Class-8 Heavy Truck Duty Cycle Project Final Report - Center for ...

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LIST OF TABLES Table Page 1 Pilot Test List of Signals ........................................................................................................... 9 2 Tire Sizes and Types ............................................................................................................... 16 3 Tires per Route ........................................................................................................................ 16 4 HTDC Pilot Test Routes..........................................................................................................17 5 FOT Measures of Performance and Associated Sensors......................................................... 24 6 Test Truck Information ........................................................................................................... 28 7 Test Trailer Information .......................................................................................................... 29 8 Equipment for DAS 1.............................................................................................................. 29 9 Gear Ratio and Maximum Torque for Transmission Model FRO-16210C* .......................... 50 10 Operating Speeds by Gear for Proposed Vehicle Mapping Duty Cycle ................................. 53 11 General Statistics and Error Type by Channel ........................................................................ 63 12 Percentage of Data Points with Errors per Channel (Selected Channels) ............................... 63 13 Comparison of Truck Weight Prediction Model vs. Truck Weight Read from On-board Air-Weigh Devices.................................................................................................................. 70 14 General Statistics for the Instrumented Tractors ..................................................................... 79 15 General Statistics: Total, Moving, Stopped, and Idling Times for all Trucks by Trip Type......................................................................................................................................... 80 16 General Statistics: Fuel Consumed for the Total, Moving, Stopped, and Idling Fuel for All Trucks by Trip Type.......................................................................................................... 80 17 Fuel Efficiency: Tractors with NGSWBTs vs. Tractors with Dual Tires (Trailers with Any Type Tire)........................................................................................................................ 82 18 Fuel Efficiency* by Transmission Type: Tractors with NGSWBTs vs. Tractors with Dual Tires (Trailers with Any Type Tires).............................................................................. 83 19 Fuel Efficiency Comparison by Truck-Tire Configuration (Averages Computed Using Fuel Efficiencies Calculated for 100-Mile Segments) ............................................................ 86 20 Fuel Efficiency Comparison by Truck-Tire Configuration (Averages Computed Using Total Distance Traveled and Total Fuel Used)........................................................................ 86 21 Fuel Efficiency Comparison by Truck-Tire Configuration (Null Hypothesis: All Fuel Efficiency Distributions Are the Same) .................................................................................. 91 22 Fuel Efficiency as a Function of Load Level and Truck-Tire Configuration.......................... 92 23 Fuel Efficiency Comparison by Truck-Tire Configuration and Load, Null Hypothesis: All Fuel Efficiency Distributions Are the Same...................................................................... 96 24 Fuel Economy for Class-8 Trucks as a Function of Speed and Truck-Tire Combination ...... 97 25 Fuel Economy for Class-8 Trucks as a Function of Type of Terrain and Type of Tractor Tires......................................................................................................................................... 98 26 Summary of Average Fuel Economy Benefits of NGSWBTs vs. Standard Dual Tires for the Cases Addressed in this Report.................................................................................. 100 ix
Page 1 and 2: Class-8 Heavy Truck Duty Cycle Proj
Page 3: Vehicle Systems Program ORNL/TM-200
Page 6 and 7: 2.7 LAUNCH OF THE FOT (OCTOBER 23,
Page 8 and 9: 40 Connection and Support Structure
Page 13: Term Definition ACRONYMNS AND ABBRE
Page 17 and 18: EXECUTIVE SUMMARY The Heavy Truck D
Page 19 and 20: xvii
Page 21 and 22: 1. PROJECT OVERVIEW This U.S. Depar
Page 23 and 24: • total kinetic energy • total
Page 25 and 26: evening and they maintain a daily l
Page 27 and 28: Fig. 4. Modified HHDDT Cruise Modul
Page 29 and 30: Significant research has been accom
Page 31 and 32: Data # Performance Measure Benefit
Page 33 and 34: Fig. 7. Vaisala WXT510 Road surface
Page 35 and 36: this period of time, the sensors we
Page 37 and 38: The on-road portion of the Pilot Te
Page 39 and 40: 1.5.3 Data Collected Two Chicago-to
Page 41 and 42: 2. FIELD OPERATIONAL TEST The prima
Page 43 and 44: Near the end of the FOT, ANL indica
Page 45 and 46: Signal Sensor 11 Driver's Demand En
Page 47 and 48: Fig. 21. Vaisala Weather Station 2.
Page 49 and 50: Table 7. Test Trailer Information T
Page 51 and 52: partnerships and with cooperative e
Page 53 and 54: Fig. 26. Mr. Ronnie Osborn (Driver
Page 55: 2.8.3 Test Routes Because the FOT r
Page 58 and 59: 3.2 HOW TO ACCESS THE TOOL The HTDC
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4. DUTY CYCLE GENERATION TOOL The D
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Data Display Tool: MultiPlot Elevat
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Merged Fig. 34. Segment Tailing and
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Fig. 37. Compressed Duty Cycle with
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5. DYNAMOMETER TESTING In order to
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Fig. 42. Engine Torque and Vehicle
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Engine Speed [RPM] Fig. 45. Test Po
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Speed [mph] 90 80 70 60 50 40 30 20
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Vehicle Speed [mph] 80 70 60 50 40
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6. FOT DATA ANALYSIS The primary ob
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collected on November 13 th , 2006)
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Table 11. General Statistics and Er
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This methodology worked well at the
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sliding exponential smoothing filte
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directly assessed. A truck total we
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Weight [lb] Weight [lb] 60,000 55,0
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Frequency 100 90 80 70 60 50 40 30
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uns 91 to 100. Just by chance, the
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( D3 − D2) 1 fea = = Eq. (3) FCa
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the course of the year-long data co
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operations, especially those close
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Table 18. Fuel Efficiency* by Trans
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Fig. 70. All Trips with NGSWBTs Mou
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To statistically corroborate these
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Frequency 350 300 250 200 150 100 5
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three rows of Table 21 show the ave
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Frequency 350 300 250 200 150 100 5
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duty cycles was used to compute one
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intervals, going from 0+ mph (i.e.,
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Fuel Efficiency [mpg] Percent of To
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7. LESSONS LEARNED The HTDC project
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Another performance measure was als
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7.2.2.2 Driver communication Again,
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7.2.2.8 Database manipulation The p
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fuel sensor could not be calibrated
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data on representative duty cycles.
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Heavy Vehicle Duty Cycle (HVDC) Pro
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3.3.5 Task 5: Installation of the D
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Letter Report Phase 1 - Heavy Vehic
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Task 8: Prepare Phase 1 Report Task
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develop versions that could be sent
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elevation, precipitation, barometri
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• For weather information - Vaisa
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Figure 6 - SOMAT eDAQ DAS A Letter
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Table 1 ORNL Equipment and Sensors
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Figure 16: Exhaust Gas Thermo-Coupl
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initiation of pilot testing, a requ
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Figure 34: The North-South Route (T
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• Selection of a DAS that stores
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Appendix A-A Pilot Test Data Channe
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Data # 13 14 15 16 Performance Meas
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Measure Measure Value System Locati
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Data # Performance Measure 54 55 56
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Data # Performance Measure Performa
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Data # Performance Measure 97 Gear
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HEAVY-TRUCK DUTY CYCLE DATA FROM RE
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The metrics (Performance Measures)
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24 Yaw Rate 25 Slip Angle Describes
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46 47 48 49 50 51 52 53 54 55 56 57
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74 75 76 77 78 Axle Oil Temperature
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98 99 100 Actual Gear Ratio CAN J19
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The SoMat eDaq data acquisition sys
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allow for sustained testing such as
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conventional 6x4 tractor, while the
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Figure 4.2 Kalamazoo to Portland Ro
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Table 5.2 November Route and Schedu
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6.0 OVERALL PROJECT SCHEDULE The ov
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1 Performance Measure Average Fuel
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17 Performance Measure Performance
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Appendix A-D Sensor System Letter R
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• Vehicle weight, including load,
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Measure Ouput Measure Value Locatio
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APPENDIX Task 2: Identification of
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Memorandum of Understanding No. MOU
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MOU-UTB-2007001 Schrader Trucking C
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MOU-UTB-2007001 Schrader Trucking C
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Oak Ridge National Laboratory Natio
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Argonne National Laboratory (ANL) w
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Signal Sensor 19 Total Idle Hours J
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Figure 4.3: Vaisala Figure 4.4: J19
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Figure 4.6: Schrader Tractor and Tr
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VBOX 006879 TTG 002 VBOXTools 1.2.1
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• On-Vehicle Testing • Vehicle
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• Directions • At Schrader Truc
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stated in the Data Upload checklist
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Figure 6.4: Weather Station Figure
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HTDC Data Storage This procedure is
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8) After you have downloaded the da
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Oak Ridge National Laboratory Natio
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5.4. Weather Station Connections 5.
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Phase 1 - Pilot Test: Design, Testi
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Equipment Quantity Product Name Air
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on vehicle motion and position. The
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Figure 5.0: Wiring Overview 5.1. Po
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Figure 5.3: J1939 (Vehicle Bus) & J
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Table 5.5.1: EDAQ Turck Cable Pin-o
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Figure 6.1: Fuse Panel in Volvo Das
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6.5. Data Bus Run a single cable co
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NOTE: The purpose of this cable is
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1) Start the computer and log on, b
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i) Channels (Standard) - Deselect a
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Figure 7.1.3-3: Connection Setup 5)
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the eDAQ can be finalized. This sec
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i) Click OK. ii) Click FCS Setup >
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Hardware Setup and Configuration. F
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Figure 7.2.4-1: Transducer and Mess
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Interface Original ID New ID Units
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shown within each section to avoid
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ID: AirTempr_0 Description: Air Tem
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5 / 3 7. Channel Type: Desk Calcula
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Description: Tractor Air-Weigh func
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Figure 7.2.5-5: Down Sampler Setup
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Type: Angle Units: deg Full Scale E
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Figure 7.2.6-1: Time History Data M
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8. OPERATIONAL PROCEDURES 8.1. Gene
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test of the memory card capacity. T
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Figure 8.2.1: HTDC Routine Data Upl
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- remote computer at ORNL The data
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necessary to restart the computer a
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1) Re-establish communication with
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Figure 9.1.4-1: Setting the Field C
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Constructing VBM databases NOTE: Da
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AirWeigh_Alone.txt J1708 Database F
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ActEgPctTq CAN 0x83FFFF 0x80F004 Ac
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9.1.6. VBOX ColdStart Procedure NOT
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9.2. Appendix B: Additional Informa
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Channel ID Description Units TimeUT
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Table 9.2.2-3: Invalid Data Values
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Channel ID Resolution Accuracy Note
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Channel ID Resolution Accuracy +/-
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the secondary as the static IP nece
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F004 FEC1 FEE9 FEF1 9.3.2. EDAQ Not
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Checking Data Storage Capabilities
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Potential J1708 Issues The J1708 da
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D-95
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D-97
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Appendix E DYNOMOMETER TESTING FINA
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E-4
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E-6
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E-8
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E-10
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E-12
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E-14
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E-16
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E-18
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E-20
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E-22
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E-24
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E-26
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E-28
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E-30
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E-32
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E-34
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E-36
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E-38
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E-40
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