The Thermodynamic Design, Analysis and Test of Cummins’ SuperTruck 2 50% Brake Thermal Efficiency Engine System 2019-01-0247
Current heavy duty diesel engines have a brake thermal efficiency (BTE) between 44-46%. In partnership with the Department of Energy (DOE) as part of the Supertruck 2 program, Cummins has undertaken a research program to develop a new heavy duty diesel engine designed to deliver greater than 50% BTE without the use of waste heat recovery. A system level optimization focused on; increased compression ratio and injection rate, carefully matched highly efficient turbocharging, variable lube oil and cooling components, dual loop EGR and low restriction after treatment designed to deliver 50% BTE at a target development point. This work will also illustrate the system level planning and interaction required to allow that same 50% BTE heavy duty diesel to be integrated with a WHR to deliver system level efficiency of 55% BTE at a single point. In addition to a test bench demonstration, the above described system is also planned to be demonstrated at a vehicle system level. This paper summarizes the process and results of that engine development effort with a focus on efficiency, performance, and robustness.