SuperTruck Yields Exciting Fuel Mileage Numbers During Testing

Cummins and Peterbilt Motors Company say a demonstration tractor-trailer they partnered on achieved a 54 percent increase in fuel economy during testing in the fall of 2012, averaging nearly 10 miles per gallon (mpg) under real world driving conditions.

The “SuperTruck” developed by the two companies features a higher-efficiency engine and an aerodynamic tractor-trailer that significantly reduces drag. The truck also includes a system that converts exhaust heat into power delivered to the crankshaft, electronic controls that use route information to optimize fuel use, tires with lower rolling resistence and lighter-weight material throughout.

The Class 8 Peterbilt 587 powered by a Cummins ISX15 engine averaged 9.9 mpg during testing on U.S. Route 287 between Fort Worth and Vernon, Texas. The testing was conducted over 11 runs meeting SAE International test standards along a 312-mile route. The tractor-trailer had a combined gross weight of 65,000 lbs.

Today’s long-haul trucks typically achieve between 5.5 and 6.5 mpg. The 54 percent increase in fuel economy would save about $25,000 annually based on today’s diesel fuel prices for a long-haul truck traveling 120,000 miles per year. It would also translate into a 35 percent reduction in annual greenhouse gases per truck.

The potential savings in fuel and greenhouse gases are enormous, with about 2 million registered tractor-trailers on U.S. roads today, according to The American Trucking Association.

In addition to the fuel economy improvements, the truck also demonstrated a 61 percent improvement in freight efficiency during testing compared to a baseline truck driving the same route. That significantly exceeded the 50 percent SuperTruck program goal set by the U.S. Department of Energy. Freight efficiency is an important metric in the transportation industry that is based on payload weight and fuel efficiency expressed in ton-miles per gallon.

“Many of the technologies we are testing on the engine and truck will be integral parts of the trucks of tomorrow,” said David Koeberlein, Principal Investigator for the SuperTruck program at Cummins. “We are focused on developing innovations that meet and exceed the needs of our customers, while helping to create a cleaner, healthier and safer environment.”

Cummins personnel have been focused on the engine and its integration with the powertrain. They have been working with several other companies and research institutions to develop numerous changes in the combustion system as well as advances to reduce internal friction and so-called “parasitic power” – excess power the engine needs to run such things as lube and coolant pumps and air compressors.

In addition to the truck’s exterior, Peterbilt, a division of PACCAR, and its partners have been working on improvements in the drivetrain, the idle management system, weight reduction and vehicle climate control. Eaton's advanced transmission facilitates further engine downspeeding for additional fuel economy benefits.

“Aerodynamics has been a significant contributor to the efficiency gains,” said Scott Newhouse, Senior Assistant Chief Engineer of Product Development at Peterbilt, . “We are very pleased with what our team has been able to accomplish using a comprehensive tractor-trailer approach.”

Cummins is a prime contractor leading one of four teams under the Department of Energy’s SuperTruck project. SuperTruck is one of several initiatives under the 21st Century Truck Partnership, which is a public-private partnership founded to further stimulate innovation in the trucking industry.

Cummins, Peterbilt and their program partners will have invested $38.8 million in private funds over the four-year life of their SuperTruck program, which started in 2010, with critical support coming through awarded matching grants from the Department of Energy’s Vehicle Technologies Program.

Testing will continue in 2013 on a new Peterbilt 579 that Cummins and Peterbilt are confident will take what has been achieved so far to even higher levels. The testing will address use of the tractor-trailer over a 24-hour period; including periods when drivers are at rest but still need power for such things as air conditioning and small appliances.

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Cummins Custompaks are being used for water management as Thailand struggles with its water crisis

CustomPak on site

Water crisis

Sixty Cummins Inc. CustomPaks are in service in Thailand as part of a critical water management plan aimed at easing the country’s water crisis – a crisis that has caused enormous economic and social damage and stirred conflict among communities.

Over the past several decades, Thailand has continually faced water problems caused by severe drought. Water reserves in dams and reservoirs are insufficient while water resources are often contaminated with toxins caused by urban communities and the industrial and agricultural sectors.

Severe flooding is a threat, too, at a time when the realities of climate change are hanging over the country.

As a result, the allocation of precious water resources, which must be shared among various stakeholders including new and existing industry, large and small agriculture, and cities and villages has become a flashpoint.

Kittithanapat Engineering Co. (KTP), has been involved in the water management system since 1996, working closely with authorities such as the Royal Irrigation Department, Department of Water Resources, Bangkok Metropolitan Authority and others.

CustomPaks on site

600 hp CustomPaks

To help KTP meet its often urgent requirements, Cummins DKSH (Thailand) has recently supplied 60 Australian-built CustomPaks – 45 powered by Cummins’ X15 engine rated at 600 hp, and 15 powered by the QSL9 rated at 325 hp. These fully self-contained powerpacks are emissions certified to Tier 3.

The CustomPaks are coupled to hydraulically-driven, large-volume submersible water pumps sourced by KTP from US company Moving Water Industries (MWI); KTP is the exclusive distributor in Thailand for these MWI Hydroflo pumps.

Prior to Cummins’ involvement, KTP was using another diesel engine brand but service support wasn’t up to the standard required.

Long-serving KTP engineer Kittisak Thanasoot says Cummins DKSH’s reputation for technical and aftersales support along with the reliability of the Cummins product were a key reason behind KTP’s decision to specify the CustomPaks for the Royal Irrigation Department.

The ability of Cummins DKSH to respond to short delivery times was also important.

“Supplying large quantities of high horsepower diesel engines for emergency situations such as flash flooding can be a challenge for KTP,” says Kittisak Thanasoot.

“Responding to the needs of the government agencies to manage such problems in a timely manner and with least impact on communities, KTP has found the answer in our partnership with Cummins DKSH.”

Power, pride and passion

Parked semi truck

The switch back to Cummins power has been beneficial for iconic New Zealand company Uhlenberg Haulage. It's all about whole-of-life costs.

Uhlenberg Haulage is closing in on 60 years in business, having been founded in 1966 by Mike and Carol Uhlenberg.

Based in Eltham, Taranaki, in New Zealand’s North Island, the operation is today owned and operated by their sons Chris, Daryl and Tony Uhlenberg.

Describing the Uhlenbergs as “old school family truckies”, Daryl talks about the company’s time-honored journey with a definite tone of pride, especially the work of his parents in laying the foundations for what is today an iconic fleet in its own right.

Cummins Inc. made its debut in the Uhlenberg fleet in 1971 with an NH250 powering a second-hand Kenworth K923 used in logging. A second Kenworth, a new W924 with a Cummins NTC335, followed soon after hauling an LPG tanker.

The Uhlenberg operation today comprises 40 prime movers and a variety of trailing gear to cater for the myriad of a jobs the fleet is involved in.

A number of Peterbilts feature in the fleet although Kenworth is now the brand of choice with six new units to be delivered over the next 12 months to cater for business growth.

Cummins’ X15 Euro 5 engine rated at 550 or 600 hp is the preferred power specification, with 18 red engines currently in the fleet.

Uhlenberg family in front of truck

Whole-of-life support

“The switch to Cummins has been a very good experience for us. We have nothing but praise for the Cummins organization,” says Daryl.

“The whole-of-life picture is the key thing for us and we’ve got that nailed with the support we get from Cummins – parts availability, scheduled maintenance, life expectancy and in-frame rebuilds.

“So the red engines turn up, we run them to life, which is 900,000 to 1.2 million kilometers, and then Cummins does an in-frame overhaul in a timely manner. If there’s an issue, parts and support are close by.

“The support we get from Cummins Palmerston North is fantastic, second to none.”

Daryl recently looked under a Kenworth that was in the workshop for a service and was surprised to see no oil leaking from the one-million-kilometer X15. “I remember when I was a fitter we had to wear a raincoat when working under a truck,” he jokes.

Fuel agnostic

Acknowledging that the push to decarbonize is now “very real”, Daryl likes the idea of Cummins’ fuel agnostic concept where one base internal combustion engine, optimized to run on diesel, can also be customized to run on ultra-low and zero-carbon fuels like renewable natural gas and hydrogen.

“My father was a pioneer of linehaul trucking in New Zealand and he always embraced new technology. He was never scared of it,” he says.

“I tend to be a little more cautious but I can see where a 500 hp natural gas or hydrogen engine would work for us in short haul applications,” he admits. “We’re certainly willing to look closely at these alternative fuel technologies when suitable infrastructure is in place.”

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