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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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Fleet DNA

Available online at www.nrel.gov/fleetdna, the Fleet DNA clearinghouse of commercial fleet vehicle operating data helps manufacturers and developers optimize vehicle designs and helps fleet managers choose advanced technologies for their fleets. Sponsored by the U.S. Department of Energy, this online tool provides data summaries and visualizations similar to real-world genetics for medium- and heavy-duty commercial fleet vehicles operating in a variety of vocations. If you use Fleet DNA data in a publication, please notify NREL at fleetdna@nrel.gov and include a citation consistent with the following format: “Fleet DNA Project Data.” ([YEAR]). National Renewable Energy Laboratory. Accessed [DATE]: www.nrel.gov/fleetdna.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Fleet DNA Project Data Summary Report (Presentation)

This presentation includes graphical data summaries that highlight statistical trends for medium- and heavy-duty commercial fleet vehicles operating in a variety of vocations. It offers insight for the development of vehicle technologies that reduce costs, fuel consumption, and emission.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

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↗

FleetREDI Dashboard Fleet DNA Data Summaries

Developing daily duty cycle summaries for every vehicle-day within NLR’s Fleet DNA database was a key output of the FleetREDI project. This project captured second-by-second GPS and controller area network (CAN) data on in-use medium- and heavy-duty fleet vehicles and then summarized the data to provide an overview of vehicle operation throughout the United States. These data summaries were then displayed in aggregated formats on the FleetREDI dashboard, where users can explore the data within Fleet DNA. Fleet DNA’s clearinghouse of commercial fleet vehicle operating data helps vehicle manufacturers and developers optimize vehicle designs and helps fleet managers choose advanced technologies for their fleets. This online tool, which provides data summaries and visualizations similar to real-world "genetics" for medium- and heavy-duty fleet vehicles, helps users understand the broad operational range of commercial vehicles across vocations and weight classes.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Contributing Data to the Fleet DNA Project (Brochure)

The Fleet DNA clearinghouse of commercial fleet transportation data helps vehicle manufacturers and developers optimize vehicle designs and helps fleet managers choose advanced technologies for their fleets. This online tool - available at www.nrel.gov/fleetdna - provides data summaries and visualizations similar to real-world 'genetics' for medium- and heavy-duty commercial fleet vehicles operating within a variety of vocations. To contribute your fleet data, please contact Adam Duran of the U.S. Department of Energy's National Renewable Energy Laboratory (NREL) at adam.duran@nrel.gov or 303-275-4586.

33 ADVANCED PROPULSION SYSTEMS↗

Fleet DNA Project (Fact Sheet)

The Fleet DNA Project - designed by the U.S. Department of Energy's National Renewable Energy Laboratory (NREL) in partnership with Oak Ridge National Laboratory - aims to accelerate the evolution of advanced vehicle development and support the strategic deployment of market-ready technologies that reduce costs, fuel consumption, and emissions. At the heart of the Fleet DNA Project is aclearinghouse of medium- and heavy-duty commercial fleet transportation data for optimizing the design of advanced vehicle technologies or for selecting a given technology to invest in. An easy-to-access online database will help vehicle manufacturers and fleets understand the broad operational range for many of today's commercial vehicle vocations.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Evaluating the Impact of Road Grade on Simulated Commercial Vehicle Fuel Economy Using Real-World Drive Cycles

Commercial vehicle fuel economy is known to vary significantly with both positive and negative road grade. Medium- and heavy-duty vehicles operating at highway speeds require incrementally larger amounts of energy to pull heavy payloads up inclines as road grade increases. Non-hybrid vehicles are then unable to recapture energy on descent and lose energy through friction braking. While the on-road effects of road grade are well understood, the majority of standard commercial vehicle drive cycles feature no climb or descent requirements. Additionally, existing literature offers a limited number of sources that attempt to estimate the on-road energy implications of road grade in the medium- and heavy-duty space. This study uses real-world commercial vehicle drive cycles from the National Renewable Energy Laboratory's Fleet DNA database to simulate the effects of road grade on fuel economy across a range of vocations, operating conditions, and locations. Drive-cycles are matched with vocation-specific vehicle models and simulated with and without grade. Fuel use due to grade is presented, and variation in fuel consumption due to drive cycle and vehicle characteristics is explored through graphical and statistical comparison. The results of this study suggest that road grade accounts for 1%-9% of fuel use in commercial vehicles on average and up to 40% on select routes.

33 ADVANCED PROPULSION SYSTEMS↗

Medium-duty Urban Range Extended Connected Powertrain (Final Scientific Technical Report)

The project goal is to develop and demonstrate a Class 4 delivery vehicle that reduces fuel consumption by 50% or more when compared to an equivalent vehicle with a conventional internal combustion engine (ICE) powertrain driven on a comparable duty cycle. This shall be achieved using a plug-in hybrid electric (PHEV) configuration that optimizes the efficiency of the ICE. The proposed solution aims to be commercially viable for fleets to procure the system without additional incentives. To accomplish this, commercialized light-duty vehicle electric drive components shall be used. A PHEV configuration for Class 4 MD/HD vocational vehicles using commercialized light-duty vehicle electric drive components will require the development of a new topology for the hybrid powertrain applicable to medium-duty vehicles. Prior research indicates that an identified novel power split device could provide a fuel economy improvement potential of up to 51%. Utilizing an advanced battery management algorithm that will allow operation closer to the battery limits, the project will minimize battery capacity to achieve the desired performance results while maintaining the cost target for high commercialization. The solution must be cost effective to purchase and integrate into a Class 4 delivery vehicle, deliver the intended fuel economy improvement, and perform as well, or better, than the current conventional ICE powertrain. MD/HD vehicles typically require higher power, which is one factor that results in high costs for the powerful electric machines typical in larger HEV/PHEV systems. A key element in the project is the use of commercially available Bosch electric drive components (e.g., motors, batteries, and power electronics) from the larger passenger vehicle segment. This leverages the economies of scale to decrease cost and improve reliability beyond current purpose-built low-volume commercial vehicle components. These innovations will result in a game-changing PHEV system that meets DOE’s 50% fuel consumption reduction target, grants the vehicle an uncompromised driving range, and achieves the cost point for widespread adoption.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

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↗

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↗

Truck Platooning Performance with ADAS and Onboard Camera Data Describing Traffic Interactions

This project was part of the Characterizing Behaviors and Capabilities for Emerging Connected and Automated Vehicle Technologies, Sensors, and Connectivity project. The National Laboratory of the Rockies partnered with Cummins Inc. to collect data from Class 8 tractor trailer combinations in platoon (cooperative adaptive cruise control) operations on public roads in southern Indiana. Data collected include J1939 CAN bus, radar, intervehicle position, and video data. The video data could not be shared in the raw form, so they were processed to extract information on the other vehicles on the road, their relative positions, and intrusion events. This information was then columnized for modeling use and further enhanced by appending road information including road type, speed limit, altitude, and grade. The test route included free-flowing traffic, highway interchanges, and construction zones, as well as low-, medium-, and high-grade sections. Individual test conditions varied by day, with advanced driver-assistance system (ADAS) features engaged or disengaged and different combined vehicle masses tested in addition to uncontrolled variables such as weather and traffic interactions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Electrification Beyond Light Duty: Class 2b-3 Commercial Vehicles

The class 2b-3 truck market covers a wide range of commercial truck applications across a half-million vehicle sales annually. This report collected public information and stakeholder input to assess the opportunity for electrification in this market. Although class 2b-3 pickup truck and van bodies are very similar to personal light vehicles, their functional requirements are quite different due to the demands of the commercial market. These demands vary by application and often vary from day to day for a single application. Fleet customers purchase these vehicles to perform a particular job for their business and are concerned about the overall cost of doing that job. Therefore, the vehicles must meet the job requirements cost effectively. Customers also are sensitive to initial cost. Electrification offers the potential to reduce vehicle operating costs and possibly improve vehicle functionality. However, the current market for class 2b-3 electrified trucks is very small, and the trucks are costly. Increased production volumes are key to cost reductions and may be assisted by sharing components with larger or smaller truck classes. Expanding demand is also crucial and stakeholders identified several niche markets with duty cycles that are likely well-suited to electrified class 2b-3 trucks. To expand beyond these niches, class 2b-3 electric solutions must be robust, flexible, and adaptable in order to cover a wide range of vocations, applications, and duty cycles.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗