TECHNOLOGIES AND APPROACHES TO REDUCING THE FUEL CONSUMPTION OF MEDIUM- AND HEAVY-DUTY VEHICLES Committee to Assess Fuel Economy Technologies for Medium- and Heavy-Duty Vehicles Board on Energy and Environmental Systems Division on Engineering and Physical Sciences Transportation Research Board THE NATIONAL ACADEMIES PRESS 500 Fifth Street, N.W. Washington, DC 20001 NOTICE: The project that is the subject of this report was approved by the Governing Board of the National Research Council, whose members are drawn from the councils of the National Academy of Sciences, the National Academy of Engineering, and the Institute of Medicine. The members of the committee responsible for the report were chosen for their special competences and with regard for appropriate balance. This study was supported by Contract DTNH22-08-H-00222 between the National Academy of Sci- ences and the U.S. Department of Transportation, National Highway Traffc Safety Administration. Any opinions, fndings, conclusions, or recommendations expressed in this publication are those of the author(s) and do not necessarily refect the views of the organizations or agencies that provided support for the project. International Standard Book Number-13: 978-0-309-14982-2 International Standard Book Number-10: 0-309-14982-7 Copies of this report are available in limited supply, free of charge, from: Board on Energy and Environmental Systems National Research Council 500 Fifth Street, N.W. Keck W934 Washington, DC 20001 202-334-3344 Additional copies of this report are available for sale from: The National Academies Press 500 Fifth Street, N.W. Lockbox 285 Washington, DC 20055 (800) 624-6242 or (202) 334-3313 (in the Washington metropolitan area) Internet: http://www.nap.edu Copyright 2010 by the National Academy of Sciences. All rights reserved. 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The National Academy of Engineering also sponsors engineering programs aimed at meeting national needs, encourages education and research, and recognizes the superior achievements of engineers. Dr. Charles M. Vest is president of the Na- tional Academy of Engineering. The Institute of Medicine was established in 1970 by the National Academy of Sciences to secure the services of eminent members of appropriate professions in the examination of policy matters pertaining to the health of the public. The Institute acts under the responsibility given to the National Academy of Sciences by its congressional charter to be an adviser to the federal government and, upon its own initiative, to identify issues of medical care, research, and education. Dr. Harvey V. Fineberg is president of the Institute of Medicine. The National Research Council was organized by the National Academy of Sciences in 1916 to associate the broad community of science and technology with the Academy’s purposes of furthering knowledge and advising the federal government. Functioning in accordance with general policies determined by the Academy, the Council has become the principal operating agency of both the Na- tional Academy of Sciences and the National Academy of Engineering in providing services to the government, the public, and the scientifc and engineering communities. The Council is administered jointly by both Academies and the Institute of Medicine. Dr. Ralph J. Cicerone and Dr. Charles M. Vest are chair and vice chair, respectively, of the National Research Council. www.national-academies.org COMMITTEE TO ASSESS FUEL ECONOMY TECHNOLOGIES FOR MEDIUM- AND HEAVY-DUTY VEHICLES ANDREW BROWN, JR., Chair, NAE, Delphi Corporation DENNIS N. ASSANIS, NAE, University of Michigan ROGER BEZDEK, Management Information Services, Inc. NIGEL N. CLARK, West Virginia University THOMAS M. CORSI, University of Maryland DUKE DRINKARD, Southeastern Freight Lines DAVID E. FOSTER, University of Wisconsin ROGER D. FRUECHTE, Consultant RON GRAVES, Oak Ridge National Laboratory GARRICK HU, Consultant JOHN H. JOHNSON, Michigan Technological University DREW KODJAK, International Council on Clean Transportation DAVID F. MERRION, Detroit Diesel (retired) THOMAS E. REINHART, Southwest Research Institute AYMERIC P. ROUSSEAU, Argonne National Laboratory CHARLES K. SALTER, Consultant JAMES J. WINEBRAKE, Rochester Institute of Technology JOHN WOODROOFFE, University of Michigan Transportation Research Institute MARTIN B. ZIMMERMAN, University of Michigan Staff DUNCAN BROWN, Study Director DANA CAINES, Financial Associate LANITA JONES, Administrative Coordinator JOSEPH MORRIS, Senior Program Offcer, Transportation Research Board JASON ORTEGO, Senior Program Assistant (until December 2009) MADELINE WOODRUFF, Senior Program Offcer E. JONATHAN YANGER, Senior Project Assistant JAMES J. ZUCCHETTO, Director, Board on Energy and Environmental Systems BOARD ON ENERGY AND ENVIRONMENTAL SYSTEMS 1 DOUGLAS CHAPIN, Chair, NAE, MPR Associates, Inc., Alexandria, Virginia RAKESH AGRAWAL, NAE, Purdue University, West Lafayette, Indiana WILLIAM BANHOLZER, NAE, The Dow Chemical Company, Midland, Michigan ANDREW BROWN, JR., NAE, Delphi Technologies, Troy, Michigan MARILYN BROWN, Georgia Institute of Technology, Atlanta, Georgia MICHAEL CORRADINI, NAE, University of Wisconsin, Madison, Wisconsin PAUL DECOTIS, Long Island Power Authority, Long Island, NY E. LINN DRAPER, JR., NAE, American Electric Power, Lampasas, Texas CHRISTINE EHLIG-ECONOMIDES, NAE, Texas A&M University, College Station, Texas WILLIAM FRIEND, NAE, University of California Presidents Council on National Laboratories, Washington, DC SHERRI GOODMAN, CNA, Alexandria, Virginia NARAIN HINGORANI, NAE, Independent Consultant, Los Altos Hills, California MICHAEL OPPENHEIMER, Princeton University, Princeton, New Jersey MICHAEL RAMAGE, NAE, ExxonMobil Research and Engineering Company (retired), Moorestown, New Jersey DAN REICHER, Google.org, Warren, Vermont BERNARD ROBERTSON, NAE, Daimler-Chrysler (retired), Bloomfeld Hills, Michigan MAXINE SAVITZ, NAE, Honeywell, Inc. (retired), Los Angeles, California 2 MARK THIEMENS, NAS, University of California, San Diego RICHARD WHITE, Oppenheimer’s Private Equity & Special Products, New York, NY Staff JAMES J. ZUCCHETTO, Director, Board on Energy and Environmental Systems DUNCAN BROWN, Senior Program Offcer DANA CAINES, Financial Associate ALAN CRANE, Senior Program Offcer K. JOHN HOLMES, Senior Program Offcer LANITA JONES, Administrative Coordinator MADELINE WOODRUFF, Senior Program Offcer E. JONATHAN YANGER, Senior Project Assistant 1 National Academy of Engineering. 2 National Acaedemy of Science. i Acknowledgments The Committee to Assess Fuel Economy Technologies standards for objectivity, evidence, and responsiveness to the for Medium- and Heavy-Duty Vehicles is grateful to all of study charge. The review comments and draft manuscript the company, agency, industry, association, and national remain confdential to protect the integrity of the deliberative laboratory representatives who contributed signifcantly process. of their time and efforts to this National Research Council We wish to thank the following individuals for their re- (NRC) study, either by giving presentations at meetings or view of this report: by responding to committee requests for information. We acknowledge the valuable contributions of individu- Paul Blumberg, Consultant als and organizations that provided information and made Fred Browand, University of Southern California presentations at our meetings, as listed in Appendix B. We Douglas Chapin, MPR Associates, Inc. especially recognize the organizations that hosted site visits Robert Clarke, Truck Manufacturers Association for the committee’s work as outlined in Chapter 1. Coralie Cooper, Northeast States for Coordinated Air The committee was aided by consultants in various roles Management who provided analyses to the committee, which it used in Joe Fleming, Consultant addition to other sources of information. Special recognition Winston Harrington, Resources for the Future is afforded the TIAX team of Michael Jackson, Matthew John Heywood, Massachusetts Institute of Technology Kromer, and Wendy Bockholt; and the Argonne National Larry Howell, General Motors (retired) Laboratory team of Aymeric Rousseau, Antoine Delorme, Thomas Jahns, University of Wisconsin Dominik Karbowski, and Ram Vijayagopal. James Kirtley, Massachusetts Institute of Technology We wish to recognize the committee members for taking Priyaranjan Prasad, Ford Motor Company (retired) on this daunting charter and accomplishing it on schedule Mike Roeth, Consultant within tight budget requirements. The staff of the NRC Board Russell Truemner, AVL Powertrain Engineering, Inc. on Energy and Environmental Systems has been exceptional in organizing and planning meetings, gathering information, Although the reviewers listed above have provided many and drafting sections of the report. Duncan Brown, Dana constructive comments and suggestions, they were not asked Caines, LaNita Jones, Joseph Morris, Jason Ortego, Jonathan to endorse the conclusions or recommendations, nor did Yanger, and James Zucchetto have done an outstanding job they see the fnal draft of the report before its release. The of facilitating the work of the committee and providing their review of this report was overseen by Elisabeth Drake, NAE, knowledge and experience to help the committee in its delib- Massachusetts Institute of Technology (retired). Appointed erations. Lastly, the committee chair expresses his personal by the NRC, she was responsible for making certain that an appreciation to Lori Motley, Delphi executive assistant, for independent examination of this report was carried out in her administrative support provided to this overall effort. accordance with institutional procedures and that all review This report has been reviewed in draft form by individuals comments were carefully considered. Responsibility for the chosen for their diverse perspectives and technical expertise, fnal content of this report rests entirely with the authoring in accordance with procedures approved by the NRC’s Re- committee and the institution. port Review Committee. The purpose of this independent review is to provide candid and critical comments that will Andrew Brown, Jr., Chair assist the institution in making its published report as sound Committee to Assess Fuel Economy Technologies as possible and to ensure that the report meets institutional for Medium- and Heavy-Duty Vehicles ii Contents SUMMARY 1 1 INTRODUCTION 9 Origin of Study and Statement of Task, 9 Policy Motivation, 10 Weight Classes and Use Categories, 12 Energy Consumption Trends and Trucking Industry Activity, 13 Factors Affecting Improvements in Fuel Consumption, 14 Task Organization and Execution, 14 Report Structure, 15 Bibliography, 15 2 V EHICLE FUNDAMENTALS, FUEL CONSUMPTION, AND EMISSIONS 17 Truck and Bus Types and Their Applications, 17 Sales of Vehicles by Class and Manufacturer, 17 Industry Structure, 19 Metrics to Determine the Fuel Effciency of Vehicles, 20 Truck Tractive Forces and Energy Inventory, 28 Test Protocols, 28 Test-Cycle Development and Characteristics, 31 Findings and Recommendations, 39 Bibliography, 39 3 R EVIEW OF CURRENT REGULATORY APPROACHES FOR TRUCKS AND CARS 41 European Approach, 41 Japanese Approach, 42 U.S. Approach: EPA Smartway Voluntary Certifcation Program, 43 California Regulation Based on EPA Smartway Program, 45 Light-Duty-Vehicle Fuel Economy Standards, 45 Heavy-Duty-Engine Emissions Regulations, 45 Regulatory Example from Truck Safety Brake Test and Equipment, 49 Findings, 50 References, 50 4 P OWER TRAIN TECHNOLOGIES FOR REDUCING LOAD-SPECIFIC FUEL 51 CONSUMPTION Diesel Engine Technologies, 51 Gasoline Engine Technologies, 57 Diesel Engines versus Gasoline Engines, 63 Transmission and Driveline Technologies, 65 Hybrid Power Trains, 68 ix