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Hydraulic Hybrid Parcel Delivery Truck Deployment, Testing & Demonstration Final Report

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Hydraulic Hybrid Parcel Delivery Truck Deployment, Testing & Demonstration Final Report NATIONAL HYBRID TRUCK MANUFACTURING PROGRAM Hydraulic Hybrid Parcel Delivery Truck Deployment, Testing & Demonstration Final Report DOE Contract Number DE-FC26-06NT42791 Prepared by: Jean-Baptiste Gallo Project Engineer CALSTART (626) 744-5605 (work) (626) 744-5610 (fax) [email protected] 3/7/2014 NHTMP / DOE Contract # DE-FC26-06NT42791 Final Report Disclaimer This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof. 1 NHTMP / DOE Contract # DE-FC26-06NT42791 Final Report Acknowledgements CALSTART would like to express its appreciation to the U.S Department of Energy for providing funding for this project. This material is based upon work supported by the Department of Energy under Award Number DE-FC26-06NT42791. The author would like to thank Freightliner Custom Chassis Corporation for providing technical support to the project and to FedEx Ground, Purolator and UPS who purchased the three first hydraulic hybrid pre-production parcel delivery vehicles and deployed the vehicles in commercial operation. In particular, the author expresses his appreciation to all fleet maintenance staff, drivers and mechanics who facilitated the in-use data collection and on-road testing activities. Finally the author expresses his appreciation to Parker Hannifin and particularly to Tamar Williamson and Prasad Venkiteswaran who provided their technical expertise and advice throughout the entire project. 2 NHTMP / DOE Contract # DE-FC26-06NT42791 Final Report Abstract Although hydraulic hybrid systems have shown promise over the last few years, commercial deployment of these systems has primarily been limited to Class 8 refuse trucks. In 2005, the Hybrid Truck Users Forum initiated the Parcel Delivery Working Group including the largest parcel delivery fleets in North America. The goal of the working group was to evaluate and accelerate commercialization of hydraulic hybrid technology for parcel delivery vehicles. FedEx Ground, Purolator and United Parcel Service (UPS) took delivery of the world’s first commercially available hydraulic hybrid parcel delivery trucks in early 2012. The vehicle chassis includes a Parker Hannifin hydraulic hybrid drive system, integrated and assembled by Freightliner Custom Chassis Corp., with a body installed by Morgan Olson. With funding from the U.S. Department of Energy, CALSTART and its project partners assessed the performance, reliability, maintainability and fleet acceptance of three pre-production Class 6 hydraulic hybrid parcel delivery vehicles using information and data from in-use data collection and on-road testing. This document reports on the deployment of these vehicles operated by FedEx Ground, Purolator and UPS. The results presented provide a comprehensive overview of the performance of commercial hydraulic hybrid vehicles in parcel delivery applications. This project also informs fleets and manufacturers on the overall performance of hydraulic hybrid vehicles, provides insights on how the technology can be both improved and more effectively used. The key findings and recommendations of this project fall into four major categories: Performance, Fleet deployment, Maintenance, Business case. Hydraulic hybrid technology is relatively new to the market, as commercial vehicles have been introduced only in the past few years in refuse and parcel delivery applications. Successful demonstration could pave the way for additional purchases of hydraulic hybrid vehicles throughout the trucking industry. By providing unbiased, third-party assessment of this “hybrid without batteries” technology, this report offers relevant, timely and valuable information to the industry. 3 NHTMP / DOE Contract # DE-FC26-06NT42791 Final Report Table of Contents Disclaimer ............................................................................................................................................................................ 1 Acknowledgements ........................................................................................................................................................... 2 Abstract ................................................................................................................................................................................ 3 Table of Contents .............................................................................................................................................................. 4 List of Figures ...................................................................................................................................................................... 6 List of Tables ....................................................................................................................................................................... 7 Executive Summary ........................................................................................................................................................... 9 Chapter 1: Introduction ................................................................................................................................................. 15 1.1 Purpose of the Report ..................................................................................................................................... 15 1.2 Hydraulic Hybrid System Technology ......................................................................................................... 16 1.2.1 Overview ....................................................................................................................................................... 16 1.2.2 Benefits of Hydraulic Hybrid Vehicles .................................................................................................... 17 1.2.3 Comparison with Hybrid Electric Vehicles ........................................................................................... 18 1.3 Hydraulic Hybrid Vehicle Market ................................................................................................................. 19 1.3.1 Hydraulic Hybrid Refuse Trucks ............................................................................................................. 19 1.3.2 U.S. EPA / Eaton Corporation Hydraulic Hybrid Parcel Delivery Truck ...................................... 20 1.3.3 FCCC / Parker Hannifin Hydraulic Hybrid Walk-in Chassis ............................................................ 21 1.4 Project Team ..................................................................................................................................................... 24 Chapter 2: Vehicle Deployment ................................................................................................................................... 25 2.1 Static and Pass-By Noise ................................................................................................................................. 25 2.2 Fleet Deployment ............................................................................................................................................. 25 2.2.1 FedEx Ground .............................................................................................................................................. 26 2.2.2 Purolator ....................................................................................................................................................... 26 2.2.3 UPS ................................................................................................................................................................. 27 Chapter 3: Performance Evaluation ............................................................................................................................ 28 3.1 General Monthly Summary ............................................................................................................................. 28 3.1.1 Methodology ................................................................................................................................................ 28 3.1.2 Results & Discussions................................................................................................................................. 28 3.2 High Resolution Data ....................................................................................................................................... 31 3.2.1 Methodology ................................................................................................................................................ 31 3.2.2 Results & Discussions................................................................................................................................
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