eaton corporation innovations in power...
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© 2012 Eaton Corporation plc. All rights reserved.
Eaton Corporation Innovations in Power Management
Dr. Ankur Ganguli
Director, Research & Technology
Eaton Global Innovation Center
2 © 2012 Eaton Corporation plc. All rights reserved.
Powering businesses worldwide for more than 100 years
• Founded in 1911 by J.O. Eaton
• Chairman & CEO – Alexander M. Cutler
• Eaton Center in Cleveland, Ohio USA
• Regional centers in Shanghai, China; Morges, Switzerland; Sao Paulo, Brazil
• Innovation Centers in regions around the world
• Customers in more than 150 countries
• Sales of $21.8 billion*, more than 50% of sales outside the U.S.
• Approximately 100,000 employees * Combined results of Eaton and Cooper for the four quarters ending September 30, 2012.
3 © 2012 Eaton Corporation plc. All rights reserved.
Eaton’s commitment to sustainability gives businesses a sustainable advantage
• Strong financial record and history
• Leadership in environmental practices
• Committed to doing business right • Ranked among Fortune Magazine’s World’s Most
Admired Companies in the Industrials sector
• One of Corporate Responsibility Magazine’s 100 Best Corporate Citizens, 2008 - 2012
• One of Ethisphere Magazine’s World’s Most Ethical Companies, 2007 – 2012
• Cited in China’s Business Watch magazine’s China Green Company Top 10 and Fast Company Top 100
• Named one of Carta Capital Magazine’s Most Admired Companies in Brazil, 2008 – 2011
• Named among India’s Best companies To Work For, Economic Times and Great Places to Work Institute - 2012
4 © 2012 Eaton Corporation plc. All rights reserved.
Eaton’s two sectors
Industrial Sector
$8.9 B Sales
Vehicle
Aerospace
Hydraulics
Electrical Sector
$12.6 B Sales*
Electrical Americas
Electrical Rest of World
* Based on Eaton Corporation and Cooper combined 2011 performance statistics
5 © 2012 Eaton Corporation plc. All rights reserved.
Powerful megatrends will help drive our markets to grow at a multiple of global GDP
23…Percentage decrease in electricity demand possible through the
application of energy efficient equipment and demand management
services
100…Percentage increase in agricultural output by 2050 necessary in
developing countries to feed the global population
30…Percentage decrease in fuel consumption of next generation
single-aisle aircraft planned by 2020
20…Percentage decrease in fuel consumption by model year 2018
resulting from the first ever U.S. emissions standards for heavy-duty
trucks
90…Percentage increase in proposed Corporate Average Fuel
Economy (CAFE) standards by 2025 for passenger cars
Eaton is uniquely positioned to provide safe, reliable, efficient and
sustainable power management solutions for our global customers.
6 © 2012 Eaton Corporation plc. All rights reserved.
The Eaton power management advantage
• Building more energy-efficient buildings, communities and
infrastructure.
• Accelerating the development of renewable energy technologies.
• Powering mobile and stationary equipment more productively and
safely, while reducing their environmental impact.
• Designing eco-efficient aircraft that reduce fuel consumption and
operating costs.
• Improving fuel economy and reducing emissions in autos, trucks
and other essential forms of transportation.
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7 © 2012 Eaton Corporation plc. All rights reserved.
We have transformed our company …
Eaton Mission:
To provide safe, reliable, efficient and sustainable power
management solutions for our global customers.
Eaton’s Past
A Vehicle Component
Manufacturer…
Eaton Today
A Leader in
Power Management!
Eaton’s Past
A Vehicle Component
Manufacturer…
Eaton Today
A Leader in
Power Management!
8 © 2012 Eaton Corporation plc. All rights reserved.
The power of One Eaton
Over the years, Eaton has
expanded its expertise and
portfolio of products and
services by integrating the
competencies and equities
of some of the world’s
most respected names into
Eaton to build a brand you
can trust to meet every
power management need.
9 © 2012 Eaton Corporation plc. All rights reserved.
A few of our notable customers
• Airbus
• Akzo Nobel
• Alstom
• AVIC
• Bank of America
• Boeing
• Chery
• Coca-Cola
• Daimler
• Ford
• Foton
• Hino
• HP
• IBM
• Ingersoll Rand
• Invista
• John Deere
• LT
• Mahindra
• NAPA
• Pepsico
• Peterbilt
• Petrobras
• PNC
• Rexel
• SANY
• Shell
• Sonepar
• Sprint
• TATA
• ThyssenKrupp
• UPS
• Vestas
• Volkswagen
• Volvo
• Walmart
Every day, some of the best-known companies in the world choose Eaton when
there’s a lot at stake. Our customer list includes:
10 © 2012 Eaton Corporation plc. All rights reserved.
Developing pragmatic, break-through innovations for specific customer needs
• Providing more integrated and
cost-effective power management
for wind, solar and hydro power
projects
• Innovating new electro-hydraulic
technologies that deliver more
power for on and off road heavy
duty vehicles
• Pioneering the design and
commercialization of hybrid
power technology for
commercial vehicles
• Developing advanced
uninterruptible power systems
for data centers, network
servers, and home computers
11 © 2012 Eaton Corporation plc. All rights reserved.
Eaton provides energy efficient solutions for electrical, mechanical, and fluid applications
Our products & services deliver reliability, efficiency, safety for:
…helping to bridge the gap between rapidly rising demand for energy
and naturally constrained sources of supply with sustainable solutions
Cities & Buildings Transportation Industrial &
Machinery
Information
Technology
Energy & Utilities Infrastructure
12 © 2012 Eaton Corporation plc. All rights reserved.
Eaton provides energy efficient solutions for electrical, mechanical, and fluid applications
Our products & services deliver reliability, efficiency, safety for:
…helping to bridge the gap between rapidly rising demand for energy
and naturally constrained sources of supply with sustainable solutions
Transportation
13 © 2012 Eaton Corporation plc. All rights reserved.
Eaton HEV History & Progress: Over 300 Million Miles Reached and nearly 6,000 systems deployed
14 © 2012 Eaton Corporation plc. All rights reserved.
Eaton MD Hybrid Electric Power Systems
• >6,000 system shipments to-date
• >300 Million safe & reliable customer miles
• Over 8 million gallons of fuel avoided
Eaton is the Market Leader in Hybrid Technology
15 © 2012 Eaton Corporation plc. All rights reserved.
Goal is 3 year payback based on fuel saved Today it is 7+ years payback
Miles driven/year 32,000
Fuel 8-10 mpg
Improvement 30% - 40%
Value of saved fuel $4k - $6k
3 year payback $12-18k
True economic value proposition at
$15k-$20k cost for base system…
• $26k >> $15-20k
• Hybrid volumes are
decreasing
• Hybrid manufacturers
exiting the business
• Specialized military
solutions even more
expensive
Typical end customer value proposition
Cost reduction through incremental engineering
and volume increase: $46k $26k
16 16
Recent Press Releases
DE-FOA-0000675 Department of Energy - Advanced Management and Protection of Energy-Storage Devices (AMPED):
Won a grant for “Predictive Power Management for Integrated Battery Management for HEVs” in partnership
with NREL (National Renewable Energy Lab). Awarded funding 2M with Eaton cost share 30% for period of
performance 3 years.
Eaton to Develop Predictive Battery Management Technology for Hybrid Vehicles
… developing a cost-effective power control system for hybrid vehicles to reduce the size of the system
battery without a loss of battery life or vehicle performance.
This is the second ARPA-E grant that Eaton has received within the past month.
17 © 2012 Eaton Corporation plc. All rights reserved.
• Battery life prognostics model based on
electrochemical dynamics, capable of fast and
accurate estimation of battery health and residual
battery life
• Predictive Powertrain Controls with Intelligent Electric
Power Management System, capable of vehicle duty
cycle prediction and real-time optimization of fuel
economy and battery life
Predictive Battery Management for Commercial Hybrid Vehicles
Performance Targets
Metric State of the Art Proposed
Battery pack
cost, weight
and capacity
Oversized by
factor of 4
Battery downsizing by
50% while maintaining
life and performance
Battery residual
life prediction
Prediction
uncertainty of
nearly 30%
Electrochemical model
capable of error of less
than 10%
Battery
Prognostics
Predictive Power
Management
Predictive Battery
Management System Baseline HEV
Predicted
Vehicle
duty cycle
over
horizon
Battery
health/life
over
predicted
horizon
Battery
health/life
optimized
HEV energy
management
Battery
condition
monitoring
Vehicle
monitoring
Need integrated battery management & optimization
• Battery packs in current state-of-the-art HEVs
are underutilized
• Need significant battery downsizing to lower
cost and higher ROI for HEVs
• Accurate residual battery life estimation can
provide improved estimation of secondary
market value of used battery packs
Hypothesis
Technologies
18 © 2012 Eaton Corporation plc. All rights reserved.
Eaton provides energy efficient solutions for electrical, mechanical, and fluid applications
Our products & services deliver reliability, efficiency, safety for:
…helping to bridge the gap between rapidly rising demand for energy
and naturally constrained sources of supply with sustainable solutions
Information
Technology
19 © 2012 Eaton Corporation plc. All rights reserved.
Eaton Un-interruptible Power Supply (UPS) Business
All product lines use batteries
Eaton UPSs are designed to deliver high quality backup
power from desktop PCs to large data centers, facilities,
electrical engineering infrastructure and other critical IT
applications.
Promising our customers …. clean,
uninterrupted power and scalable battery
runtimes
20 © 2012 Eaton Corporation plc. All rights reserved.
The Nine Power Problems
21 © 2012 Eaton Corporation plc. All rights reserved.
Today Batteries are the weakest link in delivering power reliably …
• 75%…of unplanned power outages are due to battery failure.
• 5%...of batteries fail within their warranty period. VRLA batteries can fail in as little as 2 days.
• 95%...of “critical” sites use quarterly battery maintenance to insure battery integrity.
• Quarterly checks alone are like having a security alarm on your house… but only turning it on 4
nights a year !
*Source: National Survey on Data Center Outages, sponsored by Emerson
Network Power, conducted by Ponemon Institute LLC, Sept. 30, 2010
Top Root Causes of unplanned outages in Data Centers*
Need advanced battery monitoring technologies
22 © 2012 Eaton Corporation plc. All rights reserved.
Serving many industries - sharing one focus
• Understanding and helping our customers succeed.
• Anticipating tomorrow. Achieving today.
23 © 2012 Eaton Corporation plc. All rights reserved.