美国超级卡车项目-佩卡结项报告

2021AnnualMeritReview

DevelopmentandDemonstrationof

AdvancedEngineandVehicle

TechnologiesforClass8Heavy-Duty

Vehicle(SuperTruckII)

MaartenMeijer,Ph.D.–PrincipalInvestigator

BenGrover–KenworthTruckCompany

PACCARInc.

June24,2021

ProjectID#ACE124

Thispresentationdoesnotcontainanyproprietary,confidential,orotherwiserestrictedinformation

2

Overview

Timeline

•StartDate:

•EndDate:

•PercentComplete:

October2017September202275%

Budget

•TotalProjectFunding

–DOE:$20M

–Partnership:$20M

•FY2021Funding:$32.4M(ProjectTotal)

Barriers

•IdentifyingCostEffective,ProductionRepresentativeProcessForCabStructure

•Cost,RobustnessAndPackagingNeedsOfEngineTechnologiesToAchieve55%BTE

•AbilityToDemonstrateBenefitsInMoreThanOneApplication/UseCase

Partners

3

ObjectivesandRelevance

•OverallObjectives

–GreaterThan100%FreightEfficiencyImprovementRelativeToa2009Baseline

–GreaterThanorEqualto55%EngineBrakeThermalEfficiency

–Targetisa3YearPaybackPeriodonDevelopedTechnologies

•ObjectivesThisPeriod

–WHRDemonstration

–EngineBuild

–MildHybridPowertrainValidation&Integration

–FreezeVehicleDesign

•Impact

–EvaluationofHigherRiskTechnologiesWithPotentialForEnergyEfficiency

–PotentialModernizationofKeyTechnologiesinFreightTransportIndustry

–EvaluationofImpactofTechnologiesinMoreThanOneReal-WorldDriveCycle

4

ComponentTestAndValidation

•VehicleControlsDevelopment50%

•ProtoVehiclesTesting50%

•NewEngineTechnologiesTesting75%

•WHRIntegrationAndInitial

Testing

•HybridPowertrainTesting

ProgramOutline

Year1(2018)

Analysis&BaselineTesting

•SimulationToEvaluateEngine,PowertrainAndVehicleEfficiencyBuildingBlocks

•BaselineTesting

Year2(2019)

Design&Prototype

Build

•EngineDesign

•PowertrainAndControlsArchitectureSelection

•PrototypeBuilds

•CabAndChassisDevelopment

Year4(2021)

PowertrainTesting&SuperTruckBuild

•PowertrainAnd30%VehicleIntegration

•EngineEfficiencyDemo

•InitialTestingOfDrivability&FuelEconomy

Year5(2022)

Engine&Freight

EfficiencyDemo

•Engine&WHR55%BTEDemo

•SuperTruckFreightEfficiencyDemo>100%

•FinalReport

•ProjectClose

Year3(2020)

5

Milestones

BudgetPeriod3:October2019–December2020September2021

Milestone

Type

Description

%

EngineComponentsFabricationComplete

Technical

FinalInternalAndExternalEngineComponentsAreFabricated

75%

PowertrainComponentsFabricationComplete

Technical

FinalElectrifiedPowertrainComponentsAreFabricated

100%

SuperTruckIITractorComponentDesignsFrozen

Technical

DesignIsFrozenForComponentsOfTheSuperTruckIITractor

45%

SuperTruckIITractorDesignIsComplete

Go/No-go

AllEngineAndPowertrainComponentsHaveBeenFabricated.SuperTruckIITractorDesignIsComplete

75%

•BudgetPeriod3Extendedby9Months

•NoExtensionoftheProgramDeadlineatThisPoint

EngineFuelEfficientDOHCMX-12

•

•

•

No

EngineEfficiency

UltraLow

BasicArchitectureChanges

48VAux./FEADRemoval

NOxCompliant

OverWHR

•

ChassisLight-Weight&Modular

SupportsAllNewPowertrains

30%WeightSavingsChassisand

EaseofManufacturing

-

e

Suspension

Steering

•

•

•

•

KeyConcepts

48VMild-Hybrid

•

•

•

P2.5e

-

SupportsVehicleAux.

Ion

Batteries

Dev.of48VComponents

Powertrain

Motor/Generator

Electrification

Gen.Li

Next

30kW

•

-

TractorAerodynamicCabin

•

•

•

6

Energy

HVAC&e

-

SystemLevelEnergy

PredictiveAdaptiveCruise

Management

Hoteling

Efficient

Control

e

•

-

7

FlowBench

55%BTEEngine

EfficiencyImprovementContributions

EngineWithArtificialBoost

LongStrokeSingleCylinderEngine

•EngineDesignCompleted

•Long-StrokeConceptValidated

•SuperTruckIIEngineBuild:Q42021

EngineDesign

NewCasting:TallerDeck

WHROptimizedInter-Coolers

TwoStageTurboCharging

Optimized/CoatedPistons

LongStroke

VariablePistonCoolingJets

FluidDampener

EngineDesign

ChargeAirCoolerHighandLowPressure

(LiquidCooled)

48VEGRPump

CylinderPulseExhaustManifold

InsulatedExhaustPath

RedesignedCylinderHead

-ExhaustPulseTurboCharging

-PortInsulation

CrankDrivenFuelPump

Status

–AllComponentsFabricated

–PerformanceofKeyComponents,IncludingtheTurbineExpander,ExperimentallyValidated

–4%.BTEonTrack

10

WasteHeatRecovery

Approach

‒TailoredWHRArchitecture,ForMaximum

OverallBTEPotential

‒Co-OptimizedApproachWithEngine

Simulations

Close-CoupledEAS

‒48Ve-Heater

‒CarbULN2027(FTP0.02g/bhp-hr)

‒IncludedinVehicleDemo

11

UltraLowNOx

GasolineCompressionIgnition

‒HighBTEandULN

‒SimulationsShowPotential

‒TestingQ42021

‒DieselRemainsPrimePathforEngineDemo

BasePowertrain

13%

7%

22%

Status

–ValidatedonDyno-stand

–IntegratedonProtoVehicle

MildHybrid/Electrification

LowRollingResistanceTires

PowertrainEfficiency

40%Improvement

Powertrain

12

HybridPowertrain

–48VForIncreasedPowerCapacity

–Developmentof48VComponents

–PTOMounted30kWe-Machine

–GearboxforCrankingandOptimumFE

BatterySystem

–Tailored48VLi-IonBMS

–Supportse-Hoteling

Hybridization

e

MildHybridArchitecture

48VBMS

MDC

-Machine

2SpeedGearbox

13

PathtoFreightEfficiency

PowertrainEfficiency40%Improvement

BaseEngine

MildHybrid/Electrification

LowRollingResistanceTires

WeightReduction25%Reduction

SystemsEngineering

ModularIntegration

MaterialsApplication

Aerodynamics

60%Reduction

IdealShape

FlowManagement

TrailerSkirt&Tail

175%FreightEfficiencyImprovementForecasted14

DemonstrationVehicle

StylingandAerodynamics

–½ScaleModelComplete

–OuterbodyDesign>FinalStylingTuning

CustomerFeedback,MarketFeasibility

–RefinedDemonstratorDesigns

–ROIAssessment

VehicleDesign

–CabStructureRefinementPhase

–BodyinWhiteInProgress>NextStepBuilding

–ChassisandPowertrainHardwareProcurement

15

AERODYNAMICS

•KeyElementtoImprovingFreightEfficiency

•IdealTractorShape:

–EnclosedFrontWheels

–ShorterNose

•SkirtandTailAeroTreatments

–30%DragReduction

•TotalDragReduction60%

FocusonWeightReduction

AccommodatingRideHeight

Changes

StructuralStreamliningforWeightReduction

FinalDesign

ImproveSuspensionPerformance

UpdatesResultin250lbsReduction

ChassisandSuspension

Chassis

CabSuspension

RearSuspension

RevisedDesignBasedonMuleTesting

CabAnti-DiveSystemProvedExtremelyEffective.

CoolingSystem

2-LoopDesign

e-HVACSingleIn-CabDesign

Predictive

ProbabilisticModelsfor

18

AsaFunctionof:

Hoteling

Weather

HotelLoads

Route

•

•

•

•

Improved

•

•

•

•

NoidleRequirement

WindshieldMultilayerIRRCoating

,BEV,and

Insulation

Hybrid

Pump

Built

Fuel

Cell

Heat

in

-

-

VehicleEnergyManagement

UWProject

Spontaneous

Energy

Maintaining

Sufficient

Solar

Control

LuminousTransmission

•

•

•

19

Vehicle48VElectrification

DC-DCconverter

CoolingPump

Fans

20

ResponsestoReviewers’Comments

•ItwouldbehelpfulifPACCARcanpointoutspecificdifferencesbetweenPACCAR&itscompetitorWHRstructures.

–ThePACCARORC-baseddual-loopWHRsystemfeaturesacompletelyuniquesystemarchitecturetailoredtothePACCARengineheatsourcesandoperatingconditions,includingfirstofitskinddual-coretwo-stagechargecoolers,anddual-coretailpipeboiler.Additionally,isthefirstand,todate,onlysystemtousethelatestdual-entryturbinetechnologyfromCummins,demonstratingthehighestefficiencyofanyturbineofthistype.

•Thepathtotarget55%BTEclearlyidentifiedWHRasrequired,butdiscussioninQ&AindicatedthisteamdidnotthinkWHRwascommerciallyviableandwaspursuinghybridelectricsolutions.

–Forthe55%BTE(enginedemo)WHRiskey.ForoptimumFreightEfficiency(vehicledemo)thefuelsavingsundertransientconditionsdon’toutweightheadditionalweight,andimpactonaerodynamics.Inaddition,thecostandcomplexityofahighestBTEWHRsystemremainsachallengefornearfuturecommercialization.

GHGregulationsMayAlterThisAssessment.

•Theaerowasnotasclear.PACCARshowsaerodragreductionof20%and5%onthetrailer.Doesthismeantherewillbe35%reductioninthetractoraerotoequateto60%reductionoverall?

–Ourlatestsimulationsshowa60%reductionoverall,witha30%trailer/30%tractordistribution.

•Itwouldbehelpfulifthecompanylogocanbeinsertedtotheslides,wherethosepartnershavemadethecontributiontotheprogram

–Acknowledged

21

Partnerships/Collaborations

VehicleDevelopment,VehicleLevelSupervisoryControls

EngineDevelopment,EngineManagementSystems

PowertrainDevelopment,AdvancedPredictiveFeatures,ProgramAdministration

ElectrifiedPowertrain,Transmission,andAirManagementSystemsDevelopment

EngineDevelopment

DriveCycleDevelopment,andThermalManagement

WasteHeatRecoveryIntegration

AxleIntegration

TireDevelopment

ModelDevelopmentforCabinHotelingOptimization

Windscreencoatingandenginethermalbarriercoatings

Engine

•Turbo-ChargerEfficiency

•ThermalBarrierSwingCoatings

RemainingChallenges

•ForallTechnologyConcepts:De