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

May 16, 2013

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

Project ID: ACE057
Innovation You Can Depend On

Relevance - Program Objectives

(DoE Vehicle Technologies Goals)

Objective 1: Engine Development 

Engine system demonstration of 50% or greater BTE in a test cell at an 

operating condition indicative of a vehicle traveling on a road at 65 mph.

Objective 2: Vehicle Integration & Development

a: Tractor-trailer vehicle demonstration of 50% or greater freight efficiency 

improvement (freight-ton-miles per gallon) over a defined drive cycle. 

b: Tractor-trailer vehicle demonstration of 68% freight efficiency improvement

(freight-ton-miles per gallon) over a defined 24 hour duty cycle (above drive 

cycle + extended idle) representative of real world, line haul applications. 

Objective 3: Engine Development

Technology scoping and demonstration of a 55% BTE engine system. Engine 

tests, component technologies, and model/analysis will be developed to a 

sufficient level to validate 55% BTE.

2

Baseline Vehicle and Engine: 2009 Peterbilt 386 Tractor 

and Cummins 15L ISX Engine

All Technologies must meet Current US EPA 2010 

Emissions Standards and Transportation/Safety Standards
Innovation You Can Depend On

Overview - Program Schedule and Budget

3 

Budget: DoE Share $38.8M (49%) 

Contractor Share $40.3 M (51%)

$31 M total DoE share spend to date

4 Year Program: April 2010 to April 2014 

Today
Innovation 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

4 

More vehicle specific details are included in Peterbilt’s 2013 AMR presentation ARRA-081
Innovation You Can Depend On

Overview - Program Partners

Cummins Inc.

- Cummins Fuel Systems

- Cummins Electronics

- Cummins Turbo Technologies

- Cummins Emissions Solutions

- Cummins Filtration

- Modine

- Oak Ridge National Lab.

- Purdue University

- VanDyne SuperTurbo Inc.

Peterbilt Motors Company

 - Eaton

 - Delphi

 - Modine

 - Utility Trailer Manufacturing

 - Bridgestone

- Goodyear

 - U.S. Xpress

 - Dana

 - Bergstrom

 - Logena

 - Bendix

 

5

Program Lead
Innovation You Can Depend On

Participants – Who’s doing what 

Roles and Responsibilities

6

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
Innovation 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 $62M total spend to date

• 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

7

Year 2010 2011 2012 2013

Full Time Equivalent 75.5 85 60 46

States: Indiana, Texas, Michigan, Wisconsin, Tennessee, Illinois, California, Colorado, New York 

Projections
 Innovation You Can Depend On 

Approach – Vehicle Energy Analysis 

8 

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 

Delphi & Eaton & Dana 

Bergstrom Weight Reduction 
Innovation You Can Depend On

Approach - Integration of Cummins 

Component Technologies

9

Air Handling 

& EGR

Fuel 

Systems

Combustion

Aftertreatment (AT)

Electronic Controls

Waste Heat Recovery
Innovation You Can Depend On

Technical Accomplishments –

 50+% Thermal Efficiency Gains 

10

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
Innovation You Can Depend On

Engine Friction & Parasitic Reduction

• Mechanical efficiency improved

– Improvements should be witnessed across speed/load map

• Greatest efficiency improvements in the lower load portions of map

11
Innovation You Can Depend On

Technical Accomplishment – Supplemental

Emission Test (SET) Weighted Modal Cycle NOx Emissions

12

• System capability to proceed forward to calibration to 

prevailing 2010 emissions of 0.2 g/(hp-hr).

• Next process step is calibrating for the RMCSET and FTP 

cycle with the Demo 2 truck engine during Q1 2013. 

4.3

0.08

0.0

1.0

2.0

3.0

4.0

5.0

50% BTE Demonstration

SET 12 mode emission roll-up

Engine Out NOx (g/hp-hr) System Out NOx (g/hp-hr)

 Aftertreatment Progress

• Phase 2 50% Aftertreatment changes:

- SCR catalyst formulation

• Phase 1 50% improvements: 

- Improved design of NOx sensing 

across face of catalyst

- Close loop control

- WHR heat exchanger integration
Innovation You Can Depend On

WHR Engine 

System

Transmission/Axle 

Technology

Next Generation 

LRR Tires

Advanced 

Aerodynamics

Idle Management 

(APU)

Route

Management

System

Driver Display with 

Fuel Economy Tools

Weight 

Reduction

Freight Efficiency Enabling Technologies

13
Innovation You Can Depend On

Technical Accomplishment –

Freight Efficiency Test Results

50 + %

Achieved!

Reference: Objective 2

• Vehicle details are included in Peterbilt’s

 2013 AMR presentation ARRA-081
Innovation You Can Depend On

Technical Accomplishment – 

Freight Efficiency Status

15

Reference: Objective 2

• Vehicle details are included in Peterbilt’s 2013 AMR presentation ARRA-081
Innovation You Can Depend On

ηthermal =ηclosed

*ηopen*η mechanical +WHR



































 =

D

Energy

GIMEP

fuel

ηclosed

Approach – 55% Thermal Efficiency

1. Exhaust

2. Coolant/Lube

3. Air





 



 + =



 



 = GIMEP

GIMEP PMEP

GIMEP

NIMEP

ηopen





 





+ =



 



 = BMEP FMEP

BMEP

NIMEP

BMEP

η mechanical

Using 50% testing formulation
Innovation You Can Depend On

Technical Accomplishments - Improvements 

(Based on Engine, AT & WHR Testing)

17

Engine Brake Thermal Efficiency (%)

2013 – 2014 

55% BTE Efforts 

Program Baseline 

– 42%

Status 2012 Merit Review: 

Engine + High Efficiency AT + WHR

(Engine, AT & WHR System Testing)

Final

Opt.

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

Objective 3

55% BTE
Innovation You Can Depend On

Approach –

55% Engine Technology Scoping - Fuels

18

Diesel 

PreMix

Dual Fuel 

AFCI

Conventional 

Premix Fuel Quantity**

Diesel

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 
Innovation You Can Depend On

TDC

Increased efficiency

Technical Accomplishment –

55% Engine Analytical Data

19

2013 advancement plan

• Combustion design

• Air handling system matching

• Cycle simulation 

• WHR integration

• Targeted engine tests

• Correlate to simulation

Nov12

Single cylinder 

validated

55% Goal
Innovation You Can Depend On

Collaborations– ORNL & Purdue Participation

• ORNL 

–Sensing methods for:

• Combustion uniformity studies

– High response spatial & 

temporal EGR variation study

– Enables validation of CFD and 

analysis led design

– Experimental testing complete

» Dec 2012

• AT performance studies

– Enhanced SCR understanding 

to improve models & control 

methods fundamental to high 

efficiency AT

20

Modeling & Simulation

Presented: 

 ACE077 - Partridge

• Purdue University 

– Completed diesel PCCI study

– Explore range expansion

– Diesel engine VVA

– Commissioned intake & exhaust 

 VVA test bed

– VVA functional analysis
Innovation You Can Depend On

Milestones and Technical 

Accomplishments

• March 2012 to March 2013 – Technical Accomplishments

√ Demonstrated 50+% BTE (Objective 1)

√ Demonstrated 61% freight efficiency improvement (Objective 2a)

√ Completed wind tunnel and vehicle testing of Waste Heat Recovery

√ Tested advanced transmission

√ Performance tested SOFC APU

√ Path-to-Target analysis for a 55% thermal efficient engine

• March 2013 to March 2014 – Future Work

– Engine “vehicle” calibration and optimization work

– APU technology study – investigate alternatives to SOFC

– Build and test for Vehicle Demonstration #2 (Objective 2b)

• Vehicle freight efficiency on 24hr cycle

– Hotel load APU testing

– End user testing of Tractor – Trailer Aerodynamics Solution

– 55% analysis and demonstration tests (Objective 3)

21
Innovation You Can Depend On

Summary

• Program remains on schedule

– Meeting the ARRA and DoE VT MYPP goals

• Demonstrated a 50+% BTE engine system

• Demonstrated a 60+% vehicle freight efficiency improvement

• Analytical roadmaps updated with experimental component data

• Vehicle packaging and integration proceeding without major issues

• 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 lab and vehicle tests (Objective 2b)

– Tractor-Trailer aerodynamic aids (Objective 2a)

• Developed framework and analysis for 55% thermal efficiency

• Developed working relationship with excellent vehicle and engine 

system delivery partners

22
Innovation You Can Depend On

Technical Back-Up Slides

23
Innovation You Can Depend On

Approach – Freight Efficiency Path to Target

24

Ref: 2011 AMR - Stanton
Innovation You Can Depend On

Improvements – Technical Accomplishments

(Based on Analysis and Engine Component Testing)

25

42% 43% 44% 45% 46% 47% 48% 49% 50% 51%

Program

Baseline – 42%

Program 

Requirement

50% BTE

Engine System Meets US EPA 2010 Emissions Regulation

Engine Brake Thermal Efficiency (%)

*WHR - Cummins Organic Rankine Cycle Waste Heat Recovery

WHR System

•Working Fluid

•Cooling System Controls

•Turbine Expander Efficiency

Increased PCP

Increased CR

Turbo Efficiency

Improvements

Power Cylinder

Friction Reduction

Lower ∆P EGR

Volumetric Eff.

Powertrain

Optimization

Cummins Advanced Engine + High 

Efficiency AT + WHR*

Ref: 2011 AMR - Stanton
Innovation You Can Depend On

Technical Accomplishments - Improvements 

(Based on Engine, AT & WHR Testing)

26

Engine System Meets US EPA 2010 Emissions Regulation

*WHR - Cummins Organic Rankine Cycle Waste Heat Recovery

42% 43% 44% 45% 46% 47% 48% 49% 50% 51%

Engine Brake Thermal Efficiency (%)

Status 2011 Merit Review: 

Engine + High Efficiency AT + WHR

(Analysis & Component Testing)

 Analysis based 

improvements

Program Baseline 

– 42%

Status 2012 Merit Review: 

Engine + High Efficiency AT + WHR

(Engine, AT & WHR System Testing)

Final

Opt.

Program

Requirement

50% BTE

ηbrake =ηigηocη m + ∆WHR

• Engine demonstration showed improvements in all terms

Ref: 2012 AMR - Koeberlein
Innovation 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%

• 1st vehicle installation Sep2011

27

Boiler

Comp

Turb

Exh.Manifold

Exhaust

Air In

Intake Manifold

Ram Airflow ISX Engine

Power Out

FP

EGR

Valve

CAC

WHR

Condenser Cooler

Engine

Radiator

Mechanical Fan

Aftertreatment

Exh. Boiler

Recuperator

Turbine Superheater Speed Reduction

Gear Train

Exhaust

Control

Valve
Innovation You Can Depend On

Vehicle Freight Efficiency of Aerodynamic 

Drag Reduction

28

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 - 24.9% 

Freight Efficiency Improvement
Innovation You Can Depend On

Vehicle Weight Reduction 

– Freight Efficiency Improvement

29

-6%

-4%

-2%

0%

2%

4%

6%

8%

10%

Freight Efficiency 

Gains/Losses (%)

>3% Freight Efficiency Improvement

With Vehicle Weight Reduction