WHITE PAPER ON FUEL ECONOMY KENWORTH TRUCK COMPANY

Transcription

1 March 2006 WHITE PAPER ON FUEL ECONOMY KENWORTH TRUCK COMPANY

2

3 WHITE PAPER ON FUEL ECONOMY KENWORTH TRUCK COMPANY White Paper Overview Fuel economy has always been an important consideration for truck owners whether you re a fleet owner or an owner-operator. In the trucking industry, fuel is one of the leading operating costs. Fuel economy is even more important with high diesel prices and the coming EPA January 2007 engine emissions standards. Kenworth Truck Company has a history of using technology to improve fuel economy. This Kenworth White Paper on Fuel Economy will examine Kenworth s wide-ranging activities and offer information designed to assist truckers and fleets regarding this important topic. Each year, Kenworth invests significant resources and conducts extensive road and other testing in pursuit of advances in this area. Kenworth engineers and dealers also work closely with customers on a continuing basis to strive for enhanced fuel economy. There are six major areas covered in this Kenworth white paper: Aerodynamics Component Spec ing Tire Tips (Courtesy of Bridgestone) Advanced Technology Route Management Driver Behavior Proper Maintenance In addition, Kenworth s website ( will provide continuing information on this topic. Target Miles Per Gallon & Approximate Yearly Savings ($ / %) Current MPG 5.5 mpg $5,455 $10,000 $13,846 $17,143 $20,000 $22,500 (9.1%) (16.7%) (23.1%) (27.2%) (33%) (37.5%) 5.5 $4,545 $8,392 $11,688 $14,545 $17,045 (8.4%) (15.4%) (21.4%) (26.7%) (31.2%) 6 $3,845, $7,143 $10,000 $12,500 (7.7%) (14.3%) (20%) (25%) 6.5 $3,297 $6,154 $8,654 (7.2%) (13.3%) (18.8%) 7 $2,857 $5,357 (6.7%) (12.5%) 7.5 $2,500 (6.3%) SUMMARY 5.0 miles per gallon/100,000 miles = 20,000 gallons x $3.00/gallon = $60, miles per gallon/100,000 miles = 18,181 gallons x $3.00/gallon = $54, miles per gallon/100,000 miles = 16,666 gallons x $3.00/gallon = $49, miles per gallon/100,000 miles = 15,385 gallons x $3.00/gallon = $46, miles per gallon/100,000 miles = 14,285 gallons x $3.00/gallon = $42, miles per gallon/100,000 miles = 13,333 gallons x $3.00/gallon = $39, miles per gallon/100,000 miles = 12,500 gallons x $3.00/gallon = $37,500 Fuel Economy: A Matter of Dollars and Sense Calculate your own potential fuel savings by finding your current mpg on the left. The column to the right shows your approximate dollar savings per year as you improve your fuel economy. Numbers are based on driving 100,000 miles per year and purchasing fuel at an average of $3.00 per gallon. 1

4 Aerodynamics Approximately half the energy used by a truck traveling 55 mph is to simply move the air around that truck. At 65 mph, about two-thirds of the energy is used to cut through the air. Kenworth can truly be called the industry s leader in the use of aerodynamics in truck design. After all, it was Kenworth that brought aerodynamics to the forefront with the 1985 introduction of the industry s first truly aerodynamic Class 8 truck the Kenworth T600A. Kenworth engineers possessed the vision and leadership to take the concept of using aerodynamics in truck design to produce fuel savings and made it reality. The result has been billions of dollars in fuel savings for the trucking industry since the mid-1980s. Any discussion of Kenworth and aerodynamics would not be complete without mentioning the late Larry Orr, the trucking industry s Father of Aerodynamics. Orr was a trucking industry visionary and innovator. Aerodynamic Developments in the Trucking Industry Mid-1970s Airshield (Patented Vari-Shield) Late 1970s through Early 1980s Rounded Corners on COEs Trailer Bubble Nose Cab Extenders Roof Fairings 1985 First Industry-Wide Aerodynamic Truck the Kenworth T600A with Aerodynamic Hood, Bumper and Partial Chassis Side Fairings Late 1980s and Beyond Full Chassis Side Fairings Aerodynamic Mirrors Curved Windshield Orr was best known for his leadership role in the development of T600A. In recognition of their pioneering achievement, Orr and his Kenworth engineering and design team received the U.S. Department of Transportation s National Award for the Advancement of Motor Vehicle Research and Development in Kenworth s heritage of the aerodynamic truck continues with the aerodynamic Kenworth T2000, which builds upon the lessons learned from the T600A. How do Kenworth engineers pursue even greater fuel efficiency? They use a five-pronged attack consisting of: Computational Fluid Dynamics (CFD) Wind tunnel testing PACCAR Technical Center testing Real-world highway testing Kenworth Research & Development Center testing

5 WHITE PAPER ON FUEL ECONOMY KENWORTH TRUCK COMPANY Computational Fluid Dynamics (CFD) The integration of CFD in aerodynamics helps Kenworth evaluate and optimize basic truck shape. CFD results are then used to guide wind tunnel tests that are more representative of the final design. In addition to the study of external aerodynamics, CFD is used to study the underhood heat transfer of the fan and radiator and the internal flow of the Heater/Ventilation/Air Conditioning (HVAC) system. Kenworth uses sophisticated computer technology to offer aerodynamics and fuel economy improvements. The technology called computational fluid dynamics (CFD) allows Kenworth engineers to conduct virtual aerodynamic testing. With CFD, Kenworth engineers simulate wind tunnel conditions on the computer screen. This tool enables Kenworth to evaluate different hoods, cab-sleeper configurations and roof fairing designs. Wind Tunnel Testing Kenworth has conducted wind tunnel testing since the mid-1970s. This database serves as an information asset in meeting today s challenges. Kenworth uses wind tunnel testing of 20% scale truck models in pursuit of fuel economy advances. Tests are conducted at the University of Washington Aerodynamics Laboratory wind tunnel in Seattle. The overall objective is to identify opportunities to improve aerodynamic performance of the trucks, validate Kenworth s computational fluid dynamics (CFD) simulation results, and evaluate the aerodynamic properties, such as drag coefficients. Wind tunnel test programs typically run over a one-week period with individual tests going five minutes or less to collect aerodynamic drag force data. Tests that utilize a smoke wand enable engineers to visualize the airflow characteristics over the vehicle. Wind tunnel testing helps Kenworth study the aerodynamics of various body shapes. Engineers also examine the impact of all the attachments and accessories such as mirrors, sun visors and cab extenders on aerodynamic performance. 3

6 PACCAR Technical Center A third part of Kenworth s testing program for fuel economy takes place at the PACCAR Technical Center in Mount Vernon, Washington. The PACCAR Technical Center features the latest state-of-the-art equipment for testing and product evaluation. Fuel economy tests are regularly undertaken on the facility s 1.6-mile, high-speed, banked oval track. Testing methodology follows scientific practices developed by the Society of Automotive Engineers (SAE). Since fuel consumption performance varies according to the ambient conditions, the average temperature, wind speed and barometric pressure are recorded during the test runs. Road tests are often preceded by a one-hour warm-up of the vehicles. Tests often involve a series of at least three 50-mile runs on the oval with fuel calculations taken after each is completed to ensure high accuracy. One complete test cycle covers at least 150 miles. The data and results collected at the PACCAR Technical Center are used by Kenworth engineers to help confirm Kenworth s over-the-road fuel economy test results and to assess the performance of new designs. Real-World Testing Kenworth engineers also take to the road for test runs designed to increase fuel economy knowledge. This real-world testing is used to help confirm and verify results gathered from the wind tunnel, computational fluid dynamics and PACCAR Technical Center. Kenworth has conducted such test runs to study aerodynamics since the 1980s. The program began in 1985 when Kenworth took two T600s approximately 2,000 miles from Phoenix to Miami. In 1991, Kenworth ran Tour America, taking three T600s equipped with different engines nearly 7,500 miles. The tour started from Seattle, traveled east to Pennsylvania, south to Jacksonville, west to Los Angeles and then north to Seattle. In 1994, Kenworth s Test of the Best tour began in southern California and traveled nearly 2,400 miles to Jacksonville, Fla. Four vehicles were involved three T600s and one T800. For the first time, Kenworth started using its own self-contained, fueling trailer to utilize a consistent fuel supply for the tests. The trailer carries six, 500-gallon fuel tanks. This allows Kenworth to simultaneously run

7 WHITE PAPER ON FUEL ECONOMY KENWORTH TRUCK COMPANY up to five trucks each with its own designated tank on long-distance fuel economy tests. The sixth tank is used as a spare. In April 2001, Kenworth conducted over 1,000 miles of tests with a T2000 on the 7.7-mile oval track at the Bridgestone/Firestone Proving Grounds in Fort Stockton, Texas. Another on-highway test of approximately 550 miles was conducted from Fort Stockton to Tucson. During the summer of 2001, Kenworth began a series of 17 fuel economy runs with several T2000s with different engine models on a nearly 500-mile course from Renton, Washington to The Dalles, Oregon and back again. These runs provide Kenworth with data covering a total of 17,000 miles among the test trucks. In addition, Kenworth uses this real-world testing to evaluate prototype aerodynamic enhancements to various components, such as cab and cab roof extenders. Whether it s in the wind tunnel, on the computer, on the test track, or on the road across America Kenworth s commitment is to continually explore ways to achieve fuel economy advances that will benefit its customers. 5

8 Component Spec ing A truck uses energy to overcome aerodynamic, mechanical and rolling resistance. Enhancing fuel economy can be achieved by reducing aerodynamic drag, minimizing mechanical and rolling resistance or enhancing engine/powertrain efficiency. A vehicle s basic specifications and options can have a significant impact on fuel use. Kenworth s Applications Engineering Team works in conjunction with Kenworth dealers, truck salespeople, and customers to spec vehicles to meet customers fuel economy requirements. For example, Kenworth engineers work to help customers hit the sweet spot regarding the most efficient engine operation and fuel consumption curve for their specific application. Here are some tips to consider. To enhance aerodynamics: Select a more aerodynamic model T2000 or T600 which can increase fuel economy by an estimated 15% for over-the-road. Select a sleeper package appropriate for the trailers you expect to pull. (For example, a flat-top sleeper as opposed to an Aerodyne sleeper will achieve Impact of Selected Components better aerodynamic performance (Potential Percent Fuel Economy Improvement in MPG*) with a tank or flatbed trailer.) Full Roof Fairing (for use with van trailer) 5-10% Aerodynamic treatments will further enhance the fuel economy performance. This includes a roof fairing for use with van trailers, chassis fairings, cab extenders and Kenworth aerodynamic mirrors. (A roof fairing and cab extenders typically may reduce aerodynamic drag by 10% to 20%. A chassis fairing may reduce drag by 2% to 3%.) Remove accessory components from the air stream where possible. For example, the use of underhood-mounted air cleaners not cowl-mounted air cleaners can improve aerodynamics by 3% to 4%. Wheelbase and fifth-wheel setting are important considerations. For aerodynamics, get the trailer as close to the back of the cab/sleeper as possible. The narrower the gap, the better the aerodynamics. For example, decreasing the trailer gap by 10 inches represents a 0.5% to 1% increase in fuel economy. To reduce mechanical resistance: Cab Extenders 2-4% Chassis Fairings 1-2% Air Cleaners (underhood) 1-2% Aerodynamic Mirrors 1-2% * - gains are not cumulative Select components that are sized for the job larger gear sets generally have lower efficiencies; larger capacity tires have more resistance. Use low-profile tires and aluminum wheels. Use all-position tires on the rear, same tread as the steer-axle tires.

9 WHITE PAPER ON FUEL ECONOMY KENWORTH TRUCK COMPANY Reduce the weight of rotating components such as tires and wheels. Use wide base radial tires, replacing less fuel-efficient dual tire assemblies. Reduce the inertial resistance of the combination by reducing the truck s weight. (If more weight can be added in cargo, you do not reduce the inertial loads on the engine. But, you do improve the fuel consumption per pound of cargo.) Select the right engine and gearing for the intended operation: Engine power settings have unique torque, horsepower, and fuel-consumption curves. Selecting an engine with excessive power can lead to inefficiencies. Select a transmission for the gears that you ll normally be running. Selecting a gear set that has the truck cruise at the wrong rpm may decrease fuel economy by 10% to 15%. A 13- or 18-speed transmission is often the most likely selection. It s also important to select a transmission and rear axle to match the engine and load requirements for the specific application. This selection should take into account the terrain over which the vehicle will operate. The old saying Gear fast, run slow is really the key to the best fuel economy. Consider spec ing an automated transmission in order to enhance fuel economy through computer controlled shift logic. If you have a route that you typically run, contact your Kenworth dealer for assistance in spec ing the vehicle for that route. Kenworth dealers work closely with the engine suppliers to take into account a variety of speeds and grades. This allows the truck to be fine-tuned for optimum fuel economy. BRIDGESTONE TIRE TIPS Don t forget the impact of tires on the vehicle and trailer. Bridgestone has extensive information available on fuel economy. Bridgestone has conducted fuel economy tests under strict scientific conditions for over 20 years. The tire manufacturer uses the Bridgestone/Firestone Proving Grounds in Fort Stockton, Texas, and Transportation Research Center, Inc. in East Liberty, Ohio, to test the effects of speed, load, and tire-related factors on fuel efficiency. Bridgestone also collects data from real-world testing conducted by customers using their trucks to haul freight. Here are some tips to remember: Tire rolling resistance accounts for about one-third of a truck s fuel consumption. In other words, a 3% reduction in rolling resistance produces about a 1% gain in fuel economy. 7 Tread depth has a significant effect on tire fuel economy. As a tread wears, the fuel efficiency of the tire usually increases. The increase is fairly rapid at first, then slows as the tire wears out. Tire fuel efficiency, especially with fuel-saving tires, is cut nearly in half when speed is increased from 55 mph to 75 mph. Tire treads wear faster at higher speeds. Tests show that the removal mileage point may come 10% to 30% sooner. Overinflation is neither effective nor recommended as a fuel economy improvement method. All axle positions are not equal; tires on different axles make different contributions to fuel economy.

10 Changing trailer tires to fuel-efficient types produces a larger effect than changing tractor tires to fuel-efficient types. All tires are not alike. Some are better than others when it comes to fuel economy. Increased tire pressure generally means less rolling resistance and better mileage. But conversely, it can mean more tire wear. Bridgestone offers a video called, What Drivers Can Do To Save Fuel. The 9-minute program examines such topics as: Why saving fuel benefits drivers, How to save fuel before the trip starts, Why idle control is so important, The advantages of progressive shifting, How to use time management to save fuel, and Why excessive speed doesn t pay. Bridgestone also published a comprehensive, 56-page brochure entitled Guide To Large Truck Fuel Economy for a New Millennium. See your Bridgestone representative, call , or your request to contact@trucktires.com to obtain the guide and video. For more details on tires and fuel economy, go to Bridgestone s website ( com). Click on Library, then Publications and scroll down to Feature Publications. Click on Guide to Large Truck Fuel Economy for a New Millennium, which offers an electronic version of the guide.

11 WHITE PAPER ON FUEL ECONOMY KENWORTH TRUCK COMPANY Advanced Technology The use of advanced technology is a key area of focus at Kenworth to further enhance the fuel economy of tomorrow s truck. Kenworth engineers regularly explore a variety of technologies that can help to significantly reduce fuel consumption. Is 10-plus miles per gallon feasible for a heavy-duty truck in the future? Perhaps. But it will take technology advancements and initiatives to pursue and achieve such a goal. Kenworth research and development engineers are working in a number of areas to study advanced technologies that impact fuel economy. These include: A digital fuel economy gauge to provide the driver with feedback on the instantaneous fuel consumption. Telematics to provide driver/vehicle utilization and productivity data for fleet operations. Advanced tire-pressure monitoring systems to ensure that the tires are maintained at the proper inflation pressure. Electronic vision systems offering the potential to reduce the size of, or eliminate the need for, external mirrors, thus providing improved aerodynamics. Stricter engine emissions standards. Hybrid electric systems to power accessory devices. Kenworth High-Tech Trucks to validate promising technologies. 9

12 Kenworth s digital fuel economy display under development will help a driver easily monitor fuel parameters such as road speed, engine speed and turbo boost. The display will also provide easy-to-read data on instantaneous fuel consumption, trend graphs and average trip fuel economy to help the driver achieve outstanding results. Kenworth GPS and cellular communications, will help fleets monitor driver performance trends in real-time. This system can also be used by fleets to monitor fuel consumption and provide feedback for driver training. In addition, fleets may elect to use the system to provide incentives to drivers for exceptional performance. Advanced tire-pressure monitoring systems will keep drivers updated on the status of pressure of all tires and ensure low rolling resistance. These systems will also provide early warning of tire-pressure changes that can lead to premature wear or sudden tire damage. Kenworth s Advanced Idle Management System provide heating, cooling and hotel power without the need to idle the truck engine. This reduces fuel consumption in additional to complying with state and federal regulations. Additional benefits include elimination of engine noise and vibrations, which improves rest quality. The package includes enhanced sleeper insulation and LED lighting and is fully compatible with short power. Kenworth is involved in several projects involving object recognition technologies. In the future, vision systems may replace mirrors, subject to government approval. It is estimated that eliminating the current mirrors and holders will offer a 3% to 4% reduction in aerodynamic drag or a 1% to 2% increase in fuel economy. In addition to these efforts, Kenworth has been studying how the tougher EPA 2007 engine emissions standards will impact fuel economy performance. The industry will face an increased challenge of achieving current fuel-economy performance with the reduced emissions. Kenworth engineers are identifying opportunities to further optimize the integration of this powertrain and cooling system into the vehicle, thus mitigating the impact to customers. Even more stringent engine emissions standards are coming in To meet this challenge, Kenworth and Caterpillar have contracted with the Department of Energy on a major project in conjunction with the 21 st Century Truck Initiative. The 42-month research and development program is exploring ways to significantly reduce truck fuel consumption and emissions. It involves engine parasitic energy-loss reduction (mechanical losses from accessory devices driven by the engine) and enabling technologies for Class 7 and 8 trucks. Major goals are to reduce: Parasitic losses, Idling emissions, and Refrigerant gas leakage. Finally, Kenworth showcases technologies that enhance customer productivity and profitability through High-Tech Trucks annually developed as concept vehicles and displayed at many of the North American truck shows. These trucks highlight promising technologies which may eventually go into production and further help customers reduce fuel and operating costs.

13 WHITE PAPER ON FUEL ECONOMY KENWORTH TRUCK COMPANY Route Management Route management is another important factor in fuel economy. In trucking, there are different ways to go from Point A to Point B. The goal is to get from Point A to Point B in the most efficient and economical manner while also meeting delivery deadlines. This can be easier said than done because even veteran truck drivers may sometimes have trouble finding a delivery location. Some companies and drivers make many deliveries to new locations especially on backhauls. Searching for a customer s location can add stress to driving. Out-of-route miles and lost time can result if a driver misses a turn, impacting on-time delivery. Of course, out-of-route miles also result in burning more fuel. It s estimated that out-ofroute miles may account for between 3% to 10% of a driver s total mileage each year. Let s assume 100,000 miles driven a year at 6 miles per gallon and an average cost of $3.00 per gallon. Out-of-route miles of 3% or 3,000 miles requires 500 extra gallons of diesel fuel. Multiply that by $2.50 per gallon and it equals $1,500 in additional fuel costs. Out-of-route miles of 10% or 10,000 miles equates to 1,666 extra gallons of diesel fuel. Multiply again by $3.00 gallon and it equals mearly $5,000 in additional fuel costs. And these figures are just for one truck. Kenworth believes it s essential to help drivers and fleets find ways to reduce their out-of-route miles and boost overall fuel economy and route efficiency, thus increasing truck asset productivity. Driver Behavior While Kenworth engineers and the Kenworth dealer network can work closely with customers to spec a vehicle for fuel economy, driving techniques and habits have a major impact on achieving what the specs set out to do. Kenworth offers these tips for getting the most out of your equipment: A fuel economy display is essential as the driver must be able to monitor and correct fuel economy performance by the minute. Once the fuel is used, it is very difficult to retrieve the loss. Examples of fuel economy displays are the Cummins RoadRelay and Caterpillar Driver Information Display (DID). 11 Excessive speed is the largest single factor in reduced fuel mileage. Reduce speed to a reasonable level of say 60 mph and eliminate all non-essential stops. A general rule of thumb is that every mph increase above 50 mph reduces fuel mileage by 0.1 mpg. Use restraint when accelerating from stop. Short-shifting at 1,100 to 1,200 rpm in all the low-range gears keeps fuel consumption low and still moves the truck. The step to high range requires a bit more RPM and then use 1,500 rpm as maximum shift point. Lug the engine to 1,150 rpm before downshifting. The upper end of the power curve 1,500 to 1,800 or 2,100 rpm has the most severe fuel burn rate so try to avoid this.

14 Minimize idling. Five minutes of warm-up is generally adequate and cool-down is accomplished when pulling in for parking. To verify the negative effect of excessive idling, watch the fuel economy display. Utilize these fuel-economy tips and you ll be well on your way to receiving better fuel economy for your truck or fleet. Proper Maintenance Proper maintenance is also important in the fuel economy equation. Here are some things to remember: Make sure to maintain proper tire inflation pressure. Check tire wear. Replace air & fuel filters at the proper intervals. Keep all axles drive and steer properly aligned to minimize rolling resistance. Monitor your fuel quality at the pump. Make sure that you are not getting dirty fuel that causes the fuel injectors to clog or disrupt the spray pattern. Repair any body damage. For example, that front corner of the dinged-up bumper hanging down hurts the vehicle s aerodynamics, and thus, fuel economy. Use a good synthetic or semi-synthetic oil in the engine and drive axles. Also use a good synthetic transmission fluid. Kenworth uses synthetic oil in the axles and transmissions of new trucks coming off the production line. Don t use a higher viscosity oil than actually needed for the operating conditions.

15 WHITE PAPER ON FUEL ECONOMY KENWORTH TRUCK COMPANY 13

16 To learn more about fuel economy, be sure to visit Kenworth s website ( for continuing information on this important topic. ISO Kenworth Truck Company, A Division of PACCAR. For more information, please call or visit your local Kenworth dealer or visit us at WP-FE05