost mode. Communication with Spheros Entelligence is mapped via the Spheros Body Interface (SBI). SBI stands for an evolutionary Human Machine Interface (HMI) for buses and is the first interface for analytical values and feedback to the user. In summary, Spheros Entelligence stands for innovative HVAC solutions which ensure that the best use is made of existing energy resources, thereby significantly increasing the range of hybrid and electrobuses according to the motto Entelligence makes the distance.

3 Our heroes of the Entelligence bus climate We need heroes, even if they are only special HVAC components; but they are indispensable for turning bus air conditioning into a best-ebus climate. Systems that are specially tailored to the demands placed on electromobility public transport and we have them! Battery cooling Battery cooling Anyone who reflects on electromobility now and in the future should place a special focus on the core element of these drives: the battery. In order to optimally harness the power before and during operation, it must be kept within a narrow temperature window. For this purpose we developed the ECooler, designed to relieve the battery from the heat generated during the charging and discharging process. If needed, it can also warm up the battery, because the ECooler also functions as a heater. Air conditioning E-Cooler PTC Booster heater REVO-E Compact unit Air conditioning The REVO-E with its elegantly packed compressor on the roof is our completely new concept for hybrid, electric and trolley buses. It offers warmth-giving reverse circulation and thanks to its hermetically sealed refrigerant circuit it is virtually maintenance-free. Heater Pump Controller Frontbox Alu-Frontbox Frontbox In view of today s demands on intelligent bus air conditioning, a familiar component has acquired a new role: it must think in advance! Whether heating or cooling, it must support the other components and control the climate in the driver s section independently of the passenger compartment. PTC booster heater PTC booster heater The new high-voltage PTC heaters complement our heating systems. They are intended for use whenever the air outlet temperature must be increased in heat pump operation, de-icing procedures are in progress or there is simply an additional need for heating. In operation the PTC heaters can be infinitely adjusted by means of an electronic control unit developed by Spheros. Thermo H Heaters Our Thermo H hybrid heater combines the benefits of both forms of energy (electric and diesel) in one appliance. Before the start of the journey the vehicle can be pre-heated without emissions and the booster mode activated at low outside temperatures while in motion to avoid creating an unnecessary burden on the traction battery. The core component here is the heat exchanger, on each side of which an E-control actuator and burner head are mounted. Citysphere Compact units Our compact Citysphere unit for urban, mini- and midibuses with the wind chill effect developed by us never fails to create a pleasant temperature. Maintenance costs are eliminated and service expenses are extremely low. SPump Pumps In the course of development of innovative HVAC components, several years ago Spheros decided to produce the required pumps in-house. A Spheros pump with a watertight EC motor (IP 68 tested) is now available for the first time brushless and magnetically coupled, that goes without saying! The integral control unit can be used for additional functions which enable completely new mounting positions and fields of application, e.g. cooling of hybrid components. Spheros Body Interface (SBI) Controller The solutions to modern electromobility lie in the intelligent interconnection of HVAC components in the bus. In the modular Spheros Body Interface Concept (SBI) the key element is an ergonomically designed and self-explanatory controller. Display elements are already existing displays or the Spheros 4.3 display. Technology for your bus, as we know it from luxury cars!

4 The film that says more than a thousand words It s a world premiere, maybe even more than that. It is possibly the first film to be dedicated to the theme of innovative HVAC solutions for electromobility in public transport. It shows an E-bus journey through an imaginary city in four seasons (winter spring summer autumn winter) and in the course of a day (morning, midday, afternoon, evening). A film explains the Entelligence see for yourself: World Bus Demand by Fuel Type The film features fine pictures, attractive illustrations and an appealing design to cleverly explain complex concepts such as air conditioning solutions in public transport or load-synchronous thermal management. It s early morning in winter, a bus is still standing at the overnight depot and its systems are preparing for operation. The different conditions inside and outside the bus are displayed in an easily understandable data graphic with the aid of a head-up presentation. Now the journey begins, the bus leaves the depot and travels through a city at various times of the day, accompanied by changing seasons. The data graphic provides information on the varying conditions, for example, outside temperature or the charge status We are not the only ones who see the future in electromobility. 14, (thousand units) of the batteries. It becomes clear that the demands on electromobility and in particular on the innovative HVAC solutions likewise change according to the various ambient conditions. We quickly recognise that driving on a winter morning places quite different demands on the energy flow in an E-bus than an afternoon journey in autumn. But see for yourself, at or on the Spheros youtube channel. Diesel Gasoline CNG / LNG Hybrid / Electric Source: The Freedonia Group, Inc. All-electric REVO-E rooftop air conditioner with heat pump and Citysphere S form a single unit on the hybrid bus. Extensively tried and tested How can the energy balance in the hybrid bus be improved, thereby conserving resources and increasing the range? Answers to this are delivered by the Spheros Entelligence concept not only in theory, but also in two ongoing pilot projects: in cooperation with E-bus manufacturer Bozankaya and with Dresdner Verkehrsbetriebe (Dresden Transport). In both cases a special all-electrically powered air conditioning system which operates according to the heat pump principle was implemented. The idea is to use the system primarily for heating by extracting energy from the ambient air in the transitional periods of spring and autumn, as well as in winter. This enables the passenger compartment to be effectively air conditioned at moderate outside temperatures, thereby saving energy. A booster heater is then only necessary at extremely low temperatures. In summer the reverse effect is used for interior cooling. Efficient actuation of air conditioning components and the use of the heat pump save electricity. The diesel motor must be started less frequently to recharge the battery, which in turn reduces CO2 emissions. There is no perceptible difference in the comfort level in the passenger compartment. For research purposes within the scope of the project Pilot Route 64 Efficient Electromobility in Dresden a city bus belonging to Dresden Transport was fitted with two REVO-E type air conditioning units with heat pump function, Citysphere S driver s section air conditioning and two diesel heaters (Thermo 230 and Thermo 350 ). The REVO-E base unit with its highly efficient individual components and intelligent control concept was introduced to the market in 2013 and has proven itself many times over in traffic. The unit s cooling capacity is 26 kw, the heating output 14 kw. Specially developed component connection also enables the air conditioning unit to be used as a heat pump (heating) at low outside temperatures. For validation trials the vehicle was equipped with numerous sensors, with the aid of which all necessary data such as temperature, pressure, flow, voltage and brightness was recorded. In this project scientists from the TU Dresden are aiming to develop specific measures for boosting the efficiency of buses in scheduled operation. With Spheros Entelligence in our opinion currently the most efficient air conditioning system for buses the first validation trials with an electrobus built by Bozankaya were conducted with very successful results. Here again, all necessary data such as temperature, pressure, flow, voltage, SOC, etc. was recorded by numerous sensors in the vehicle. In addition, the respective position of the bus was monitored by GPS system. Sileo E-bus from Bozankaya. On the basis of the acquired data, the most efficient climate control strategy can be determined in advance for the respective application. The expectations of our experts have not only been confirmed by the first measurement results, they have been exceeded. Validation runs have proven the functionality of the system and underscored the enormous potential of Spheros Entelligence.

5 weight reduction electricity air conditioning R134a refrigerant e-bus e-heater filter change diesel good CO2 maintenance level R744 R1234yf battery leak fleet 100 megawatt bad CO2? downhill New headquarters with technology centre at German location In early 2015 the Spheros Group moved into its new head office at Gilching near Munich which accommodates central development, testing, prototype construction and administration on a total floor space of about 4,600 m 2. The rapid growth of the market, ongoing development of existing product lines and reorganization in new product groups and fields of technology makes increasing demands on the main Spheros location. Our new office, laboratory and test building with about 4,600 m 2 of floor space provides room not only for further growth in personnel; due to its technical facilities it also creates the prerequisites for catering for growing demands on the market as well as new development and customer projects. In 2016 a mobile bus climate testing laboratory for (double-decker) buses of up to 20 metres in length is due to be taken into operation. Parallel to climate tests, a second lane will enable test vehicles to be equipped and retrofitted or, e.g. prepared for field trials. 09/15 We reserve the right to make changes and corrections Printed in Germany Spheros GmbH 2015