SwRI Program Review Program Review

Houshun Zhang

December 10 December 10-11 2014 11, 2014

DRAFT & DELIBERATIVE 
Outline

• Program Objectives Program Objectives• Overview of Technical Work Scope Overview of Technical Work Scope

DRAFT & DELIBERATIVE 
EPA & NHTSA Program Objectiv

EPA

& NHTSA Program Objectiv

EPA: Focused on Compliance 

Methods and Test Procedures

NHTSA : Focused on C

Methods and Test Procedures Stringencies

• Provide comprehensive data sets for 

GEM validations

• Develop and refine various test

Stringencies

• FE/GHG technology base

class 2b-8 engines, vehic

Develop and refine various test trailers

procedures

• Evaluate the relationship between 

aerodynamic trailer devices and fuel 

consumption/CO2 emissions

– Current fleet segments– End of Phase 1 baseline

• Phase 2 technology proje

appro

priate dut

y c

ycles consumption/CO2 emissions

• Evaluate MD/HD powertrain systems 

as one of certification options

• Evaluate different driving cycle impacts 

pp p y y

– Effectiveness– Availability– Cost

• Review of international F

on vehicles regulatory approaches

Vehicles Modeling

Shared

, 

Engines, & 

Test Data

Modeling, 

Engine Maps, 

& Cost Info
Comprehensive GHG II Rulemaking Supp

• Provide valuable data set for GEM 

validation

• Play a critical role in introducing road 

grade into Phase II certification cycles

• Evaluate aero impacts and refine test

• Make dyno test more repre

Evaluate aero impacts and refine test • Provide realistic road grad

procedure

Provide realistic road grad

• Provide dyno coefficient to 

Full Vehicle Test

Engine Test Full Chassis Dyno Tes

Simulate vehicle tests

• • 

Full Vehicle Simulation GEM

• 

• Develop engine fuel mapping 

procedures

• Simulate powertrain test

• Provide most reliable and re

• Identify sources of variability • Prove the values of powertrai

as a viable alternative 

• Simulate engine FTP and SET with 

powertrain system

• Understand relationship between 

powertrain and en

gine tests

GEM validation

• Prove the concept of power

of viable certification option

• Develop powertrain test pro• Identify issues and solution

p g

Powertrain Test
Hardware Tests Hardware Tests

Trucks/Powertrains/Engines 

• Vehicle Tests

1. Kenworth T270 box truck with ISB engine and Allison transmissi2. F650 two truck with ISB engine and Allison transmission3. K th T700 t k ith ISX 15L i d E t AMT Kenworth T700 truck with ISX 15L engine and Eaton AMT4. Cascadia truck with DD15 engine and Eaton Manual transmissio5. Transit city bus with ISX 9L engine and Voith transmission6. Refuse truck with ISL engine and Allison transmission Refuse truck with ISL engine and Allison transmission7. Prostar truck with N13 engine and Eaton AMT

• Powertrain Tests

– MD: Cummins’ ISB 300hp g ratin with Allison transmission– HD: Navistar’s N13 455hp rating with Eaton AMT transmission

• Engine Benchmark Tests

– MD: Cummins’ ISB 240/300 hp g ratin s– HD: Navistar’s N13 410/455/475 hp ratings 

DRAFT & DELIBERATIVE
EPA-SwRI Project Overview Project Overview

- Vehicle Tests

• P i f f hi l t t i t id h i d 

Primary focus of vehicle tests is to provide comprehensive da

for GEM validations

• Three trucks are selected to run a text matrix (T700, T270, an

vehicles)

– 6 additional sets of vehicle variants per vehicle ( “a” and “c” coeff

weights, optimized road load coefficient , etc.)

• Drive cycle evaluations

– Three EPA certification cycles: 55 mph and 65 mph and transien– Three or four additional cycles were run depending on application

delivery, parcel, world harmonize test cycle, city cycle, and refuse 

• Over-the-road hi l t t ith l 8 t k d vehicle tests with a class 8 truck

– One of critical routes to validate GEM with road grade measurement

DRAFT & DELIBERATIVE 
EPA-SwRI Project Overview Project Overview

- Powertrain Test

• Two p y owertrain systems are evaluated

– Medium duty powertrain with Cummins ISB 300hp rating engine and Allison 

transmission 

– Heavy duty powertrain with Navistar N13 engine 455hp rating engine and E

transmission

• The main purposes of the powertrain tests are 

– Evaluate feasibility of powertrain certification options– Develop test procedure of powertrain tests

– Evaluate test-to-test variation between chassis and powertrain tests

• The same driving cycles as vehicle will be evaluated The same driving cycles as vehicle will be evaluated

DRAFT & DELIBERATIVE 
EPA-SwRI Project Overview Project Overview

- Aerodynamic Assessment

• E l t d fi t t d f t d d t 

Evaluate and refine test procedure for coast down and consta

tests

• Tractor trucks trailers trailer aerodynamic devices and equip

Tractor trucks, trailers, trailer aerodynamic devices and equip

– Heavy duty class 8 sleeper cab tractor truck– Heavy duty class 8 day cab tractor truck– 53’ dry box van trailer – Aerodynamic trailer devices

• On-road evaluations of a full road, evaluations of a full-size class 7/8 tractor size class 7/8 tractor-trailer com

trailer com

with and without aerodynamic trailer devices

DRAFT & DELIBERATIVE 
EPA-SwRI Project Overview Project Overview

- GEM Validation

121416

G)

68

10

GEM (MPG

1:11:1+5%1:1‐5%

246

2 4 6 8 10 12 14 16

Results

2 4 6 8 10 12 14 16

Experimental Tests (MPG)

• GEM has been validated against chassis dyno tests covering 1

variants. Excellent agreements between GEM and tests have 

DRAFT & DELIBERATIVE 

obtained.
Publications

• J. W. Anthony, J.V. Sarlashkar, A. Phan, C. E. Roberts, Jr., H

J. Sanchez, M. Spears, A. Cullen, Powertrain test cell and its procedure development for greenhouse gas emission measurA t d b ASME I t J V l N Accepted by ASME Int. J. , Vol. x, No. x, xxxx, 2014

• H. Zhang, M. Spears, and A. Cullen, Technology recognition 

next phase heavy-duty greenhouse gas emission and fuel effi

standards SAE 2014 Commercial Vehicle Engineering Congrstandards, SAE 2014 Commercial Vehicle Engineering Congr

7-9, 2014

• J. Anthony, J. Sarlashkar, H. Zhang, J. Sanchez, M. Spears, A

Chassis testing versus powertrain testing for heavy-duty vehic

greenhouse gas emission measurements, SAE 2014 CommeVehicle Engineering Congress, Oct. 7-9, 2014

DRAFT & DELIBERATIVE