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

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GPS information collected with the VBOX equipment, and a few problems with the data stream [especially at the beginning of each data collection period]). 1.5.4.3 Mapping utility As the Pilot Test data was received, ORNL began the development of a mapping utility that would allow users to access, in a geo-spatial manner, the information collected during the runs. This tool allowed the user to select a certain portion of the data on the map, to view the data for that selected area in a graphical form, and to export the information to other formats (e.g., Excel) for further analyses. This tool was essential for the data analysis task and provided the basis for the DCGenT. 1.5.4.4 Data analyses The data analyses efforts for the Pilot Test were focused on the demonstration of the capability of generating usable duty cycles for input into PSAT, based on the data collected in the Pilot Test. In addition, the ORNL staff also looked for interesting long-haul characterization statistics including fuel usage vs. tire configuration, emission profiles, etc. The results of the data analyses efforts were presented in the Pilot Test Letter Report (Appendix A, Section 3.3.7). A number of lessons learned came from the Pilot Test efforts. These included the following: - A DAS should be selected on the basis of its ability to store data in an easily extractable format. - Accurate and reliable time stamping is of critical importance for data analyses and comparison purposes. - An indicator should be provided for those periods in which data is inadvertently not collected for various technical reasons. This indicator should explicitly tell when data is missing so that the analysis will not have to infer such information. Without such an indicator, data synchronization would be a problem. - The collection of data can be done at a rate that is much less than 100 Hz. A rate of two-toten Hz is felt to be sufficient. - The data collection rate should be the same for all performance measures. - Data handling and processing, especially with extremely large data sets, were found to be extremely resource-intensive and therefore need to be appropriately accounted for in the project planning. 20
2. FIELD OPERATIONAL TEST The primary objective of the HTDC Project was to collect real-world performance and situational data for long-haul operations of Class-8 trucks from a fleet engaged in normal freight operations. It was desirable for the selected fleet to cover a wide variety of geography and to engage in the FOT for at least one year to ensure that seasonal data is collected. The collected data will support the development and evaluation of the Class-8 module of PSAT, and as such needs to incorporate a rich source of information beyond velocity and time (basic duty cycle data). In particular, other types of information of interest pertain to the engine/vehicle performance, fuel consumption, road conditions, weather, and congestion. Data not collected included aerodynamics, emissions, rolling resistance, and driver performance. Much of the data was accessible through the vehicle’s databus, but some additional sensors were added as well. The FOT was done in partnership with Michelin and Schrader, and involved attention to the impact of tires on fuel efficiency. The analysis of the fuel efficiencies in the FOT is presented in Section 6. The FOT resulted in data (60 channels) from six instrumented tractors and ten instrumented trailers, taken at 5 Hz for at least 12 months. Data was collected for nearly 700,000 vehicle-miles traveled and involved more than 200 gigabytes of data. Dynamometer (dyno) testing was conducted on one of the instrumented vehicles at West Virginia University (WVU) in Morgantown, West Virginia in order to obtain drive torque data, which was not collected during the field test. For the dyno testing, three duty cycles were addressed including one that was generated by the vehicle engaged in the dyno testing while it was engaged in the field testing. In addition, fuel consumption and emissions data were collected during dyno testing, and the fuel consumption data from the field test for the selected duty cycle will, in the future, be compared to the fuel consumption from the dyno test for the same duty cycle. Two major software tools were developed by ORNL to be used in conjunction with the data collected during the FOT. The DCGenT was developed to generate duty cycles based on the collected data, and based on characteristics selected by the user (e.g., road grade, time-of-day, type of highway, road condition, weather, etc.). This tool also allows the user to specify the desired length of the duty cycle, and generates them in a format that is directly usable by PSAT. The DCGenT is available to users through arrangements made with the project staff at ORNL. The second tool, called simply the HTDC data access tool, allows analysts to specify duty cycle characteristics within a Boolean “OR” structure to generate a set of files for future analyses. DOE will determine how non-DOE or non- ORNL staff can have access to the HTDC data access tool. Data analyses associated with the use of standard dual tires vs. NGSWBTs were conducted by the ORNL staff. Overall, at least 6% fuel savings was experienced when NGSWBTs were utilized on either the tractor or the trailer. More than 9% fuel savings was experienced when the tractor and trailer had NGSWBTs compared to the tractor and trailer with standard dual tires. When tractors and trailers that both had NGSWBTs were compared to tractors and trailers both having standard duals, and the comparison was made across low-, medium- and high-payloads, the NGSWBTs provided more than a 10 % fuel savings for the high-payload cases. The HTDC database is unique in the depth and breadth of data collected on Class-8 long-haul operations, and in the capability to generate real-world-based, Class-8, long-haul duty cycle and performance data. The following sections provide greater details of the FOT efforts. 21
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 11: LIST OF TABLES Table Page 1 Pilot T
Page 15: ACKNOWLEDGEMENTS The Oak Ridge Nati
Page 18 and 19: Sixty channels of data were collect
Page 20 and 21: xviii
Page 22 and 23: The data analyses performed in Phas
Page 24 and 25: Fig. 2. HHDDT Transient Mode In add
Page 26 and 27: vehicle; 3) a transit bus; 4) a nei
Page 28 and 29: payload and accessory load would al
Page 30 and 31: Data # Performance Measure Benefit
Page 32 and 33: Data # Performance Measure Benefit
Page 34 and 35: Fig. 10. NGK NOx/O2 Sensors Fig. 11
Page 36 and 37: 1.3.4 De-instrumentation: Following
Page 38 and 39: Fig. 16. Pilot Test North-South Rou
Page 42 and 43: 2.1 REVIEW OF PERFORMANCE MEASURE R
Page 44 and 45: 2.3.2 Performance Measures Fig. 18.
Page 46 and 47: Signal Sensor 53 Road Grade Calcula
Page 48 and 49: 2.3.6 Tractor and Trailer Details F
Page 50 and 51: determined that the particular CANo
Page 52 and 53: Cable runs to and from sensors were
Page 54 and 55: 2.8 CONDUCTION OF FOT The FOT laste
Page 57 and 58: 3. INTERNET DATA ACCESS TOOL The HT
Page 59: Fig. 30. Search Results The file se
Page 62 and 63: When the button “Extract Data”
Page 64 and 65: Data Fig. 33. Segment Merging In ad
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Page 68 and 69: Fig. 39. A Synthetic Duty Cycle wit
Page 70 and 71: tractors) as well as the maximum to
Page 72 and 73: vehicle was carrying a heavy load o
Page 74 and 75: Vehicle Speed [mph] Vehicle Speed [
Page 76 and 77: 5.2 REAL-WORLD DUTY CYCLES Informat
Page 78 and 79: Vehicle Speed [mph] 70 60 50 40 30
Page 80 and 81: Given the size and complexity of th
Page 82 and 83: data or out-of-range data. Therefor
Page 84 and 85: 6.1.1 Spatial Information Using the
Page 86 and 87: For those cases in which an instrum
Page 88 and 89: 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
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85 Longitude 86 Velocity 87 Heading
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3.2 Sensors The PMs listed in Table
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vehicles will be dedicated to the p
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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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