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MTAG Supertruck Review
The document discusses the SuperTruck program initiated in 2009, which aims to enhance freight and brake thermal efficiency through public-private partnerships in the trucking industry. It outlines various technologies explored, including engine optimization, aerodynamics, weight reduction, and hybrid systems, while noting the involvement of key industry partners. The program is nearing completion, with several technologies poised for commercial deployment that could also benefit military applications.
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MTAG Supertruck Review
- 1. Transitioning SuperTruck Technologiesto Commercial and Military Applications June 17th, 2014 Ted Bloch-Rubin, Jean-Baptiste Gallo, CALSTART
- 2. Agenda 1 Background Overview of SuperTruck Review of Technologies Transition to Market
- 3. Agenda 2 Background Overview of SuperTruck Review of Technologies Transition to Market
- 4. Agenda 3 Background Overview of SuperTruck Review of Technologies Transition to Market
- 5. Agenda 4 Background Overview of SuperTruck Review of Technologies Transition to Market
- 6. Background • MilitaryTruck 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. 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 6
- 8. Why Long-Haul Heavy-Duty? 7 Source: Transportation Energy Data Book, Edition 32
- 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 • DOEShare $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 • DOEShare $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 11
- 13. Review of Technologies • Engine Optimization • Improved Tractor Aerodynamics • Weight Reduction • Electrified Auxiliaries • Waste Heat Recovery • Hybrid Electric • Transmission & Driveline Improvement • Other – Notes: 12 Bolded Black = Commercially Available Bolded Red = Key Interest to Military
- 14. Engine Optimization 13 Engine Optimization Technique Detail Combustion Improvements 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 Predictive Engine Controls Engine control algorithms to predict future response of engine Downsized Engine Reduce engine displacement Engine Downspeeding Reduce engine RPM Engine Optimization Improved Tractor Aero. Weight Reduction Electrified Auxiliaries Waste Heat Recovery Hybrid Electric Transmission & Driveline • Predictive engine control first step toward vehicle automation • Optimum engine efficiency requires integration with other key component systems
- 15. 14 Engine Optimization Improved Tractor Aero. Weight Reduction Electrified Auxiliaries Waste Heat Recovery Hybrid Electric Transmission & Driveline Engine Optimization
- 16. Improved Tractor Aerodynamics 15 Tractor Aerodynamic Technique Detail External Body Additions 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 Engine Optimization Improved Tractor Aero. Weight Reduction Electrified Auxiliaries Waste Heat Recovery Hybrid Electric Transmission & Driveline • Readily available technologies • Some are widely adopted • Tractor & Trailer aerodynamic synergies
- 17. 16 Engine Optimization Improved Tractor Aero. Weight Reduction Electrified Auxiliaries Waste Heat Recovery Hybrid Electric Transmission & Driveline Improved Tractor Aerodynamics
- 18. Weight Reduction 17 Advanced Technique Detail Body Light-weighting 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 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 Engine Optimization Improved Tractor Aero. Weight Reduction Electrified Auxiliaries Waste Heat Recovery Hybrid Electric Transmission & Driveline • Most readily available technologies for fleet introduction • Light-weighting can offset additional hybridization components
- 19. 18 Engine Optimization Improved Tractor Aero. Weight Reduction Electrified Auxiliaries Waste Heat Recovery Hybrid Electric Transmission & Driveline Weight Reduction
- 20. Electrified Auxiliaries 19 Advanced Technique Detail Electrified Auxiliaries Oil pump Water pump Power steering pump A/C compressor Cooling fans Air system (clutched air compressor + electric air dryer) HVAC (eHVAC, Thermoelectric HVAC) Auxiliary Power Unit Power cab accessories from separate fuel source or auxiliary batteries Engine Optimization Improved Tractor Aero. Weight Reduction Electrified Auxiliaries Waste Heat Recovery Hybrid Electric Transmission & Driveline • Enables idle reduction (start-stop) • Many EPA SmartWay-verified products (HVAC, APU, Fuel- Fired Heater)
- 21. 20 Engine Optimization Improved Tractor Aero. Weight Reduction Electrified Auxiliaries Waste Heat Recovery Hybrid Electric Transmission & Driveline Electrified Auxiliaries
- 22. Waste Heat Recovery 21 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 Engine Optimization Improved Tractor Aero. Weight Reduction Electrified Auxiliaries Waste Heat Recovery Hybrid Electric Transmission & Driveline • Large interest in WHR • Well-suited for steady-state travel of OTR trucks
- 23. 22 Engine Optimization Improved Tractor Aero. Weight Reduction Electrified Auxiliaries Waste Heat Recovery Hybrid Electric Transmission & Driveline Waste Heat Recovery
- 24. Hybrid Electric 23 Advanced Technique Commercial Offering Idle Shutdown Program automatic engine shut-off system Micro/Mild Hybrid Electric Vehicle Micro: can shut down engine when idling Mild: 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 Engine Optimization Improved Tractor Aero. Weight Reduction Electrified Auxiliaries Waste Heat Recovery Hybrid Electric Transmission & Driveline • Full powertrain hybridization is difficult to implement for OTR trucks driving at constant speed • Idle Shutdown & Start/Stop systems may make more sense
- 25. 24 Engine Optimization Improved Tractor Aero. Weight Reduction Electrified Auxiliaries Waste Heat Recovery Hybrid Electric Transmission & Driveline Hybrid Electric 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
- 26. Transmission & DrivelineImprovement 25 Advanced Technique Detail Automated Manual Transmission Automatic clutch actuation Automatic Transmission Torque converter Engine Optimization Improved Tractor Aero. Weight Reduction Electrified Auxiliaries Waste Heat Recovery Hybrid Electric Transmission & Driveline • Advanced transmission enables other key technologies: – Hybridization, – Downspeeding, – Downsizing.
- 27. 26 Advanced TechniqueCommercial Offering Automated Manual Transmission Volvo iShift Eaton UltraShift Detroit DT12 Automatic Transmission Widely available Engine Optimization Improved Tractor Aero. Weight Reduction Electrified Auxiliaries Waste Heat Recovery Hybrid Electric Transmission & Driveline Transmission & Driveline Improvement
- 28. Other Technologies 27 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… Engine Optimization Improved Tractor Aero. Weight Reduction Electrified Auxiliaries Waste Heat Recovery Hybrid Electric Transmission & Driveline • Other technologies have made their way into the market • Focus on driver is a cost-effective solution
- 29. Other Technologies 28 Engine Optimization Improved Tractor Aero. Weight Reduction Electrified Auxiliaries Waste Heat Recovery Hybrid Electric Transmission & Driveline
- 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.
Editor's Notes
- #7 HTUF effort to align industry/commercial technology development efforts to military’s tactical wheeled & combat vehicle fleet needs Identifying cross-cutting issues & industry/military collaboration opportunities to quicken military adoption of new comm’l technologies Operates bi-directionally – military OEMs/suppliers + military requirements writers, planners and end-users Use action group as a mechanism to transfer HTUF process, knowledge base/relationships to insert advanced efficiency tech on military platforms Provide focused attention & action on key cross-cutting issues that support TARDEC’s long-term strategy Connect industry stakeholders with developers of military requirements (TRADOC) & end-users (PMs & PEOs) TARDEC Themes: Weight Reduction Autonomy Efficiency
- #8 Freight efficiency is gallons per ton-mile Current BTE ~42%
- #9 Heavy duty is 4% of vehicles on U.S. roads, 18% total fuel consumption (including non-vehicle usage)
- #10 Demonstrated WHR system on-vehicle, completed Advanced AMT Predictive cruise control installed Engine system optimized and calibrated Additional Focus: Tractor & trailer combination, aerodynamics, light weighting, battery APU
- #11 Completed drive train improvement Modeled WHR system Developed predictive engine control system Additional Focus: Hybridization, downsized (11L) engine, electrification of auxiliary systems, aerodynamics, weight reduction
- #12 Completed simulations in hybridization and combustion efficiency Achieved major aerodynamic and light-weighting gains Additional focus: WHR, idle reduction, reduced rolling resistance tires
- #13 Demonstrated major efficiency gains from powertrain integration Validated initial trailer on-road optimization gains and completed modeling of aero systems Additional focus: engine efficiency, aerodynamics, Rankine WHR, idle reduction, reduced rolling resistance tires, light-weighting
- #15 Note: From here onward, Bolded Black text is commercially available, Bolded Red text is of key interest to Military
- #16 Clockwise From Left: Cummins ISX 15L w/Eaton Automated Manual Transmission, DD15, Volvo XE Powertrain Package (11,13,16L Volvo Engine and iShift automated manual transmission)
- #18 Clockwise from Top: wheel covers on back tractor wheels, side skirts and rear fairing on trailer, rear view cameras, vortex generators
- #20 Tires are different for military
- #22 Clockwise from top right: Kohler APU (diesel-powered), ThermoKing TriPac APU (diesel-powered), Bergstrom BAC (battery-powered), Airtronic Fuel-Fired Heater (diesel)
- #23 A Flywheel Turbine: DD15 adds 50 hp and still improves fuel economy by 5 percent. The system works by using a conventional Holset HX55 turbo without a wastegate that feeds into a unique "turbo compound axial power turbine" that transfers power directly to the engine flywheel. By scavenging exhaust heat that would normally fly out of the tailpipe, the "axial power turbine" is able to spin a small gearbox that helps create up to 100 lb-ft of torque when the engine is under a full load.
- #24 Clockwise from Top Left: Cummins-Peterbilt Organic Rankine WHR layout, Bowman Power electric turbo generator A Flywheel Turbine: DD15 adds 50 hp and still improves fuel economy by 5 percent. The system works by using a conventional Holset HX55 turbo without a wastegate that feeds into a unique "turbo compound axial power turbine" that transfers power directly to the engine flywheel. By scavenging exhaust heat that would normally fly out of the tailpipe, the "axial power turbine" is able to spin a small gearbox that helps create up to 100 lb-ft of torque when the engine is under a full load.
- #26 Left to right: Eaton Hybrid (Coke), ArvinMeritor Hybrid (WALMART), BAE hybrid
- #29 Driver Aid systems important to automation of military vehicles Highlight military applicability
- #30 Clockwise from Top Right: Volvo LED lights (standard on new vehicles), Road Train (Longer Combination Vehicles), Driver Aid System, Automatic Tire Inflation System Driver Aid systems important to automation of military vehicles Highlight military applicability