Innovation You Can Depend On 

### David Koeberlein

- Principal Investigator Cummins Inc. 

# Cummins SuperTruck Program Technology and System Level Demonstration of Highly Efficient and Clean, Diesel Powered Class 8 Trucks

June 20, 2014

This presentation does not contain any proprietary, confidential, or otherwise restricted information Project ID: ACE057Innovation You Can Depend On 

## Overview

Budget:

• Total: $77,662,230

• DoE s hare* $36,335,608

• CMI share* $36,335,608 * actuals as of 12/31/2013 Today

Period



### Partners:

• Cummins

– Program Lead & Engine

• Modine

• Oak Ridge National Lab

• Purdue University

• Peterbilt

– Vehicle Integrator

• Peterbilt Partners Peterbilt partner details are included in Peterbilt’s 2014 AMR presentation ARRA

- 081

20Jun2014 2Innovation You Can Depend On 

# Overview

– Program Barriers

• Engine Downspeed (Reduced Engine Speed)
 Powertrain component response

– Closed cycle efficiency gains



### • High Conversion Efficiency NOx Aftertreatment
 Fuel Efficient Thermal Management 

###  Vehicle and Engine System Weight Reduction  Underhood Cooling with Waste Heat Recovery

• Powertrain Materials
 Increased Peak Cylinder Pressure with Cost Effective Materials for Block and Head

– Thermal Barrier Coatings for Reduced Heat Transfer 

###  Trailer Aerodynamic Devices that are Functional

• Parasitic power reductions

More vehicle specific details are included in Peterbilt’s 2013 AMR presentation ARRA

- 081

20Jun2014 3Innovation You Can Depend On 

## Relevance

- American Recovery and Reinvestment Act (ARRA) & VT ARRA Goals

• ARRA Goal: Create and/or Retain Jobs

• ARRA Goal: Spur Economic Activity

• Greater than $72.6M total spend to date (ref: thru Dec 2013)



## • Goals align with VT Multi

- Year Program Plan 2011

- 2015

• Advanced Combustion Engine R&D (ACE R&D):

• 50% HD engine thermal efficiency by 2015 (ref: VT MYPP 2.3.1)



### • Vehicle and Systems Simulation and Testing (VSST):

• Freight efficiency improvement of 50% by 2015 (ref: VT MYPP 1.1)



## • Invest in Long Term Economic Growth

– Freight transport is essential for economic growth

• Commercial viability assessment Year 2010 2011 2012 2013 2014
Full Time Equivalent 75.5 85 60 46 17 States: Indiana, Texas, Michigan, Wisconsin, Tennessee, Illinois, California, Colorado, New York Projections

20Jun2014 4Innovation You Can Depend On 

## Approach

– Vehicle Energy Analysis

Analysis of 27 Drive Cycles for Class 8 Vehicles with a Variety of Seasons (Summer, Winter, etc.)



## Analyze: Where is the energy going? Identify priority. Cummins Peterbilt

Bridgestone & Goodyear Eaton & Dana Delphi & Bergstrom Weight Reduction

20Jun2014 5Innovation You Can Depend On WHR Engine System Advanced Cab and Trailer Aerodynamics

Battery

APU Weight Reduction 

## Technical Accomplishments

- Freight Efficiency Enabling Technologies

GPS Cruise Control

Advanced Single Tires Advanced Formula Aftertreatment

Efficient Cooling Package

Retractable Trailer Skirts

Reference: Objective 2

• Vehicle details are included in Peterbilt’s 2013 AMR presentation ARRA

- 081

6 20Jun2014Innovation You Can Depend On 

## Technical Accomplishment

– 24 hour Freight Efficiency Test Results

75% Fuel Efficiency Improvement 86% Freight Efficiency Improvement

43% CO2 Reduction

Reference: Objective 2

• Vehicle details are included in Peterbilt’s 2013 AMR presentation ARRA

- 081 SuperTruck @ DoE Headquarters

– 19Feb2014

20Jun2014 7Innovation You Can Depend On 

## Technical Accomplishment

– Freight Efficiency Status

Reference: Objective 2

• Vehicle details are included in Peterbilt’s 2013 AMR presentation ARRA

- 081

20Jun2014 8Innovation You Can Depend On 

# Approach

- Integration of Cummins Component Technologies Air Handling & EGR

Fuel Systems Combustion
Aftertreatment (AT)

Electronic Controls

Waste Heat Recovery

20Jun2014 9Innovation You Can Depend On 

### WHR mechanical open closed thermal 

### + = η η η η * *

   

 

   

 

      =

D Energy

GIMEP

fuel closed η 

# Approach

– 55% Thermal Efficiency

1. Exhaust 2. Coolant/Lube 3. Air

      +

=      

= GIMEP PMEP GIMEP GIMEP NIMEP

open η

     

+ =      

= FMEP BMEP BMEP NIMEP BMEP

mechanical η

Reference: Objective 3

20Jun2014 10Innovation You Can Depend On 

## Approach

– 55% Engine Technology Scoping

- Fuels

Diesel PreMix Dual Fuel AFCI

Conventional DieselPremix Fuel Quantity**



### Quantity of Alternative Fuel* 0% 100% Dual Fuel HCCI

Conventional Dual Fuel Diesel

PCCI

Diesel LTC



### 0% 100% 

## Single Alternate Fuel HCCI

Compression Ignition



### 1. Analytical >> Experimental 2. Design Space is Broad 3. Fuel Study

• Lower Heat Transfer

• Control Burn Duration

• Increase Effective Expansion Approach #1

Approach #2

20Jun2014 11Innovation You Can Depend On 

## Technical Progress

- Improvements (Based on Engine, AT & WHR Testing)

Engine Brake Thermal Efficiency (%)Program Baseline–42% Objective 1 50% BTE

*WHR

- Cummins Organic Rankine Cycle Waste Heat Recovery Status 2013 Merit Review: Engine + High Efficiency AT + WHR (Engine, AT & WHR System Testing)

42% 43% 44% 45% 46% 47% 48% 49% 50% 51% 52% 53% 54% 55% Achievement to date 51% Objective 3

55% BTE

Dual Fuel Engine only (10bar) WHR Load increase Diesel Engine only WHR Inj , Piston & Parasitic Revisions 2014 55% BTE Efforts

20Jun2014 12Innovation You Can Depend On 

## Technical Progress Optimized Piston Bowl

– Genetic Algorithm

• 131 bowl generations computed

– Compression ratio increase 

###  O ptimized profile outperformed P1

13 Objectives

 Minimize GISFC

 Constrain NOx, PM, Peak Cylinder Pressure & Pressure Rise Rate

BTE impact: + 0.5% BTE

20Jun2014Innovation You Can Depend On 

## Technical Progress Optimized Injector

– Single Cylinder Engine

TDC

Increased efficiency



### • Seeking to minimize combustion duration

• Seeking to control combustion phasing for optimum efficiency 1.3pt Close Cycle Efficiency Gain

Impact of injection rate shape at constant intake conditions 

### • Injection rate shape revised with injector specification

– Controls combustion heat release rate

14 20Jun2014Innovation You Can Depend On 

## Technical Progress

– Piston Thermal Solutions

15 Piston A: Max Temp = 345 C Piston B: Max Temp = 386 C Base Piston: Max Temp = 254 C

0.6 pt heat loss reduction 0.3 pt GITE improvement 0.3 pt heat loss reduction 0.1 pt GITE improvement
BTE impact: + 0.8% BTE

20Jun2014Innovation You Can Depend On 

## Technical Progress – Improved WHR T urbine Expander & Parasitic Reductions

• Friction and Parasitic reduction

– Piston/ring pack/liner changes

– Piston cooling flow reduction

– Main & rod bearing 

### • Improved turbine efficiency

• System heat exchanger architecture arrangement

– Pre

- heat of low pressure loop

~50 % Reduction +1.8hp

BTE impact: + 0.7% BTE

BTE impact: + 0.6% BTE

16 20Jun2014Innovation You Can Depend On Demonstrated SuperTruck 

## Technical Progress Conventional Diesel Path to 55% BTE

17 20Jun2014Innovation You Can Depend On 

## Technical Progress

- Alternate Fuel Compression Ignition (AFCI)

– Analysis to Experiment Status

• Experiments align to analysis

– Analysis showed peak efficiency between 14 to 16bar

– Temperature sensitivities observed

• Control system compensation algorithms helpful to manage cyl

- cyl variation

• ORNL probe test for residual gas & Tivc

• WHR estimates revised to experimental heat availability 55% Goal Untested Load Range

20Jun2014 18Innovation You Can Depend On 

## Technical Progress AFCI Efficiency and Emission Capability

• Demonstrated AFCI engine efficiency of 49.4% BTE

• NOx emission low

• HC emission reasonable for DOC formulations

19 20Jun2014Innovation You Can Depend On 

## Technical Progress AFCI Combustion Phasing Control

CONTROLLER ON CONTROLLER OFF 

## • Combustion phase control system developed

– Cylinder

- to

- Cylinder & Cycle

- to

- Cycle controller

– Enables independent control

• Maximized overall multi

- cylinder engine capability

• Robustness to cylinder

- to

- cylinder and cycle

- to

- cycle variations

20Jun2014 20Innovation You Can Depend On 

### • Purdue University

– Completed diesel PCCI study

– Explore range expansion



### – Diesel engine VVA

– Commissioned intake & exhaust VVA test bed

– VVA functional analysis 

## Collaborations – ORNL & Purdue Participation

• ORNL

– Sensing methods for model development and validation of:

• Tivc determination

– EGR fraction

– Residual fraction

Modeling & Simulation Presented: ACE077 - Partridge

21 20Jun2014Innovation You Can Depend On 

## Reviewer Comments and Responses

Many complimentary comments:

• Project had accomplished objectives on time to date

• Observed a large project team, incorporating laboratories, industry and universities. Recommendations:

• Cautioned that the 55 % goal approach relied upon HCCI and dual fuel, where these two technologies have not been experimentally proved to be BTE improvement friendly technologies. The reviewer warned that while dual fuel showed some promising feature, high pumping loss and stability control for transient operation was too tough to overcome. Both technologies suffered high HC emissions. The contractor should demonstrate the technical feasibility with preliminarily convincing data at the current level.

– Comments: We are taking both a conventional diesel and a dual fuel approach. Our analysis path last year had identified a viable path with dual fuel. Over the course of last year, our efforts toward advancing conventional diesel has shown a viable conventional diesel path.

• Cautioned that reliance on dual fuel was risky for a 55% goal, partially due to high HC and CO emissions for cold start.

– Comments: Dual fuel would start on diesel. E mission and speciation sampling during our dual fuel testing has shown HC emission that are reasonable for effective and efficient conversion with a conventional diesel oxidation catalyst (see 2014 slide 20).

• The reviewer commented that Slide 20 only showed two key partners for technical progress (i.e., ORNL and Purdue University), while Slide 7 showed a large number of partners. The information was kind of misleading in terms of collaboration and coordination.

– Comments: As the prime PI, I try to give a program perspective of the overall related partnerships, i.e. 2013 Slide 7, however, the details of this presentation focused more detail on those collaborations and partnerships pertinent to our engine related activities, i.e. 2013 slide 20.

20Jun2014 22Innovation You Can Depend On 

## Milestones and Technical Accomplishments

• March 2013 to March 2014

– Technical Accomplishments √ Demonstrated 86% freight efficiency improvement (Objective 2b

– 24hr) √ 75% fuel economy increase 

### √ Demonstrated 76 % freight efficiency improvement (Objective 2a

– Drive) √ 66% fuel economy increase 

### √ Demonstrated Li

- Ion Battery & SOFC capability √ Completed wind tunnel and vehicle testing of Waste Heat Recovery √ Validated an advanced transmission efficiency model √ Path

- to

- Target analysis for a 55% thermal efficient engine √ Demonstrated AFCI ‘engine only’ efficiency of 49.4% BTE @ 10bar (Objective 3)



## • March 2014 to September 2014

– Future Work

– 55% BTE path to target roll

- up analysis ( Objective 3 )

• Targeted verification testing

20Jun2014 23Innovation You Can Depend On 

# Summary

• Program remains on schedule

– Meeting the ARRA and DoE VT MYPP goals



### • Demonstrated a 50+% BTE engine system (Objective 1)



### • Demonstrated a 70+% vehicle freight efficiency gains (Objective 2a & 2b)

– Analytical roadmaps updated with experimental component data

– Built and tested sub

- systems

• Cummins Waste Heat Recovery vehicle testing (Objective 2a)

• Advanced transmission dynamometer and vehicle test (Objective 2a)

• Solid Oxide Fuel Cell APU in lab and vehicle tests (Objective 2b)

• Li

- Ion battery APU (Objective 2b)

• Tractor

- Trailer aerodynamic aids (Objective 2a)



### • Developed framework and analysis for 55% thermal efficiency

– Completed analytical roadmaps for both diesel and dual fuel approaches

– Completing targeted engine tests to validate roadmaps



### • Developed working relationship with excellent vehicle and engine system delivery partners

20Jun2014 24Innovation You Can Depend On 

# Technical Back

- Up Slides

20Jun2014 25Innovation You Can Depend On 

## Participants

– Who’s doing what Roles and Responsibilities

Participant Responsibility

Cummins Inc. • Prime contractor

• Team coordination

• Engine system

• Vehicle system analysis

Peterbilt Motors Co. • Vehicle Build Coordination

• Vehicle Integration

• Tractor

- Trailer Aero

• Freight efficiency testing
Cummins Turbo Technology Turbomachinery & WHR power turbine
Cummins Fuel Systems Fuel system

Cummins Emissions Solutions Aftertreatment

Eaton Advanced transmission
Delphi Solid Oxide Fuel Cell idle management technology

Bendix Reduced weight brake system and drive axle control Participant Responsibility Bridgestone & Goodyear Low rolling resistance tires

Modine WHR heat exchanger & vehicle cooling module

U.S. Xpress • End User Review

• Driver Feedback

• Commercial Viability Oak Ridge National Laboratories Fast response engine & AT diagnostic sensors

Purdue University • Low temp combustion

• Control models

• VVA integration
VanDyne SuperTurbo Turbocompounding/ Supercharging
Utility Trailer Lightweight Trailer Technology

Dana Lightweight Drivetrain Technology Bergstrom HVAC

Logena Network interface
20Jun2014 26Innovation You Can Depend On 

# Technical Accomplishments

– 50+% Thermal Efficiency Gains
Gross indicated gains

 Comp. ratio increase

 Piston bowl shape

 Injector specification

 Calibration optimization 

### Gas flow improvements

 Lower dP EGR loop

 Turbocharger efficiency 

### Parasitic reductions

 Shaft seal

 VF Lube pump & viscosity

 Geartrain

 Cylinder kit friction

 Cooling & fuel pump power 

### WHR system

 EGR, Exhaust, Recuperator

 Coolant & Lube CP2

Reference: Objective 1

27 20Jun2014Innovation You Can Depend On 

# Cummins Waste Heat Recovery

• Organic Rankine Cycle

• Recovery of:

– EGR

– Exhaust heat

• Mechanical coupling of WHR power to engine

• Low global warming potential (GWP) working fluid refrigerant

• Fuel Economy improvement goal of ~6%

• 1 st 

### vehicle installation Sep2011 Boiler Comp

TurbExh.Manifold

Exhaust Air InIntake Manifold Ram AirflowISX Engine

Power Out FP

EGR Valve CAC WHR Condenser Cooler

Engine Radiator

Mechanical Fan

After

treatment Exh. BoilerRecuperator

Turbine SuperheaterSpeedReduction

Gear Train

Exhaust Control Valve

20Jun2014 28Innovation You Can Depend On 

# Vehicle Freight Efficiency of Aerodynamic Drag Reduction

Configurations Demo 2

- 24% Target Demo 1

- 14% Target Baseline Demo 1

– 18.1%

* Cd's Shown Are Adjusted to SAE J1252 Baseline Using % Average Deltas From 0 and 6 Degree CFD Runs 

### Demo 2

- 24.6%Freight Efficiency Improvement

29 20Jun2014Innovation You Can Depend On 

## Vehicle Weight Reduction

– Freight Efficiency ImprovementWeight Reduction (lb)



### -3000 -2000 -1000 0 1000 2000 3000

WHR/2010 Emissions Aero Devices Idle Systems Onboard Fuel Truck Savings Trailer Savings Net Weight Difference 

### 1305 lb Bonus Freight

30 20Jun2014