AuraGen - Aura Systems Inc

1
History
• Founded in 1987 by a team of
defense industry veterans.
• Early Applications
-- SDI (Star Wars) Programs
-- Navy Programs
• Recognition and numerous
awards from the U.S.
Government
2
Patents
• 2 related to AuraGen expiration ~2019
• 25 magnetic patents for
automotive/industrial applications
• 18 electrooptical patents related to
MEMS technology
3
Mobile Power System
The AuraGen®, offered by Aura
Systems, Inc., turns a full-sized vehicle
into a versatile mobile power source.
When the vehicle is running (idle to
red-line, makes no difference) the
AuraGen produces up to 8.5kW
continuous of highly regulated, clean
120/240 Volt AC power. Our optional
battery charger provides 200 amps of
14 Volt DC power at the same time!
When the engine is shut down, our new inverter option continues to provide AC
power from a battery pack, which is automatically recharged whenever your engine is
running.
4
Induction Power System
A. Vehicle Independent
1. AuraGen® Induction
Power Source
2. ECU - Electronic Control Module
3. Power Cables and Hardware
B. Vehicle Dependent
1. Mounting Bracket System Module
2. Idle Control Module
5
How is the AuraGen® Induction Power
System Different than an Inverter?
The AuraGen® doesn’t rely on the Alternator or Shore Power for Charging Batteries:
– Alternator failures due to overheating are eliminated
– Provides its own optimal battery charging system extending battery life
• monitors battery current to prevent damage
• monitors battery temperature to prevent damage
• provides minimum possible recharge time without need for shore power
AuraGen® has added Operating Modes not found in Inverters:
• Generator mode provides full power and minimum time battery recharging
• Low battery alarm allows option to continue full power operation in generator mode
• Transition to generator mode is seamless so no interruption in operation is needed
• Provides high amperage DC output
• Safety shutoff if battery alarm ignored prevents battery damage
AuraGen® improves system reliability
and reduces maintenance cost
6
Available Options
1.
DC Mode – Adds to your AuraGen the capability of producing DC output at
either 14V or 28V up to 5.3kW. The hardware is integrated into the ECU.
2.
Inverter Mode – Built into the undercarriage of the ECU, the Inverter Mode
provides up to 5kW of AC and/or DC power. The DC Mode is included with
the Inverter Mode. When you restart your engine, the AuraGen recharges the
auxiliary battery pack automatically. No shore power is required. Battery pack is
sized to meet operating time required.
3.
Remote Power Strip –
4.
Manual Transfer Switch – A hook-up device enabling you to power up your
business or home during power outages.
Remote Power Strip
Manual Transfer Switch
7
AuraGen® Integrated System
ECU
(Electronic Control Unit)
Control Unit
(Usually mounted under dash)
Mounting Bracket
(Vehicle and engine specific)
Idle Control
120/240 VAC
Outlets
(optional)
(Location may vary)
AuraGen
Power
Induction System
Remote Power Strip
120/240 VAC Optional
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Electronic Control Unit Block Diagram
+
5 Amp Start-Up
Power
Vehicle
Battery
ECU
Idle
Control
RPM Sensor
Processor
Thermal Sensor
Control Panel
3 Phase
Vector
Controller
2-Phase
Inverter
120 VAC
0 Phase
120 VAC
180 Phase
120 VAC
240 VAC
Outlets
400 VDC Bus
Optional Power Strip
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This is How the AuraGen ® Works
z
z
y
ν
Bo
x
π/k
x
λ
Magnetic Wave Produced
by Stator
B o ω / k = Bo ν
Resulting Electric Wave
Produced in Rotor
j=σ E
Currents Created in Rotor
By Ohm’s Law
H . dl = current encircled
b
Stator
a
Rotor
F
Force Created in Rotor
by Lorentz Law
F=jxB
τ = n (π / 2) (b + a) x (b - a) x
µ0 (Ν Ι0 2)
(g
2+
γ
2)
x
γ
(g
2+
γ
Yielding the AuraGen Torque Formula
2)
xε
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AuraGen® Installation Engine
Mounted, Belt Driven
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AuraGen® installed in a Ford F-350 with a 7.3L
Power Stroke Diesel Engine
Belt path for the Ford F-350 with a 7.3L
Power Stroke Diesel Engine
We have complete mounting bracket assemblies for over
90 different model/year/engine combinations of full sized
trucks, vans, SUV’s and medium duty commercial vehicles.
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AuraGen® Installation Driven
by Hydraulic Motor
• Mounting bracket designed
to fit onto 9 in. frame rails
• Requires 10.8 GPM flow at
2,200 PSI for 5 kW operation
(configuration also available
for 8.5kW)
• Great option for vehicles with
existing hydraulic systems
Hydraulic Mount
12
AuraGen® Installation Driven
Directly by PTO
• Works with “hot shift” and manually
engaged PTO’s
• With 1.25 to 1 PTO, can generate full
power at under 1,000 engine RPM
• Mounts under chassis, comes with
rugged sheet metal enclosure
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Physical Specifications
Mechanical
• Diameter
• Width
• Weight
G-5000
G-8500
• Environ. temperature range
• Altitude
• Environmental conditions
12.2 in
5.085 in
62 lbs.
65 lbs.
-40°F to +200°F
No altitude derating
Under hood
ECU
•
•
•
•
Length
Width
Height
Weight
• Environ. temperature range
• Environmental conditions
19.27 in
10.50 in
8.12 in
52 lbs.
-40°F to +120°F
Weather-proof, can be mounted
in or under truck bed
14
Power Specifications
G-5000, AC Only
120 VAC and 240 VAC Combination
Power Type
Power Level
(watts)
Continuous
5,000
Emergency standby* 6,000
Surge
7,200
Amps at
120 VAC
21, 2 circuits
25, 2 circuits
30, 2 circuits
Amps at
240 VAC
21
25
30
Amps at
14 VDC
-
Amps at
28 VDC
-
Amps at
14 VDC
-
Amps at
28 VDC
-
120 VAC Only
Power Type
Power Level
(watts)
Continuous
5,000
Emergency standby* 6,000
Surge
7,200
Amps at
120 VAC
42
50
60
Amps at
240 VAC
-
*Power delivered continuously under normal varying load factors for duration of a power
outage.
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Power Specifications
G-5000 AC/DC Combination
120 VAC and 14 VDC Combination
Power Type
Power Level
(watts)
Continuous
5,300
Emergency standby* 6,000
Surge
6,400
Amps at
120 VAC
21
26
30
Amps at
240 VAC
-
Amps at
14 VDC
200
200
200
Amps at
28 VDC
-
120 VAC and 28 VDC Combination
Power Type
Power Level
(watts)
Continuous
5,300
Emergency standby* 6,000
Surge
6,400
Amps at
120 VAC
21
26
30
Amps at
240 VAC
-
Amps at
14 VDC
-
Amps at
28 VDC
100
100
100
*Power delivered continuously under normal varying load factors for duration of a power
outage.
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Power Specifications
G-8500
Power Type
Power Level
Amps at
(watts)
120 VAC
Continuous
8,000
33, 2 circuits
Emergency standby* 8,500
35, 2 circuits
Surge
9,000
37.5, 2 circuits
Amps at
240 VAC
33
35
37.5
Amps at
14 VDC*
200
200
200
Amps at
28 VDC*
150
150
150
* DC module available as an option. System will provide full AC output, used remaining capacity for DC up to
power level limit.
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Power Specifications
Inverter-Charger Option
Inverter-Charger option available for both G-5000 and G-8500
Provides same pure AC output with engine off!
Battery Pack
Voltage
12 volts
24 volts
Power Level
Amps at
(watts)
120 VAC
2,500
10.5, 2 circuits
5,000
21, 2 circuits
Amps at
240 VAC
10.5
21
Amps at
14 VDC*
200
-
Amps at
28 VDC*
150
* DC used for battery charging when engine is running.
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Advantages
Technical
–
–
–
–
Power quality and stability
Low weight and minimal effect on the vehicle
No noise above idling engine
Convenient and safe to use
Economic
–
–
–
–
No cost of maintenance or down time for preventative measures
No duty cycle issues or need for shore power to charge batteries
No effect on vehicle maintenance, especially batteries and alternator
Lower life cycle cost
Environmental
– Major reduction in air pollution categories
• CO by as much as 95%
• NOx by as much as 82%
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Power Quality Comparison
Voltage
Time
Voltage
AuraGen Output
Pure Sine Wave
• 60 ±0.16 Hz
• 120 V ± 2%
• 2.1% THD
Gen-Set Output
Distorted Sine Wave
• Frequency, Voltage are
Engine RPM Dependent
AuraGen Can Operate
•
•
•
•
•
•
Computers, video equipment
Street intersection lights
Flicker-free lighting
Tools (saws, drills, etc.)
Compressors
Etc.
• All at the same time without
affecting power quality!
Time
Inverter Output
Modified Square Wave
• Very High Distortion
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Power Quality and Stability
• 2.1% THD (Total Harmonic
Distortion) allows AuraGen® to
power the most sophisticated
electronics safely and without fault.
• Ample peak power reserve (G-5000
up to 7.5 kW and G-8500 up to 9.0
kW for 3 seconds) allows AuraGen
to start even powerful compressors
without shutting down. (In actual
tests the G-5000 AuraGen
outperforms the 6.5 kW Onan
Marquis and the 7.5 kW Honda EX
series generators)
• No power spikes that can damage
equipment
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Compared to Gas Driven Genset
• By substituting AuraGen® for all Gensets in the U.S., a 10% reduction in total
air pollution could be achieved.
• Secondary benefits from use of electric rather than gas driven tools would
also occur.
Pollutant
CO
NOx
PM10
AuraGen
425
11.8
3.29
Generator Type
Pre 1999 Difference Post 1999 Difference
6500
57.8
3.465
93.5%
79.6%
5.1%
2200
27.6
3.465
80.7%
57.2%
5.1%
Pollutant reduction in kilotons/year
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Manufacturing Capacity
• Available fabrication capacity - over 10,000 units per month
• All manufacturing done off hard tooling
• High Quality suppliers (majority comply with ISO 9002)
• Strong alliance with key suppliers
• Final assembly line set up and operational
• Interactive Material Requirement Planning to support material management
• All necessary assembly, kitting and warehousing space
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Manufacturing
No exotic materials
• Cast steel, aluminum die casting, copper wire, aluminum and
steel sheet metal
• Off the shelf electronic components
• Off the shelf automotive parts
No exotic processes
• Shell casting, die casting, core winding, wire winding, stamping,
machining, welding
Design For Manufacturing (DFM)
• Concurrent engineering with the manufacturers in the loop
• Ongoing cost reduction and yield improvement
• TQM/In Process Inspection using automated tools and SPC
(Statistical Process Control)
Design solidified and field tested
24
Design for Durability
• No wear/contact points except bearings
• Balanced magnetic fields on both sides of rotor greatly reduce
bearing side load
• Bearings sized for infinite life
• Stator wire insulation and varnish rated for continuous
operation at 356°F, well in excess of operating conditions
• Durability experience
– First prototype installed on truck in Feb. 1996, still operational
– Endurance testing of unit at 12,000 hours continuous operation and counting
– No generator design service failures to date
25
Design for Safety
User Protection
• Over-voltage, over-current shut-down
• GFI plugs
• Super-fast circuit breakers
• Over-RPM shut-down
• All high voltage lines encased in grounded metal conduit
• Any fault causes idle control to mechanically disengage
System Protection
• Generator short-circuit causes the system to shut down
• AC-Output short circuit causes system to shut down
• ECU overheating causes system to shut down
• Generator overheating causes system to shut down
• Idle control failure causes system to shut down, idle
control to release
• Battery voltage line interruption causes system to shut down
• Battery voltage lines protected with re-settable fuses
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Quality System
•
ISO 9001, QS9000 in process
•
Highly qualified suppliers (majority comply with ISO 9002)
•
Product test qualified to meet all performance, environmental and endurance
specifications (lab and field testing)
•
Document and configuration fully controlled
•
Acceptance test and compliance procedures established at all manufacturing levels
including suppliers
•
Focus on source certification and source inspection with verification at Aura receiving
•
TQM/In Process Inspection using automated tools and SPC
•
Manufacturing lot traceability
27
Product Support
• The AuraGen® group is a system house, providing a turn key product and integrated services
to support the consumer in every area
• All engineering, down to basic physics, is conducted in house, providing a solid foundation
to challenge every technical problem and develop an ongoing line of products
• Provides routine training to installers nation wide. All training materials are fully developed
• Provides field support through regional resident field engineers
• Provides technical information, documentation and software, through installation manuals,
catalogs and service bulletins. Installation software includes "Call Home" feature and remote
diagnostic capability
• Tracks performance and field failures to enhance product reliability and customer
satisfaction
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Product Support Vehicle
Integration
• The AuraGen® is sold as a turn key, fully integrated system including all the
vehicle specific components
• The AuraGen® Vehicle Integration Group develops, engineers, manufactures
and supplies all the brackets, pulleys, idlers, belts, tensioners and other
components that comprise an induction power mounting system.
• The group also specifies all the requirements for the implementation of the
AuraGen with other mobile drives like hydraulic systems and Power Take Off
(PTO's)
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Product Warranty
3 Year Standard
• No hidden exemptions
• Unparalleled for power
generating equipment
• No maintenance
required!
• Exceptional Life Cycle
savings
• Extendable to 5 years
Installers and OE’s:
• Field maintenance is limited to remove
and replace major components
Aura Provides:
• Software to perform system level test to
isolate failures to major component
• Software that automatically maintains
service records of each system
• Failure analysis on returned units
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Applications - Law Enforcement
Control Unit
(as mounted under dash)
ECU
(Electronic Control Unit)
31
General Motors Approves AuraGen®
On Goodwrench Fleet Trucks
ECU as mounted
Night Lights powered by AuraGen®
Remote Power Strip
“The pièce de résistance is the 5000 watt on-board, engine-driven
AuraGen generator, which provides Power on the Go™.”
"There’s enough power to operate an entire house using the 110*
and 220 outlets in the tailgate area,"
-GMC Design Manager Carl Zipfel.
All equipment provided in the
GM Goodwrench Mobile Service
van is GM approved.
*actual specification for low voltage is 120
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Government Customers
• US Army
• US Air Force
• FBI
• US Border Patrol
HMVVW – Light bar powered by AuraGen
• US Marine Corps
• Armed Forces Radio
• US Postal Service
• Air National Guard
Note: Numerous State and Local DOT, Police, Fire Departments and
City Services are also customers.
Dodge COMBATT and engine close up showing mounted AuraGen Induction Power Module.
GSA Approved #
CMAS Approved#
GS-30F-0012K
4-00-23-0006A
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Targeted Markets
Military
Telecommunication
Utilities
RV
Emergency Rescue
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Targeted Markets
Catering
Agriculture
Oil & Gas
Marine
Public Works /Construction
35
Applications - Samples of
Various Industries
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Power Induction System
• The AuraGen® is a fully developed product, supported by an
integrated infrastructure to facilitate all it’s areas of business
• Both the 5 kW and 8.5 kW AuraGens are available on over 90
different vehicle/engine configurations.
• The AuraGen® is configured for most GM, Ford and Chrysler full
size pick ups, vans and SUV’s. It is also available for many other
manufacturer’s medium sized duty commercial vehicles.
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The
AuraGen
Induction
Power
System.
The reliable, pure sine wave,
environmentally clean, cost effective
and maintenance-free solution for all
your mobile power needs.
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