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

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ACKNOWLEDGEMENTS The authors wish to gratefully acknowledge the contributions of Mr. Paul Pollock, Mr. Dan Coleman, and Mr. Jim Ridge of Dana Corporation; and Mr. Ibrahim Janajreh and Mr. John Melson of Michelin Americas Research and Development Corp. for their invaluable contributions to this project. Mr. Pollock has been a Dana champion for this research since 2002, and without his dedication, focus, technical insight and generous partnering spirit, this project would not have been successful. Mr. Coleman provided strong technical support in this research and provided insights, technical advice and strong enthusiasm which were critical for success. Mr. Ridge assumed most of the data acquisition responsibilities in this project, including in-vehicle data acquisition across the two Chicago-Portland routes. He played a pivotal role in preparing the sensor suite and electronics, applying technical solutions to complex instrumentation problems, and organizing the trip logistics and data set. He put in long hours in the office, garage, and on the road to see this project become successful. Mr. Janajreh had an early recognition of the value of this research and recognized the benefits of jointly pursing this study. His willingness to creatively discuss research directions helped to shape the nature of this work. His untimely passing created a significant void in the project team and he has been missed. Mr. Melson provided the continuity that was needed in this research after the passing of Mr. Janajreh in August, 2005. His professional and unselfish approach in picking up this project and quickly moving on critical issues prevented it from coming to a halt. Additionally, we are also very thankful for the contributions of Mr. Ralph Long (CCC) for piloting the test vehicle and for Mr. Kevin Gates (Clark Engineering Services) who provided the instrumentation integration. We are indebted to the extremely capable team of professionals from Dana, Michelin, CCC, Clark Engineering Services and ORNL for their contributions to this Pilot Test. We sincerely hope that research opportunities continue to emerge that will allow ORNL us to again partner with this outstanding team. Bill Knee Director- ORNL Heavy Vehicle Safety Program Center for Transportation Analysis Oak Ridge National Laboratory Gary Capps Research Engineer Center for Transportation Analysis Oak Ridge National Laboratory A-6
Letter Report Phase 1 - Heavy Vehicle Duty Cycle (HVDC) Project 1.0 BACKGROUND Prepared by: H. E. (Bill) Knee and Gary J. Capps Oak Ridge National Laboratory February 28, 2006 This Project involves efforts to collect, analyze and archive data and information related to heavy truck operation in real-world highway environments. Such data and information will be usable to: • provide input to the Department of Energy (DOE) regarding technology investment decisions, • support the development and evaluation of the Argonne National Laboratory (ANL) developed class-8 module for the Powertrain System Analysis Toolkit (PSAT), • provide a real-world-based data archive capable of supporting heavy truck research, and • provide a means of accounting for real-world driving performance within heavy truck research and analyses. The Project is being led by the Oak Ridge National Laboratory (ORNL), and involves two industry partners (Dana Corporation [Dana] of Kalamazoo, MI, and Michelin Americas Research and Development Corp. [Michelin] of Greenville, SC) and will have support from ANL. Participation by the US Department of Transportation (USDOT) has been actively sought, but with little success. This lack of success is strongly linked to the unavailability of funding due to a USDOT continuing budget resolution during FY2004 and FY2005. Additionally, although a FY2006 USDOT budget has been agreed to, funding of earmarks amounted to the budget being about 25% over-subscribed to. As of the end of February, 2006, this budget issue had not been resolved. As a result, new USDOT research has not been forthcoming. 2.0 PROJECT OVERVIEW This project involves efforts to collect, analyze and archive data and information related to heavy truck operation in real-world driving environments. One of the primary deliverables of this project is a set of heavy truck duty cycles based on typical heavy vehicle driving performance generated from a working fleet(s). The project will be conducted in two phases. Phase 1: Design, Testing and Evaluation of a Duty Cycle Data Collection System. Phase 2: Fleet Instrumentation, Data Collection, Analyses, and Archiving. Phase 1 is a 15-month effort that will be completed in March, 2006. Within Phase 1, Pilot Testing to A-7
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Class-8 Heavy Truck Duty Cycle Proj
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Vehicle Systems Program ORNL/TM-200
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2.7 LAUNCH OF THE FOT (OCTOBER 23,
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40 Connection and Support Structure
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LIST OF TABLES Table Page 1 Pilot T
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ACKNOWLEDGEMENTS The Oak Ridge Nati
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Sixty channels of data were collect
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xviii
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The data analyses performed in Phas
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Fig. 2. HHDDT Transient Mode In add
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vehicle; 3) a transit bus; 4) a nei
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payload and accessory load would al
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Data # Performance Measure Benefit
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Data # Performance Measure Benefit
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Fig. 10. NGK NOx/O2 Sensors Fig. 11
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1.3.4 De-instrumentation: Following
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Fig. 16. Pilot Test North-South Rou
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GPS information collected with the
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2.1 REVIEW OF PERFORMANCE MEASURE R
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2.3.2 Performance Measures Fig. 18.
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Signal Sensor 53 Road Grade Calcula
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2.3.6 Tractor and Trailer Details F
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determined that the particular CANo
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Cable runs to and from sensors were
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2.8 CONDUCTION OF FOT The FOT laste
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3. INTERNET DATA ACCESS TOOL The HT
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Fig. 30. Search Results The file se
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When the button “Extract Data”
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Data Fig. 33. Segment Merging In ad
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Fig. 36 shows the synthetic cycle g
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Fig. 39. A Synthetic Duty Cycle wit
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tractors) as well as the maximum to
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vehicle was carrying a heavy load o
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Vehicle Speed [mph] Vehicle Speed [
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5.2 REAL-WORLD DUTY CYCLES Informat
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Vehicle Speed [mph] 70 60 50 40 30
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Given the size and complexity of th
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data or out-of-range data. Therefor
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6.1.1 Spatial Information Using the
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For those cases in which an instrum
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Page 100 and 101: Table 15. General Statistics: Total
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Page 110 and 111: Speed [mph] 80 70 60 50 40 30 20 10
Page 112 and 113: vehicle is hauling light or heavy l
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Page 116 and 117: A summary of the statistics describ
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Page 120 and 121: 6.3.2.4 Summary of Fuel Efficiency
Page 122 and 123: Lesson Learned: A technology progre
Page 124 and 125: Lesson Learned: Adding external sen
Page 126 and 127: know if the vehicle was “filled u
Page 129 and 130: 8. SUMMARY OF RESULTS AND CONCLUSIO
Page 131 and 132: 9. FUTURE DIRECTIONS The Heavy Truc
Page 133: Appendix A PILOT TEST LETTER REPORT
Page 136 and 137: 1.0 BACKGROUND 2.0 PROJECT OVERVIEW
Page 140 and 141: evaluate the data collection system
Page 142 and 143: performance of their next generatio
Page 144 and 145: March and provided to the ORNL Prog
Page 146 and 147: Between January, 2005 and May, 2005
Page 148 and 149: Figure 4: NGK Sensor Figure 5: Omeg
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Page 152 and 153: Figures 28 through 31 show the ball
Page 154 and 155: Figure 22: Airweigh System Figure 2
Page 156 and 157: DVD. Figures 35 and 36 show some of
Page 158 and 159: 3.3.7.1 Pre-Analysis Efforts: As th
Page 160 and 161: Task 1: Identification of Fleet(s)
Page 162 and 163: Data # Performance Measure Performa
Page 164 and 165: Sensor or eDaq Performance Performa
Page 166 and 167: 45 46 47 48 49 50 51 52 53 Measure
Page 168 and 169: Data # 62 63 64 65-67 68-69 70-71 7
Page 170 and 171: Data # Performance Measure 87 Headi
Page 172 and 173: Appendix A-B Final Pilot Test Plan
Page 174 and 175: • DAS/sensor suite/cabling operab
Page 176 and 177: 9 10 11 12 13 14 15 Lateral Velocit
Page 178 and 179: 34 Rain Intensity 35 36 37 38 39 40
Page 180 and 181: 59 60 61 62 63 64 65-67 68-69 70-71
Page 182 and 183: 85 Longitude 86 Velocity 87 Heading
Page 184 and 185: 3.2 Sensors The PMs listed in Table
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DATE TEST ENGINEER: DRIVER: DEPARTI
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Jim Ridge, Dana Product Engineer, w
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Table 5.1 October Route and Schedul
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Table 5.2 December Route and Schedu
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Appendix A-C Field Test Signals 64
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9 Performance Measure Performance M
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Performance Measure 25 Rain Duratio
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Letter Report SUMMARY OF RELEVANT H
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Sensor or Performance Data Sensor o
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GAWR 44 lb AirWeigh 5800 Road Surfa
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Appendix B SCHRADER MEMORANDUM OF U
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MOU-UTB-2007001 Schrader Trucking C
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MOU-UTB-2007001 Schrader Trucking C
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Appendix C FIELD OPERATIONAL TEST P
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Collection, Analysis, and Archiving
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4.0 APPROACH Phases 2 and 3 of the
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Signal Sensor 60 Tractor-Trailer Ma
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Schrader Trucking will provide six
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Sensitive Information] [Partner Sen
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4.6 Sensor and DAS Integration to T
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5.5 Vehicle Deployment Methodology
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Start address: 2360 Cherahala Blvd
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Figure 6.2: Schrader Shop, Far Left
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Figure 6.7: eDAQ Lite with two Vehi
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6.5 Safety Information For Student
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Appendix D SYSTEM DESIGN AND OPERAT
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TABLE OF CONTENTS Collection, Analy
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9.1.2. Shutdown Procedure 9.1.3. SI
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Signal Sensor 26 Cruise Control Acc
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Figure 4.1: Air-Weigh System Compon
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4.5. EDAQ The eDAQ Lite is connecte
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the equipment inside from overheati
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5.4. Weather Station Connections Fi
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Figure 5.5.3: VBOX Cable Table 5.5.
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Figure 6.3: Weather Station Locatio
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6.6 Power Supply Use a second cable
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can also be changed from this windo
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on and the yellow light should begi
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Figure 7.1.3-1: Weather Station and
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Speed unit: m/s Sampling frequency:
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iii) Click on Browse to find and op
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c) Power Controller (Power) - no co
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1) Select the Transducer and Messag
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Figure 7.2.4-2: Adding Transducer C
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Figure 7.2.4-3: Editing DIO Vehicle
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A. Changing Units - Converting tran
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C. Coordinates - Assign correct sig
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switch) Table 7.2.5: Contents of Ti
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Trigger Delay Setup: Check Enable d
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Figure 7.2.5-6: Time Base Shifter S
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Units: Full Scale Estimate - Min: 0
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Figure 7.2.6-2: Burst History Data
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Press Ctrl+3 (or click Run in the T
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8.2. Procedures for Heavy Truck Dut
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d) Turn on the ignition. e) Turn on
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4) Change the IP address field to t
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5) Check to see that the computer c
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e) When all SIC files have been sav
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4) To verify the time setting, go t
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e) Alter the id, mask, value, etc.
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Longitudinal CAN 0x87FF 0x0304 Long
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ULSB 0x98EAFFFBC1FE00 MaxVehSpLm CA
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Figure 9.1.6-2: Performing a ColdSt
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Table 9.2.2-1: Descriptions and Uni
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Channel ID Sensor Format Integer? P
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Channel ID eDAQ Invalid Data Value
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Channel ID Resolution Accuracy Note
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9.3. Appendix C: Additional DAS Not
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e replicated and saved as five iden
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2) Type in “cmd” 3) Type “ipc
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Producing multiple setup files 1) G
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9.4. Appendix D: Checklists and For
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D-96
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9.5. Appendix E: References and Web
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E-3
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E-5
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E-7
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E-9
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E-11
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E-13
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E-15
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E-17
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E-19
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E-21
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E-23
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E-25
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E-27
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E-29
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E-31
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E-33
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E-35
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E-37
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E-39
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E-41
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