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HEAVY-DUTY VEHICLES: SAFETY, ENVIRONMENTAL IMPACTS and NEW TECHNOLOGY “RASTU” Summary Report 2006–2008

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HEAVY-DUTY VEHICLES: SAFETY, ENVIRONMENTAL IMPACTS and NEW TECHNOLOGY “RASTU” Summary Report 2006–2008 PROJECT REPORT VTT-R-04084-09 2 JUNE 2009 HEAVY-DUTY VEHICLES: SAFETY, ENVIRONMENTAL IMPACTS AND NEW TECHNOLOGY “RASTU” Summary report 2006–2008 Editors Matti Kytö, Kimmo Erkkilä and Nils-Olof Nylund Disclosure: Public Performing organisation and address Client VTT Technical Research Centre of Finland The Finnish Funding Agency for Technology and P.O. Box 1604 Innovation Tekes et al. FI-02044 VTT, Finland Responsible person Client's contact person Matti Kytö Martti Korkiakoski Document number of the project (VTT) Client's order or reference number 40521/05, Reg.no. 2699/31/05 Project name, short name and code Report number and number of Date Heavy-duty vehicles: Safety, environmental impactsVTT-R-04084-09pages 2 June 2009 and new technology, RASTU 114 pages + Appendix 1 p. 3155 Name of project report and authors Heavy-duty vehicles: Safety, environmental impacts and new technology, “RASTU”. Summary report. Edited by Matti Kytö, Kimmo Erkkilä and Nils-Olof Nylund Abstract Research on fuel savings for heavy-duty vehicles was carried out within the framework of the three-year (2006–2008) “RASTU” project. The research integrate also included tasks relating to emissions, IT applications and safety. Five research parties and nearly 20 sponsors took part in the project. During the research period, a total of approximately 140 heavy-duty vehicles were tested using a chassis dynamome- ter. An overall trend that emerged is a decline in the emissions and fuel consumption of new vehicles (Euro IV, V and EEV). However, there are significant differences between vehicle makes. Emissions of buses in particular vary a lot, and the emissions of only a few diesel vehicles correspond to the class in which the vehicle is certified. In trucks, the actual emission levels correspond, on average, to the emission class stated. The Euro IV emissions regulations brought to market solutions that are based on both EGR and SCR technology. At the beginning of the research period, SCR vehicles, on average, offered both lower exhaust emission and fuel consumption values. At the end of the period, the situation became a bit more balanced, particularly for trucks. Fuel savings of approximately 5-10 % are, however, possible with the right selection of vehicle. The exhaust emission tests also measured emissions not regulated by legislation regarding new low-emission vehicles, such as aldehydes, ammonia, individual gaseous hydrocarbons, NO2- content, PAH compounds and mutagenicity of particulate matter as well as the quantity and size distribution of parti- cles. Overall, EEV-level diesel powered vehicles were "cleaner" than the Euro III and Euro IV vehicles in terms of emissions other than NO2. Natural gas powered buses continue to offer emission advantages even when compared to the newest diesel buses. Several vehicle engineering development subtasks were completed as academic theses. Potential development areas included aerodynamics, tyres, reducing the weight of heavy-duty vehicles by means of light-weight structure technol- ogy, axle alignment, stability of the modular combination as well as energy efficiency benchmarking of 40 and 60 ton combinations. A tyre recommendation was developed for actual trailer combinations that ensures safety but also mi- nimises fuel consumption. The project developed vehicle IT applications such as driver aid systems as well as auto- matic skid detection and load detection. The driver aid system focused on city buses. A driver aid system prototype was installed in a total of 15 buses in the Helsinki metropolitan area and in Jyväskylä. An incentive system for drivers aimed at improving and prolonging the impacts of economical driving style training was demonstrated in the project. In the subtask for evaluating the efficiency of energy-saving measures, calculations to evaluate the measures were developed. Distribution: Disclosure RASTU management team Public Revisions: Date: Responsible person Inspection and approval signatures Matti Kytö Jukka Lehtomäki 2 June 2009 CONTENTS 1 “RASTU” RESEARCH INTEGRATE OVERVIEW.................................................................2 2 PERFORMANCE OF NEW EURO IV/V/EEV VEHICLES (VTT)..........................................4 2.1 MEASUREMENTS OF CITY BUSES..................................................................................4 2.1.1 General...........................................................................................................................4 2.1.2 Nitrogen oxides and particulate matter.............................................................................7 2.1.3 Carbon dioxide emissions and fuel efficiency....................................................................8 2.1.4 Follow-up vehicles.........................................................................................................10 2.1.5 Summary .......................................................................................................................12 2.2 MEASUREMENTS OF TRUCKS......................................................................................13 2.2.1 General.........................................................................................................................13 2.2.2 Comparison measurements of 42 ton trucks....................................................................13 2.2.3 Comparison measurements of 18 ton delivery trucks.......................................................17 2.2.4 Comparison measurements of 26 ton trucks....................................................................20 2.2.5 Follow-up measurements ...............................................................................................21 2.2.6 Summary .......................................................................................................................26 3 FUEL AND LUBRICANTS FOR EURO IV/V/EEV VEHICLES...........................................27 3.1 GENERAL ...........................................................................................................................27 3.2 FUEL TESTING.....................................................................................................................27 3.2.1 Light-duty vehicle tests...................................................................................................27 3.2.2 Heavy-duty delivery vehicle tests....................................................................................28 3.2.3 Tests on buses (NExBTL) and trucks (MK1) ...................................................................29 3.3 LUBRICANT TESTING....................................................................................................29 3.4 FUEL ALTERNATIVES OF TRANSPORT - PROGRESS REPORT .....................................................34 4 DEVELOPMENT OF VEHICLE ENGINEERING.................................................................34 4.1 GENERAL ...........................................................................................................................34 4.2 LIGHTWEIGHT STRUCTURE ENGINEERING (HUT)..................................................................35 4.3 THE STABILITY OF MODULAR VEHICLE COMBINATIONS AND THE EFFECT OF TYRES (HUT) .....35 4.4 FUEL EFFICIENCY COMPARISON OF 42/60 TON VEHICLE COMBINATIONS (VTT)36 4.4.1 Vehicle selection............................................................................................................37 4.4.2 Carrying out the tests.....................................................................................................38 4.4.3 Chassis dynamometer measurements..............................................................................40 4.4.4 Comparison with the results of the HDEnergy project ....................................................43 4.5 TYRE TESTS (VTT) .............................................................................................................44 4.6 AERODYNAMICS .................................................................................................................44 4.6.1 General.........................................................................................................................44 4.6.2 Trucks ...........................................................................................................................45 4.6.3 Buses.............................................................................................................................50 4.7 MASS OF HEAVY-DUTY VEHICLES (TURKU UNIVERSITY OF APPLIED SCIENCES) 51 4.8 AXLE ALIGNMENT.........................................................................................................52 4.8.1 General.........................................................................................................................52 4.8.2 Database.......................................................................................................................53 4.8.3 Determining tractive resistance......................................................................................53 4.8.4 Impact of axle misalignment...........................................................................................54 5 DEVELOPMENT OF METHODOLOGY...............................................................................56 5.1 GENERAL ...........................................................................................................................56 5.2 PEMS MEASUREMENTS.......................................................................................................56
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