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# SuperTruck Program: Engine Project Review Recovery Act
– Class 8 Truck Freight Efficiency Improvement Project PI: Sandeep Singh (Engine)

Detroit Diesel Corporation June 20, 2014 Project ID: ACE058 This presentation does not contain any proprietary, confidential, or otherwise restricted information2 

### Overview

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### Project start: April 2010

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### Project end: March 2015

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### Percent complete: 80 %  WHR performance trade - offs and cooling challenges on - board vehicle.

 Complex controls architecture and integration of powertrain and novel technologies.

 Reliability of prototype systems in development and demonstration phase.

 Low temperature transient emissions controls.

 Realistic 55% engine BTE roadmap. 

# Budget Timeline Barriers & Challenges

Partners  

### Engine Budget $31,633,001

 

### DOE Share* $12,883,779

 

### Detroit Share* $12,883,779
* Program spending through March 2014 for engine R&D; vehicle R&D expenses reported separately.  

### Department of Energy
 

### Oak Ridge National Laboratory
 

### Massachusetts Institute of Technology
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### Atkinson LLC
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### Daimler Trucks North America
 

### Daimler Advanced Engineering

# Daimler Truck SuperTruck Program

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

 

### 30% increase via vehicle improvements.

 

### 20% increase via engine improvements; specifically 50% brake thermal efficiency.

 

### Identify pathway to 55% brake thermal efficiency via modeling and analysis. Approach and Relevance

 ARRAVT080

– DTNA SuperTruck vehicle program; PI – Derek Rotz

 ACE058

– Detroit Diesel SuperTruck engine; PI

– Sandeep Singh Engine Downspeed & Downsize4 

# SuperTruck Demonstration Status

 Prototype A - sample SuperTruck vehicle built and being utilized for testing and development.

 Successful integration of complex technologies

– EHR , hybrid & HV systems, controllers and network architecture, new cooling layout, new hydraulic systems, powertrain.

 Final demonstration truck builds in progress.



### 46.8% 47.9%

1.3% 2.3%

PY3 PY4 

## Brake Thermal Efficiency Engine WHR 48.1% 50.2% Enablers for Project Year 4 (PY4) BTE Improvement  2.1%

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

 Third iteration of turbo - charger.

 Optimized liner cooling.

 EGR waste heat recovery.

 WHR component and calibration optimization. 

### Technical Accomplishments and Progress

# SuperTruck Core Engine BTE Status 47.9% BTE SuperTruck Core Engine Technology P ackage
• Downsizing to 10.7L from 14.8L
• Reduced EGR & o ptimized turbocharger and air system match
• Higher c ompression ratio, piston bowl optimization, matching injector nozzles
• Variable speed water pump
• Low viscosity oil and higher oil film temperatures
• Piston kit improvements
• High efficiency, lower restriction aftertreatment 

# + + + +

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### Technical Accomplishments and Progress

# Piston and Compression Ratio

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# Fuel Injection System  Optimized combustion package for best fuel economy.

 Peak firing pressure increased by 15%.

 Plans to test even higher CR. (55% scoping )

 Efficient part load operation, but challenges with high load durability, head & block design and material, NVH, emissions.

 Best injector and piston combination selected after extensive testing.

 C ombination of single cylinder and multicylinder platforms used for this investigation. 

### Technical Accomplishments and Progress

# Air Handling

 Turbo sized for reduced EGR and air mass contributing to lower pumping losses.

 Tuned for a downsped engine.

 Engine air system design leverages a lower power rating required for the aerodynamically and parasitically efficient SuperTruck.

 Approach requires a very high efficiency SCR and low backpressure aftertreatment (ATS).

7  Variable speed water pump, lower viscosity oil, bundled cylinder kit improvements.

 Altered cooling to mid stroke area of the liner (Detroit/MIT). 

# Parasitic Reductions

Further Investigations (55% Scoping)...

 Next evolution of liner cooling optimization (Detroit/MIT).

 New lubricant formulation ( MIT+oil supplier ).

 Oil circuit and pump optimizations (MIT ). 

### Technical Accomplishments and Progress

# SuperTruck Engine Control Approach

8  Model based controls (MBC) optimize fuel economy and constraint emissions in real time .
 Extensive transient & steady state mapping used to calibrate engine models.

 Both offline & real time optimization of engine set - points for improved transient performance & fuel economy. 

### Approach and Relevance9 

# Engine Controller Accomplishments

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### Controller implemented on a micro -autobox on- board vehicle.
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### Standardized and reduced calibration process for each hardware iteration.
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### Real time optimization on dynamometer successfully drives the engine to a broad range of emissions/fuel economy trade -offs.
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### Preparation for demonstration vehicle testing is currently underway, to quantify transient fuel economy impact on the vehicle.

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### Future development of MBC includes
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### P redictive route adaptation
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### E nvironmental and aging adaptation
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### Virtual sensing for diagnostics Technical Accomplishments and Progress10 • Low EGR reduces pumping losses.

• Lower backpressure further reduces pumping losses.

• Higher engine out NOx:PM ratio lends to an over the road passive regeneration tendency.

• Savings in over the road active regeneration fuel . ATS Engine

• Lower backpressure device

• High performance SCR catalyst, thin
- wall DPF, high flow DEF doser

• Insulated exhaust and ATS on the vehicle

• Very high NOx conversion over the road to maintain emissions compliance with high engine out NOx (steady state) 

# Aftertreatment System

• EPA10 RMC and road load compliance demonstrated.

• Low temperature transient challenges being addressed by engine+ATS systems approach

• Real world degradation/ aging of a system required to consistently perform at high efficiency is a challenge Emissions Compliance 

### Technical Accomplishments and Progress

# Waste Heat Recovery (WHR)

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### System functional on A - sample SuperTruck prototype.

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### Successful integration with the HV hybrid system and a modified cooling package. Scroll Expander Boiler

Prototype Components Coupled Expander Generator

S tator model Wound field, n o - rare earth e - machine 

### Technical Accomplishments and Progress

Lab schematic of Rankine heat engine

# WHR Progress & Accomplishments

12 • Primary contributor to PY4 efficiency improvement is EGR heat recovery and component optimizations.

• Current approach has numerous vehicle integration challenges.

• Analytical stretch projections assume improved component efficiencies, CAC heat recovery, and a low temperature condenser approach.

• Analytical stretch may prove to be impractical with state of the art vehicle technology. 

### Technical Accomplishments and Progress

# WHR Vehicle Integration

13 Underhood cooling challenges, bigger condenser radiator 

### T exh,avg Smaller, efficient, boiler



### T amb 

### T

b ,avg 

### T

c,avg Bigger boiler 

### T

b ,avg 

### T

c,avg Compact condenser radiator  WHR vehicle cooling requires a holistic approach.

 Integrated vehicle, engine & WHR system models leveraged for design and layout. 

### Process Temperature I mpact on D esign Electrical Vs. Mechanical Feedback Electrical Mechanical Pros Better energy management Higher efficiency Cons Hybrid dependent System sealing challenges w/ shaft seals, mag coupling etc. 

### Barriers & Challenges

# ORNL C ollaboration on Dual Fuel

• E xplore dual - fuel operation within the constraints of a stock engine

• Potential petroleum displacement in conventional modes

• Potential ɳ % and emissions impact in low temperature combustion (LTC) modes (55% BTE scoping)

• Evaluate LTC and limitations on a multi - cylinder engine

• C ombustion stability & phasing

• H igh PMAX, dP / dt & EGR

• Detroit engine modified for PFI natural gas, DI diesel

• Fyda Energy Solutions providing Sequential PFI hardware

• Engine installation and system integration underway, dual - fuel experiments scheduled for Summer 2014

• Fundamentally targeting a more optimum ROHR at part load, within the mechanical constraints of the engine

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### Approach and Relevance

# 55 % BTE Scoping Activities in 2014

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### Analytical Sub - System Testing Combustion Even Higher CR LTC & Dual fuel WHR

Friction Reduction Air System I deal HRR scoping In - cylinder insulation Mechanical Feedback Component optimization, Beyond exhaust recovery, Low temperature condensation
Further EGR reduction Engine Simulations Parameterized models for engine design & configuration impact on part load efficiency Liner insulation iterations, New oils Oil circuit modifications High efficiency turbo, Low restrictions E

- TC

Preliminary analytical estimates for 55% BTE roadmap 

### Approach and Relevance

# SuperTruck Partnerships and Collaborations Collaborations/Partnerships
Department of Energy:  Roland Gravel  Gurpreet Singh  Ken Howden  Carl Maronde

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### Engine

Fleet Powertrain/Parasitics Hybrid

Transmission 

### Aero/Cooling Atkinson LLC 

### Aftertreatment

# SuperTruck Program Summary

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### 50.2% engine BTE demonstrated including WHR.

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### Weight neutral engine target; downsized engine with WHR.

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### WHR functional on prototype A - sample SuperTruck.

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### Remaining 1 year of SuperTruck
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### Demonstrate efficacy and FE advantage of model based real time engine controls on board the demonstrator SuperTruck vehicle.

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### Performance and controls tuning for engine & WHR ongoing for demonstrator chassis.

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### Demonstrator chassis and truck build ongoing; FE and performance demonstration to start September.

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### Sub - system level testing and analysis for 55% BTE building blocks initiated.

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### Final reporting.

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### Summary and Future Work