Delivering a cleaner vehicle: FedEx teams with Eaton, Environmental Defense on hybrid truck program - powertrain components

Diesel Progress North American Edition, Nov, 2003 by Amanda Freiberg

FedEx Express, one of five business units of FedEx. Corp., in conjunction with Environmental Defense and Eaton Corp., has begun operating a low-emissions hybrid electric-powered delivery vehicle that could become a standard mediumduty delivery truck for the FedEx fleet.

An OptiFleet decal on the sides and rear of the new FedEx Express E700 delivery track differentiates it from the standard FedEx Express W700 delivery vehicle, but what truly sets it apart is the hybrid electric powertrain designed to improve environmental performance and reduce fuel consumption while eliminating the need for high electrical-demand infrastructure costs.

The E700 vehicle is a modified version of the standard W700 vehicle which incorporates a Cummins engine and Allison automatic transmission as part of a medium duty, Freightliner Custom Chassis MT-45. The hybrid E700 configuration is equipped with Eaton's Hybrid Drive Unit, which incorporates an automatic clutch, Eaton AutoShift transmission and an electric traction motor to drive the vehicle.

"The motor is a motor/generator," explained Don Alles, Roadranger marketing services manager. "As the power is coming through the back of the drivetrain in reverse, during a deceleration, it is being taken from the drivetrain into the generator and pushed back into the batteries. During an acceleration phase, energy is pulled from the batteries into the motor/generator and used to provide power, in addition to diesel power, to the drivetrain."

The Hybrid Drive Unit in the FedEx Express E700 prototype is coupled with a 4.3 L four-cylinder DaimlerCbrysler OM904 diesel engine rated 170 hp at 2300 rpm with 420 lb.ft, of torque at 1600 rpm. An Englehard particulate matter trap is also included to further reduce emissions. The FedEx OptiFleet E700 hybrid electric vehicle is expected to decrease particulate emissions by 90 percent, reduce smog-causing emissions by 75 percent and increase fuel efficiency by 50 percent.

"Working together with Environmental Defense, FedEx has developed a truck that will deliver cleaner and healthier air, reduce oil dependency and reduce climate change impacts," said Fred Krupp, president of Environemtal Defense, a national nonprofit environmental organization that approached FedEx about three years ago with the idea to transform the FedEx fleet to develop a hybrid electric prototype.

Hitachi lithium-ion batteries (340 Vd.c. and 2.5 kWh) capture and store energy during the regenerative braking phase of the vehicle's operation, providing a source of stored electric power for subsequent accelerations. Battery charging is also provided by the hybrid electric powertrain and no electrical infrastructure such as a power cord or electrical outlet is needed.

In the next few months, FedEx Express hopes to have 20 preproduction vehicles--with a gross vehicle weight of approximately 16,000 lb. and a cargo capacity of about 670 cu.ft.--operating in four yet-to-be-named states, Rollout will occur over several months continuing into spring of 2004.

As the vehicles succeed in meeting project goals, FedEx OptiFleet E700 hybrid electric trucks will be placed in the company's pick-up and delivery fleet as early as next fall. FedEx Express would purchase hybrid electric vehicles on the company's normal purchasing schedule for routes in the United States and Canada, where medium-sized delivery trucks are used. With a ground fleet of about 70,000 motorized vehicles for express, ground, freight and delivery service, this program has the potential to replace the company's 30,000 medium-duty trucks over the course of 10 years, according to FedEx Corp.

Eaton was one of three companies selected from an original field of 20 to submit a prototype design for the FedEx project. "Eaton is pleased to make this innovative, environmentally advanced technology available to FedEx Express and Environmental Defense for this groundbreaking project," said Jim Sweetnam, senior vice president and group executive for Eaton Corp.'s Truck business. "We are proud of the achievements to date and we look forward to working with our colleagues to prove out the economic and environmental benefits of this technology."