1. Patch Box for Diesel Natural Gas Dual Fuel Kits
Achieving Real Fuel Cost Savings by Improving Dual Fuel Blend Algorithm and Incorporating Vehicle Network Data

2. Penn State Hybrid and Hydrogen Vehicle Research Lab
Problem Statement
Ten million Diesel trucks in existing fleets
Long expected useful life
High and rising Diesel fuel costs
Cost of natural gas about half Diesel fuel
Bolt on “dual fuel kits” add natural gas to Diesel engines
Kits simply add natural gas on top of stock Diesel fuel
Creates more power but minimal fuel savings realized
Factory emissions are effected
Need optimal control of Diesel/NG blend
11/14/2018
Penn State Hybrid and Hydrogen Vehicle Research Lab

3. Penn State Hybrid and Hydrogen Vehicle Research Lab
Solution
Diesel/NG engine tests determine best blend
Patch Box reads digital network truck data
Patch Box alters truck and kit fuel signals:
Calculates best blend to save fuel and lower emissions
Intercepts and changes gas pedal signal
Lowers signal for Diesel flow to engine
Lowers signal for gas flow through kit
Altered blend retains stock engine power curve, feel
Retrofitted Diesel truck fleets can then reduce fuel costs and utilize natural gas
11/14/2018
Penn State Hybrid and Hydrogen Vehicle Research Lab

4. Steps to Conversion 1: Engine Mapping
Dyno test engine at constant speed and load
Engine installed on an engine dynamometer
Vehicle on chassis dynamometer
Vary Diesel natural gas blend ratio
Measure emissions and efficiency points
Build a map of best operating points
Load operating map into Patch Box software
Develop algorithm using map and vehicle CAN data
Calibrate engine throttle signal to map algorithm
11/14/2018
Penn State Hybrid and Hydrogen Vehicle Research Lab

5. Steps to Conversion 2: Install Kit, Fuel System, and Patch Box
Lower
Diesel
Flow
Map and
Algorithm
Reduce
Diesel throttle
signal TPS
Throttle Signal TPS
Truck Network Data
11/14/2018
Penn State Hybrid and Hydrogen Vehicle Research Lab

6. Penn State Hybrid and Hydrogen Vehicle Research Lab
Patch Box Development
In-house electronics design
Microprocessor
Power supply
Signal input and outputs
Controller Area Network CAN channels
Market survey of commercial electronics
Compare performance, features, cost
Leverage engine data from current Ben Franklin funded Hawbaker CNG project
11/14/2018
Penn State Hybrid and Hydrogen Vehicle Research Lab

7. PATCH BOX Business Model
Products and services to be provided:
Engineering services
Non-recoverable engineering fees to add new models/years
Partner with truck manufacturers and engine test labs
Use existing engine test data where available
Patch Box electronics package
Market electronics and installation kit to large fleets
Customer installed
Provide diagnostics , service, and repair
11/14/2018
Penn State Hybrid and Hydrogen Vehicle Research Lab

8. PATCH BOX Business Model (cont.)
Annual truck fuel costs and potential savings
Typical 300 miles per day
4 mpg Diesel at $4 per gallon is $300/day
$78,214 per year
Replace 25% at $2 per gallon
12.5% savings on fuel or $9777/year
Total payback less than two years
Savings could reach 30-40% with refinement of engine map
Truck life 10+ years
Pricing
Dual fuel conversion kits $3000-$5000
Natural gas tanks $5000-$10,000
Installation ~$3000~$5000
Patch Box target price would be ~$1000-$2000
11/14/2018
Penn State Hybrid and Hydrogen Vehicle Research Lab

9. Penn State Hybrid and Hydrogen Vehicle Research Lab
Team and Partners
Joel Anstrom, PhD Penn State Larson Institute
Electronics packaging, product development experience with IBM
Timothy Cleary, Penn State Larson Institute
Vehicle control systems experience with GM
Penn State Bus Research Center
Penn State Energy Institute
11/14/2018
Penn State Hybrid and Hydrogen Vehicle Research Lab

10. Commercialization Path Forward
Complete testing current system
Finalize features and design
Optimize design for cost and features
Engage technical and business partners
Finalize business model
11/14/2018
Penn State Hybrid and Hydrogen Vehicle Research Lab

11. Penn State Hybrid and Hydrogen Vehicle Research Lab
Summary Slide
Very large built Diesel Truck fleets
Truck service life typically years
Potential savings 12.5% ~ 30%
Two year payback per vehicle
Significant increase in natural gas utilization in Pennsylvania
Significant reduction in foreign imports of petroleum
11/14/2018
Penn State Hybrid and Hydrogen Vehicle Research Lab

12. Penn State Hybrid and Hydrogen Vehicle Research Lab
Contact
Joel Anstrom 205 Transportation Research University Park, PA
11/14/2018
Penn State Hybrid and Hydrogen Vehicle Research Lab