mike kenyon caterpillar

© 2017 Energy Technologies Institute LLP - Subject to notes on page 1

Mike Kenyon

Caterpillar

Heavy Duty Vehicle Project

Caterpillar: Non-Confidential

Caterpillar – ETI HDV Land


Caterpillar in the UK

500,000Engine capacity

Over 20 million engines built

85% exported

20 UK manufacturing facilities

Over 80 years of experience

Over 9,000 UK employees

60% Of all Caterpillar engines

in Peterborough

designed and manufactured in the UK


Heavy Duty Vehicle Project

Phase 1

Define the HDV Sector

Identify Potential Technologies

Phase 2

Technology Development

• Air system – Caterpillar with Honeywell

• Aftertreatment – high efficiency SCR -

Caterpillar with Johnson Matthey

• Cooling and high temperature fluids –

Petro Canada

• HVAC system - Climatewell

• Transmission – high efficiency

continuously variable transmission -

Caterpillar

• Lower powertrain – parasitic loss

reduction – Romax

• Kinetic energy recovery systems –

hydraulic and flwheel – Caterpillar and

Flybrid

Phase 3

Technology Integration and

Demonstration

• Engine system

• Air system

• Aftertreatment system

• Cooling and High Temp Fluids

• HVAC system

• Hydraulic system

• Transmission system

• Lower Powertrain

• Rolling resistance optimisation

• Kinetic energy recovery system

• Full benefits only come from complete integration of

all systems

• Drivetrain Simulator (DTS) allows back to back

testing of different drivetrain configurations - allows

for repeatable test cycles

• Controls models can be used to drive the DTS

allowing rapid development

• Once developed on the DTS learning can be

transferred to Demo machine for validation


Articulated Truck Demo for HDV Sector

High Conversion

efficiency SCR

Continuously

Variable

Transmision

Optimised Rolling

Resistance Tyre

Optimised Rolling

Resistance Tyre

Optimised Rolling

Resistance Tyre

Optimised Rolling

Resistance Tyre

Optimised

Cooling system

with High Temp

Fluids

KERS

Optimised Engine

(No EGR)

Autonomous

HVAC

High

Eff.

Axle

High

Eff.

Axle

Implements

Optimised Rolling

Resistance Tyre

Optimised Rolling

Resistance Tyre

High

Eff.

Axle

Basic driveline layout is common to:• HGV

• MGV

• Bus

• Wheel Loader

• Ag Tractor

Articulated truck application is a challenge for:• Application intensity – load factor, environmental range

• Space claim

• Cost effectiveness


ETI HDV Technology Benefits


H-KERS - System specification:

• 200 kW maximum charge power (@2000 rpm)

• 115 kW maximum discharge power (@1700 rpm)

• 0.9MJ useable storage at PTO

Project Highlights

F-KERS - system specification:

• – 200 kW maximum charge and discharge power (1240 Nm torque at PTO)

• – >0.9 MJ useable storage at PTO(1440 kJ absolute storage)

• – 2000 Nm per second (0.6s time from stand-by to maximum torque available)

• – 30,000 rpm maximum flywheel speed

Drivetrain Simulator (DTS)

• Four Quadrant, 268 kW Dynamometer

• Flexibility to run different machine

types and cycles

• Constant Torque of 9,000 Nm, peak

torque of 12,000Nm for 10 seconds

• Overload capability: upto 1300 rpm:

200% for 3 secs. 150% for 60

seconds, 1,305 rpm to 3,000 rpm:

125% for 60 seconds

High Efficiency SCR

• Allows removal of EGR from engines

• Improved low temperature (real world) capability

• Meets cost targets

• Winner of ‘The Engineer: Collaborate to Innovate awards


• Developing valuable technologies for Caterpillar (and the wider HDV sector)

• Enabled expansion of the UK Research team during global recession

• Catapult for other UK funding mechanisms

• Expanded our interaction with UK Universities

• Expanded our collaboration with UK companies

Caterpillar and the ETI

Flybrid

Avid Technologies

Grainger and Worrall

Denso Marston

Concentric

Romax


• Real benefits to the UK in terms of CO2 emission reductions in the HDV sector• Projected 24% reduction in CO2 emissions across the sector

• Caterpillar membership benefits• In the right place for discussions about carbon emissions

• Caterpillar HDV project benefits• Technology developments that will benefit Caterpillar machines

• Research investment during a lean period

• UK PLC benefits• Direct benefits through ETI and indirect benefits from follow on projects

• UK University benefits• Industry links, Research projects, student placements and Graduate positions

ETI HDV Project Benefits and Legacy

mike kenyon caterpillar

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