Joint Military Evaluation of the Benefits of an Electric ... · Joint Military Evaluation of the...
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Joint Military Evaluation of the Benefits of an Electric‐Drive BulldozerSteven Sokolsky, CALSTART
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CALSTARTCALSTART is a unique national, non‐profit, advanced transportation technologies organization.
Founded in 1992 as a public‐private partnership to launch and grow a clean transportation industry.
Mission: via programs and services support and expand the growth of a clean transportation technologies industry that will:
»Create high‐quality jobs;»Clean the air;»Reduce dependence on foreign oil; and»Reduce global warming emissions
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HTUF – More Than A Decade of Progress
» User‐driven process to commercialize medium‐ and heavy‐duty hybrid, electric & advanced vehicles
» Partially funded by U.S. Army (TARDEC‐NAC); operated by CALSTART
» Process speeds advanced dual‐use truck commercialization» By creating common fleet requirements,
volume purchase commitments, targeted development, leveraging DOE/DOD/DOT investments
» Working Groups formed around high‐promise candidate commercial truck applications in weight/function benefitting military needs
All Major Truck Makers and System Suppliers involved
(partial list)
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Cat D7E Evaluation ProjectElectric‐Drive Bulldozer – Data Collection and Verification
• Goals were to verify expected 25% fuel savings, 10% increase in productivity
• Tests completed November 2011
• Project Partners: U.S. Army (TARDEC), U.S. Navy (Seabees), Caterpillar, Trimble
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Cat D7E Electric‐Drive Bulldozer Specs» Engine: Cat C9.3 ACERT; 235 hp (175 kW) net power
» Drivetrain: Electric drive» Operating weight: 56,669 lbs.
» Engine turns electric generator that converts mechanical energy to AC current for propulsion & DC power for accessories
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Cat D7E Bulldozer Evaluation» Purpose: Evaluate fuel consumption & efficiency of conventional & electric‐drive dozers in field tests
» Variables measured: fuel consumption, productivity, engine RPM, effect of operator experience, use of GPS‐based machine control systems
» Desired outcomes: establish fuel consumption baselines for hybrid & conventional machines, identify limitations or potential improvements to operating methods
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Measurement Criteria
» Fuel efficiency = cubic yards of soil moved/gallons of fuel consumed (yd3per gallon)
» Productivity = cubic yards of soil moved/time to move (yd3 per hour)
» Fuel consumption = gallons of fuel consumed/time (gallons per hour)
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Bulldozer Evaluation: Tests Performed
Slot dozing: dig an 80‐foot trench to depth of 1 blade height ‐required ~ 20 passesBackfilling: fill in all slots dug in initial cycleNo load travel @ high idleIdling without movementPad building: 100’ x 100’ helicopter landing pad with 1‐degree pitch3 dozers performed each test: D7E electric‐drive, D7R (Army), D6T (Navy)
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D7E Productivity Study
» 5 Navy Operators and one expert operator» Each of 4* tractors dug 12 slots for 48 slots total» 3 hours of slot dozing, 3 hours of backfilling in AM
» 3 hours of slot dozing, 3 hours of backfilling in PM
*D7E ran two sets of slots, one set with blade control and one without.
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Project DetailDuty Cycles» Repeatable» Representative of
military activity» Consistent with
commercial practice when possible
» Evaluate full machine operational capability (idle, travel, full load, part load)
» Defined machine and site conditions
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Pad Building with Blade Control» D7E with GPS‐guided blade control» D7E without blade control» D7R without blade control» Surveyors needed for tests of without of dozers w/o blade control system
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Pad Building with Blade Control
D7E w/ blade control completed task 48% faster than D7R, 16% faster than D7E w/o controlsD7E w/ blade control fuel consumption slightly higher than other configurations
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Project DetailResults
Favorable results have been observed, 5%‐30% efficiency increase. Distribution of actual test results is limited due to:» Operator influence (technique and operating parameters)» Site Conditions (ground and environment)» Duty Cycles» Equipment Type» Sample Size Limitations » Army is not endorsing a product or manufacturer Training is the low hanging fruit.− Expert operators showed higher productivity− Military operators receive limited stick time− Machine operating parameters are not optimized− Efficient operating technique has not been taught
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Test Results
» Productivity (slot dozing & backfilling): D7E was 1 to 7% better than D7R and D6T
» Fuel consumption (light and heavy dozing, no‐load travel & idling): D7E was 11 to 30% better than D7R and D6T
» Pad‐building results were mixed when measuring effects of blade‐control – need to re‐run some tests due to soil condition
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Field Evaluations at Port Hueneme, CA
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Challenges for Military• JP‐8 Single Fuel Policy: Future operational energy technologies (at OEM level) are being engineered for Tier IV compliant systems. JP‐8 is not compatible with Tier IV emission control technologies.
• Business case development – wartime vs. peacetime operation: Many systems operate at extremely low hours during CONUS operations. Business case for many fuel efficient technologies cannot be justified in this scenario.
• Technology integration with primarily commercial systems: Army relies on commercial industry for extended system support (beyond normal commercial life expectancy). Integration of technology may impair the OEM’s ability to support.
• Technology integration with military systems: Added cost of technical manuals, provisioning and soldier training complicates integration to existing systems.
• Rely on Commercial Market: For the Army to benefit, in most cases the commercial market must adopt the technology – is commercial payback reasonable?
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Next Steps
» Two additional D7E evaluations underway:
1. 5‐mile border road building at Nogales, AZ
2. UAV airstrip building through grassy area at Fort Riley, KS
» Evaluating D7E efficiency, productivity, and affects of blade‐control technologies
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Calif Energy Commission Off‐Road Hybrid Demos
» Two pre‐production projects chosen by CEC for demos involving Caterpillar & Volvo
» First is a large hybrid excavator used for earthmoving by commercial contractors
» Second is a mid‐size hybrid wheel loader used at a landfill
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CALSTART Clean Transportation Technologies
and SolutionsSteven Sokolsky, Senior Project Manager
[email protected](510) 307‐8772