Engineering Center Steyr GmbH & CoKG Dr. techn. Dipl.-Ing. Christoph Brenner, VDI June 1 st, 2010
Commercial Vehicles: On the Way to Green Transport Source: http://www.boingboing.net/images/_upload_2008_08_a_truck_grows_in_ sacramen_planttruck081808.jpg Source: http://www.keys2drivepilot.com.au/images/ bigstockphoto_green_planet_3720932.jpg 2
Commercial Vehicles Main Target Used to Perform Defined Tasks and Make Profit 3
Commercial Vehicles - Characteristics Workplaces They must pay off Total cost of ownership (Trucks) Purchasing price Operating costs Payload Transport volume Fuel consumption (30% of OC) Reliability Maintenance Emissions (Taxes, Toll) 16,5 m /18,75m Used Vehicle Price 40t (- 44t) GCW Insurance / Taxes Logistics / Fleet Management (empty drive) European Modular System 25,25 m 60t GCW Source: http://www.euro-combi.de/ 4
Why should transport become green? Global CO 2 emissions CO 2 reduction = less fuel consumption = lower operating costs Required by Laws Operation Restrictions (No restrictions for low or zero emission vehicles) More and more transport Fossil fuels are scarce Limited transport infrastructure 5
Reduction of Traffic Larger Trucks (European Modular System) Use max. trailer length / optimize payload volume Payload Increase (save weight) Optimized Fleet Management considering GPS, Traffic Information Reduce empty drives (~10 % in Europe) Source: Mercedes-Benz Source: http://truckonline.de/blog/wp-content/uploads/2008/09/giga.jpg 6
Current Truck Technology conventional, brick shaped trailer add-on air-flaps and spoilers Side underrun protection / add-on parts block-shaped steel cab air suspended steel axle Ladder-type steel frame Source: MAN Efficient and powerful internal combustion engine regular tires / super single tires conventional powertrain some electronic systems exterior plastic parts 7
On the Way to Green Transport Each part of a truck shall be optimized. AND Each optimization must pay off. AND Performance must remain the same. Source: http://www.mz-eurasien.de/ wp-content/uploads/2009/04/abgase.jpg AND A truck must remain a work place.? Source: http://i846.photobucket.com/ albums/ab30/gerhard Brandstaetter/P70900376.jpg 8
Future Truck Technology Controlled (electrified) auxiliaries (working as needed) Power generation + recuperation Complete truck: Aerodynamically shaped Maximised transport capacity LED s Low resistance tires / Complete truck: lift axles Lightweight / optimized structural design + materials Downsized highly efficient internal combustion engine + hybrid booster + GPS supported driving strategy + driver assistance + safety systems 9
Power Distribution of Modern Long-Haul Trucks Flat highway, semi-trailer truck, 85 km/h, 40 t, stationary operation Power Distribution (115kW) 45% 40% Aerodynamics Powertrain 8% 7% Auxiliaries Rolling resistance Engine Efficiency (32l/100km) 30% 40% mechanical Values based on ATZ 110 für an IVECO truck 30% exhaust cooling 10
Drag Reduction / Energy Savings (Fuel Savings) Aerodynamic Improvements Aerodynamic Design (5% to 10%) Truck Convoys (5% to 10%) ACC + legal permission Rolling Resistance Improvements Super Single Tires (2 to 4%) Low Resistance Tires (up to 6%) Correct Tire Pressure (up to 2%) Tire monitoring / inflation system Other Energy Savings LED Lighting Cab Thermal Insulation Source: http://www.bridgestone.co.jp/english/news/ c_02_img/020911-05.jpg 11
Lightweight Design Increase payload capacity Lightweight frame (-150kg) with integrated add-on parts Single parabolic leaf springs + stabilizer Super single tires Downsized engine Weight-optimized systems and components: Cab Axles Powertrain Add-on parts Trailers Exterior parts Interior parts E / E 12
Electrification / Energy Generation / Recuperation Hybrid Powertrain (efficiency gains up to 10% to 20%) Recuperation Electrical Boost Engine Downsizing O.k. for Delivery Trucks Long Haul needs anticipatory systems Energy generation (solar cells, TEG, steamers, Stirling engines) Electrification of Auxiliaries Start / Stop System / Idling reduction Plug-in during breaks / over-night stays MAGNA Heavy Duty Truck Battery 2.5 7 kwh 60 180 kw cylindric cells SOP: 2009 13
HCV: Demonstrator Layout & Components HCU & Operating Strategy HCU development: ECS Operating Strategy: ECS IMG Design: ECS Incl. Clutch (ICE IMG) HV Net Layout: ECS Cabeling: ECS PDU Traction Inverter Battery MAGNA LiOn Brake air compressor electrical HVAC compressor ECS Prototype electrical Steering Pump ECS Prototype eaux Inverter 14
Truck Hybrid System Operating Strategy 15
Hybrid Driving Strategy / Downsizing Hybrid for Long Haul Trucks Anticipatory systems: GPS information with altitude information in navigation system Traffic information from road and traffic ahead Trip plan (e.g. breaks, stops) Automated Cruise control with distance control optimum hybrid driving operation fuel consumption down -20 to -30% Significant downsizing of engine Combine with other energy saving options Source: http://www.rennradschlag.de/skins/custom/ hpdiagram.php?width=525&height=200&data=hprofile/ brenner.csv 16
Summary and Future Outlook Transport / CVs can become significantly greener Green CVs must perform Greening Transport / CVs by technological improvements adaptations of legal restrictions Fuel savings / CO 2 reduction by: Traffic reduction Drag reduction and energy saving Lightweight design Electrification, Energy Generation, Recuperation Hybrid Trucks Hybrid driving strategy Let s make transport greener! 17
Engineering Center Steyr GmbH & CoKG