DTNA / DDC Super Truck Team

Road Mapping Engine Technology for Post-2020 Heavy Duty Vehicles

Detroit, October 5th 2011

Dr. Igor Gruden, Marc Allain, Craig Savonen

Security Classification Line

Daimler Truck

• Total operating costs

• CO2 Regulatory

• Truck requirements

• Supertruck Technology elements

• Downsizing

• Combustion System

• Parasitics

• Integrated Powertrain Optimization

• Transient control

• Summary Roadmap

Agenda

DTNA / DDC Super Truck Team 2

Daimler Truck

Fuel Economy Is Still King

• Fuel Economy Is Expected To Continue To Be #1 Priority From Our Trucking Customers.

• Yet, Their Profitability, If Not Survival Depends Keenly In Knowing and Anticipating Total Truck Life Cycle Operating Costs, Including Reliability /Up-Time, Durability, and Payback Duration For Newer, Higher Complexity Technology.

• Cyclical Fuel Market Trends – Future Optimized NOx/BSFC Variable Engine Maps Would Adjust Dynamically To DEF/Fuel Price Ratios While Ensuring Regulatory Compliance.

DTNA / DDC Super Truck Team

Combined On-road Fuel and DEF

Consumption vs . Engine out NOx

NOx in g/kWh

3

Daimler Truck

Europe

EC Ordered 2 studies:

Policy Options

Measurement procedure of

HDV fuel consumption

ACEA proposes simulation based

approach similar to Japanese

legislation extended by vehicle

improvements.

CO2 Regulatory Activities for Heavy Duty Markets

USA

Legislation Finalized

September 2011

• Reduction target between

6 and 23% depending on

vehicle class

• (2017 compared to 2010)

Engine targets based on FTP-, SET-

cycle tests

Separate vehicle targets based on

„bin mapping“ method for 5

technologies.

Simulation based approach with

focus on engine and drivetrain ratios.

Vehicle class specific target values.

Japan

Legislation in Place

Since 2006

• Reduction target 12.2%

2015 compared to 2002

(target tightening expected)

China

Legislation Targeted To Be

Finalized by End of 2012

Proposal for standardized

fuel consumption

Vehicle category

Gross vehicle weight (GVW) / gross

combination vehicle weight (GCW),

kg

Share of urban

portion,

Durban

Share of highway

portion,

Dhighway

9,000 < GCW ≤ 25,000 0 40% Semi-trailer towing

vehicle GCW > 25,000 0 10%

Tipper GVW > 3,500 0 100%

3,500 < GVW ≤ 5,500 40% 40%

5,500 < GVW ≤ 12,500 10% 60%

12,500 < GVW ≤ 24,500 10% 40%

Goods vehicle

GVW >24,500 10% 30%

Chassis dyno test for base type

vehicles. Simulation allowed for

variants.

C-WHVC (Chinese version).

Vehicle class specific target values.

DTNA / DDC Super Truck Team 4

Daimler Truck

VehicleVehicle

SafetySafety

Affordability Affordability

& Reliability& Reliability

Serviceability Serviceability

& Packaging& PackagingFuel EconomyFuel Economy

Emission Emission

ComplianceCompliance

Environmental Environmental

ImpactImpact

Performance Performance

& Weight& Weight

Thermal Thermal

Management Management

& Durability& Durability

Truck Customer Value ($)Truck Customer Value ($)

Public AcceptancePublic Acceptance

Engine Engine

BrakingBraking

AccelerationAcceleration

Hauling CapacityHauling Capacity

Driver Driver

ComfortComfort

NOx, NOx,

HC, HC,

PMPM

NH3, NH3,

N20, N20,

CxHyCxHy,,

CO2CO2 NoiseNoise

Idle Idle

Quality Quality

& Time& TimeAerodynamicsAerodynamics

ParasiticsParasitics

Heat RejectionHeat Rejection

Deterioration Deterioration

FactorsFactors

Minimized Minimized

Thermal Thermal

VariationsVariations

CompactnessCompactness

Elegant SimplicityElegant SimplicityIntegrated Integrated

Stretch Stretch

Technology Technology Unforced Unforced

TechnologyTechnology

Range Range

ManagementManagement

SelfSelf--Diagnostic, Diagnostic,

& Prognostic& Prognostic

Benign Benign

FluidsFluids

Opposite Opposite

Spokes Spokes

Tend to Be Tend to Be

Polar Polar

OppositesOpposites

OBD

Reqmts

The Truck Requirements Wheel

DTNA / DDC Super Truck Team 5

Daimler Truck

Engine

Motor Clutch

T/M

Inverter

Battery

SUPERTRUCK

Next Generation Controller

Aerodynamics

Hybrid

Concepts

Exhaust

Heat

Recovery

& turbocharging

Optimized

Combustion

Including VVT Enhanced high pressure

fuel injection system

Optimized

Aftertreatment

Hybrid

Transmission

Concepts

Predictive

Torque & Auxiliary

Management

Super Truck Technology Elements

DTNA / DDC Super Truck Team 6

Daimler Truck

Engine Technology Forged To Meet Future Requirements

Heavy Duty Engine Displacement

En

gin

e /

Dri

vetr

ain

/ V

eh

icle

Sp

eed

s

Reduced Weight &

Space Claim,

Higher BMEP /

lower ISFC,

Optimized Exhaust

Thermal Signature,

Freight Efficiency

Reduced Gas and

Fluid Parasitics,

Optimized

Engine/Vehicle

Aerodynamics &

Cooling

Reduced cruise

load

Thermal Efficiency vs BSFC

0.140

0.150

0.160

0.170

0.180

0.190

0.200

0.210

0.220

0.230

35.0 40.0 45.0 50.0 55.0 60.0

Engine Thermal Efficiency (%)

BS

FC

(kg

/kw

hr) 50% eff = 0.167 kg/kWhr

55% eff = 0.152 kg/kWhr

Supertruck Targets

DTNA / DDC Super Truck Team 7

Daimler Truck

Perennial Combustion System Levers

• Combustion Chamber

• Piston / Head / Liner Shape &

Robustness Refinement

• Increased Compression Ratio &

Cylinder Pressure

• Thermal Coatings & Focal Point

Cooling

• Injection

• Evolutionary Nozzle Geometry

• Optimized Hydraulic Flow

• Dynamic Rate Shaping

• Increased Injection Pressure

• Multiple Injection

DTNA / DDC Super Truck Team

A – Square

B – Ramp

C - Boot

0

50

100

150

200

250

300

2000 2004 2007 2010 2020

historical pmax increase

and forecast

Cyl

ind

er

Pre

ssure

8

Daimler Truck DTNA / DDC Super Truck Team

Parasitic Management

•Smarter Use Of Optimized Accessories And

Pumps

•Increased Flexibility In Component Outputs

•Tighter Control of Emission Constituents

•Self-Learning Feedback Control System

9

Daimler Truck

Integrated Powertrain Performance Metrics

0 20 40 60 80 1000

5

10

15

speed (km/h)

gra

de

ab

ilty (

%)

1-2

2-3

3-4

4-5

5-6

6-7

7-8

8-9

9-1

0

10-1

1

11-1

2

SHIFTABILITY

0 10 20 30 40 50 60 70 80 90 1001101201301401501600

1

2

3

4ACCELERATE

speed (km/h)

acce

lera

te (

m/s

²)

1

2

3

4

5

6

7

8 9

10 11

12

0 50 100 1500

1

2

3ACCELERATE ZOOM

0 10 20 30 40 50 60 70 80 90 1001101201301401501600

10

20

30

40

50

60GRADEABILITY

speed (km/h)

gra

de

ab

ilty(%

)

1

2

3

4

5

6

7 8

9 10 11 12

0 50 100 1500

20

40

60GRADEABILITY ZOOM

0 10 20 30 40 50 60 70 80 90 1001101201301401501600

20

40

60

80

100

120

140

160

180

200

220

240

260

280

300

320

340POWER

speed (km/h)

po

we

r (k

W)

0%1%2%3%4%5%6%7%8%9%10%

0 50 100 1500

100

200

300

400POWER ZOOM

Gradeability Shiftability

Max.Acceleration Max.Power Traction Force

0 10 20 30 40 50 60 70 80 90 1001101201301401501600

10

20

30

40

50

60

70

80

90

100

110120

130

140

150

160

170

180TRACTION FORCE

speed (km/h)tr

actio

n fo

rce

(kN

)

1

2

3

4

5

6

7

8 9

10 11 12

0 50 100 1500

50

100

150

200TRACTION FORCE ZOOM

•Load Response

•Drive Time

•Driveability

•Low Speed Maneuvering

•NVH

•Thermal/Mechanical

Stress

• Surge Margin

•Emission Compliance

DTNA / DDC Super Truck Team 10

Daimler Truck

Post-2020 Powertrain Optimization

•Optimized Powertrain Interface

• Torque

• Cooling & Heating Flows

• Data Exchange

•Engine - Exhaust Aftertreatment Thermal Marriage

•Turbo Compounding

• Mechanical

• Electrical

•Waste Heat Recovery System

DTNA / DDC Super Truck Team 11

Daimler Truck

Transient Road Mapping

• Factorial Increase In Calibration

Space

• Multiple Performance Targets

• Cost Function That Minimizes

Emissions And Fuel

Consumption

• Optimizes Engine Operation In

Real-time

• Use of Neural networks

• Predictive Control In Vehicle

DTNA / DDC Super Truck Team 12

Daimler Truck

Improved combustion

Including Varible Valve timing

Improved

Air/EGR

Friction reduction

Increased P max

Real time control

DTNA / DDC Super Truck Team

Advanced , fully integrated

powertrain

Downsizing

Summary Supertruck Technology Road Map

Increased turbocharger efficency

Downspeeding

Improved Aftertreatmen /

thermal management

13

Hybrid Concepts

Daimler Truck DTNA / DDC Super Truck Team

Department of Energy Headquarters

• Gurpreet Singh

• Roland Gravel

National Energy Technology Laboratory

• Carl Maronde

This material is based upon work supported by the Department of Energy National

Energy Technology Lab under Award Numbers 409000-A-N8, DE-FC26-00-

OR22805, and DE-EE-0003348.

Disclaimer: This report was prepared as an account of work sponsored by an

agency of the United States Government. Neither the United States Government

nor any agency thereof, nor any of their employees, makes any warranty, express or

implied, or assumes any legal liability or responsibility for the accuracy,

completeness, or usefulness of any information, apparatus, product, or process

disclosed, or represents that its use would not infringe privately owned rights.

Reference herein to any specific commercial product, process, or service by trade

name, trademark, manufacturer, or otherwise does not necessarily constitute or

imply its endorsement, recommendation, or favoring by the United States

Government or any agency thereof. The views and opinions of authors expressed

herein do not necessarily state or reflect those of the United States Government or

any agency thereof.

Acknowledgments

14

Daimler Truck

Thank you for your attention !

DTNA / DDC Super Truck Team DTNA / DDC Super Truck Team 15