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
• 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
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
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
• 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
10
12. 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
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
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
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
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
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
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
Freight efficiency is gallons per ton-mile
Current BTE ~42%
Heavy duty is 4% of vehicles on U.S. roads, 18% total fuel consumption (including non-vehicle usage)
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
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
Completed simulations in hybridization and combustion efficiency
Achieved major aerodynamic and light-weighting gains
Additional focus: WHR, idle reduction, reduced rolling resistance tires
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
Note: From here onward, Bolded Black text is commercially available, Bolded Red text is of key interest to Military
Clockwise from Top: wheel covers on back tractor wheels, side skirts and rear fairing on trailer, rear view cameras, vortex generators
Tires are different for military
Clockwise from top right: Kohler APU (diesel-powered), ThermoKing TriPac APU (diesel-powered), Bergstrom BAC (battery-powered), Airtronic Fuel-Fired Heater (diesel)
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.
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.
Left to right: Eaton Hybrid (Coke), ArvinMeritor Hybrid (WALMART), BAE hybrid
Driver Aid systems important to automation of military vehicles
Highlight military applicability
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