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The assessment of fuel economy of new vehicles is typically based on regulatory driving cycles, measured in an emissions lab. Although the regulations built around these standardized cycles have strongly contributed to improved fuel efficiency, they are unable to cover the envelope of operating and environmental conditions the vehicle will be subject to when driving in the “real-world”. This discrepancy becomes even more dramatic with the introduction of Connectivity and Automation, which allows for information on future route and traffic conditions to be available to the vehicle and powertrain control system. Furthermore, the huge variability of external conditions, such as vehicle load or driver behavior, can significantly affect the fuel economy on a given route. Such variability poses significant challenges when attempting to compare the performance and fuel economy of different powertrain technologies, vehicle dynamics and powertrain control methods.

A team of student engineers at the University of Texas at Austin has designed and built “Texas Native Sun”, a solar powered vehicle for competition in GM Sunrayce U.S.A. The single-seat vehicle uses conventional photovoltaic solar cells to produce electricity for vehicle propulsion. The vehicle features graphite/epoxy composite monocoque construction, a high power-density permanent magnet electric motor, a mechanical/hydraulic continuously variable transmission, nickel-hydrogen satellite batteries, and a composite leaf spring suspension. The race strategies and tactics of energy management are optimized through use of a computer code which simulates the vehicle under race conditions. Much of the technology employed in the vehicle may one day become an ordinary part of future transportation systems which seek greater energy efficiency and less damage to the environment.

The Texas Department of Transportation began using an emulsified diesel fuel in 2002. They initiated a simultaneous study of the effectiveness of this fuel in comparison to 2D on-road diesel fuel and 2D off-road diesel. The study included comparisons of fuel economy and emissions for the emulsion, Lubrizol PuriNOx®, relative to conventional diesel fuels. Two engines and eight trucks, four single-axle dump trucks, and four tandem-axle dump trucks were tested. The equipment tested included both older mechanically-controlled diesels and newer electronically-controlled diesels. The two engines were tested over two different cycles that were developed specifically for this project. The dump trucks were tested using the “route” technique over one or the other of two chassis dynamometer cycles that were developed for this project In addition to fuel efficiency, emissions of NOx, PM, CO, and HCs were measured. Additionally, second-by-second results were obtained for NOx and HCs.

In order to determine the factors that affect fuel economy quantitatively, the power flows through the major powertrain components were measured during operation over transient cycles. The fuel consumption rate and torque and speed of the engine output and axle shafts were measured to assess the power flows in a vehicle with a CVT. The measured power flows were converted to energy loss for each component to get the efficiency. Tests were done at Phase 1 and Phase 3 of the FTP and for two different CVT shift modes. The measured energy distributions were compared with those from the ADVISOR simulation and to results from the PNGV study. For both the Hot 505 and the Cold 505, and for both shift modes, the major powertrain loss occurs in the engine, including or excluding standby losses. However, the efficiency of the drivetrain/transmission is important because it influences the efficiency of the engine.

Global fuel economy and CO2 reduction mandates are driving the need for a substantial increase in vehicle fuel efficiency over the next several years, with improvements coming from many sources. This paper describes a vehicle demonstration program to improve fuel economy by implementing a systems approach to reduce friction and parasitic losses. The work concentrated on nearer term technologies that can be quickly transferred to production vehicle programs. Major technologies demonstrated on the vehicle included gasoline direct injection (GDi) with cooled EGR, advanced valvetrain, rollerization of both crankshaft and camshaft, and stop-start engine operation. The work described in this paper comprises Phase I of a two phase program funded by DOE contract DE-EE0003258. It includes a hardware overview and a description of the system development activities. Results focus on vehicle fuel economy benefits compared to a production baseline vehicle.

The Rotating Linear Engine (RLE) derives improved fuel efficiency and decreased maintenance costs via a unique lubrication design, which decreases piston assembly friction and the associated wear for heavy-duty natural gas and diesel engines. The piston ring friction exhibited on current engines accounts for 1% of total US energy consumption. The RLE is expected to reduce this friction by 50-70%, an expectation supported by hot motoring and tear-down tests on the UT single cylinder RLE prototype. Current engines have stationary liners where the oil film thins near the ends of the stroke, resulting in metal-to-metal contact. This metal-to-metal contact is the major source of both engine friction and wear, especially at high load. The RLE maintains an oil film between the piston rings and liner throughout the piston stroke due to liner rotation. This assumption has also been confirmed by recent testing of the single cylinder RLE prototype.

The effects of fuel properties on the emissions of a production vehicle with a gasoline direct injection engine operating over the Federal Test Procedure (FTP) cycle were investigated. The vehicle used was a 1998 Toyota Corona passenger car with a direct injection spark ignition (DISI) engine. Engine-out and tailpipe FTP emissions for six fuels and a California Phase 2 RFG reference fuel are presented. Four of the test fuels were blended from refinery components to meet specified distillation profiles. The remaining test fuels were iso-octane and toluene, an iso-alkane and an aromatic with essentially the same boiling point (at atmospheric pressure) that is near the T50 point for the blended fuels. Statistically significant effects, at the 95% confidence level, of the fuels on tailpipe emissions were found. Correlations were sought between the properties of the five blends and the Emissions Indices for engine-out hydrocarbons and NOx and for tailpipe particulates.

Global regulatory targets and customer demand are driving the automotive industry to improve vehicle fuel efficiency. Methods for achieving increased efficiency include improvements in the internal combustion engine and an accelerating shift toward electrification. A key enabler to maximizing the benefit from these new powertrain technologies is proper systems integration work - including developing optimized controls for the propulsion system as a whole. The next step in the evolution of improving the propulsion management system is to make use of available information not typically associated with the powertrain. Advanced driver assistance systems, vehicle connectivity systems and cloud applications can provide information to the propulsion management system that allows a shift from instantaneous optimization of fuel consumption, to optimization over a route. In the current paper, we present initial work from a project being done as part of the DOE ARPA-E NEXTCAR program.

A key enabler to maximizing the benefits from advanced powertrain technologies is to adopt a systems integration approach and develop optimized controls that consider the propulsion system and vehicle as a whole. This approach becomes essential when incorporating Advanced Driver Assistance Systems (ADAS) and communication technologies, which can provide information on future driving conditions. This may enable the powertrain control system to further improve the vehicle performance and energy efficiency, shifting from an instantaneous optimization of energy consumption to a predictive and “look-ahead” optimization. Benefits from this approach can be realized at all levels of electrification, from conventional combustion engines to hybrid propulsion systems and full electric vehicles, and at all levels of vehicle automation.