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  • Periodic Report Summary 2 - LORRY (Development of an innovative low rolling resistance truck tyre concept in combination with a full scale simulation tool box for tyre performance in function of material and road parameters)

LORRY Report Summary

Project reference: 314463
Funded under: FP7-TRANSPORT

Periodic Report Summary 2 - LORRY (Development of an innovative low rolling resistance truck tyre concept in combination with a full scale simulation tool box for tyre performance in function of material and road parameters)

Project Context and Objectives:
Transport sector depends on oil for about 96% of its energy needs; it accounts for 58% of the global oil consumption and 20% of GHG emissions. Latest projections on global oil use predict another increase in transportation activity of almost 90% in the next decade. Transport system will remain an essential vector for a strong economic growth: a mutation from a classical transport system to an intelligent transport system appears to be an absolute necessity: greener, safer and smarter.

Through the European Green Car initiative a series of measures have already been taken to boost Research, Development and Innovation to increase global competitiveness for automotive industries with the deployment of new generations of trucks, buses and cars which are life and environment compliant. Today’s priorities for heavy duty vehicles are the efficiency of vehicles by energy management, aerodynamics and low rolling resistance, as well as eco-driving and innovative truck designs .

In line with this objective the LORRY project will contribute to a greener, safer and more efficient mobility in freight transport by combining a new tyre concept and a comprehensive tool for energy efficient heavy duty transportation.

It has been established that tyre rolling resistance can account for as much as one third of the total fuel consumption of a truck, while the contribution is recognized to be at least one quarter in any case. The RR parameter cannot only be analyzed as a stand-alone parameter but is strongly correlated to other listed parameters. LORRY project thus proposes to study RR in its whole environment, and optimize truck fuel consumption by correlating it with tyre pressure, load, driving style, road and weather conditions.

The overall LORRY objective is to develop a new tyre concept allowing reaching a gain of 5% in truck fuel consumption, of 20% in tyre rolling resistance and of 20% in tyre wear reduction. These gains will be obtained without compromising tyre safety, wet grip and wear resistance. A virtual road performance measurement tool will also be developed to optimize and lean road transportation via heavy duty vehicle.

LORRY project proposes improvements in tread pattern technology, material composition and processing in combination with enhanced characterization and simulation tools. Finally the tyre performance benefits will be directly demonstrated through experimentation but also complemented by virtual performance assessment tools. Research key challenges of the project are: understanding interaction between new tread pattern design and novel fillers in compounding, the simultaneous improvement of RR, wear and wet performance and the fine scale correlation to fuel consumption in function of driving and road parameters.

Within LORRY, an interdisciplinary consortium of experts in the fields of tyre technology, rubber and filler technology, nanotechnologies, composite physics, sensorics and transport and road infrastructure will deliver a new tyre concept with proven benefits via a full scale fleet road measurement campaign. A complete set of complementary scientific evaluation methods, risk analysis and profitability calculations are also part of the project to ensure its success. Different innovation outcomes of LORRY project can be highlighted as follows:
• New validated tyres including new tread pattern and material features for steer in 2 sizes and for trailer in 1 size,
• New methodology for tyre deflection measurement and RR /wear/fracture-fatigue predictive measurement,
• Smart systems for tracking and analyzing trucks driving and environmental conditions,
• Virtual analytical tool for optimization of trucks fuel consumption.

Project Results:
The LORRY project has been extended by six month during the reporting period. This delay, was mainly induced by the late delivery of the tyre for the tests and the demonstration phase. The project is currently on line with this revised schedule. It has to be noted that considering this extension the demonstration phase had to be reduced and new tests (not originally foreseen) such as Coast Down measurements had to be foreseen in order to maximize the demonstration of the improvements achieved by the innovative tyre designs and compounds developed within the LORRY project.
Below you may find a summary WP by WP of the achievement of the LORRY projects between M18 and M36.
Concerning the WP1, during reporting period important improvements have been done especially regarding multizone compounding and regarding the possibility to keep truck tyre performance all along their lifetime (Wagan). Multizone has demonstrated +9% of improvement in RR combined with a much longer tyre durability when Wagan has shown a RR improvement of 5% combined with 20% improvement in Wet Grip (safety parameter).
The tasks 1.1 and 1.2 have been completed and fully reported during the 1st interim report. The tasks 1.3 has been finalized during this periodic period with the production of the related deliverable D1.6, and tyres combining new technology features and the selected new compound have been built for lab testing with Goodyear premises and have been shipped to other partners for testing, including for field tests through the WP4.
It is worth noting that all foreseen deliverables and milestones have been achieved.
Concerning the WP2, this WP is almost completed, except regarding some tyres which need to be selected for the testing and demonstration phase. The main achievements during the reporting period was:
• Completion of the task 2.1 “Raw materials and Reference compounds”: choice of new CB grades and characterization
• Completion of the task 2.2 “compound mix and preparation”: mixing of new CB grades in compounds, application of two innovative mixing techniques and results analysis, study on the partial substitution of CB and Silica with MWCNTS (investigations on triplet hybrid systems)
• Completion of the task 2.3 “Compound characterization” : filler dispersion andpase distribution analysis and investigations on filler distributions in dimer and trimer blends
• Continuation of the task 2.4 “New Compound Concepts Tyre testing”: development of new tread cap compounds for low resistance and high wear resistance for tests and demonstration. This development has been refined in 3 building iterations.

All foreseen deliverables and Milestones for the WP2 have been well been achieved during the reporting period.
Concerning the WP3, concerning the task 3.1, the MS12 (Laser tools ready) related to Aalto activities (task3.1) has been reached in time and field measurement were completed in Finland in 10-11/2014. The results have been reported in a scientific article. The laser tool measurements were continued in WP1.4.2
Concerning the task 3.3, all foreseen activities have been completed during the reporting period and different publications have been realized summarizing the activities performed during whole project. The submitted D3.11 is one of these publications
For LPMA (Task 3.4), no MS regarding development of laboratory wear measurements within the period. MS10 (laboratory tribometer setup ready to operate was delivered with a couple of month delay, as reported in previous periodic report. The ability to characterize full friction curves of tread rubber samples as a function of load and sliding velocity over a broad range, as well as to characterize dynamic contact conditions in real time during wear tests has been demonstrated, as reported in report for deliverable D3.6. Preliminary investigation on obtained wear pattern evolution was performed, as preliminary step to wear mechanism study, as required in deliverables 3.8, 3.9 and 3.13 (which are delayed for reasons explained below within the deviation sections).
Concerning the WP4, the following tasks have been achieved or are in progress:
• Setting up of measurement equipment for the selected customers and selection of the route for the fleet testing
• Once LORRY tyres have been received, tyres have been mounted first on Visbeen trucks and also on TNT tyres. Both fleet tests are now running. Results will be an
• A third customer for fleet tests is currently being selected
On top of that it is worth noting that originally it was only foreseen to assess RR only through fuel consumption measurements, however it appears that this was more complex and difficult than estimated. Since reduction of RR is one of the main results to be demonstrated within the proposed LORRY project the Consortium agreed on performing tests, which were not originally foreseen in the project proposal: Coast down measurements (performed by BRRC). These tests have demonstrated their accuracy and a new session will be performed before the end of the project
Concerning the WP5, first, the partner Aalto published their work on a field experiment conducted on existing road pavements to characterise macro- and micro-texture variations at actual road conditions and to substantiate links to friction values. Fraunhofer ITWM continued their work on a method for predicting rolling resistance and tread wear for a certain truck-tyre combination traveling over an arbitrary route with a corresponding velocity profile. The essential tyre simulations are carried out using the CDTyre model suite, where a corresponding interface has been developed which transfers the necessary tyre model inputs from the vehicle MBS environment. The basic idea of the workflow is to decompose real life routes into a suitable set of load cases including variation of curvature radius, longitudinal slope and driving speed. The validity and accuracy of the proposed workflow has been demonstrated by its application to a reference track where the results from the load case extrapolation are compared against the full reference simulation.
As explained above, BRRC has performed Coast down measurements as complement to the field tests and they have analyzed the results. According to the first tests performed, the measurement seem very efficient to demonstrate impact of new tyre designs and compounds to fuel consumption. Additional tests will then be performed.
Concerning the WP6 the main achievements were the following:
• Update of the Strategic Dissemination Plan;
• Organization of the LORRY Mid-Term seminar;
• Publication of various articles and newsletters;
• Participations to conferences / workshops;

Concerning the WP7, the main achievements during the reporting period have been the following:
• Distribution of the templates for deliverables to partners;
• Submission according to the schedule of the deliverables;
• Preparation and submission of amendment (for the extension);
• Management of administrative changes;
• Organization of Steering and Executive Committees meeting (semester basis);
• Preparation and submission of the 2nd Periodic report;
• Support to organize the mid-term seminar.

Potential Impact:
New tyres developed in the framework of this project will show an improvement of 18% minimum in rolling resistance. Fleet operator as well as truck manufacturers will get great advantages in having these tyres on their trucks and trailers: they will be environmental policies compliant, can set future standards and save money. Our combined integrated Tread pattern and material design reaches 20% rolling resistance improvements for steer and trailer tyres in combination with a 10% wear improvement. In addition as we move to a silica enriched tread pattern we also are able to reach an improvement in wet braking performance in the range of 3%. The hidden grove technology will lead to a change in the rib and grove design as well as the net to gross ratio in function of non-skid and thus we can reach a further very significant improvement in wet on partially worn tyres (as of half non-skid) of almost 20%. The integrated technology approach will result in a 20/10 scale improvement of the most important environmental performance parameters of a tyre: RR and wear, resulting in a very significant life cycle impact reduction of the tyre over its use phase to which the RR improvement contributes with about a 5 times higher weighing factor than the mileage improvement.

Additionally, specifications will show high values for safety and longevity parameters as well, in parallel tyre price will be maintained at the market level thanks to the parallel weight reduction measures, providing tyres users with important competitive advantages.

To better prove the evolution and impact of RR for the developed tyres, a full scale fleet demonstration with full sensorics and telematics equipped trucks and tyre wheels will be performed measuring all relevant tyre vehicle driving parameters such as pressure, load, motional G factors or velocity. Telematics in combination with geo-localization will also permit real time fleet tracking and collection of the environmental impact parameters including road topology, road surface topography and climate conditions.

Simulation of tyre road performance in terms of RR and wear impact through a virtual measurement campaign tool will allow us making an assessment of tyre/vehicle and environmental parameters in a statistic data environment. By this way, LORRY will fully establish the interaction of road parameters with parameters of tyre and material design. The robustness of tyre engineering will be an important outcome as well as the capabilities for fine scale adaptation in function of the predominant use and environmental parameters. It will give an overview of tyre behavior over a broad range of type of driving and environmental parameters across Europe reducing the future need for time consuming and expensive road test campaigns. The ultimate outcome of the road demonstration and simulation WP 4 and 5 efforts will be a comprehensive tool relating fuel consumption to tyre parameters in combination with use and environmental parameters. The transportation factor will profit from the inherent safety and logistics benefits offered by sensorics and telematics and get a comprehensive calculation tool for controlling fuel efficiency and the related cost savings considering a full cost of ownership model for tyres.
Enabling experimental and virtual methodologies from WP3 will also enhance the fundamental understanding, bridge knowledge gaps between material and tyre design scales. This enhancement in predictive design at the macro scale of tyre design and micro scale of material design resulting in reliable structure property relationships which are validated through various development and simulation phases is essential. Indeed the road campaign simulation tool and the tyre and material simulation tools will lead to a gain in development cycle time of up to 2 years and in R&D resources allowing consortium member to deliver innovations in a shorter timeframe.

List of Websites:


DUEZ, Benoit (Lead Engineer)
Tel.: +352 81 99 28 94
Fax: +352 81 99 38 56
Record Number: 182326 / Last updated on: 2016-05-23
Information source: SESAM