2011 sept autoworld_c_vpres
- 1. Aluminum’s Role in Meeting First-Ever Heavy Truck Fuel Economy Standards Randall Scheps Alcoa, Inc. on behalf of The Aluminum Association’s Aluminum Transportation Group (ATG)
- 2. Defining Who We Are The Aluminum Association’s Aluminum Transportation Group (ATG) www.aluminumintransportation.org 2
- 3. Many Challenges Facing the Commercial Vehicle Industry Today Transportation Energy Consumption • Rising energy Organisation for Economic Cooperation Non-OECD Countries costs and Development (OECD) Countries • Growing concern over greenhouse Quadrillion BTU gas emissions • Federal mandates continue to add weight to heavy- duty vehicles • First-ever fuel efficiency standards Freight energy use increasing faster than passenger energy use Source: International Energy Outlook 2010; U.S. EIA www.aluminumintransportation.org
- 4. Federal Mandates Add Weight New emissions technologies have reduced fuel economy and increased weight Fuel Economy Impact Average Weight Emissions Mandate of Emissions Impact (lbs.) Technologies 2002 EPA Engine Emissions +150 -8% 2007 EPA Engine Emissions +400 -3% 2010 EPA Engine Emissions (SCR) +300 +3% TOTAL 850 lbs. -8% www.aluminumintransportation.org
- 5. Landmark Fuel Standards for Trucks • First-ever fuel economy and greenhouse gas emissions regulations for medium- and heavy-duty trucks built from 2014 to 2018 • The rule aims to: – Reduce annual oil consumption by 530 million barrels – Cut annual greenhouse gas emissions by about 270 million metric tons www.aluminumintransportation.org
- 6. Aluminum’s Potential Recognized by Regulators • The EPA and NHTSA evaluated materials for the greatest mass reduction opportunities – Aluminum – High-strength steel – Composites • Aluminum ranked far above the others – “Greatest potential” to safely reduce vehicle weight while boosting fuel economy and cutting emissions www.aluminumintransportation.org
- 7. 2010 Industry Sponsored Study on Lightweighting and Freight Efficiency • Objective – Quantify fuel economy impact of weight reduction with aluminum specific to U.S. drive cycles • Methodology – Analytical simulation (Ricardo) • U.S. drive cycle simulations – EPA HWFET – WVU Interstate – HUDDS • Load conditions – Un-loaded, ½ GVW Load, GVW • Engine and transmission Photo Credit: East Manufacturing – Displacement: 13-liter, diesel – 10-speed automated manual transmission (AMT) • Vehicle specifications – Frontal area: 10.68 m2 – Coefficient of drag (Cd): .60 (baseline) www.aluminumintransportation.org Source: Ricardo
- 8. Vehicle Configurations Studied Tractor & Tractor % Weight Trailer % Weight % Weight Trailer (lbs.) Saved (lbs.) Saved Saved (lbs.) Conventional (baseline) 16,000 13,500 29,500 “Traditional” Lightweighting 15,500 3.1% 12,500 7.4% 28,000 5.1% (1,500 lb) “High” Aluminum Content 14,500 9.4% 11,700 13.3% 26,200 11.2% (3,300 lb) Cab rear wall Rear door Cab roof RR door surround save 49 lbs. save 187 lbs. save 60 lbs. save 150 lbs. Save 20 lbs. per door Side Wall Save 1,000 lbs. Cab floor save 56 lbs. Landing gear save 50 lbs. Slider box save 150 lbs. Frame rails Cab X-member Save 30 lbs. per save 435 lbs. save 38 lbs. wheel Source: Ricardo www.aluminumintransportation.org
- 9. Payload Configurations Studied Vehicle Tractor Mass Trailer Mass Payload Total (lbs.) Configuration (lbs.) (lbs.) (lbs.) 50,500 80,000 GVW Conventional 16,000 13,500 (baseline) 52,000 80,000 GVW “Traditional” 15,500 12,500 Lightweighting 6.5% more payload 53,800 80,0006.5% fewer trips GVW “High” Aluminum 14,500 11,700 Content www.aluminumintransportation.org Source: Ricardo
- 10. Payload Configurations Studied Vehicle Tractor Mass Trailer Mass Payload Total (lbs.) Configuration (lbs.) (lbs.) (lbs.) 50,500 80,000 GVW Conventional 25,250 54,750 half load 16,000 13,500 (baseline) 0 29,500 unloaded 52,000 80,000 GVW “Traditional” 25,250 53,250 half load 15,500 12,500 Lightweighting 0 28,000 unloaded 53,800 80,000 GVW “High” Aluminum 14,500 11,700 25,250 51,450 half load Content 11.2% mass 0 26,200 unloaded saved www.aluminumintransportation.org Source: Ricardo
- 11. U.S. Drive Cycles Simulated Via Physics-Based Model Highway Fuel Economy Test Heavy-Duty Urban West Virginia University (HWFET) Dynamometer Drive Schedule Interstate Drive Cycle – One of EPA’s official highway (HUDDS) (WVUIDC) cycles – One of EPA’s drive cycles for – Simulates interstate operation – Duty cycle designed for heavy-duty vehicles – Speeds vary from medium to medium to high speed – Several idle and start-stop high, many moderate operation, no mid-cycle stops positions acceleration events – Many acceleration and deceleration events Source: Ricardo www.aluminumintransportation.org
- 12. Weight Savings Increases Fuel Economy for All Drive Cycles Transient Drive Cycles HWFET 13.00 HUDDS WVUIDC 11.00 Fuel Economy (mpg) 9.00 7.00 5.00 3.00 0 GVW 10000 20000 30000 40000 50000 60000 Unloaded Weight Reduction (lbs) Source: Ricardo www.aluminumintransportation.org
- 13. Weight Reduction and Aerodynamic Improvements are Complimentary HWFET 12.00 0.45 • Weight savings has 11.00 0.5 greater impact at 0.55 10.00 lower drag coefficient 0.6 0.65 9.00 Fuel Economy (mpg) • 3,000 lb. reduction 8.00 equivalent to 0.05 Cd 7.00 improvement 6.00 5.00 4.00 3.00 0 GVW 10000 20000 30000 40000 50000 60000 Unloaded Weight Reduction (lbs) “High” Aluminum Content Truck Source: Ricardo www.aluminumintransportation.org
- 14. Aluminum Impacts Fleet Freight Efficiency “High” Aluminum Content – 3,300 lb. Weight Reduction Payload Fuel Efficiency % Annual Miles* (% GVW) Improvement 0 – 25 % 10 % 4.1 % 25 – 75 % 25 % 3.7 % 6.5% more 75 – 100 % 65 % 6.5 % payload / fewer trips Fleet Average = 5.7 % * Average results from Aluminum Association Heavy-Duty Truck Use Survey Source: Aluminum Association www.aluminumintransportation.org
- 15. Aluminum is a Part of the Solution • More payload – Carry 3,300 lbs or 6.5% more cargo at GVW • Improved fuel efficiency – As high as 1,612 gallons each year for a weight constrained vehicle • Nearly one billion gallons of diesel annually for the current U.S. fleet • Reduced CO2 emissions – Up to 17.9 tons annually for a weight constrained vehicle • Approximately 10 million tons of CO2 per year for the current U.S. fleet www.aluminumintransportation.org
- 16. Time for Down Weighting is Now • A necessity in the holistic approach to meeting U.S. and global regulations without sacrificing safety or functionality • Complements advanced powertrains • Offers more CO2 and fuel savings than other materials • Transition can happen faster than alternative powertrain breakthroughs while preserving U.S. jobs www.aluminumintransportation.org
- 17. Thank You Contact Us For additional aluminum research in the areas of safety, cost, alternative powertrains, growth and sustainability, to sign-up for the ATG’s monthly newsletter and/or download this presentation, please visit us online at www.aluminumintransportation.org or e-mail atginfo@aluminum.org