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Accurately characterizing vehicle drive cycles plays a fundamental role in assessing the performance of new vehicle technologies. Repeatable, short duration representative drive cycles facilitate more informed decision making, resulting in improved test procedures and more successful vehicle designs. With continued growth in the deployment of onboard telematics systems employing global positioning systems (GPS), large scale, low cost collection of real-world vehicle drive cycle data has become a reality. As a result of these technological advances, researchers, designers, and engineers are no longer constrained by lack of operating data when developing and optimizing technology, but rather by resources available for testing and simulation. Experimental testing is expensive and time consuming, therefore the need exists for a fast and accurate means of generating representative cycles from large volumes of real-world driving data.

A 2002 Cummins ISM engine was modified to be optimized for operation on gas-to-liquid (GTL) fuel and advanced emission control devices. The engine modifications included increased exhaust gas recirculation (EGR), decreased compression ratio, and reshaped piston and bowl configuration. The emission control devices included a deNOx filter and a diesel particle filter. Over the transient test, the emissions met the 2007 standards. In July 2004, the modified engine was installed into a Class 8 tractor for use by a grocery fleet. Chassis emission testing of the modified vehicle was conducted at the National Renewable Energy Laboratory's (NREL) Renewable Fuels and Lubricants (ReFUEL) facility. Testing included hot and cold replicate Urban Dynamometer Driving Schedule (UDDS) and New York Composite (NYComp) cycles and several steady-state points. The objective of the testing was to demonstrate the vehicle's with the modified engine.

The application of cooperative adaptive cruise control (CACC) to heavy-duty trucks known as truck platooning has shown fuel economy improvements over test track ideal driving conditions. However, there are limited test data available to assess the performance of CACC under real-world driving conditions. As part of the Cummins-led U.S. Department of Energy Funding Opportunity Announcement award project, truck platooning with CACC has been tested under real-world driving conditions and the results are presented in this paper. First, real-world driving conditions are characterized with the National Renewable Energy Laboratory’s Fleet DNA database to define the test factors. The key test factors impacting long-haul truck fuel economy were identified as terrain and highway traffic with and without advanced driver-assistance systems (ADAS).

Some CO2-reducing technologies have real-world benefits not captured by regulatory testing methods. This paper documents a two-layer heating, ventilation, and air-conditioning (HVAC) system that facilitates faster engine warmup through strategic increased air recirculation. The performance of this technology was assessed on a 2020 Hyundai Sonata. Empirical performance of the technology was obtained through dynamometer tests at Argonne National Laboratory. Performance of the vehicle across multiple cycles and cell ambient temperatures with the two-layer technology active and inactive indicated fuel consumption reduction in nearly all cases. A thermally sensitive powertrain model, the National Renewable Energy Laboratory’s FASTSim Hot, was calibrated and validated against vehicle testing data. The developed model included the engine, cabin, and HVAC system controls.

Accurate vehicle parameters are valuable for design, modeling, and reporting. Estimating vehicle parameters can be a very time-consuming process requiring tightly-controlled experimentation. This work describes a method to estimate vehicle parameters such as mass, coefficient of drag/frontal area, and rolling resistance using data logged during standard vehicle operation. The method uses a Monte Carlo method to generate parameter sets that are fed to a variant of the road load equation. The modeled road load is then compared to the measured load to evaluate the probability of the parameter set. Acceptance of a proposed parameter set is determined using the probability ratio to the current state, so that the chain history will give a distribution of parameter sets. Compared to a single value, a distribution of possible values provides information on the quality of estimates and the range of possible parameter values. The method is demonstrated by estimating dynamometer parameters.

In-use, light-duty vehicles were recruited in Cary, North Carolina for emissions testing on a transportable dynamometer in 1999. Two hundred forty-eight vehicles were tested in as received condition using the IM240 driving cycle. The study was conducted in two phases, a summer and winter phase, with half of the vehicles recruited during each phase. Regulated emissions, PM10, carbonaceous PM, aldehydes and ketones were measured for every test. PM2.5, individual volatile hydrocarbons, polycyclic aromatic hydrocarbons, sterane and hopane emissions were measured from a subset of the vehicles. Average light-duty gasoline PM10 emission rates increased from 6.5 mg/mi for 1993-97 vehicles to 53.8 mg/mi for the pre-1985 vehicles. The recruited fleet average, hot-stabilized IM240 PM10 emission rate for gasoline vehicles was 19.0 mg/mi.

When operated, the cabin climate control system is the largest auxiliary load on a vehicle. This load has significant impact on fuel economy for conventional and hybrid vehicles, and it drastically reduces the driving range of all-electric vehicles (EVs). Heating is even more detrimental to EV range than cooling because no engine waste heat is available. Reducing the thermal loads on the vehicle climate control system will extend driving range and increase the market penetration of EVs. Researchers at the National Renewable Energy Laboratory have evaluated strategies for vehicle climate control load reduction with special attention toward grid-connected electric vehicles. Outdoor vehicle thermal testing and computational modeling were used to assess potential strategies for improved thermal management and to evaluate the effectiveness of thermal load reduction technologies. A human physiology model was also used to evaluate the impact on occupant thermal comfort.

Passenger compartment climate control is one of the largest auxiliary loads on a vehicle. Like conventional vehicles, electric vehicles (EVs) require climate control to maintain occupant comfort and safety, but cabin heating and air conditioning have a negative impact on driving range for all-electric vehicles. Range reduction caused by climate control and other factors is a barrier to widespread adoption of EVs. Reducing the thermal loads on the climate control system will extend driving range, thereby reducing consumer range anxiety and increasing the market penetration of EVs. Researchers at the National Renewable Energy Laboratory have investigated strategies for vehicle climate control load reduction, with special attention toward EVs. Outdoor vehicle thermal testing was conducted on two 2012 Ford Focus Electric vehicles to evaluate thermal management strategies for warm weather, including solar load reduction and cabin pre-ventilation.

Researchers at the National Renewable Energy Laboratory conducted outdoor vehicle thermal soak tests in Golden, Colorado, in September 2002. The same environmental conditions and vehicle were then tested indoors in two DaimlerChrysler test cells, one with metal halide lamps and one with infrared lamps. Results show that the vehicle's shaded interior temperatures correlated well with the outdoor data, while temperatures in the direct sun did not. The large lamp array situated over the vehicle caused the roof to be significantly hotter indoors. Yet, inside the vehicle, the instrument panel was cooler due to the geometry of the lamp array and the spectral difference between the lamps and sun. Results indicate that solar lamps effectively heat the cabin interior in indoor vehicle soak tests for climate control evaluation and SCO3 emissions tests. However, such lamps do not effectively assess vehicle skin temperatures and glazing temperatures.

In the United States, intercity long-haul trucks idle approximately 1,800 hrs per year primarily for sleeper cab hotel loads, consuming 838 million gallons of diesel fuel [1]. The U.S. Department of Energy's National Renewable Energy Laboratory (NREL) is working on solutions to this challenge through the CoolCab project. The objective of the CoolCab project is to work closely with industry to design efficient thermal management systems for long-haul trucks that keep the cab comfortable with minimized engine idling. Truck engine idling is primarily done to heat or cool the cab/sleeper, keep the fuel warm in cold weather, and keep the engine warm for cold temperature startup. Reducing the thermal load on the cab/sleeper will decrease air conditioning system requirements, improve efficiency, and help reduce fuel use. To help assess and improve idle reduction solutions, the CoolCalc software tool was developed.

There has been an increasing interest in exploring the potential to reduce energy consumption of future connected and automated vehicles. People have extensively studied various eco-driving implementations that leverage preview information provided by on-board sensors and connectivity, as well as the control authority enabled by automation. Quantitative real-world evaluation of eco-driving benefits is a challenging task. The standard regulatory driving cycles used for measuring exhaust emissions and fuel economy are not truly representative of real-world driving, nor for capturing how connectivity and automation might influence driving trajectories. To adequately consider real-world driving behavior and potential “off-cycle” impacts, this paper presents four collaborative evaluation methods: large-scale simulation, in-depth simulation, vehicle-in-the-loop testing, and vehicle road testing.

This paper describes the need for dynamic (transient) simulation of automotive air conditioning systems, the reasons why such simulations are challenging, and the applicability of a general purpose off-the-shelf thermohydraulic analyzer to answer such challenges. An overview of modeling methods for the basic components are presented, along with relevant approximations and their effect on speed and accuracy of the results.

This work presents a methodology to determine the off-cycle fuel economy benefit of a 2-Layer HVAC system which reduces ventilation and heat rejection losses of the heater core versus a vehicle using a standard system. Experimental dynamometer tests using EPA drive cycles over a broad range of ambient temperatures were conducted on a highly instrumented 2016 Lexus RX350 (3.5L, 8 speed automatic). These tests were conducted to measure differences in engine efficiency caused by changes in engine warmup due to the 2-Layer HVAC technology in use versus the technology being disabled (disabled equals fresh air-considered as the standard technology baseline). These experimental datasets were used to develop simplified response surface and lumped capacitance vehicle thermal models predictive of vehicle efficiency as a function of thermal state.

Increasing fuel costs, the need to reduce dependence on foreign oil as well as the high efficiency and the desire for superior durability have caused the diesel engine to again become a prime target for light-duty vehicle applications in the United States. In support of this the U.S. Department of Energy (DOE) has engaged in a test project under the Advanced Petroleum Based Fuels-Diesel Emission Control (APBF-DEC) activity to develop a passenger car with the capability to demonstrate compliance with Tier 2 Bin 5 emission targets with a fresh emission control catalyst system. In order to achieve this goal, a prototype engine was installed in a passenger car and optimized to provide the lowest practical level of engine-out emissions.

With the introduction of more fuel cell electric vehicles (FCEVs) on U.S. roadways, especially in California, the need for available hydrogen refueling stations is growing. While funding from the California Energy Commission is helping to solve this problem, solutions need to be developed and implemented to help reduce the time to commission a hydrogen station. The current practice of hydrogen station acceptance can take months because each vehicle manufacturer conducts their own testing and evaluation. This process is not practical or sufficient to support the timely development of a hydrogen fueling station network. To address this issue, as part of the Hydrogen Fueling Infrastructure Research and Station Technology (H2FIRST) Project Sandia National Laboratories and the National Renewable Energy Laboratory along with a team of stakeholders and contractor Powertech Labs has developed the Hydrogen Station Equipment Performance (HyStEP) Device.

Emissions of six 32 passenger transit buses were characterized using one of the West Virginia University (WVU) Transportable Heavy Duty Emissions Testing Laboratories, and the fixed base chassis dynamometer at the Colorado Institute for Fuels and High Altitude Engine Research (CIFER). Three of the buses were powered with 1997 ISB 5.9 liter Cummins diesel engines, and three were powered with the 1997 5.9 liter Cummins natural gas (NG) counterpart. The NG engines were LEV certified. Objectives were to contrast the emissions performance of the diesel and NG units, and to compare results from the two laboratories. Both laboratories found that oxides of nitrogen and particulate matter (PM) emissions were substantially lower for the natural gas buses than for the diesel buses. It was observed that by varying the rapidity of pedal movement during accelerations in the Central Business District cycle (CBD), CO and PM emissions from the diesel buses could be varied by a factor of three or more.

The energy used to air condition an automobile has a significant effect on vehicle fuel economy and tailpipe emissions. If a small reduction in energy use can be applied to many vehicles, the impact on national fuel consumption could be significant. The SCO3 is a new emissions test conducted with the air conditioner (A/C) operating that is part of the Supplemental Federal Test Procedure (SFTP). With the 100% phase-in of the SFTP in 2004 for passenger cars and light light-duty trucks, there is additional motivation to reduce the size of the A/C system. The U.S. Department of Energy's National Renewable Energy Laboratory (NREL) is investigating ways to reduce the amount of energy consumed for automobile climate control. If the peak soak temperature in an automobile can be reduced, the power consumed by the air conditioner may be decreased while passenger comfort is maintained or enhanced. Solar reflective glass is one way to reduce the peak soak temperature.

Chassis based emissions characterization of heavy-duty vehicles has advanced over the last decade, but the understanding of the effect of test schedule on measured emissions is still poor. However, this is an important issue because the test schedule should closely mimic actual vehicle operation or vocation. A wide variety of test schedules was reviewed and these cycles were classified as cycles or routes and as geometric or realistic. With support from the U.S. Department of Energy Office of Transportation Technologies (DOE/OTT), a GMC box truck with a Caterpillar 3116 engine and a Peterbilt over the road tractor-trailer with a Caterpillar 3406 engine were exercised through a large number of cycles and routes. Test weight for the GMC was 9,980 kg and for the Peterbilt was 19,050 kg. Emissions characterization was performed using a heavy-duty chassis dynamometer, with a full-scale dilution tunnel, analyzers for gaseous emissions, and filters for PM emissions.

The exhaust emissions from a single-cylinder version of a heavy-duty diesel engine with exhaust gas recirculation (EGR) were studied using 12 diesel fuels derived from oil sands and conventional sources. The test fuels were blended from 22 refinery streams to produce four fuels (two from each source) at three different total aromatic levels (10, 20, and 30% by mass). The cetane numbers were held constant at 43. Exhaust emissions were measured using the AVL eight-mode steady-state test procedure. PM emissions were accurately modeled by a single regression equation with two predictors, total aromatics and sulphur content. Sulphate emissions were found to be independent of the type of sulphur compound in the fuel. NOx emissions were accurately modeled by a single regression equation with total aromatics and density as predictor variables. PM and NOx emissions were significantly significantly affected by fuel properties, but crude oil source did not play a role.

This paper reports the development of new fuel ignition quality and combustion experiments performed using the Ignition Quality Tester (IQT). Prior SAE papers (961182, 971636, 1999-01-3591, and 2001-01-3527) documented the development of the IQT constant volume combustion chamber experimental apparatus to measure ignition qualities of diesel-type fuels. The ASTM International test method D6890 was developed around the IQT device to allow the rapid determination of derived cetane number (DCN). Interest in chemical kinetic models for the ignition of diesel and biodiesel model compounds is increasing to support the development of advanced engines and fuels. However, rigorous experimental validation of these kinetic models has been limited for a variety of reasons. Shock tubes and rapid compression machines are typically limited to premixed gas-phase studies, for example.