## Advanced Technologies

1 SuperTruck

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

- EE0003303 This presentation does not contain any proprietary, confidential, or otherwise restricted information 

# 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 DE

- EE0003303 

# 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 DE

- EE0003303 • In Progress √ Completed

## Advanced Technologies

6 

# Approach: Vehicle Vs. Chassis Efficiency

SuperTruck

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

- EE0003303 

# 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. Light weight 3. Driveline

4. Hy brid

## Advanced Technologies 

# Approach: Technology Roadmap

- Vehicle

7 

## Projection

SuperTruck

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

- EE0003303 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 '15Percent 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 5 th 

# 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

8 SuperTruck

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

- EE0003303

## Advanced Technologies 

# Approach: Technology Roadmap

- Vehicle

9 SuperTruck

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

- EE0003303 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

10 SuperTruck

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

- EE0003303 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 1/8 th 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%

SuperTruck

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

- EE0003303

## Advanced Technologies 

# Technical Accomplishments 2. Lightweighting

12 SuperTruck

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

- EE0003303 - 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 W eight 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.

13 SuperTruck

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

- EE0003303

## 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

14 SuperTruck

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

- EE0003303 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

15 SuperTruck

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

- EE0003303 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

16 SuperTruck

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

- EE0003303

0.00% 20.00% 40.00% 60.00% 80.00% 100.00% 120.00%

0 2000 4000 6000 8000 10000 12000Time 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

17 SuperTruck

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

- EE0003303 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 5 th 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.

18 SuperTruck

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

- EE0003303

## 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 1/8 th 

## and 1/3 rd 

## scale wind tunnel testing

• Finalize the demo truck concept

19 SuperTruck

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

- EE0003303

## 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.

20 SuperTruck

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

- EE0003303

## Advanced Technologies 

# Technical Back

**- Up Slides** 

21

## Advanced Technologies 

# Technical Accomplishments 1. Aerodynamics

– Timeline of activities

22 SuperTruck

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

- EE0003303 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 1/8 th scale, rolling

- road wind tunnel facility

moving 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

23 SuperTruck

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

- EE0003303 

# • 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

24 SuperTruck

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

- EE0003303 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 30Aero 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

SuperTruck

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

- EE0003303

## 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

27 SuperTruck

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

- EE0003303 Instrument Panel

- Mounted Touch

- Screen Typical Display Graphics