# SuperTruck

Development and Demonstration of a Fuel

- Efficient Class 8 Highway Vehicle


# Vehicle Systems

DOE Contract: DE

- EE0004232

P.I.: Pascal Amar, Volvo Technology of America

2014 Annual Merit Review Washington, DC June 19, 2014

This presentation does not contain any proprietary, confidential, or otherwise restricted information Project ID: VSS081

## Timeline
Start: June 2011 End: June 2016 55% complete



## Budget Total Cost: $38M Cost share: $ 19M

Cost to date: $18.3M Funds to date: $ 9.1M 

## Barriers
 Cost effective & timely evaluation of advanced components and configurations  Operational effectiveness & end

- user acceptance of advanced concepts



## Team Lead : Volvo Technology of America



## Partners: 

# Project Overview 2

### • In support of DOE’s mission “[...] more energy efficient and environmentally friendly highway transportation [...]”

• Project Objectives Objective 1 50 % more ton

- miles per gallon than a ‘best in class’ 2009 truck Objective 1a 50 % Brake Thermal Efficiency Objective 2 55 % Brake Thermal Efficiency Concept

• Reporting Period Objectives

– Evaluate candidate technologies on concept vehicle

– Complete technology selection (Phase I)

– Start development & integration of technologies into demonstrator (Phase II) 

# Relevance 34 

# Approach: T echnology Selection & Integration

Demo Truck Techn. Refinement

Optimization Validation Phase II - Development & Integration

Integration demonstrator chassis mule truck Concept Truck Phase I - Concept Selection Baseline Tests

engine bench Virtual Optimization Energy Management Dev. Techn. Development

engine bench Concepts Evaluation

Validation Model Development 2011 2012 2013 2014 2015 2016

Identify, evaluate and select most promising technologies 45 

# Designing for real operating conditions

Speed distribution (%) Simulated vs. log data Customer Duty Cycles >1 billion miles of logged data System Simulations 5Trailer add

on devices Tractor redesign

Integration

Rankine Cycle

Rankine Cycle

Turbo compounding Downsizing Downspeeding Combustion Improvements

Friction reduction Next gen. tires Weight reduction

Smart 6x2 Intelligent controls 

# Typical Fuel Energy Analysis (Long

- Haul) 6

# Importance of Integrated Design Vehicle vs. Powertrain Improvements

Road Load, Heat Rejection,

... Packaging, Cooling Needs,

... 7

# Accomplishments: Phase I Testing Complete

• 16 configurations of Tractors & Trailer Modifications

• > 6,000 miles of on
- road testing

• Correlated to chassis dynamometer & simulations 89 

# Phase I Results

On

- road Chassis Dyno



### 41% 43%

**Phase I Phase II**  9

# Complete Vehicle Aerodynamic OptimizationNormalized aerodynamic drag



### Target > **40% lower drag ”best in class” MY2009** 

Tractor tweaks Trailer add

on devices

Co

- optimization Fleet testing on

- going to verify operational performance

Integrated design 

### Status: 30% drag reduction 10• Demonstrator engine running in test cell

• 11liter engine capable of same power as the 13liter

• Targeting ~400lbs powertrain weight reduction

• 50% BTE technologies in test on component test rigs 

# Accomplishments: Powertrain Improvements

14 11

# Accomplishments: Ultra Light Frame Assembly

**Q3’2012**

**Q1’2014**



### > 40 % lighter - Bending

- Innovation

- Weight savings

- Manufacturing

- ... **Q2’2013**

- FEA

- Virtual test track

- ... From idea to prototype in 18 months 12

# New Opportunities for 

# Energy Management

Speed

Accelerate Hold Gear Reduce Speed Roll

Roll Engage Aux. Terrain Set Speed Brake Speed Intelligent Controls

Conventional cruise

• Intelligent Controls leverage vehicle improvements to achieve further fuel efficiency gains

• - Auxiliary Integration maximizes use of free energy

• - Powertrain Management minimizes fuel use 132014

Cab BIW assembly

Begins Cab Installed on Chassis

Engine Transmission Installation Exterior Chassis components ordered 

# Future Work: Demonstrator Build Plan

2015 Assembly begins for Chassis components

Axles, Brakes, Wheels, Tires, etc ordered Hood/Bumper, Roof, Ground Effects, Chassis Fairings, Side Deflectors Ordered

Axle Installation In Chassis Chassis Built and Delivered to VOLVO APU Delivered

Chassis Components Complete 14

# Summary: Reporting Period Objectives

• Accomplishments at 55% Project completion

– Candidate technologies evaluated on concept vehicle

– Demonstrated 43% Freight Efficiency Improvements

– Demonstrated 48% BTE powertrain in vehicle

– Completed Concept selection (Phase I) on schedule

– Started development & integration of technologies into demonstrator (Phase II)

• Next Steps

– Integrate technologies in Demonstrator vehicle for initial tests by next AMR

– Continue on
- going operational testing of trailer aero improvements 15

# Partners & key Collaborations

Organization Key Contribution Volvo Technology of America Project lead & concept simulations Volvo Group Truck Technology Complete vehicle integration & vehicle testing Volvo Group Powertrain Engineering Efficient complete powertrain solutions Ridge/Freight Wing Advanced aerodynamic devices for trailers
Grote Advanced lighting systems Penn State University Advanced combustion modeling & simulation
Hendrickson Lightweight trailer axle & suspension components
ExxonMobil Advanced fuels & lubricants
Alcoa Wheels Lightweight wheels
Michelin Advanced low

- friction tires
Metalsa Ultra

- Light Frame Assembly 16

### This material is based upon work supported by

– DOE & NETL under Award Number DE

- EE0004232

– DOE & NETL under Award Number DE

- FC26

- 07NT43222

– DOE Project ID VSS006, Reduce Truck Aerodynamic Drag w/ LLNL

– DOE Project ID VSS022, CoolCab

– Reduce Thermal Load w/ NREL

This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United Sta tes Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or res pon sibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its us e w ould not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, ma nuf acturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Governme nt or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Go ver nment or any agency
thereof.



# Relevant Research 17