Advanced Technologies

1 SuperTruck – Development and Demonstration of a 

This presentation does not contain any proprietary, confidential, or otherwise restricted information Fuel Efficient Class 8 Tractor & Trailer DE-EE0003303

SuperTruck – Development and Demonstration of a 

Fuel-Efficient Class 8 Tractor & Trailer

Vehicle Systems

DOE Contract: DE-EE0003303

NETL Project Manager: Ralph Nine

Program Investigator : Dennis W. Jadin, Navistar

DOE MERIT REVIEW

WASHINGTON, D.C.

May 17th, 2012

National Energy Technology Laboratory

Department of Energy

Project ID: VSS064
Advanced Technologies

Project Overview

2 SuperTruck – Development and Demonstration of a Fuel Efficient Class 8 Tractor & Trailer

DE-EE0003303

Outline

• Program Overview

• Barriers and Technology Roadmap

• Approach

• Technical Accomplishments

• Future Work

• Summary
Advanced Technologies

Project Overview

3 SuperTruck – Development and Demonstration of a Fuel Efficient Class 8 Tractor & Trailer

DE-EE0003303

Goals and Objectives

Demonstrate 50% improvement in overall freight efficiency of a combination Tractor-Trailer - 30/50% improvement achieved through tractor/trailer technologies - 20/50% improvement achieved through Engine technologies

Attain 50% BTE Engine

Demonstrate path towards 55% BTE Engine

Barriers

Achieving 50% freight efficiency while balancing Voice of Customer Needs 

Packaging of hybrid drive unit and Waste Heat Recovery Systems

Maintaining tractor weight while adding new systems

Availability of Suitable Battery Technology

Budget 

DOE recently approved new budget periods / phases >>>> 

An increased level of resources planned in budget periods 2 & 3 will accommodate project 

deliverables in periods 4 & 5.

Total Project Funding: DOE $37,328,933

Prime Contractor $51,801,146

DOE Funding Received : $ 13,393,868 

Program Overview
Advanced Technologies

Project Overview

4 SuperTruck – Development and Demonstration of a Fuel Efficient Class 8 Tractor & Trailer

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Partners (Collaboration and Coordination with Other Institutions)

Navistar Principal Investigator, Vehicle Systems Integrator Controls 

Systems, Engine & Vehicle Testing

Alcoa Lightweight Frame Structures & Wheel Materials

ATDynamics Trailer Aerodynamic Devices

Behr America Cooling Systems

Meritor Hybrid Powertrain, Axles 

Michelin Low Rolling Resistance Tires

Wabash National Trailer Technologies

TBD Composite Material Structures (was TPI)

Argonne National Lab Hybrid Drive Simulation and Controls & Battery Testing 

Lawrence Livermore Aerodynamic Testing

National Lab

Program Overview
Advanced Technologies

Barriers (Challenges)

And Technology Roadmap

5

System 

Area

Barriers Technology Roadmap

Engine & 

Vehicle

Achieving 50% freight efficiency while 

balancing Voice of Customer Needs 

Seek and Prioritize Voice of Customer Inputs

• Rely on analysis (tradeoff) to select technology

Vehicle Packaging of hybrid drive unit and Waste 

Heat Recovery Systems

 Redesign drive unit and batteries to achieve 

overall size reduction.

Vehicle Maintaining tractor weight while adding 

new systems

• Optimize Body Structure Requirements for over 

the road usage.

• Utilize Advanced Materials for Light Weighting 

(Polycarbonate Glazing, Composites, Alloys)

Hybrid 

Drive

Suitable batteries (rugged, affordable, 

powerful) are not commercially available

Weight penalty affecting FE

Develop a detailed battery specification

Reach out world-wide to potential suppliers

Select new supplier

• Collaborate to develop lighter SuperTruck

batteries

• Identify additional lightweighting opportunities

SuperTruck – Development and Demonstration of a Fuel Efficient Class 8 Tractor & Trailer

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•In Progress √ Completed 
Advanced Technologies

6

Approach:

Vehicle Vs. Chassis Efficiency

SuperTruck – Development and Demonstration of a Fuel Efficient Class 8 Tractor & Trailer

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30%

Target

% Fuel Economy Improvement

1. Aero

Enhancements •Gap Reduction

•Aero Drop at Highway Speed

•Surrogate Camera Mirrors

•Tractor Shapes

•Trailer Shapes & Features

•SMARTandem 6x2 Gears

•Next Gen Wide Based Singles Tires

•Tire Inflation Maintenance System

•Opti Lube Level Axle Fill

•Electronic Leveling Air Consumption

•Dual Mode Hybrid Drive

•Electrified Accessories

•Power Steering

•Air Compressor

•AC Compressor

•SMARTandem 6x2 axles

•Composite Cab

•Composite Trailer Structure

•Next Gen Wide Based Singles and Wheels

2. Lightweight

3. Driveline

4. Hybrid
Advanced Technologies

Approach:

Technology Roadmap - Vehicle

7

Projection

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Mule 1 Hybrid Highway and City FE Results

Final SuperTruck Vehicle Demonstrator

Mule 2 w/Hybrid, TuCo, Aero Trailer, etc.

Target

0

10

20

30

40

50

60

Q1

'11

Q2

'11

Q3

'11

Q4

'11

Q1

'12

Q2

'12

Q3

'12

Q4

'12

Q1

'13

Q2

'13

Q3

'13

Q4

'13

Q1

'14

Q2

'14

Q3

'14

Q4

'14

Q1

'15

Q2

'15

Q3

'15

Q4

'15

Percent Freight Efficiency Improvement

On-Road Demo and Initial Steady-State FE Results

Completed
Advanced Technologies

Approach

Mule Vehicles

Mule Truck #2 Build Status – Planned to do for freight efficiencies for 2012

• Dual Mode Hybrid

• Electric Turbo Compounding (TuCo) 

• Active 5th Wheel

• Dynamic Ride Height (includes front air)

• Full Length Drive Wheel Skirts

• High-rise Roof Air Fairing

• ATDynamics Boat Tail

• Michelin Wide Based Single Tires (WBS Tires)

• Camera Surrogate Mirrors

• External LED Lighting, Including Headlights

• Meritor Air Disk Brakes

• Meritor SMARTandem 6x2 Axle System

• Power Steering Upgrades

• Wabash Light Weight Trailer Mule #1 items

Mule #2 new technologies

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Advanced Technologies

Approach:

Technology Roadmap - Vehicle

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Vehicle Systems Technology Rollout

(2011-2012)

Technology Category Area of Concentration Status

1. Aerodynamics Advanced Tractor Shape -Speed Form Study 2Q 2012

 Surrogate Rear View Mirrors- Initial Concepts 2Q 2012

 Advanced Trailer Shapes -PIV -Particle Image Velocimetry 3Q 2011

 Tire Skirting; Steer, Drive & Trailer 2Q 2012

 Tractor-Trailer Gap Reductions; Dyn. 5th wheel, Cab Extenders 2Q 2012

 Cooling System Exhaust location Impacts on Aerodynamics 1Q 2012

 Trade-off Studies of Cooling System Concepts 2Q 2012

 Determine Thermal Management Configuration 3Q 2012

 Aero Drop, Electronic Suspension Leveling, Tractor & Trailer 2Q 2012

2. Vehicle Lightweighting Advanced Modular Chassis Construction 4Q 2012

 Efficient Drive Axle, 6x2 Configuration 1Q 2012

 Cab Architecture Downselection 2Q 2012

 Cab Structural Design & Material Selection 4Q 2012

 Trailer Architecture Selection 4Q 2012

 Trailer Structural Design & Material Selection 4Q 2012

3. Driveline Optimized Wide-Based Single Tires & Wheel End Equipment 4Q 2011

 Next Gen Wide-Based Single, Low Rolling Resistance Tires 4Q 2011

 Tire Pressure Monitoring and Inflation 2Q 2012

 Efficient Drive Axle, 6x2 Configuration 1Q 2012

4. Hybrid Drivetrain Mule Vehicle #1 3Q 2011

 Electrified Accessories; Power Steering, AC & Air Compressors 3Q 2011

 Mule Vehicle #2 3Q 2012

- In Progress - Completed
Advanced Technologies

Technical Accomplishments

1. Aerodynamics – Development Progress

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Design & Testing of Tractor 

components such as drive 

wheel skirts, belly pans etc. for 

aero improvement

Integration of steering axle 

and cooling flow with minimal 

impact on aerodynamics

Trailer skirts design evaluation 

& optimization in collaboration 

with program partners Wabash 

National

Boat tail and rear skirts design 

verification and optimization in 

collaboration with program 

partners ATDynamics

Tractor shape development 

through 1/8th scale Wind 

Tunnel testing and CFD

Evaluation of 

Trailer design 

modifications 

planned for 

upcoming tests
Advanced Technologies

Technical Accomplishments 

1. Aerodynamics – Status

11

Configuration Measured Normalized Cd% Freight Efficiency Impact

 ProStar Short Sleeper r

 (Baseline) 2010 100 0%

 ProStar Long Sleeper 2007 94 3%

 Aero Concept 

 2010-2011

 (Tractor Only)

2010 88 6%

 Aero Concept 

 2010-2011

 (Tractor & Trailer)

2010 75 12.50%

 Best Tested Feb 2012

w/Steer Axle & Cooling 

 Flow Integrated

2012 60 20%

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Advanced Technologies

Technical Accomplishments 

2. Lightweighting

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- In Progress - Completed

SYSTEM DESCRIPTION SAVINGS (lbs.)

Axle - Smart Tandem Removes one drive axle ( 6 X 2 configuration ) -400

Brake System - Disc

Light Weight rotor & caliper yields 10#/ wheel 

end -200

Single Prop Shaft Increased tube dia. with thinner wall -70

Tires and Wheels Wide Based Singles with NG Aluminum Rims -1000

Body -Cab Composite / multi material panels -500

Plastic Fuel Tank Single one hundred gallon fuel tank -110

Fuel Second 100 gal. of fuel = 700 # -700

Trailer Composite load floor -500

Trailer Suspension Weight reduced components -220

Chassis System Weight reduced system -200

Cooling Modules Less modules -200

Third Gen. Batteries Modular style batteries -600

Third Generation E motors Improved Power density -895

Total Possible Reduction -5595

Hybrid Incremental 4700

Net Reduction -895

Proposed Target Weight Reduction for FE 4000

Lightweighting Gap 3105

Mule 1 before Hybrid Prostar 122 13L = 18140#

Mule 1 Prostar 122 13L = 22840#

22840 - 18140 = 4700# Hybrid Incremental
Advanced Technologies

Technical Accomplishments

3. Driveline - Wheel End Equipment Team

• New Wheel End Decision Matrix

– Alcoa, Michelin, Meritor, Navistar

– 25 total people participating (some full time, 

others part time)

– 6 design choices plus current production

– 3 weighted major design considerations

• 18 total categories

• Chose the Next Generation Wide 

Based Single Tire for driving and 

trailer use.

– 1.5% FE savings from aero drag reduction

– Weight savings in axle and wheel ends

– Team developing new wheel end design 

spec.

– Michelin started tooling for new tire.

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Advanced Technologies

Technical Accomplishments

4. Hybrid Powertrain – Performance Modeling

• Trade-Off Study of Electric Machine and Battery Size

– A range of hybrid machines and batteries have been studied

– Final report expected April 1

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Increasing Size of Machines and Batteries

Cost

Fuel Economy

Freight Efficiency

First iteration of SuperTruck 

Dual-mode hybrid is here

Downsizng of machines and 

batteries will move us here
Advanced Technologies

Technical Accomplishments

4. Hybrid Powertrain – Real-World Testing

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Ohio Transportation 

Research Center

•Fuel Economy 

Testing

•In progress

Colorado

•Highway Testing

•Summer, 2012

Navistar Proving 

Grounds

•Software and 

Calibration 

Development

•Fall/winter, 2012

Michigan Proving 

Grounds

•Software and 

Calibration 

Development

•Summer, 2012
Advanced Technologies

Technical Accomplishments

4. Hybrid Powertrain – Validation Route

• Navistar’s “Kentucky Route” is commonly-used to quantify fuel consumption of class 

8 vehicles

– Low traffic density for good repeatability

– Highway-type route (high speed)

– Large database to compare to

– 75% of the total weighting

• The remaining 25% can be a test-track urban cycle, like CILCC or HHDDT Transient

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0.00%

20.00%

40.00%

60.00%

80.00%

100.00%

120.00%

0

2000

4000

6000

8000

10000

12000

Time at Speed (sec)

Miles per Hour

Kentucky Route Speed Distribution

Frequency

Cumulative %
Advanced Technologies

Technical Accomplishments

4. Hybrid Powertrain – Fuel Economy Testing

Control Vehicle Pre-Hybrid 

ProStar

Hybrid Powertrain 

Mule 1

Hybrid Powertrain 

Mule 2

VIN E4173 E2933 E2941 E2933

Model Year 2009 2010 2010 2010

Transmission 10-Spd Manual Eaton AutoShift Dual-Mode Hybrid Dual-Mode Hybrid

Engine 2009 

MaxxForce 13

2010 

MaxxForce 13

2010

MaxxForce 13

2010

MaxxForce 13

Tractor Weight 19,150 18,320 22,060 TBD

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Tractor Weight 

Diff.

MPG Freight Eff at Constant Freight Weight

(Cubed-Out)

Hybrid Relative to ‘09 Control Truck +2910 3.7% Better* 3.7% Better*

Hybrid Relative to ’10 Pre-Hybrid +3760 7.1% Better* 7.1% Better*

55 mph Steady-State Test Results

*Results not complete. More runs required to achieve statistical validity 

Fleet Test Vehicles
Advanced Technologies

Technical Accomplishments

Vehicle Freight Efficiency Summary

Vehicle Technologies Target Status Estimate

4. Hybrid Dual-mode Gen II w/EiG batteries 6% 3.7%*

3. Driveline

SMARTandem & Opti Lube

Next Gen WBS Tires, Electronic Leveling

Electrified Accessories*

4% -

+4%

-**

-*

2. Lightweight

SMARTandem, Ladder assembly

Next Gen WBS Wheels & Tires

Composite Cab & Trailer Structures

4% -

+0.3%

-

-

1. Aero 

Enhancements

Dynamic 5th Wheel

Dynamic Ride Height

Surrogate Camera Mirrors

Tractor Shapes

Trailer Shapes & Features

Reduced Height w/NG WBS Tires

16% 20%

+1.5%

+1.5%

Total 30% 23.7% +7.3%

* Electrified accessories are contained within the Hybrid system results.

** Next Gen WBS Tires provide improvement through reduced vehicle height and frontal area in Aero.

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Advanced Technologies

Future Work for 2012

• Complete steady-state and urban driving cycles to demonstrate 5-10% improvement in 

freight efficiency due solely to hybrid drive

• Commission the next-gen mule 2 truck and its upgraded technologies

– Electric turbo-compounding

– Aero improvements (tractor and trailer)

– Smart tandem

– Low-rolling resistance tires

– Air suspension

– Active fifth wheel

• Upgrade both hybrid drive units for improved shift reliability

• Demonstrate a 25% improvement in freight efficiency using the next-gen mule 2 truck and a 

trailer with add-on aero features

• Build and install Gen-3 hybrid drive units and re-engineered batteries in mule trucks

• Finish 1/8th and 1/3rd scale wind tunnel testing

• Finalize the demo truck concept

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Advanced Technologies

Project Summary

Relevance:

• The potential of a class 8 truck and trailer combination configured to save 9 billion gallons of diesel fuel per year, 

reduce our dependence on foreign oil and improve our environment by reducing green house gases has significant 

national and global interests.

Approach:

• Project focus is on assessing and developing both engine and vehicle technologies to improve freight efficiency 

while balancing voice of customer requirements in a class 8 truck and trailer integrated design.

Technical Accomplishments:

1. Several aerodynamic scale-models have been developed and evaluated in the wind tunnel. A significant 

improvement over the baseline has been observed.

2. The hybrid drive unit and battery pack has been redesigned. A weight reduction of approx. 1400 lbs is predicted.

3. Highly-efficient axles and tires have been selected and will be tested this year.

4. The dual-mode electric hybrid drive system has been demonstrated on-road and is generating fuel economy data

Partnerships & Collaborations:

• Cross-functional and industry partnership teams are working well together. Good mix of skills and resources to 

address the technical tasks in this project.

Future Directions:

• Continue to progress towards a vehicle and engine demonstration of various efficiency improvement technologies.

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Advanced Technologies

Technical Back-Up Slides

21
Advanced Technologies

Technical Accomplishments

1. Aerodynamics – Timeline of activities

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2011 2012 2013

Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb

Wind Tunnel Tests (1/8th scale)

Wind Tunnel Tests (1/3rd scale)

CFD

Cooling Flow

2014

Q1 Q2 Q3 Q4

Transition to new 1/8th scale, 

rolling-road wind tunnel facilitymoving belt better simulates 

vehicle moving down the road

Phase I – Baseline model test

Phase II – Updated SuperTruck 

model test

Phase I

Phase II

Full scale wind tunnel testing

Coast down testing 

for aero performance 

validation

Design verification and 

optimization as design evolves & 

details are added
Advanced Technologies

Technical Accomplishments

1. Aerodynamic Analysis

Vehicle Thermal Management Systems

– Improve system performance

– Minimize energy usage of fans and 

pumps

– Support waste-heat recovery 

systems

– Decouple sub-system interactions

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• 1-D System Simulation Goals • Under-hood Airflow Analysis
Advanced Technologies

Technical Accomplishments

1. Aerodynamics – Gap Reduction

Advantages of Reduced Tractor/Trailer Gap

• Projected 1.5% Highway Fuel Economy Improvement

• Systems can be independent of trailer

• Potentially better aerodynamic/fuel economy payback than 

trailer mounted devices for fleets with large trailer to tractor 

ratios

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Full 

Length 

Cab 

Extender

0.00%

0.50%

1.00%

1.50%

2.00%

2.50%

3.00%

3.50%

4.00%

4.50%

0 5 10 15 20 25 30 Aero Gain

Trailer Travel (Inches)

Aero Benefit vs Gap Closure
Advanced Technologies

1. Aerodynamics - VTTI Camera 

Surrogate Mirrors

Cooperative Research Project with VTTI

• Formal kickoff meeting at Navistar 

being scheduled for April

• VTTI is researching suitable 

hardware / cameras / lenses

• Navistar arranging loan of test 

vehicle

Projected 1.5% FE potential savings

25

• Convex and Flat Mirror Replacements

• Door & Fender Camera Mounting Locations

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Advanced Technologies

Technical Accomplishments

4. Hybrid Powertrain – Gen -3 Hybrid Drive Unit

26

Torsional Isolator

Overdrive gear set

For both

Gen & Engine

1.6:1

Simple planetary reduction 5:1

vs. compound 6.5:1 for gen-2

New smaller inverter

Mounted under T.M. rather than 

Generator

Output shaft

Driven oil pump

Eliminated

Generator housing

Integrated with mid mount

Underdrive gear set

vs. overdrive for gen-2

Much shorter

Solid shaft

Sealed

Bearing
Advanced Technologies

Technical Accomplishments

4. Hybrid Powertrain – Touch-Screen Data Display

• Critical system parameters are displayed and monitored in the 

cabin

– Electric machine

– Battery

– Turbo-compounding

• Will be used to make certain calibration choices and monitor 

diagnostic messages

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Instrument Panel-Mounted Touch-Screen Typical Display Graphics