Abstract
A complex simulation model of a heavy duty truck, including an Organic Rankine Cycle (ORC) based waste heat recovery system and a vehicle cooling system, was applied to determine the system fuel economy potential in a typical drive cycle. Measures to increase the system performance were investigated and a comparison between two different cooling system designs was derived. The base design, which was realized on a Mercedes-Benz Actros vehicle revealed a fuel efficiency benefit of 2.6%, while a more complicated design would generate 3.1%. Furthermore, fully transient simulation results were performed and are compared to steady state simulation results. It is shown that steady state simulation can produce comparable results if averaged road data are used as boundary conditions.
Highlights
Truck manufacturers develop more efficient propulsion technologies to enable low total cost of ownership to their customers and because of imminent legal CO2 limits
The temperatures, are very different. This leads to a significant mismatch reached up to 103 ◦ C under full cooling system load conditions and very cold temperature at low load
The exhaust flap was used to limit the heat input into the system. This could be necessary if the expander generator was at its power limit, or if the cooling system was stressed to an extent that fan and coolant pump would consume more parasitic power than the exhaust heat recovery (EHR) system could provide
Summary
Truck manufacturers develop more efficient propulsion technologies to enable low total cost of ownership to their customers and because of imminent legal CO2 limits. Wilhelm Maybach (Stuttgart, Germany) in 1904 was the first to attempt a realization It failed because the pressure losses in the exhaust heat exchanger were so high that the overall fuel consumption was higher with steam cycle than without [5]. On the cooling air side, the vehicle regarded by them is different from the Actros The models of both cooling system approaches were stimulated with the same real-live test data, recorded with an Actros production vehicle on a route between Stuttgart and Hamburg, Germany. Both models ran at the same constant ambient temperature of 15 ◦ C. The overall weight of the vehicle was 40 t, and it was equipped with a hybrid powertrain that allowed the electrical integration of the expander into the powertrain
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