Transitioning SuperTruckTechnologies to Commercial and Military Applications June 17 th, 2014 Ted Bloch-Rubin, Jean-Baptiste Gallo, CALSTART

Transcription

1 Transitioning SuperTruckTechnologies to Commercial and Military Applications June 17 th, 2014 Ted Bloch-Rubin, Jean-Baptiste Gallo, CALSTART

2 Agenda Background Overview of SuperTruck Review of Technologies Transition to Market 1

3 Agenda Background Overview of SuperTruck Review of Technologies Transition to Market 2

4 Agenda Background Overview of SuperTruck Review of Technologies Transition to Market 3

5 Agenda Background Overview of SuperTruck Review of Technologies Transition to Market 4

6 Background Military Truck Action Group (MTAG) TARDEC Vision for the Future More Expeditionary will require major weight reductions Autonomy-Enabled assist but not replace the warfighter More Efficient utilize less fuel and water M915 truck tractor 5

7 SuperTruckProgram Initiated in 2009 Public-private partnership Program Goals: 50% freight efficiency improvement 50% Brake Thermal Efficiency (BTE) 55% BTE Concept 4 selected projects Final demonstration vehicle 6

8 Why Long-Haul Heavy-Duty? Source: Transportation Energy Data Book, Edition 32 7

9 Cummins / Peterbilt DOE Share $38.8 million/ Contractor Share $38.8 million Project Closeout : April 2014 Demonstrated 51% BTE/ 61% freight efficiency improvement Major Project Partners: Modine Cooling Module Eaton Transmission Dana Drivetrain Bridgestone Tires Alcoa Wheels Utility Trailer Manufacturing 8

10 Daimler Truck NA DOE Share $39.6 million/ Contractor Share $39.6 million Project Closeout : March 2015 Achieved >48% BTE / 27% freight efficiency improvement Major Project Partners: Detroit Diesel Powertrain Oregon State University: Frame Analysis Fuel Routing ARC Aerodynamics Great Dane - Trailer 9

11 Navistar DOE Share $37.3 million/ Contractor Share $51.8 million Project Closeout : April 2015 Achieved >47% BTE Major Project Partners: Alcoa Lightweight Frame & Wheel Materials AT Dynamics Trailer Aerodynamic Devices ArvinMeritor Hybrid Powertrain & Axles Behr America Cooling Systems Michelin Tires Wabash National Trailer Tech 10

12 Volvo DOE Share $18.9 million / Contractor Share $19.1 million Project Closeout : June 2016 Demonstrated 48% BTE Major Project Partners: Mack Trucks Ricardo West Virginia University: Powertrain development Penn State University: CFD Models & Biodiesel Studies 11

13 Review of Technologies Engine Tractor Aerodynamics Improvement Other Notes: Bolded Black = Commercially Available Bolded Red = Key Interest to Military 12

14 Engine Engine Technique Engine Predictive engine control first step toward vehicle automation Optimum engine efficiency requires integration with other key component systems Detail Combustion Improvements Predictive Engine Controls Increased peak combustion pressure Optimum valve timing Higher injection pressure Compression ratio increase Piston bowl shape Calibration optimized for fuel efficiency Turbo optimization Reduced EGR rates Thermal barrier coating Engine control algorithms to predictfuture response of engine Downsized Engine Engine Downspeeding Reduce engine displacement Reduce engine RPM 13

15 Engine 14 Engine

16 Engine Tractor Aerodynamics Readily available technologies Some are widely adopted Tractor & Trailer aerodynamic synergies Tractor Aerodynamic Technique External Body Additions Detail Roof fairings / Vortex generators Cab extender fairings Chassis skirts / Side tank fairings Aerodynamic front bumper Aerodynamic mirrors Wheel covers Fly-swatter mudflaps Minimize 5th wheel height Fixed 5th wheel minimum gap 15

17 Tractor Aerodynamics 16 Engine

18 Engine Advanced Technique Body Light-weighting Tandem (6 x 2) Axle Wide-BaseSingle Tires Most readily available technologies for fleet introduction Light-weighting can offset additional hybridization components Detail Light weight brake rotor & caliper Plastic fuel tank Single prop. shaft Cast aluminum alloy wheels Aluminum axle hubs Composite front axle leaf springs Aluminum clutch housing Aluminum cab frames Remove drive axle from rear tractor wheels Replace a dual-tire configuration by a wide base single tire 17

19 18 Engine

20 Engine Enables idle reduction (start-stop) Many EPA SmartWay-verified products (HVAC, APU, Fuel- Fired Heater) Advanced Technique Auxiliary Power Unit Detail Oil pump Water pump Power steering pump A/C compressor Cooling fans Air system (clutched air compressor + electric air dryer) HVAC (ehvac, Thermoelectric HVAC) Power cab accessories from separate fuel source or auxiliary batteries 19

21 20 Engine

22 Engine Large interest in WHR Well-suited for steady-state travel of OTR trucks Advanced Technique Organic RankineCycle Detail Recapture a portion of the waste heat from the EGR and/or exhaust heat to generate power Thermoelectric Generator Electrical Turbo-Compounding Mechanical Turbo-Compounding Generate current across high-temp low-temp gradient Use turbine to recover energy from the exhaust system to generate electrical power Use turbine to recover energy from the exhaust system to generate mechanical power Electrically-Assisted Turbocharger Use small motor on turbo shaft to generate power or to help spin the turbo 21

23 22 Engine

24 Engine Full powertrain hybridization is difficult to implement for OTR trucks driving at constant speed Idle Shutdown & Start/Stop systems may make more sense Advanced Technique Idle Shutdown Micro/Mild Vehicle Vehicle Range-Extended Series Hybrid Commercial Offering Program automatic engine shut-off system Micro: can shut down engine when idling Mild: can shut down engine when coasting, braking or idling Parallel, series or dual mode Series HEV with range extender 23

25 Advanced Technique Commercial Offering Idle Shutdown Commercial Micro/Mild Vehicle Commercial for Light-Duty Vehicle Prototype, pre-commercial and commercial Range-Extended Series Hybrid Prototype & pre-commercial 24 Engine

26 Improvement Advanced transmission enables other key technologies: Hybridization, Downspeeding, Downsizing. Advanced Technique Detail Automated Manual Transmission Automatic clutch actuation Automatic Transmission Torque converter 25 Engine

27 Improvement Advanced Technique Commercial Offering Automated Manual Transmission Volvo ishift Eaton UltraShift Detroit DT12 Automatic Transmission Widely available 26 Engine

28 Engine Other Technologies Other technologies have made their way into the market Focus on driver is a cost-effective solution Advanced Technique Detail Longer Combination Vehicles Pull 2 or more full-length trailers Automatic Tire Inflation Systems Reduced Cruising Speed Monitor and continually adjust air tire pressure Limit top cruising speed Reduced Engine Friction Efficient Lighting Use synthetic low-viscosity lubricants Use more efficient LED lighting Driver Aid Systems Driver Training Display critical system parameters for ecodriving, update engine calibration and/or monitor diagnostic Learn progressive shifting, engine speed optimization, idle reduction, smoother braking and acceleration, optimal gearing 27

29 Other Technologies 28 Engine

30 Key Takeaways SuperTruck program almost complete Comprehensive approach / Vehicle integration is key (1+1 > 2) Acceleration to Market Program provided opportunity for engine test & road testing Some technologies starting to enter commercial truck market Will deliver technologies critical to meeting regulation within next 5 years Many technologies could be applicable to military vehicles (M915) 29

31 Questions? 30