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# DoE SuperTruck Program Technology and System Level Demonstration of Highly Efficient and Clean, Diesel Powered Class 8 Trucks

Principal Investigator: David Koeberlein (Cummins) Presenter: Kenneth Damon, P.E. Peterbilt Motors Company Project ID: ARRAVT081 19 June 2014 **This presentation does not contain any proprietary, confidential, or otherwise restricted information**2 

# Relevance
- Program Objectives (DoE Vehicle Technologies Goals) Objective 1 : Engine system demonstration of 50% or greater BTE in a test cell at an operating condition indicative of a vehicle traveling on a level road at 65 mph. Objective 2 a: Tractor - trailer vehicle demonstration of 50% or greater freight efficiency improvement (freight - ton - miles per gallon) over a defined drive cycle utilizing the engine developed in Objective 1. 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 : 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. Baseline Vehicle and Engine: 2009 Peterbilt 386 Tractor and Cummins 15L ISX Engine3 

# Relevance
- American Recovery and Reinvestment Act (ARRA) Goals

• Create and/or Retain Jobs

• Spur Economic Activity

– Greater Than $72.6M 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

– Commercial Viability Assessment

– Adopt Technologies into Product Plans to Meet GHG and CO2 Regs Year 2010 2011 2012 2013 2014 Full Time Equivalent 75.5 85 60 46 17
States: Indiana, Texas, Michigan, Wisconsin, Tennessee, Illinois, New York, Ohio, Mass, California Projections4 

# Response to 2013 AMR **Reviewer Comments**

• Long list of suppliers was misleading

– List partners supported as subcontractors to the program 

## Addressed in Slides 5 & 12

• Be sure to include detailed plans on battery sizing and durability Addressed in Slide 10 2013 Reviewer Scorecard5 

# Collaborations
- Peterbilt Participants

• Sub

- contractors

– Eaton

– Transmissions

– Delphi

– Solid Oxide Fuel Cell

• New Supplier in 2013 (Not Sub

- contracted)

– Corvus Energy

– Lithium Ion APU

• OEM (Not Sub

- contracted)

– Utility Trailer Manufacturing

• End User

– US Xpress6 

# Overview
**-** Schedule and Budget

Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 50% or Greater BTE Engine Demonstration
Vehicle Demonstration of 50% or Greater Freight Efficiency Improvement Phase 1 Phase 1 Phase 2 Phase 2 Phase 3 Phase 3 Phase 4 Phase 4

Objective 2a - Drive Cycle Vehicle Demo. Objective 1 – Engine Demo. 2010 2011 2012 2013

Vehicle Demonstration of 68.5% or Greater Freight Efficiency Improvement Objective 2b – 24 hour Duty Cycle Vehicle Demon.

55% BTE Engine Demonstration Objective 3 – 55% BTE Engine Program Close - Out Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 50% or Greater BTE Engine Demonstration
Vehicle Demonstration of 50% or Greater Freight Efficiency Improvement Phase 1 Phase 1 Phase 2 Phase 2 Phase 3 Phase 3 Phase 4 Phase 4

Objective 2a - Drive Cycle Vehicle Demo. Objective 1 – Engine Demo. 2010 2011 2012 2013

Vehicle Demonstration of 68.5% or Greater Freight Efficiency Improvement Objective 2b – 24 hour Duty Cycle Vehicle Demon.

55% BTE Engine Demonstration Objective 3 – 55% BTE Engine Program Close - Out **4 -**  **1/2 Year Program: April 2010 to Sept 2014** 

### Budget DoE Share: $38.8M (49%) DOE Spend To

- Date: $36M Contractor Share: $40.3M (51%)7 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 2010 2011 2012 1Q 2Q 3Q 4Q 2013 

# Overview
- DoE SuperTruck Program

WHR System Calibration 50% BTE Engine Demonstration

68% Freight Efficiency Demo Model 587 Mule Build Cummins Hardware Devo and Lab Testing

Set Duty Cycle and Baseline Testing Funding Approval

System and Fuel Economy Testing 50% Freight Efficiency Demo Baseline Truck Model 386

Mule Definition and Design Integrated Tractor - Trailer CFD Analysis

Demo 1 Demo 2

USX Driver Feedback Model 579 Demo 2 Build Model 587 Demo 1 Build8 

# Overview
- Program Barriers

• Underhood Cooling with Waste Heat Recovery

• Vehicle and Engine System Weight Reduction

• Engine Downspeed (Reduced Engine Speed)

– Powertrain Components

– Vibration/Customer Acceptance

• Vehicle and Powertrain Communication Speed

• Trailer Aero Devices That Meet Operational Requirements

• Alternate Power Unit

– Technology Change9 

# Technical Progress
- Program Barriers Alternate Power Unit

• Solid Oxide Fuel Cell (SOFC)

– Integrated into Demo 1 (Aug 2012)

– Functionality Verified (Dec 2012)

– Development Challenges

• Warm Up Time

• Peak Power

• Efficiency

• Weight



### – Delphi Put Development on Hold (Jan 2013)

– Demo 2 Options:

• Use Demo 1 Level SOFC

• Choose Another Technology



### – Request to Pursue Alternate Technology Approved By DOE Feb 201310 

# Technical Progress
**- Program**  Barriers Alternate Power Unit

• Lithium Ion APU

– (4) Li Ion Pack + Start Battery

– 240a Alternator

– 13.2 kW

- h Capacity

– 12.2 kW

- h Load Profile

– 400lb Battery, Structure, and Cables

– 6hr Highway Re

- charge

– Capable Development Level System

A S Truck Battery HoteleHVAC Alt In v PDM CAN
- Buss

CAN
- Buss
A11 

# Technical Progress **Model 579 Demo 2**

Cummins 15L High Efficiency ISX Engine Advanced Formula Aftertreatment Cab and Trailer Aero Components GPS Cruise Control Advanced Super Single Tires

180o Trailer Tandem Service Door Pneumatically Retractable Trailer Skirts Waste Heat Recovery System High Efficiency Cooling Package High Speed Routers12 

# Collaboration

Ceramic Brake Drums Cooling Package and Heat Exchangers Power Distribution Alum Hybrid Driveshaft

Light Steer Axle and Trailer Tandem

Integrated Air Suspension Bags 6x2 Rear Tandem w/ eTrac Magnesium Crossmembers Variable Gage Steel Frame Rails Downspeed

- enabling Transmission Route Display Li Ion Start Batt & APU

Advanced Light Wheels Alum 5 th Wheel13 

# Objective 2b: 24 **hr Duty Cycle Testing**  **Technical Progress**

Start of Testing: Dec 201314 

## • Identical 12.2 kW

- hr Load over 10 Hours

• Baseline Supported with Engine Idling

• Demo 2 Supported with Lithium Ion Batteries 

# Objective 2b: 24 **hr Duty Cycle Testing**  **Technical Progress** 

Hotel Cycle/Battery Conditioning 10 hrsWatts15 **GVW**

**( lb**  **) Freight**  **( lb**  **) MPG**  **(Range) (**  **Avg ) FTMPG**  **Improvement (**  **Avg ) MPG**  **Improvement 579**  **Demo 2** 

### 65k 32,576 9.4 - 9.5 **+1305** 

# 75% 86% Objective 2b: 24 hr Duty Cycle Results Technical Accomplishment (Dec 2013)

Goal: 68% Temp Min/Avg/Max: 30/46/70oF Wind Avg/Max Gust: 14/28 mph16 

# Testing Beyond Scope Demo 2 vs. Baseline
- Drive Cycle Route 

# Technical Accomplishment

(Demo 1: 61%) **GVW**

**( lb**  **) Freight**  **( lb**  **) (**  **Avg ) FTMPG**  **Improvement (**  **Avg ) MPG**  **Improvement 579**  **Demo 2** 

### 65k 32,576 **+1305** 

# 76% **66%**
Temp Min/Avg/Max: 22/36/52oF Wind Avg/Max Gust: 13/33 mph (Demo 1: 61%) (Demo 1: 54%)17 

# Technical Accomplishment Freight Efficiency Status18 

# Testing Beyond Scope **Demo 2 vs. Demo 1**  **- Drive Cycle Route**  

# Technical **Accomplishment**

**GVW Run 1**  **Run 2 579**  **Demo 2** 65k 9.9 

# 10.7 **587 Demo 1** 65K 8.9 10.1 Temp Min/Avg/Max: 38/47/53oF Wind Avg/Max Gust: 6 mph/steady19 

# Testing Beyond Scope Technical Accomplishment

Demo 2 Tractor w/ Demo 2 Trailer 80K GVW 

# 10.4 **Peak MPG** 

# 9.4 Demo 2 Tractor w/ Trailer Skirts 65K GVW

Demo 2 Tractor w/ Demo 2 Trailer 32.5K GVW (Empty Trailer) 

# 12.7 Temp Min/Avg/Max: 55/68/77oF Wind Avg/Gust: 9/18 mph

Temp Min/Avg/Max: 49/56/64oF Wind Avg/Gust: 6.5 mph/steady

Temp Min/Avg/Max: 54/63/68oF Wind Avg/Gust: 23/40 mph20 

# Aerodynamic Improvements
**– Technical Progress** 

Configurations Demo 2
- 24% Target Demo 1
- 14% Target Baseline

Demo 1

– 18.1%Freight Efficiency Improvement

Demo 2

– 24.3% 

### Demo 2 Progress Since Last Review Target Exceeded21 -3000 -2000 -1000 0 1000 2000 3000

WHR/2010 Emissions Aero Devices Idle Systems Onboard Fuel Truck Savings Trailer Savings Net Weight Difference 

# Demo 2 Truck/Trailer Weight Technical Progress

BaselinePounds 

### 1305 lb Bonus Freight22 

# Driver Acceptance Collaboration

• US Xpress Drive Event, Demo 1

– Mar 21, 2013

– Irving, TX to Laredo, TX (950 mile round trip)

– Commercial Freight

– US Xpress Drivers



## • Feature/Functional Evaluation

– Loading/Unloading Aero Trailer

– Drivability



## • Very Positive Event

• Critical and Valuable Feedback23 

# Driver Acceptance Collaboration/ Technical Progress

Retractable Skirt Service Access Added Trailer Features for Demo 224 

# Promoting the DOE Program Technical Progress25 

# White House Press Event February 18, 2014 Technical Accomplishment

Safeway Distribution Center Upper Marlboro, MD26 

### Energy Secretary Dr. Ernest Moniz Asst. Energy Secretary Dr. David Danielson 

# Department of Energy February 19, 2014 Technical Accomplishment27 

# Mid

- America Truck Show March 27

- 29, 2014 Technical Accomplishment/Collaboration28 

### • March 2013 to March 2014

– **Technical Accomplishments** √ Demonstrated 86% freight efficiency improvement (Objective 2b

– 24hr) √ 75% fuel economy increase √ Demonstrated 76% freight efficiency improvement (Objective 2a

– Drive) √ 66% fuel economy increase √ Demonstrated Li

- Ion Battery & SOFC capability √ Completed wind tunnel and vehicle testing of Waste Heat Recovery √ Validated an advanced transmission efficiency model √ Path

- to
- Target analysis for a 55% thermal efficient engine √ Demonstrated 49.4% BTE in engine only (Objective 3)



### • March 2014 to September 2014

– **Future Work**

• 55% BTE path to target roll

- up analysis (Objective 3)

• Final Report and Commercial Development 

# Milestones and Technical Accomplishments29 

# Summary

• Program remains on schedule

• Meeting the ARRA and DoE VT MYPP goals

• Demonstrated a 50+% BTE engine system (Objective 1)

• Demonstrated a 70+% vehicle freight efficiency gains (Objective 2a & 2b)

• Analytical roadmaps updated with experimental component data

• 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 APU in lab and vehicle tests (Objective 2b)

• Li

- Ion battery APU (Objective 2b)

• Tractor

- Trailer aerodynamic aids (Objective 2a)
• Developed framework and analysis for 55% thermal efficiency

• Completed analytical roadmaps for both diesel and dual fuel approaches

• Completing targeted engine tests to validate roadmaps
• Developed working relationship with excellent vehicle and engine system delivery partners30 

# 68% **50% FTE Deliverables On Track**  **Technical Accomplishment**


# 61% Demo 1

Demo 2 

# 86%