MTAG Supertruck Review
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Transcript of MTAG Supertruck Review
Transitioning SuperTruck Technologies to Commercial and Military ApplicationsJune 17th, 2014Ted Bloch-Rubin, Jean-Baptiste Gallo, CALSTART
Agenda
2
Background
Overview of SuperTruck
Review of Technologies
Transition to Market
Agenda
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Background
Overview of SuperTruck
Review of Technologies
Transition to Market
Agenda
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Background
Overview of SuperTruck
Review of Technologies
Transition to Market
Agenda
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Background
Overview of SuperTruck
Review of Technologies
Transition to Market
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• 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
Background
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SuperTruck Program
• 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
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Why Long-Haul Heavy-Duty?
Source: Transportation Energy Data Book, Edition 32
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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
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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
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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
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Volvo• DOE Share $18.9 million / Contractor Share $19.1 million• Project Closeout : June 2016• Demonstrated 48% BTE
Major Project Partners:• Mack Trucks• Ricardo – Waste Heat Recovery• West Virginia University: Powertrain development• Penn State University: CFD Models & Biodiesel Studies
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Review of Technologies
• Engine Optimization• Improved Tractor Aerodynamics• Weight Reduction• Electrified Auxiliaries• Waste Heat Recovery• Hybrid Electric• Transmission & Driveline Improvement• Other
– Notes:Bolded Black = Commercially Available
Bolded Red = Key Interest to Military
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Engine Optimization
Engine Optimization Technique Detail
Combustion Improvements Increased peak combustion pressureOptimum valve timingHigher injection pressureCompression ratio increasePiston bowl shapeCalibration optimized for fuel efficiencyTurbo optimizationReduced EGR rates Thermal barrier coating
Predictive Engine Controls Engine control algorithms to predict future response of engine
Downsized Engine Reduce engine displacement
Engine Downspeeding Reduce engine RPM
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• Predictive engine control first step toward vehicle automation• Optimum engine efficiency requires integration with other
key component systems
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Engine Optimization
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Improved Tractor Aerodynamics
Tractor Aerodynamic Technique Detail
External Body Additions Roof fairings / Vortex generatorsCab extender fairingsChassis skirts / Side tank fairingsAerodynamic front bumperAerodynamic mirrorsWheel coversFly-swatter mudflaps Minimize 5th wheel heightFixed 5th wheel minimum gap
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• Readily available technologies• Some are widely adopted• Tractor & Trailer aerodynamic synergies
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Improved Tractor Aerodynamics
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Weight Reduction
Advanced Technique Detail
Body Light-weighting Light weight brake rotor & caliperPlastic fuel tankSingle prop. shaftCast aluminum alloy wheelsAluminum axle hubsComposite front axle leaf springsAluminum clutch housingAluminum cab frames
Tandem (6 x 2) Axle Remove drive axle from rear tractor wheels
Wide-Base Single Tires Replace a dual-tire configuration by a wide base single tire
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• Most readily available technologies for fleet introduction
• Light-weighting can offset additional hybridization components
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Weight Reduction
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Electrified Auxiliaries
Advanced Technique Detail
Electrified Auxiliaries Oil pumpWater pumpPower steering pumpA/C compressorCooling fansAir system (clutched air compressor + electric air dryer)HVAC (eHVAC, Thermoelectric HVAC)
Auxiliary Power Unit Power cab accessories from separate fuel source or auxiliary batteries
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• Enables idle reduction (start-stop)• Many EPA SmartWay-verified products (HVAC, APU, Fuel-
Fired Heater)
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Electrified Auxiliaries
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Waste Heat Recovery
Advanced Technique Detail
Organic Rankine Cycle Recapture a portion of the waste heat from the EGR and/or exhaust heat to generate power
Thermoelectric Generator Generate current across high-temp low-temp gradient
Electrical Turbo-Compounding Use turbine to recover energy from the exhaust system to generate electrical power
Mechanical Turbo-Compounding 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
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• Large interest in WHR• Well-suited for steady-state travel of OTR trucks
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Waste Heat Recovery
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Hybrid Electric
Advanced Technique Commercial Offering
Idle Shutdown Program automatic engine shut-off system
Micro/Mild Hybrid Electric Vehicle Micro: can shut down engine when idlingMild: can shut down engine when coasting, braking or idling
Hybrid Electric Vehicle Parallel, series or dual mode
Range-Extended Series Hybrid Series HEV with range extender
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• Full powertrain hybridization is difficult to implement for OTR trucks driving at constant speed
• Idle Shutdown & Start/Stop systems may make more sense
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Advanced Technique Commercial Offering
Idle Shutdown Commercial
Micro/Mild Hybrid Electric Vehicle Commercial for Light-Duty
Hybrid Electric Vehicle Prototype, pre-commercial and commercial
Range-Extended Series Hybrid Prototype & pre-commercial
Hybrid Electric
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Transmission & Driveline Improvement
Advanced Technique Detail
Automated Manual Transmission Automatic clutch actuation
Automatic Transmission Torque converter
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• Advanced transmission enables other key technologies:– Hybridization,– Downspeeding,– Downsizing.
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Advanced Technique Commercial Offering
Automated Manual Transmission Volvo iShiftEaton UltraShiftDetroit DT12
Automatic Transmission Widely available
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Transmission & Driveline Improvement
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Other Technologies
Advanced Technique Detail
Longer Combination Vehicles Pull 2 or more full-length trailers
Automatic Tire Inflation Systems Monitor and continually adjust air tire pressure
Reduced Cruising Speed Limit top cruising speed
Reduced Engine Friction Use synthetic low-viscosity lubricants
Efficient Lighting Use more efficient LED lighting
Driver Aid Systems Display critical system parameters for eco-driving, update engine calibration and/or monitor diagnostic
Driver Training Learn progressive shifting, engine speed optimization, idle reduction, smoother braking and acceleration, optimal gearing…
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• Other technologies have made their way into the market• Focus on driver is a cost-effective solution
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Other TechnologiesEngin
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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)
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Questions?