Friday, 24 September 2004

De Constant Speed Power Take Off

Improving performance and fuel-efficiency, using a CVT for driving auxiliary equipment on distribution trucks
Danil de Cloe Bram Veenhuizen Nort Liebrand

Automotive Engineering Science, Technische Universiteit Eindhoven

Contents of the presentation

1. Introduction 2. Working Principle of the CS-PTO 3. Design & Development of the CS-PTO 4. Electromechanical Actuation System and Ratio-Control

5. Testing and Implementation of the CS-PTO

6. Performance results of the CS-PTO 7. Present and future developments

8. Conclusions

1. Introduction
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The ideal driving principle for auxiliary equipment in distribution trucks:

- The required amount of power is always available when needed - The efficiency of the driving principle is high - The noise emission of the driving principle is low - The total weight of the driving principle is low

85% of the market is using a small diesel-unit as a power source 10% of the market is using the truck engine as a power source

1. Introduction
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Present driving principles for auxiliary equipment in distribution trucks:

available power
diesel-unit

truck engine

500

1000 1500 2000 2400 primary engine speed [rpm]

3000

1. Introduction
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New regulations concerning emissions (exhaust gases & noise):

Market demand for a silent, clean and efficient driving principle, that delivers optimal or constant power when needed.
Truck engine as power source

Continuously Variable Transmission to optimize the required power

2. Working principle of the CS-PTO

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Variable (PTO) Speed

Truck Engine
Variable input speed

CVT unit
Optimal or constant output speed

2. Working principle of the CS-PTO

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Comparison with present driving principles for auxiliary equipment: available power
CS-PTO diesel-unit

truck engine

500

1000 1500 2000 2400 primary engine speed [rpm]

3000

3. Design & Development of the CS-PTO

From concept to market introduction in 2 years 5 months 9 months 13 months 18 months 24 months concept market introduction

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January 2002: May 2002: September 2002: February 2003: July 2003: January 2004:

preliminary research & concept design detailed design, prototype development 1st prototype, testing and optimization (test-rig) implementation in a distribution truck (2nd prototype) Start development of new applications Presentation new driving principle (market introduction)

3. Design & Development of the CS-PTO

CS-PTO development, in cooperation with Aichi Machine Industry Nagoya, Japan: Specifications Aichi-CVT: - Dry hybrid belt - Electromechanical actuation - Compact & lightweight

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- Air cooled
- High efficiency

3. Design & Development of the CS-PTO

Development of the first CS-PTO Prototype:

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4. Electromechanical Actuation System and Ratio-Control Slide 11/26

Primary pulley of the electromechanical Actuation System: transmission gears

Electric motor

Spindle mechanism Translation of pulley sheave

4. Electromechanical Actuation System and Ratio-Control Slide 12/26

Secondary pulley of the electromechanical Actuation System: Compression spring

Air cooling fins

Torque assist

4. Electromechanical Actuation System and Ratio-Control Slide 13/26

Ratio Control System structure:

Controller

Model of actuation system & CVT

4. Electromechanical Actuation System and Ratio-Control Slide 14/26

Ratio Control System functions: - Minimize the ratio error - Prevent slippage of the belt Required input for the controller: -Primary pulley speed (REV 1) -Secondary pulley speed (REV 2) -Primary pulley position (PPS)

5. Testing and Implementation of the CS-PTO

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Testing the first CS-PTO Prototype, driving a 15 kW refrigeration-unit:

Digital Analog Control System (DACS) developed by the University (TU/e)

5. Testing and Implementation of the CS-PTO

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Testing the first CS-PTO Prototype, driving a 15 kW refrigeration-unit: Electric motor (80 kW)

CS-PTO Prototype

Generator & Refrigeration unit (22 kVA & 15 kW)

5. Testing and Implementation of the CS-PTO

Measured CVT efficiency:

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The efficiency is higher than 90% when the primary torque is more than 20 Nm
CS-PTO Application:

The lowest primary torque of the CVT-unit is 24 Nm

6. Performance results of the CS-PTO

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Measured performance on the test-rig (European Transient Cycle):

CVT input speed CVT output speed

Ratio-shift is too slow

(compression spring)

6. Performance results of the CS-PTO

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Implementation in a refrigerated distribution truck (DAF CF75):

6. Performance results of the CS-PTO

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High load torques on the CVT-unit, because of peak currents at start-up

6. Performance results of the CS-PTO

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Built-in soft-start strategy to reduce the required power at start-up The CVT control system senses that the The auxiliary CVT unit control runs switches system 50 on senses Hz, at 380 30 Hz, V the auxiliary unit is at switched off the unit isunit off and shifts down to equal resulting that to the electrical in much is power on lower and load from shifts torques the up net 1800 rpm, 30 Hz

3000 rpm, 50 Hz

1800 rpm, 30 Hz

unit on

unit off

6. Performance results of the CS-PTO

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Performance results of the CS-PTO application in city distribution:

Present concept

Test-conditions:

mid-summer day
32 degrees Celsius two distribution trucks identical routes
CS-PTO concept

6. Performance results of the CS-PTO

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Performance of the Constant Speed Power Take Off

ideal driving principle measured performance

Power always available when needed High efficiency / low fuel consumption Low noise emission

100% power available while driving

(maximum truck engine speed range of 4.5 [-])

5.6% fuel consumption reduction

(compared with a truck engine without CS-PTO)

Maximum noise emission of 57 dB(A)

(officially measured on a CS-PTO driven refrigeration-unit)

Low overall weight

Total weight of the CVT-unit is 25 kg

(total weight of the CVT-unit and generator is 100 kg)

7. Present and future developments

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Present developments Development of (new) CS-PTO applications on different types of trucks Development of new ratio control functions for CS-PTO-applications Development of easy-adjustable ratio control software Future developments Development of a smaller CS-PTO with higher power density Development of CS-PTO production Standard implementation of CS-PTOs on trucks

8. Conclusions
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- A new and efficient driving principle for auxiliary equipment on

distribution trucks is presented

- A small and compact CVT-unit is used to transform the variable engine

speed into an optimal or constant speed

- The performance of the auxiliary equipment can be optimized to

performance, fuel-efficiency or noise-emission developed

- The CS-PTO has a big market potential and many new applications are - Preparations are made for CS-PTO production in higher numbers - In cooperation with truck manufacturers, standard implementation of

the CS-PTO is discussed

Thank you for your attention

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