Objective
The aim of the project is to minimise fuel consumption of industrial vehicles, coaches and buses, by means of a drive system utilising a standard gearbox and clutch assembly with electronic control. The latter permanently computes and selects the appropriate gear ratio for minimum fuel consumption. The selected gear may be engaged automatically or the driver himself. The system should offer significant advantages in terms of efficiency, cost, weight and number of possible gear ratios, by comparison with a standard automatic gear change system utilising a torque adapter or converter.
Fuel savings of 1.7 TOE/year/vehicle can be achieved. (i.e. 5% of a vehicle's normal consumption over a travel distance of 100,000 km/year). In application, payback time is expected to be 2.5 years.
The project concerns the installation of an electronically controlled power drive system on vehicles fitted with
- either a V8 engine (developing 302 kW, 1984 Nm) with diaphragm-type single disc clutch and 10-speed gearbox (optionally 20 with forward relais),
- or a 6-cylinder engine (259 kW, 1635 Nm), with diaphragm single disc clutch and 9-speed gearbox (optionally 18 with forward relais).
The various components of the existing drive system (injection pump and accelerator pedal, exhaust brake, clutch, gearbox) and their controls are modified, and sensors are fitted to the starter crown-wheel and the gearbox (2 speed sensors, gear input/output, and status sensors).
Information provided by the sensors and by a potentiometer fitted to the accelerator pedal, is processed by the electronic control system which determines the optimum gear ratio to be selected. In automatic mode, if the engaged gear does not correspond to the optimum ratio, the electronic system will effect the gear change by acting upon the clutch control, the injection pump and, if required, the exhaust brake and gearbox. When gear changing is not required, the electronic system controls the injection pump and exhaust brake according to the driver's demand, and clutch actuation during the starting phases. The semi-automatic mode enables the driver to take-over control of the powerdrive for manoeuvers in critical traffic conditions.
Tests and measurements made to check the validity of the automatic system include
- measurement of gear change time by test bench simulation,
- endurance tests of the control assembly by test bench simulation,
- consumption and performance measurements on vehcles, by
comparative tests with identical non-automated powerdrives,
- endurance tests of the complete powerdrive and control system on vehicles subjected to real travel conditions.
The extra purchase cost of a vehicle equipped with the automatic powerdrive system compared with that of a non-equipped vehicle is estimated to be 15,000 FF (VAT non included).
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Programme(s)
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Funding Scheme
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Coordinator
69800 St. Priest Cedex
France
The total costs incurred by this organisation to participate in the project, including direct and indirect costs. This amount is a subset of the overall project budget.