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

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DATE TEST ENGINEER: DRIVER: DEPARTING CITY DESTINATION BEGINNING MILEAGE ENDING MILEAGE DEPARTING TIME ARRIVAL TIME TIRE PRESSURE AT START OF DAY RT STEER RT FRONT DR RT REAR DR RT FRONT TR RT REAR TR LT STEER LT FRONT DR LT REAR DR LF FRONT TR LF LEFT TR TIRE TREAD DEPTH (to be recorded at beginning and end of tire use) RT STEER RT FRONT DR RT REAR DR RT FRONT TR RT REAR TR LT STEER LT FRONT DR LT REAR DR LF FRONT TR LF LEFT TR FUEL PURCHASED DATE STATE GALLONS TOTAL COST AIRWEIGH INFORMATION BEFORE FILLUP GVW STEER AXLE TRACTOR DRIVE TRAILER AFTER FILLUP GVW STEER AXLE TRACTOR DRIVE TRAILER MILES DRIVEN PER STATE STATE ENTER (MILES) EXIT MILES TOTAL CHECKLIST DRIVESHAFT TORGUE SENSOR 9VDC BATTERY(daily) HVDC DAILY LOG SHEET Figure 4.1 HVDC Daily Log Sheet 4.2 Ballast Federal laws offer 80,000-lbs combinations in all states, but there are varying limits for state highway systems. Tandem drive and tandem trailer axles are limited to 34,000-lbs each. Legal weight limits for state highways must be cautiously observed. If necessary, the vehicle weight will be adjusted accordingly. The trailer will be loaded with concrete ballast and sandbags to achieve a Gross Vehicle Weight Rating as near 80,000 lbs as possible without exceeding the Gross Axle Weight Rating for any axle. The ballast will be secured with load frames (previously used in Truck Rollover Characterization Testing conducted by the partners) and binders to prevent movement and provide load control during testing. A steer axle weight limit of 12,000-lbs is standard on the 56 0 0 0 0 0 0
conventional 6x4 tractor, while the drive and trailer axles shall be loaded up to the limit of 17,000-lbs per axle. 4.3 Tires The duty cycle testing will evaluate the effect of tire type on vehicle fuel economy. Michelin will provide the tires shown in Table 4.1 for HVDC testing. Table 4.1 Tire Sizes and Types No. of Tires Tire Size 2 XZA3 275/80R22.5 8 XDA-HT 275/80R22.5 8 XT1 275/80R22.5 4 Xone XDA-HT PLUS 445/50R22.5 4 Xone XTE 445/50R22.5 For each duty cycle route, the vehicle will be configured with standard dual tires (275/80R22.5) for the first run. On the repeat route, the vehicle will be configured with new generation singles tires (445/50R22.5). The route verses tires are shown in Table 4.2. Table 4.2 Tires Per Route Steer Drive Trailer Chicago-Portland #1 XZA3 XDA-HT XT1 Chicago-Portland #2 XZA3 XOne XDA-HT Plus XOne XTE Maine-Miami #1 XZA3 XDA-HT XT1 Maine-Miami #2 XZA3 XOne XDA-HT Plus XOne XTE The pressure shall be maintained at 116 psi for steer, 104 psi for drive and trailer dual tires, and 120 psi for drive and trailer new generation single tires. Tire pressure will be monitored, maintained, and recorded manually on the HVDC Daily Log Sheet. The driver will check and log tire pressure as part of the pre-trip inspect prior to driving each day. 4.4 Fuel During the Pilot Test (as will be during the Field Testing), fuel will be purchased where convenient and practical for the driver. For the Pilot Test ORNL and Dana will share the cost of the fuel. The driver will record the amount of fuel at each fill-up and the miles driven between fill-ups on the HVDC Daily Log Sheet (Figure 4.1) for cross-checking of fuel usage sensors. Each tank will be filled to a predetermined index mark on the tank to reduce the error in determining the amount of fuel required for a given fill-up. It is known that the total energy density of fuel will vary from production run-to-production run and from season-to-season. During the Pilot Testing Phase fuel sampling and assaying may be done to determine the energy density variability in order to relate this to total fuel consumption. 4.5 Pilot Test Routes 57
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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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Fig. 56. DCGenT Prototype Search Cr
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at constant speed. Parameters m, b,
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weight. Notice that, as expected, m
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the loss of information, and conseq
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consumption per unit of distance tr
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q q ( − ) ( feb'− feb) 100 '
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Table 15. General Statistics: Total
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70% 60% 50% 40% 30% 20% 10% 0% Idli
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Fig. 68. All Trips with Dual Tires
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The almost 700,000 miles logged dur
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Frequency 300 250 200 150 100 50 0
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Speed [mph] 80 70 60 50 40 30 20 10
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vehicle is hauling light or heavy l
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Frequency 350 300 250 200 150 100 5
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A summary of the statistics describ
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analysis controlling for the type o
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6.3.2.4 Summary of Fuel Efficiency
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Lesson Learned: A technology progre
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Lesson Learned: Adding external sen
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know if the vehicle was “filled u
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8. SUMMARY OF RESULTS AND CONCLUSIO
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9. FUTURE DIRECTIONS The Heavy Truc
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Appendix A PILOT TEST LETTER REPORT
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1.0 BACKGROUND 2.0 PROJECT OVERVIEW
Page 138 and 139: ACKNOWLEDGEMENTS The authors wish t
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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
Page 150 and 151: o Date and Time o Wind Speed o Wind
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
Page 186 and 187: vehicles will be dedicated to the p
Page 190 and 191: Jim Ridge, Dana Product Engineer, w
Page 192 and 193: Table 5.1 October Route and Schedul
Page 194 and 195: Table 5.2 December Route and Schedu
Page 196 and 197: Appendix A-C Field Test Signals 64
Page 198 and 199: 9 Performance Measure Performance M
Page 200 and 201: Performance Measure 25 Rain Duratio
Page 202 and 203: Letter Report SUMMARY OF RELEVANT H
Page 204 and 205: Sensor or Performance Data Sensor o
Page 206 and 207: GAWR 44 lb AirWeigh 5800 Road Surfa
Page 211: Appendix B SCHRADER MEMORANDUM OF U
Page 214 and 215: MOU-UTB-2007001 Schrader Trucking C
Page 216 and 217: MOU-UTB-2007001 Schrader Trucking C
Page 219: Appendix C FIELD OPERATIONAL TEST P
Page 222 and 223: Collection, Analysis, and Archiving
Page 224 and 225: 4.0 APPROACH Phases 2 and 3 of the
Page 226 and 227: Signal Sensor 60 Tractor-Trailer Ma
Page 228 and 229: Schrader Trucking will provide six
Page 230 and 231: Sensitive Information] [Partner Sen
Page 232 and 233: 4.6 Sensor and DAS Integration to T
Page 234 and 235: 5.5 Vehicle Deployment Methodology
Page 236 and 237: 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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