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

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4.6 Sensor and DAS Integration to Test Vehicles The test vehicles called out in Section 4.4 will be fitted with the sensors listed in Section 4.2, with the exception of the J1939 Vehicle Data Bus, which already exists on the vehicle. The sensor-to-test-vehicle integration will take place at the Schrader truck yard. Cable runs to and from sensors will be routed in a manner to allow for sustained testing and occupant safety. Consideration will be given to shielding these cables from engine/exhaust heat and damage from objects thrown from the roadway. Cable runs will have termination/inspection points to allow for trouble shooting without cable removal. The step-by-step integration process is described in the System Installation section of the System Design and Operations Document (SDOD). 4.7 Sensor/DAS Verification and Calibration All sensors, cabling, and the DAS will be verified for operation after the initial integration. This verification will take place at Schrader Trucking. Verification information is included in the Operational Procedures section of the SDOD. All fuel information collected from the truck data bus will be calibrated when enough fuel receipts are collected. One Air-Weigh tractor scale will be calibrated at a certified scale by following the Manual Calibration Procedure in the Air-Weigh tractor scale manual. The remaining Air-Weigh tractor scales will then be calibrated by following the Ratio and Offset Calibration Procedure in the Air-Weigh tractor scale manual. The Air-Weigh trailer scales will be calibrated according to the Pre- Programmed Calibration Procedure in the Air-Weigh trailer scale manual. The eDaq, VBOX, and Weather Stations have been calibrated at the factory. 4.8 Power Measurement An operating DAS system and complete sensor system will be measured for power consumption. It will be verified that the system is operating in an acceptable range. For this testing, an ammeter will be placed in series with the power wiring to the DAS and sensors. The current drawn will then be measured while all components of the DAS and sensors are turned on. 5.0 FIELD OPERATIONAL TEST 5.0 Field Operational Test Tasks This section will address the following Tasks: • Equipment Procurement • Equipment Configuration and Build-up • Equipment to Vehicle Integration C-14
• On-Vehicle Testing • Vehicle Deployment Methodology • Data Transfer Protocol 5.1 Equipment Procurement and Bill of Materials ORNL will procure all items needed for the construction of the six DASs. No individual component or circuit design is expected to be necessary nor are such efforts planned. Specialized cabling will be procured through special fabrication shops and smaller standard items will be procured via ORNL AVID system or via local purchase. The component procurement is planned for early in Phase 2 to allow for long lead items. The Bill of Materials for the DAS is shown in Table 4.4. 5.2 Equipment Configuration and Build-up Each DAS will be built and assembled per the SDOD Wiring Diagrams section. This will include the completed backplane assembly for each test vehicle and interconnection to all removable sensors, systems power, and system triggers. Individual sensors will be configured and formatted for assimilation into the DAS. Memory will be formatted, IP addresses set, and final sampling rates will be determined and set for the DAS. A connection point for downloading data will be configured into the system. Configuration will follow the Configuration Procedures section of the SDOD. 5.3 Equipment to Vehicle Integration ORNL will install the DASs and their associated remote sensors and cabling into each test vehicle via ORNL staff or contractor. The installation will be done in accordance with DOT, OSHA, and IEEE standards and will not interfere with the driver or the operation of the test vehicle. Furthermore, the equipment will be installed in such a way as to be “transparent” to the vehicle operator and will be done in such a way that driver interaction will be minimal or not required. The installation will not damage the structure of the test vehicles, affect their appearance once the equipment is removed, or decrease the value of the tractor-trailer beyond normal depreciation. Integration steps are listed in the System Installation section of the SDOD. 5.4 On-Vehicle Testing A shakedown test of the DAS will be performed on each fleet test vehicle. The test will verify that each sensor and the DAS are functioning in the desired manner. Any problems encountered during this testing will be addressed and solved before the vehicle enters the FOT. Testing information is included in the Data Upload Checklist and the Operational Procedures section of the SDOD. C-15
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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
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ACKNOWLEDGEMENTS The authors wish t
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evaluate the data collection system
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performance of their next generatio
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March and provided to the ORNL Prog
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Between January, 2005 and May, 2005
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Figure 4: NGK Sensor Figure 5: Omeg
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o Date and Time o Wind Speed o Wind
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Figures 28 through 31 show the ball
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Figure 22: Airweigh System Figure 2
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DVD. Figures 35 and 36 show some of
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3.3.7.1 Pre-Analysis Efforts: As th
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Task 1: Identification of Fleet(s)
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Data # Performance Measure Performa
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Sensor or eDaq Performance Performa
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45 46 47 48 49 50 51 52 53 Measure
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Data # 62 63 64 65-67 68-69 70-71 7
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Data # Performance Measure 87 Headi
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Appendix A-B Final Pilot Test Plan
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• DAS/sensor suite/cabling operab
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9 10 11 12 13 14 15 Lateral Velocit
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34 Rain Intensity 35 36 37 38 39 40
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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 188 and 189: DATE TEST ENGINEER: DRIVER: DEPARTI
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 234 and 235: 5.5 Vehicle Deployment Methodology
Page 236 and 237: Start address: 2360 Cherahala Blvd
Page 238 and 239: Figure 6.2: Schrader Shop, Far Left
Page 240 and 241: Figure 6.7: eDAQ Lite with two Vehi
Page 242 and 243: 6.5 Safety Information For Student
Page 245: Appendix D SYSTEM DESIGN AND OPERAT
Page 248 and 249: TABLE OF CONTENTS Collection, Analy
Page 250 and 251: 9.1.2. Shutdown Procedure 9.1.3. SI
Page 252 and 253: Signal Sensor 26 Cruise Control Acc
Page 254 and 255: Figure 4.1: Air-Weigh System Compon
Page 256 and 257: 4.5. EDAQ The eDAQ Lite is connecte
Page 258 and 259: the equipment inside from overheati
Page 260 and 261: 5.4. Weather Station Connections Fi
Page 262 and 263: Figure 5.5.3: VBOX Cable Table 5.5.
Page 264 and 265: Figure 6.3: Weather Station Locatio
Page 266 and 267: 6.6 Power Supply Use a second cable
Page 268 and 269: can also be changed from this windo
Page 270 and 271: on and the yellow light should begi
Page 272 and 273: Figure 7.1.3-1: Weather Station and
Page 274 and 275: Speed unit: m/s Sampling frequency:
Page 276 and 277: iii) Click on Browse to find and op
Page 278 and 279: c) Power Controller (Power) - no co
Page 280 and 281: 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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