SuperTruck

Project ID: VS081

This presentation does not contain any proprietary, confidential, or otherwise restricted information

Pascal Amar (PI / Presenter)Volvo Group North AmericaJune 9th, 2016

Project Overview2

$18,929,194 Funding> $40,000,000 Total Cost

Vehicle Project Partners Barriers

Apply knowledge gained to industrialization efforts

Maintain operational effectiveness while making significant improvements to aerodynamic drag

Concurrent development of complex technologies

Leverage opportunities from technology integration

Vehicle Project Goal: 50% more ton-miles per gallon than a ‘best in class’ 2009 truck

Timeline Cost

Project end date June 2016

Phase II - Development & Integration Techn. Refinement

2016

Technology Development Refinements

Phase I - Concept Selection

2011 2012 2013 2014 2015

mule truck Concept

Baseline Tests

Virtual OptimizationEnergy Management Dev.

engine bench Concepts Evaluation

ValidationModel Development

Demo

Optimization

ValidationIntegration

demonstrator truckengine bench

Approach to Freight Efficiency Improvement

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Approach: Technology Content

D13 485HP 1,650lb-ft10-spd OD Manual Transmission

3:58 RAR

[20% lower aero drag trailer][12% lower RR tires]

[13L TC & WHR gen1]400rpm downspeeding w/ AMT6x2 axle with lube level control

>40% aero drag reduction>20% lower RR tires

Predictive cruise controlDownsizing + TC + WHR gen2

Variable oil / coolant pumpsReduced friction & oil pressure

Fuel Savings Weight Savings Hotel Load Savings

Engine idle

LED lighting in & out

Improved cab thermal insulationDual-zone 24V A/C system

15kWh energy optimized batteriesPredictive kinetic energy recovery

Photovoltaics (cab ventilation + lighting + trickle charge)

31,350 lb Payload33,650 lb Tare 65,000 lb Total

Lightweight trailer (MY2012)Light gauge trailer wire harness

Aluminum drive shaftWide-base wheels & tires

6x2 axle configuration

>40% lighter Aluminum chassisEngine downsizing (13 to 11L)Composite trailer aero devicesCF tractor fairings / hood / roof

Recycled CF step door Aluminum cab side walls

4

base

line

Phas

e I

Phas

e II

5

Uvalde, TXMarch 2016

Approach: Simulations & Testing

3,000 miles on-road500 miles track testing Hotel loads testing

Complete Vehicle Simulation were used throughout the project- to guide technology selection & component sizing- to develop predictive control algorithms- to optimize software calibrations

Freight efficiency improvements were verified under- Controlled tests for repeatability- Real world conditions

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

US07MY2009

6x2 w/ LLC +lubes +

LRR WB tires +100rpm

downspeed

Aeroflex +gap fairing +chassis flare

optimizedVEV1 aero

13L TC WHR +Powershift

new tractor +11L TC +LRR gen2(aeroflexbaseline)

Achievements: Fuel Economy

BaselineMY2009

MY2011Downspeeding

LRR tires6x2

addOTS

Trailer AeroTractor tweaks

addOptimized Trailer Aero

add48% BTE Powertrain

New tractor50% BTE Powertrain

LRR tires gen2

MP

G im

prov

emen

t

6

-3,500

-3,000

-2,500

-2,000

-1,500

-1,000

-500

0

1 2 3 4 5

Achievements: Weight Savings

BaselineMY2009

add48% BTE Powertrain

Opt. Trailer Aero

New tractor50% BTE Powertrain

Lightweight OTS trailer

6x2

Alu. wheelsWB tires

Al. driveshaft

[lbs.

]

7

Achievements

69 % fuel economy improvement

3,200 lbs. / 10% payload increase

Baseline ~ 100 ton-mile/gal

~ 188 ton-mile/gal

88 % freight efficiency improvement

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SuperTruck Goal

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Baseline VEV-1 (incl. 48% BTE) VEV-2 demo

Payload % imp

Fuel Economy % imp

Freight Efficiency % imp

Phase I Phase IIBaseline

9 More Achievements: Technology Transfer

Powertrain improvements - MY2017 11L & 13L engines

Tractor aero improvements - MY2016 highway tractors

Improved trailer aero devices - 2015

Mature technolgies with

acceptable customer ROI

have been industrialized

SuperTruck Technology Assessment10

Full trailer skirting

Customer Payback

New Cab BIW

TurboCompoundPistons, Fuel inj.

Rankine WHR

Lightweight chassis

Recycled CF fairings

Efficient hotel loads

Carbon Fiber fairings

Predictive Controls

Aluminum wheels/driveshaft

Solar Panels

DownspeedingDownsizing6x2 axles

Low RR tires

Energy opt. Hotel Load batteries

Tech

nolo

gy R

eadi

ness

Kinetic energy

recovery

• RelevanceThe goals of this project were aligned with the key barriers to higher fuel efficiency of highway transportation. All work performed helped overcome a specific technical challenge

• ApproachPhase I (2011-2013) allowed us to identify technologies and concepts showing most promising mid-term freight efficiency impact and ROI.

Phase II (2014-2016) saw team members further advance concepts selected in Phase I for integration into the demonstrator and commercialize the most mature technologies with acceptable ROI.

• Milestones & Technical AccomplishmentsIn this reporting period we successfully completed a 5-year project through on-road testing of a vehicle demonstrating 88% freight efficiency improvement vs. a MY2009 baseline. Moreover several team members were able to launch new/improved products based on knowledge gained through this project, with a direct impact on fuel use by highway trucks.

• Future WorkContinue to evaluate the demonstrator to identify further areas of improvement and possible candidate solutions for commercialization.

Project Summary11

Partners & key Collaborations

Organization Key Contributions

Volvo Group North America Project lead, simulations, advanced powertrain development, complete vehicle integration & testing

Ridge Corp. Trailer aerodynamic devices development, manufacturing, validation and operational testing

Grote Advanced tractor & trailer lighting systems, light gauge electrical harness

Penn State University Advanced combustion modeling & simulation, mapping and GPS based predictive algorithms

Hendrickson Lightweight trailer axle & suspension components

ExxonMobil Advanced fuels & lubricants

Alcoa Lightweight wheels & material design for new frame concept

Michelin Advanced low-friction tires (steer, drive, tag, trailer)

Bergstrom Efficient electrified dual-zone HVAC system w/ battery APU

Metalsa Ultra-Light Frame Assembly

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The Volvo SuperTruck project has exceeded program goals

with many technologies already delivered to customers

Thank you!

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