Transitioning SuperTruck Technologies to Commercial and Military ApplicationsJune 17th, 2014Ted Bloch-Rubin, Jean-Baptiste Gallo, CALSTART

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

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?