1

VTT PROCESSES

HEAVY-DUTY TRUCK EMISSIONS AND FUEL CONSUMPTION

SIMULATING REAL-WORLD DRIVING
IN LABORATORY CONDITIONS
Nils-Olof Nylund & Kimmo Erkkil
VTT Technical Research Centre of Finland

VTT PROCESSES
Kimmo Erkkil

2005 DEER Conference

Aug 21 25, Chicago, Illinois, USA

VTT PROCESSES

CONTENTS

Research on heavy-duty vehicles

Rationale for testing complete heavy-duty vehicles

Development of test cycles

Test results
fuel consumption
exhaust emissions
Summary

VTT PROCESSES
Kimmo Erkkil

2005 DEER Conference

Aug 21 25, Chicago, Illinois, USA

VTT PROCESSES

RESEARCH INTEGRATE ON HEAVY-DUTY VEHICLES

Finland, like many other countries is highly dependent on road transports

Some 75 % of the goods within the borders of Finland are transported on
rubber wheels
VTT initiated a three-year (2003-2005) multi-client research project to seek
fuel savings for heavy-duty vehicles
6 research institutes and some 20 sponsors from government,
industry and transport companies cooperating
www.motiva.fi/raskaskalusto (in Finnish)

VTT PROCESSES
Kimmo Erkkil

2005 DEER Conference

Aug 21 25, Chicago, Illinois, USA

VTT PROCESSES

THE GOAL OF THE PROJECT

- in a 5-year perspective
Permanent
fuel savings
Vehicles &
technology
5-10 %
Systems &
operations

VTT PROCESSES
Kimmo Erkkil

Driver &
information

2005 DEER Conference

Aug 21 25, Chicago, Illinois, USA

VTT PROCESSES

EMISSION CERTIFICATION

For light-duty vehicles, certification is done running complete vehicles

both emissions and fuel consumption are reported
Both for the US and Europe, HD emission certification is done using
stand-alone engines
the outcome is specific emission values (g/hph or g/kWh) for the
engine itself tested over a certain duty cycle
the testing does not in any way reflect the properties of the vehicle
itself (weight, aerodynamic drag, design of the driveline etc.)
no requirements to report fuel economy

VTT PROCESSES
Kimmo Erkkil

2005 DEER Conference

Aug 21 25, Chicago, Illinois, USA

VTT PROCESSES

WHY TEST COMPLETE HD VEHICLES?

There is a clear need to generate emission and fuel consumption figures

that take into account the properties of the complete vehicle:

generating truthful distance based emission and fuel consumption

figures
effects of load and driving cycle
comparison of vehicles
chassis dyno testing also enables checking of in-use vehicles

Within VTTs research project, both the authorities and the transport
companies are very interested in comparable (vehicle to vehicle) emission
and fuel consumption figures for various HD vehicles
fuel economy is extremely important for the operators

VTT PROCESSES
Kimmo Erkkil

2005 DEER Conference

Aug 21 25, Chicago, Illinois, USA

VTT PROCESSES

DEVELOPMENT OF TEST METHODOLOGY

Together with one of the biggest transport companies in Finland

(Transpoint) VTT developed a methodology for chassis dynamometer
measurement of heavy-duty trucks
The key elements in the methodology are
transient type testing on dyno with 2,5 m diameter rollers
using truthful vehicle loading and speed profiles
also taking into account road gradient
determination of accurate rolling and draq resistance by conducting
coast-down measurements
The speed and road gradient profiles were recorded from actual routes
served by Transpoint
Varying speed and taking into account the road gradient creates highly
transient loading

VTT PROCESSES
Kimmo Erkkil

2005 DEER Conference

Aug 21 25, Chicago, Illinois, USA

VTT PROCESSES

TEST METHODOLOGY POWER VS. SPEED

Driving resistances against speed for different vehicle categories
(fully loaded)
200
60t truck with full trailer
42t semi-trailer
26t truck
18t truck
2-axle citybus
Large van
Small van

Overall driving resistance kW

180
160
140
120
100
80
60
40
20
0
0

10

20

30

40

50

60

Speed km/h

VTT PROCESSES
Kimmo Erkkil

2005 DEER Conference

Aug 21 25, Chicago, Illinois, USA

70

80

90

VTT PROCESSES

TEST METHODOLOGY CYCLE DEVELOPMENT

Freeway cycle for a 60 t truck with full trailer

Highway cycle for a 60 t truck with full trailer

420 hp truck + 4-axle trailer

total weight 49 050 kg
cruise control active

420 hp truck + 4-axle trailer

total weight 49 050 kg
driver controls speed

Delivery cycle for a 26 t truck

26 t truck, 420 hp

vehicle weight 21 700 kg

normal style of driving

VTT PROCESSES
Kimmo Erkkil

2005 DEER Conference

Aug 21 25, Chicago, Illinois, USA

10

VTT PROCESSES

TEST METHODOLOGY
Freeway cycle, original onroad data , 420 hp / 50 t
350

1.50

300

0.50
200
0.00
150
-0.50
100
-1.00
50

-1.50

-2.00

-50

-2.50
1400

200

400

600

800

1000

T ime s

VTT PROCESSES
Kimmo Erkkil

2005 DEER Conference

Aug 21 25, Chicago, Illinois, USA

1200

Road gradient %

1.00

250
Engine power kW
Driving speed km/h

Engine power
Driving2.00
speed
Road gradient

11

VTT PROCESSES

TEST METHODOLOGY
Highway cycle, original onroad data , 420 hp / 50 t

Engine power
Driving100
speed

350

90
300

70
60

200

50
150

40
Delivery cycle,
original onroad data , 420 hp / 50 t
350

30

100

Engine power
Driving100
speed
90

300

20
80

50
10

200

400

600
Time s

Engine power kW

250

800

70

0
1000

200

60

1200

50
150

40
30

100

20
50
10
0

0
0

VTT PROCESSES
Kimmo Erkkil

200

400

600

800

2005 DEER Conference

Aug 21 25, Chicago, Illinois, USA

1000
Time s

1200

1400

1600

1800

Driving speed km/h

Engine power kW

250

Driving speed km/h

80

12

VTT PROCESSES

TEST METHODOLOGY - ACCREDITATION

Light-duty vehicle
chassis dynamometer
emission testing
70/220/EEC
91/441/EEC
98/69/EC

Heavy-duty engine
engine dynamometer
emission testing
96/1999/EC

Heavy-duty vehicle
chassis dynamometer
measurements
VTT PRO

The Finnish Centre for Metrology

and Accreditation granted
accreditation for VTTs
measurements in 2003
Heavy-duty vehicle
chassis dynamometer
measurements
Recommended Code
of Practise
SAE J2711

General safety instructions

VTT PROCESSES
Kimmo Erkkil

2005 DEER Conference

Aug 21 25, Chicago, Illinois, USA

13

VTT PROCESSES

SUBPROJECT TRUCK 2004:

Exhaust emissions and fuel consumption
of Euro 3 certified trucks

VTT PROCESSES
Kimmo Erkkil

2005 DEER Conference

Aug 21 25, Chicago, Illinois, USA

14

VTT PROCESSES

TEST MATRIX 2004

VTT PROCESSES
Kimmo Erkkil

The measurements were done running dynamic load cycles including

simulation of road gradient (three cycles: freeway, highway and
delivery)
Measurements were conducted in four weight classes:
18 t delivery trucks: 0, 1/3, 2/3 and 1/1 load (four load levels)
26 t delivery trucks: 0, 1/2 and 1/1 (three load levels)
42 t semi-trailers: 0, 1/2 and 1/1 (three load levels)
60 t trucks with full trailers: 0, 1/2 and 1/1 (three load levels)
Vehicles of different makes were tested in parallel:
18 t: three brands
26/60 t: four brands
42 t: three brands
13 different vehicles were measured, and the number of
combinations (vehicle/load/cycle) was 63
including repetitive tests, more than 130 tests were done
2005 DEER Conference
Aug 21 25, Chicago, Illinois, USA

15

VTT PROCESSES

INFLUENCE OF VEHICLE MASS

Fuel consumption on highway cycle
60

Fuel consumption l/100km

50
40
42t semi-trailers

30

60t trucks with full trailers

20

60t trucks with full trailers

(with smaller engines)

10
0
0

10000

20000

30000

40000

50000

Vehicle weight kg

VTT PROCESSES
Kimmo Erkkil

2005 DEER Conference

Aug 21 25, Chicago, Illinois, USA

60000

70000

16

VTT PROCESSES

INFLUENCE OF LOAD
Fuel consumption per ton-kilometres on highway cycle

Fuel consumption l/ton-kilometres

0.06
42t semi-trailers

0.05

60t trucks with full trailers

60t trucks with full trailers
(with smaller engines)

0.04
0.03
0.02
0.01
0.00
0

5000

10000

15000

20000

25000

Pay load kg

VTT PROCESSES
Kimmo Erkkil

2005 DEER Conference

Aug 21 25, Chicago, Illinois, USA

30000

35000

17

VTT PROCESSES

FUEL CONSUMPTION BY VEHICLE MAKE

Fuel consumption on highway and freeway cycles.
Semi-trailers (max. 42t), three brands.
40
max diff. 4%

Highway

Freeway
max diff. 5%

Fuel consumption l/100 km

35
max diff. 7%
max diff. 8%

30

25

A/42
B/42
C/42
max diff. 14%

max diff. 15%

20

15
0-load

VTT PROCESSES
Kimmo Erkkil

1/2 load

2/2-load

0-load

1/2 load

2005 DEER Conference

Aug 21 25, Chicago, Illinois, USA

2/2-load

18

VTT PROCESSES

FUEL CONSUMPTION BY VEHICLE MAKE

Fuel consumption on highway and freeway cycles.
Trucks with full trailers (max. 60t), four brands.
60
Highway

max diff. 9%

Freeway

Fuel consumption l/100 km

55

max diff. 9%

50
max diff. 9%

45

max diff. 8%

A/60
B/60
C/60
D/60

40
35

max diff. 8%

max diff. 6%

30
25
20
15
0-load

VTT PROCESSES
Kimmo Erkkil

1/2 load

2/2-load

0-load

1/2 load

2005 DEER Conference

Aug 21 25, Chicago, Illinois, USA

2/2-load

19

VTT PROCESSES

EMISSIONS (g/kWh at the driving wheels)

VTT PROCESSES
Kimmo Erkkil

2005 DEER Conference

Aug 21 25, Chicago, Illinois, USA

20

VTT PROCESSES

EMISSIONS (g/km)

VTT PROCESSES
Kimmo Erkkil

2005 DEER Conference

Aug 21 25, Chicago, Illinois, USA

21

VTT PROCESSES

SUMMARY..

VTT PROCESSES
Kimmo Erkkil

VTT has now got measurement methods which make vehicle to

vehicle comparisons, for emissions and fuel consumption, possible
The methodology is based on transient-type chassis dynamometer
measurements simulating realistic speed profiles, vehicle loads
and also road gradient
In 2004, a matrix of 13 new heavy-duty trucks in prime condition
were measured for emissions and fuel consumption

2005 DEER Conference

Aug 21 25, Chicago, Illinois, USA

22

VTT PROCESSES

..SUMMARY..

VTT PROCESSES
Kimmo Erkkil

Fuel consumption is primarily dependent on vehicle mass:

for delivery-type service fuel consumption is 25 42 l/100 km
for highway and freeway-type driving the fuel consumption of
42 t and 60 t vehicle combinations is 22 53 l/100 km
depending on the weight of the combination
The minimum specific fuel consumption was 0.04 l/ton-km over the
delivery cycle and 0.015 l/ton-km over the highway cycle
transient-type driving increases fuel consumption significantly
The variations in fuel consumption between vehicles within the
same weight class are surprisingly big
the variation from vehicle to vehicle within the same category
is 0 16 %

2005 DEER Conference

Aug 21 25, Chicago, Illinois, USA

23

VTT PROCESSES

..SUMMARY

The variations in exhaust emissions (NOx, PM) are even bigger

for 42 and 60 t vehicles on highway NOx varies by a factor of some 2.5
and PM by a factor of some 4
the differences in emissions are so big that the influence of load and
even vehicle category is obscured
some manufacturers have succeeded in combining low emissions and
low fuel consumption
So far the vehicle makes have not been published
there is, however, an increasing demand for vehicle specific figures to
guide vehicle procurements
Euro 4 vehicles with either EGR + DPF or SCR will be introduced in Europe
starting 2005
this might increase differences in both emissions and fuel economy in
real-life service

VTT PROCESSES
Kimmo Erkkil

2005 DEER Conference

Aug 21 25, Chicago, Illinois, USA