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: ACE057Innovation 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 StandardsInnovation 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

TodayInnovation 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

- 081Innovation 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 LeadInnovation 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 interfaceInnovation 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**  **Eaton & Dana Delphi &**  **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 RecoveryInnovation 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 1Innovation 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

11Innovation 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 integrationInnovation 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

13Innovation 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

- 081Innovation You Can Depend On 

## Technical Accomplishment – Freight Efficiency Status

15 Reference: Objective 2

• Vehicle details are included in Peterbilt’s 2013 AMR presentation ARRA

- 081Innovation You Can Depend On 

### WHR mechanical open closed thermal 

### + = η η η η * *

   

 

   

 

      =

D Energy

GIMEP

fuel closed η 

# Approach

– 55% Thermal Efficiency

1. Exhaust 2. Coolant/Lube 3. Air

      +

=      

= GIMEP PMEP GIMEP
GIMEP NIMEP

open η

     

+ =      

= FMEP BMEP BMEP
NIMEP BMEP

mechanical η

Using 50% testing formulationInnovation You Can Depend On 

## Technical Accomplishments

- Improvements (Based on Engine, AT & WHR Testing)

17 

### Engine Brake Thermal Efficiency (%) 2013

– 2014 55% BTE EffortsProgram 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% BTEInnovation You Can Depend On 

## Approach

– 55% Engine Technology Scoping

- Fuels

18 

### Diesel PreMix Dual Fuel AFCI

Conventional DieselPremix Fuel Quantity**



### 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 ExpansionInnovation 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% GoalInnovation 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 analysisInnovation 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)

21Innovation 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

22Innovation You Can Depend On 

# Technical Back

- Up Slides

23Innovation You Can Depend On 

## Approach

– Freight Efficiency Path to Target

24 Ref: 2011 AMR

- StantonInnovation 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

- StantonInnovation 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 improvementsProgram Baseline–42%

Status 2012 Merit Review: Engine + High Efficiency AT + WHR (Engine, AT & WHR System Testing) Final Opt. Program Requirement 50% BTE

WHR m oc ig brake 

## ∆ + = η η η η

• Engine demonstration showed improvements in all terms
Ref: 2012 AMR

- KoeberleinInnovation 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%

• 1 st 

### vehicle installation Sep2011

27 Boiler Comp

TurbExh.Manifold

Exhaust Air InIntake Manifold Ram AirflowISX Engine

Power Out FP

EGR Valve CAC WHR Condenser Cooler

Engine Radiator

Mechanical Fan

After

treatment Exh. BoilerRecuperator

Turbine SuperheaterSpeedReduction

Gear Train

Exhaust Control ValveInnovation 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 ImprovementInnovation You Can Depend On 

## Vehicle Weight Reduction

– Freight Efficiency Improvement

29 

### -6% -4% -2%

0% 2% 4% 6% 8% 10%Freight EfficiencyGains/Losses (%) 

## >3% Freight Efficiency Improvement With Vehicle Weight Reduction