supertruck - energy.gov€¦ · volvo group north america. june 9. th, 2016. 2. project overview....
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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.
]
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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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