Daimler Trucks and Buses 1 

# Super Truck Program: Vehicle Project Review Recovery Act
– Class 8 Truck Freight Efficiency Improvement Project

Project ID: ARRAVT080 This presentation does not contain any proprietary, confidential, or otherwise restricted information 

## Derek Rotz (PI & Presenter) 

## Dr. Maik Ziegler Daimler Truck North America LLC June 19 th 

## , 2014Daimler Trucks and Buses 2 

## Overview

• 

## Project start: April 2010

• 

## Project end: March 2015

• 

## Percent complete: 80% • Resolve thermal & fluid dynamics tradeoffs between aero & cooling

• Rejecting more heat in a smaller, aerodynamic hood &

engine compartment

• Development of safe and efficient high voltage power

distribution, integrating multiple HV energy sources

• Making tradeoffs between efficiency, cost and weight

• Vehicle controls integration (aux , hybrid , powertrain ,

waste heat , predictive ) 

# Timeline

Budget Barriers

Partners • Total project $79,119,736

• Vehicle budget $47,486,735

– DOE share (*) 

## $15,526,639

– DTNA share (*) 

## $ 15,526,639 (*) through Feb, 2014 for vehicle R&D expenses only, engine R&D expenses reported separately • Detroit Diesel

• Schneider National, Walmart

• National Renewable Energy Lab

• Oregon State University

• Strick Trailer

• Michelin

• ...Daimler Trucks and Buses 

# Objectives and Milestones

Timeline Phase Description Milestones 4/10

– 3/11 Analysis: (1) Technology Modeling/Analysis and Initial Component Development and Demonstration Develop analytical roadmap:

• 50% vehicle freight efficiency improvement

• 50% engine brake thermal efficiency 4/11

– 3/12 Specification: (2) Experimental Demonstration of Technology Building Blocks for Intermediate Goals Experimentally d emonstrate technology building blocks:

• 25% vehicle freight efficiency improvement (system level test)

• 46% engine brake thermal efficiency 4/12

– 5/13 Design: (3) Technology Identifications and Final Component Development and Demonstration Identify and initially develop technology building blocks:

• 50% vehicle freight efficiency improvement (system level test & analysis)

• 50% engine brake thermal efficiency 6/13

– 6/14 Build: (4) Experimental Demonstration of Technology Building Blocks for 50% Engine Thermal Efficiency and 50% Vehicle Efficiency Experimentally demonstrate technology building blocks:

• 50% vehicle freight efficiency improvement (system level test)

• 50% engine brake thermal efficiency
7/14

– 3/15 Test: (5) Final System Integration and Demonstration Experimental demonstration:

• 50% vehicle freight efficiency improvement (entire vehicle test)

• 50% engine brake thermal efficiency (engine test)

• 55% engine brake thermal efficiency (engine analysis)

3 

## Develop and demonstrate a 50% total increase in vehicle freight efficiency:

• At least 20% improvement through a heavy

- duty diesel engine capable of achieving a 50% brake

- thermal efficiency

• Identify key pathways towards achieving 55% through modeling and analysis 

## Objectives/RelevanceDaimler Trucks and Buses 

# Phase I Milestone Completed 

#  Analytical roadmap development to 50% vehicle FEI & 50% engine BTE

4 Baseline Tractor

• 2009 Cascadia 125”BBC, 72”RR

• DD15 Engine 455hp/1550 lb

- ft Vehicle Test

• Baseline Peformance Measurements

• Highway Cycle (55 &65 mph)

• Idle Cycle (summer, winter)

• City Cycle 

## SuperTruck

Modeling & Analysis

• Establish System Level Technical Targets Roadmap: Engine Roadmap: Vehicle 

## Approach

(Engine topics covered in separate session)Daimler Trucks and Buses 

## 0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0 50.0 55.0

5 (to 48.1% BTE) (incl. idle reduction) (Scale WT) 

# Phase 2 & 3 Milestone Status 

#  Experimental testing to 25% & 50% vehicle freight efficiency* Freight Efficiency Improvement %

- ( system level measurements) 50.0

Engine 14.5%

Parasitic Losses

1.0%

Energy Management 3.5%

Lightweight 5.0%

Powertrain Drivetrain Aerodynamics 16.0%
Tractor Trailer 16.5% 2.4%

(incl. hybrid) 

## Approach

* Technical Accomplishments covered in the 2012

- 2013 Annual Merit ReviewsDaimler Trucks and Buses 

# Phase 4: Road to 50%

2009 Baseline Cascadia 6 

## Approach

A- Sample A- Sample

• Aero hood, bumper, grille

• Downsized Engine, Automated Manual Trans. + eCoast

• Waste Heat Recovery (electrical expander & vehicle cooling)

• 6x2 Axle Tall RAR + oil management

• Hybrid Electric Powertrain (120kw eMotor , 360v, 2.4 kw- hr usable Li

- Ion Bat)

• eHVAC (HV compressor, remote condensor , electrical fan)

• eMotor engine start

• Cab insulation package

• Clutched air compressor

• Electronic air control

• AccuSteer

• Low RR wide based single tires

• Thermal management

• Trailer aero., lightweighting and solar

2009 Baseline Cascadia Final DemonstratorDaimler Trucks and Buses 

# A- sample SuperTruck Build

Testing completed to date:  Full Scale Wind Tunnel ( underhood airflow)  eMotor cold start  Thermal tunnel test  

### eHVAC test & calibration  

### Vehicle Performance Testing 

## Purpose: to prototype a functional chassis to integrate vehicle systems :  Downsized Engine, Waste Heat, Hybrid, Cooling  High Voltage Power Distribution  Powertrain/Drivetrain Integration  Software integration e.g. Shift optimization  Packaging, Routing & Plumbing etc.

7 

## Technical Accomplishments A- Sample TruckDaimler Trucks and Buses 

# Waste Heat Recovery Status Accomplishments

• 

## Successful Key

- on workshop in November including HV electrical components

• 

## 6kw peak exhaust energy recovered under high load, steady state conditions

Current Tasks

• 

## Develop de

- aeration strategy

• 

## Improve control stability during transient operation

8 

## Technical Accomplishments A- Sample TruckDaimler Trucks and Buses 

# A- Sample Thermal Tunnel Testing Vehicle Measurements Ambient Capability Engine + Waste Heat

• 

## 113 ° F (45 ° C) reached
Engine Air Intake

• 

## Stayed below temperature rise limits

• 

## Pressure measurements noisy

Fan Speed Characterization

• 

## Swept temperatures ( 25

- 40 ° C)

• 

## Swept wind speeds (20

- 40mph )

• 

## Grille open & closed positions

• 

## Fan speed remained below 1000 RPM

9 

## Technical Accomplishments A- Sample TruckDaimler Trucks and Buses 

# A- Sample Air Flow Study in Wind Tunnel Vehicle Measurements

Cruise Speed (58mph) Air Flow (kg/ s) Drag A

- sample configuration Eng, WHR, CAC Δ C d (0

°

Yaw) Nominal baseline baseline Cooling optimized grille +3% 0% Aero optimized grille

- 57%

- 6%

SuperTruck Program 10 

## Technical Accomplishments A- Sample TruckDaimler Trucks and Buses 

# eMotor Cold Start Test Vehicle Measurements Test Procedure

• 

## 24 hour cold soak

• 

## 0 to

- 15 ° C by 5 ° incr. Observations

• 

## No eMotor torque increase at lower temps.

• 

## Peak Li

- ion battery current at 112A Conclusions

• 

## Temperatures of

- 15 ° C easily achievable

• 

## Data indicate

- 20 to

- 25 ° C starting possible

• 

## >1% Freight Efficiency gained

• 

## Omit starter and Pb- Acid starting batteries

11 

## Technical Accomplishments A- Sample TruckDaimler Trucks and Buses 

# Vehicle Level Performance Test  March

- April, 2014: On Highway Fuel Economy Test

12 

## Technical Accomplishments A- Sample Truck

Gross Vehicle Weight ( lb ) Total 65,000 Tare 34,000 Payload 31,000

Gross Vehicle

Weight ( lb ) Total 65,000 Tare 32,450 Payload 32,550

0 4 8 12

3/26 3/27 3/31 4/1 4/8 4/9 4/10Fuel Economy(mpg)

PCP SDS Daily Fuel Economy

A-Sample Baseline 1550 lbs. additional freight on A - Sample  5% Freight Efficiency Improvement

52.0% 61.6% 5.0% 5.0%

PCP SDSA-Sample % improvement(ton-mpg) Freight Efficiency Improvement (measured)

Fuel Weight 57% 66 % Grade Profile San Antonio Dallas (SDS)

65 mph

Portland Canyonville (PCP)

Grade Profile 55 mphDaimler Trucks and Buses 2009 Baseline Cascadia Final Demonstrator

Final Demonstrator A- Sample Technologies, plus...

• Full Tractor Aero

• 50% BTE Engine + WHR

• Predictive hybrid & engine controllers

• Axle - Active oil management with FE gear oil

• Lightweight Aluminum Frame and cross members

• Ultra Lightweight Air Suspension

• Smart 6x2

• Solar reflective paint

• Enhanced Trailer aerodynamics 

# Phase 4: Road to 50%

13 

## Approach

2009 Baseline Cascadia A- SampleDaimler Trucks and Buses 

# Aerodynamics Validation in Scale Model Wind Tunnel SuperTruck vs. Baseline

14 Tractor 67 % Trailer 33% Percentage of

Test Runs

Tractor

Δ C d

- 15 % Trailer Δ C d - 39 % Drag Reduction

Contribution 

## Technical Accomplishments Final DemonstratorDaimler Trucks and Buses 

# Final Demonstrator Build

Cab Interior

• Sleeper design complete

• Components & assy. ongoing

• Ship to Portland in June 

## Cab Exterior

• Design release complete incl. A&B side parts

• Molds & exterior parts 80% complete

• Pre- fit completed by June 

## Chassis

• Frame, Suspension, Axles complete

• Powertrain & cooling Installed

• Wiring & plumbing on

- going



## Build progressing for Sept 1 st 

## FE test start

15 

## Technical Accomplishments Final DemonstratorDaimler Trucks and Buses 

# SuperTruck Partnerships and Collaborations

16 

## Collaborations/Partnerships

Energy Management

Lightweighting Aero/Cooling

Fleet Hybrid

Powertrain/Parasitics

Engine Transmission

Trailer 

## Department of Energy:  

## Roland Gravel  

## Ken Howden  

## Gurpreet Singh  

## Carl MarondeDaimler Trucks and Buses 

# Summary and Future Work Successful completion of phases 1

- 3; Phase 4 targets met 

#  50% Vehicle Freight Efficiency target exceeded on A

- Sample vehicle through testing on Portland

- Canyonville and San Antonio

- Dallas routes 

#  50% Engine Brake Thermal Efficiency target exceeded in engine test cell Next Steps

• 

## Complete buildup of 2 final demonstrator vehicles

• 

## Conduct f uel economy testing

17 

## Summary/Future Work

### Department 

# Backup

18Daimler Trucks and Buses 19 

# Project Year 4 (PY4) Engine BTE Improvement  2.1% points

 

## PY4 Enablers

 

## Further increase in compression ratio (CR), piston bowl and matching injector profile optimization.

 

## 3 rd 

## Iteration of turbo

- charger.

 

## Optimized liner cooling.

 

## EGR waste heat recovery.

 

## WHR component and calibration optimization. 46.8% 47.9%

1.3% 2.3%

PY3 PY4 

# B rake T h ermal E fficiency Engine WHR

48.1% 50.2% Backup