Engineering topics

Kelly, Kenneth

Publications and source records attributed to Kelly, Kenneth.

12 records

DOE OSTI2022

Port of New York and New Jersey Drayage Electrification Analysis

The National Renewable Energy Laboratory (NREL) evaluated the potential for drayage electrification in the Port of New York and New Jersey (PoNYNJ), with a focus on operators: Harbor Freight Transport (HF), Safeway Trucking (SWT), and International Motor Freight Inc (IMF). This report summarizes the data collection and electrification evaluation of all three drayage operators, includes detailed operational data, and identifies the performance requirements for battery electric tractors (BETs) and corresponding infrastructure operated within the context of PoNYNJ drayage operation. This report also details a methodology to evaluate opportunities, strategies, and challenges associated with future expansions of BETs in meeting PANYNJ emissions goals. The Port Authority has established a goal of achieving Net Zero carbon emissions by 2050 across all facilities, including from tenant and stakeholder sources such as drayage trucks. NREL used real-world performance data collected on the three PoNYNJ drayage operations, along with modeling and analysis tools to compare BET to diesel trucks. From March to July 2021, NREL collected 1Hz vehicle and engine data from 46 drayage trucks at the three operators totaling nearly 121,000 miles of operation, providing enough information to assess vehicle operations for electrification potential. A Future Automotive Systems Technology Simulator (FASTSim) electric truck powertrain model was validated using PoNYNJ data and scenarios were run to evaluate drayage truck electrification requirements over the real-world cycles. The first scenario examined BET viability with minimal changes to existing operations. This assumes the trucks charge when stopped for two hours or longer, have a functional battery size of 375 kWh, and can charge at 270 kilowatts (kW) average which are the specification of the commercially available Freightliner eCascadia. The second scenario looked at what operational, charging infrastructure, and BET technology changes would be needed to fully electrify. Finally, detailed analysis was run on charging rate structure to understand operational costs to the fleets. The studied drayage trucks averaged 5.1 MPG, spent roughly 9% of their energy at idle, and drove an average of 140 miles per day with a maximum daily distance of 573 miles. The FASTSim model results indicate a comparable BET would use 417 kWh of energy per day on average accounting for cargo weight, which is close to the full usable capacity of the eCascadia currently available on the market. Based on the daily average operating data, partial fleet electrification is possible with current technology. However, some specific days of operation would require over 1,600 kWh of energy due to longer distances traveled by the trucks and more intense operation. Trucks used for long distance and intense operation cannot be readily electrified with current technology without operational changes. Full adoption of BETs could reduce CO 2 emissions from these fleets by roughly 75% today, eliminating 76 metric tons of CO 2 (MTCO 2 ) per vehicle each year, which equates to 24,100 MTCO 2 per year for all three operators. Commercially available direct current fast chargers (DCFC) have charge rates up to 350 kW. Based on the average daily modeled energy use for each operator, current industrial rate structures, and the assumption of 350 kW peak charging, full drayage electrification would increase electricity consumption. In addition, peak demand usage would increase with unmanaged charging along with cost of electricity having a direct impact on cost per mile for electric vehicles. The resulting cost per mile for BETs along with comparable cost per mile for conventional diesel trucks are also examined at $\$$4.00 per gallon of diesel. It will be important for PANYNJ and the drayage operators within the PoNYNJ to consider these load impacts to their existing electrical infrastructure and devise operational strategies that avoid coincident charging of vehicles to mitigate demand charges. Despite these electricity cost increases, savings from reductions in diesel consumption will help offset the costs of this increased electricity consumption. However, prices of both electricity and diesel are subject to change based on various factors meaning the realized savings will vary over time. This shows BETs could be cost-competitive on an energy cost per mile basis for all scenarios while diesel is above $\$$3.00/gal. Further, if diesel prices dropped to the 15-year low of $2.33/gal, it would still be cost competitive to operate the EVs with electricity costs of 16.3 ¢/kWh or less.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

Comprehensive Review of California's Innovative Clean Transit Regulation: Phase I Summary Report

This report–prepared by NREL and UC Berkeley for the California Air Resources Board (CARB)–provides a comprehensive review conducted for implementation of the Innovative Clean Transit (ICT) regulation and deployment of zero-emission transit buses in California. The ICT regulation requires California transit agencies to begin transitioning to zero-emission vehicle technologies, defining an increasing percentage of new bus purchases that must be zero-emission buses (ZEBs) each year. The purchase requirements begin in 2023, increasing to a 100% ZEB purchase requirement beginning in 2029. This schedule is designed to result in 100% ZEB fleets statewide by 2040. The focus of the Phase I study was on implementation progress, status of standard-size transit buses, and the California transit industry's readiness to meet the 2023 ICT purchase requirements.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

ASPIRES: Airport Shuttle Planning and Improved Routing Event-driven Simulation

Most of the existing traffic simulation packages require significant calibration work to be able to reflect reality. To evaluate special operations including emerging technologies, a microscopic simulation that tracks detailed interactions of all the elements of the traffic systems is usually needed. This type of simulation is usually computationally demanding. This work developed an Airport Shuttle Planning and Improved Routing Event-driven Simulation (ASPIRES) package to simulate and evaluate current, potential, and future airport shuttle operations. Here, the simulation was driven by data and thus did not require much calibration effort. The discrete-event simulation nature of ASPIRES makes the simulation computationally efficient. Simulating 1 day of shuttle operations takes less than 2s. The study site of this work is the Dallas/Fort Worth International Airport in the U.S. The shuttle service that connects the five terminals of the airport and the rental car center was studied. Travel times, dwell times, and passenger arrivals were simulated using empirical distributions derived mainly from real data to capture the stochastic nature of the rental car center shuttle bus operations. Data on bus miles traveled, bus energy consumption, passenger wait times, and passengers left behind at stops were collected to study the trade-off between energy use and passenger experience. Electric bus and on-demand bus operations were also included. The simulation outputs can show passengers statistics at terminals, shuttles statistics, and charging station statistics. ASPIRES cannot be used to model a generic traffic system but is well-suited for fleet systems.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

Advancing Platooning with ADAS (Advanced Driver-Assistance Systems) Control Integration and Assessment

Application of Cooperative Adaptive Cruise Control (CACC) to heavy duty trucks known as truck platooning has shown fuel economy improvements on the test track under ideal driving conditions. However, limited test data is available to assess the truck platooning under real-world driving conditions. Under this Cummins-led project that was funded by the U.S. Department of Energy, truck platooning with CACC has been tested on a real-world interstate highway and the results of the project are reviewed in this report. At first, the real-world driving conditions were characterized using National Renewable Energy Laboratory (NREL) Fleet DNA database to define test factors, including route, terrain, and highway traffic. Afterward, both test track and on-highway testing guided by SAE J1321 procedures were conducted to assess truck platooning under controlled and real-world driving conditions. On-highway testing was done on a highway route in Indiana, consisting of low, medium, and high road grade segments. The highway test results of 2-truck and 3-truck platooning showed considerably reduced fuel savings compared to the controlled test track data, which mainly stems from the traffic or high-grade portions of the route. However, integration of Cummins powertrain and vehicle eco-driving features such as predictive cruise control and neutral coasting called ADEPT™ on the lead truck showed an improvement of fuel saving for the trucks in CACC operation. Furthermore, the importance of tire connectivity in efficient and safe operation of the trucks in platooning is characterized.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Off-Road Vehicle Decarbonization and Energy Systems Integration: R&D Gaps and Opportunities

This report summarizes findings from the Off-Road Decarbonization and Energy Systems Integration workshop, hosted by the National Renewable Energy Laboratory (NREL) from March 22-24, 2022. The workshop focused on the importance of collaboration among the off-road vehicle industry and government to address barriers and opportunities for decarbonization. The workshop aligns with priorities of the U.S. Department of Energy (DOE) Vehicle Technologies Office and Hydrogen and Fuel Cell Technologies Office to decarbonize transportation in the agriculture, mining, construction, and military industries. This decarbonization effort is also intended to support original equipment manufacturers, industry associations, technology developers, utilities, and consultants. The sections within this report correspond to the three topic areas covered in the 3-day workshop: a high-level perspective of needs and challenges, vehicle and equipment decarbonization strategies, and energy systems integration opportunities.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

Developing a heavy-duty vehicle activity database to estimate start and idle emissions

Heavy-duty vehicle start and idling activities were characterized from two datasets to improve emission estimates in the MOtor Vehicle Emission Simulator (MOVES): 1. Fleet DNA from the National Renewable Energy Laboratory (NREL) and 2. A dataset collected by the University of California, Riverside for the California Air Resources Board. Furthermore, the combined dataset includes 564 commercial vehicles, over 23,000 vehicle days of operation and covers seven of the nine heavy-duty source types defined by MOVES. The start and idle activities are characterized and illustrated across MOVES source types, vocations, fleets, days, and hours. This study provides the most comprehensive analysis yet made publicly available to characterize start and idle activity for heavy-duty vehicles within the United States. The results also show there is significant uncertainty in the average heavy-duty idle and start activity due to the large variation in activity across fleets and vocations, and sparsity of nation-wide vehicle population data by vocation.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

Heavy-Duty Vehicle Activity Updates for MOVES Using NREL Fleet DNA and CE-CERT Data

The U.S. Environmental Protection Agency's (EPA's) Motor Vehicle Emission Simulator (MOVES) is a publicly available tool used by researchers and policymakers to help understand motor vehicle emission sources at a national, county, and project level. Estimates of heavy-duty activity in the most recent version of the model at the time this work was conducted, MOVES2014, was identified as an area in need of improvement. The start activity in MOVES2014 is based on a limited and dated data set. In addition, MOVES2014 relies on drive cycles that represent on-network activity but do not account for idling activity that occurs on off-network roads, such as at a distribution center, while the truck is queuing or during loading and unloading. As a result, MOVES2014 may currently underestimate the number of starts and idle and soak time for heavy-duty trucks in real-world operation. The National Renewable Energy Laboratory (NREL) has previously leveraged its expansive Fleet DNA database of heavy-duty vehicles to idle and start activity for six of the nine heavy-duty vehicle source types of classes in the MOVES model. The data available in Fleet DNA from 416 conventional, diesel-powered vehicles provided activity estimates from more than 120,000 hours of operation throughout 14,682 vehicle days between October 2006 and January 2016. NREL calculated start fraction, starts per day, soak fraction, and idle fraction by hour of the day for each vehicle type, state, and vocation, and provided results in .CSV files that can be translated to MOVES table inputs. The idle and start activity from this initial analysis of Fleet DNA data was used to develop default idle and start data for heavy-duty vehicles in MOVES3. Satisfied with the results from the Fleet DNA data used for MOVES3, the EPA asked NREL to extend this start/soak/idle analysis using additional data from a larger number of vehicles for a potential future update to the MOVES model. Such a data set was achieved from a project led by the University of California at Riverside, College of Engineering, Center for Environmental Research & Technology (CE-CERT) and funded by California Air Resources Board. Specifically, this data set consists of 90 heavy-duty vehicles operated mainly in California, which can be separated into five of the nine heavy-duty vehicle classes in the MOVES model. In addition, the heavy-duty activity database collected by CE-CERT provided activity estimates from more than 44,000 hours of operation throughout 4,724 vehicle days between November 2014 and September 2016. This report details the analysis of the heavy-duty activity database collected from the University of California at Riverside by providing graphical analysis and context for the start, soak, and idle distributions. The comparison of the related results from both the Fleet DNA and CE-CERT data sets are documented as well.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2021

Development of in-use engine speed/torque heat maps across multiple heavy-duty commercial vehicle vocations

The U.S. Department of Energy (DOE) established the SuperTruck program with the goal of achieving brake thermal efficiency (BTE) greater than or equal to 55% as demonstrated in an operational heavy-duty (HD) diesel engine at a 65-miles-per-hour (mph) cruise point. Beyond the line-haul application, HD engines operate in a wide range of speed and torque conditions that are unlikely to yield the same efficiency under real-world operation. Thereby, the in-use engine heat maps described in this paper are a valuable tool to illustrate whether the engine-efficiency “sweet spot” matches the most frequent operating conditions. In this study, NREL developed engine heat maps to quantify the important operating points for various vocations using our Fleet DNA database of commercial fleet vehicle operations data. These heat maps clearly show that high-frequency operating points vary significantly according to vehicle vocation, while only a few of them match the sweet spot. Beyond the illustration, engine in-use heat maps can also be leveraged to build up reduced-order engine-efficiency models, needed by many rapid powertrain simulations. As case studies, nine reduced-order models – including line-haul truck, transfer truck, transit bus, transit bus with compressed natural gas (CNG) engine, drayage, refuse pickup, local delivery, utility truck, and school bus with CNG engine – using a trust-region reflective algorithm to fit the on-road data extracted based on the engine in-use heat maps.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2021

Development of heavy-duty vehicle representative driving cycles via decision tree regression

Previously, researchers who developed representative driving cycles mainly focused on light-duty vehicles and only considered vehicle speed and related derivations. In this paper, we propose a novel approach to develop representative cycles for heavy-duty vehicles. By implementing decision tree regression (DTR) to the Fleet DNA on-road vehicle data, a broader set of metrics, such as engine power and fuel consumption, can be used for more robust cycle development. Additionally, the influence of each metric on the regression target is also accounted for by a weighted number derived through the DTR to enhance the representativenss of the developed cycle. As case studies, we applied the proposed method to five heavy-duty vocations (drayage, long haul, regional haul, local delivery, and transit bus) and derived the most representative cycle, as well as four extreme cycles (maximal energy consumption, maximal power-weighted work, maximal fraction of high speed, and minimal fuel economy) to advance the related alternative powertrain design.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2021

Characterization of commercial vehicles’ start-up operations from in-use data

Diesel engines produce disproportionate levels of emissions when the engine and after-treatment systems are operating at low temperatures. This situation arises most commonly when the vehicle is first started after overnight. To quantify emissions attributable to vehicle starts, a sizable collection of on-road commercial vehicle operating data is analyzed to identify start-up events and inspect associated emissions. Data was obtained from the National Renewable Energy Laboratory’s (NREL’s) Fleet DNA and from the Center for Environmental Research & Technology (CE-CERT). Included are 500 + diesel vehicles with more than 42,000 recorded days, drawn from 25 vocational categories across the United States. Analysis shows that vehicle behavior, in terms of engine cold- and warm-operation, starts per day, soak time, and warm-up duration, differs significantly between vehicle vocations. Also, weighting factors for cold- and hot-starts currently used in the U.S. Environmental Protection Agency’s Federal Test Procedure (FTP) for heavy-duty emissions certification accurately represent real-world operations. Although the FTP includes a comparable fraction of cold operation, the hot fraction is much shorter than real-world operation due to limited test duration. The investigation also revealed that real-world engines operate for a significant amount of time when the engine coolant is in the “hot-stabilized” region, but the selective catalytic reduction (SCR) temperature is below its effective operating temperature of 200 °C. Of the vehicles under investigation, almost 20% of their operational time is within this condition. Therefore, novel approaches to raise and maintain SCR temperature are highly required to further reduce engine emissions.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2020

Fleet-wide Electrification Impacts Assessment for the Valley Transportation Authority

This report explores the long-term electrification opportunities for the Valley Transit Authority’s (VTA) transit bus fleet. The potential for transit bus electrification at VTA as well as the economic impacts of partial and complete electrification are explored. We use the Revenue Operation and Device Optimization model to determine the optimal charging, operation and lowest capital and operating cost solution to achieve different levels of electrification to meet their existing routes. This study finds that, relying on only depot charging, around 70% of the daily trips by VTA’s transit bus fleet can be replaced with battery electric buses (BEBs) today. The benefits and drawbacks of five methods for improving the electrification potential beyond that achievable with only depot charging are discussed including (1) increase charger power, (2) purchase of larger vehicle batteries, (3) en-route charging, (4) purchasing additional buses and swapping them to enable the existing routes/blocks1 to be met, and (5) route/block redesign. A strategy is developed to enable full fleet electrification by increasing charger power or allowing intraday charging as a proxy for the options mentioned above. This method allows us to develop an understanding of the impacts and trade-offs of full fleet electrification. Two charging strategies are examined. Immediate charging, when the bus is charged as soon as it arrives at a depot or en-route charging station, and smart charging, which uses a controller to determine the best times to charge to achieve the lowest charging cost, while maintaining the same trip schedules. Smart charging is effective at reducing the peak power consumption, which can be reduced by between 31% and 65% compared to immediate charging. This translates directly to lower electricity demand charges and lower costs for possible distribution system upgrades. The total lifetime net present value (NPV) costs for different scenarios are presented in Figure ES-1. Scenarios are separated into three sections. The first stacked bar on the left is the base case (business-as-usual) where all buses are diesel hybrids, the next four bars include partial and full fleet electrification utilizing only immediate charging, and the last four bars include partial and full fleet electrification utilizing smart charging. The results show that smart charging scenarios are within ±4% of the lifetime NPV cost of the diesel-hybrid only (business-as-usual) scenario. The scenarios with full fleet electrification (i.e., including intraday charging) are 4% lower cost and those with partial fleet electrification (i.e., without intraday charging) are 2%–3% higher. However, it is important to note that the intraday charging scenarios do not include any additional costs for the equipment necessary to achieve intraday charging (e.g., additional chargers, larger batteries, new route design). Additionally, it is worth noting that the Low Carbon Fuel Standard (LCFS) credit received for implementing electric buses is essential to achieving these results.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2020

Athena - Shuttle Bus Optimization and Event Driven Simulator [SWR 20-105]

The primary purpose of the software is to optimize shuttle routes to and from terminals, given some airport campus location like the rental car center. This code was developed as part of the DOE funded Athena project. One aspect of the Athena project was to investigate if the optimization of shuttle routes that move passengers to and from the five DFW terminals and the rental car center could result in lower energy consumption from the shuttle fleet while still maintaining an acceptable level of service to passengers. Hence, the optimization done by the code determines a set of shuttle routes, the type of shuttle on each route, and the number of shuttles servicing each route. The optimization aims to make these choices in a way that the energy consumption per hour by the fleet is minimized. Additionally, the software can fast simulate airport shuttle operations with collected data. The simulation inputs are passenger arrival rates, shuttle routes and frequencies, and simulation configurations. The outputs include: time dependent shuttle energy level, time dependent charging station usage, time dependent number of passengers on each bus, time dependent number of passengers at each bus stop, history of number of passengers left at each bus stop, route history of fleet shuttle buses and on-demand buses, and time dependent bus distance traveled.

Kelly, Kenneth↗