Presentation of

Vehicle Energy consumption

Calculation TOol
(VECTO)
Dimitrios Savvidis
DG CLIMA
Transport and Ozone
Unit C2

Stakeholder Meeting
Brussels, 16th of September 2014

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 Simulation tool to calculate
both, fuel consumption and
CO2 emissions from the whole
vehicle
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Vecto development

- VECTO has been developed by the Commission

(DG CLIMA and JRC) with TUG support over the last
two years
- ACEA, OEMs and component manufacturers have
been also involved and provided key input and test
vehicles
- DG CLIMA is the leader for this project
- Further development will take place in the next
years (contract already launched).
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Why do we want to measure HDVs

No official/unified measurement or certification

scheme for HDVs in EU (unlike for cars and vans)

Some single data

exist but indicative
in nature

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HDVs are more complicated than LDVs

- Low, medium, high, long, short cab etc

- 2,3,4,5,6 axles, 4x2, 4x4, 6x2, 6x4, 6x6 etc
- Different tires for each axle, single/twin tires etc
- Same engine but different gear boxes/axles ect
- Rigid, semi-trailer, tractor, coach, bus, citybus etc
- Any combination mentioned above

Millions of types!!!
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HDV CO2 in the EU Policy context
• HDVs account for
• About 6% of total EU GHG emissions
• About 25% of total GHG road transport emissions
• Freight transport (trucks) main source of HDV emissions
• Passenger transport: buses and coaches

• Roadmap for low carbon economy in 2050 :

• Reduce GHG emissions from 80% to 95% by 2050 (Base 1990)
• Transport sector foreseen to reduce emissions between 54 and 67%
by 2050

• White Paper on Transport:

• Target 60% reduction in GHG emissions by 2050 (Base 1990)
• 20% by 2030 (Base 2008)

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Regulatory situation in EU
Existing Regulations setting performance standards for:
• Cars (Reg. 443/2009), and
• Vans (Reg. 510/2011)

Currently no legislation setting performance standards for

HDV CO2 emissions or parts thereof

Current test cycle procedure for HDVs is based on the engine

(e.g. for regulation air pollutant emissions), not the whole
vehicle

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Scope
• Serve for all possible policy steps including:
• Monitoring, reporting and certification
• Improve market forces (e.g. by comparable customer
information)
• Labelling
• Improve/help foot-printing schemes
• Give a reliable real world picture of the fuel
consumption/CO2 emissions – accuracy ~ 95 %
• Fit for the future (include new technologies)
• Minimize burden on OEMs

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 History
So far examined and result:

Approaches explored:
• Measurement on a chassis dynamometer
• Measurement with PEMS
• Component measurement and model simulation

Selected option:
Component measurement and model simulation for the whole
vehicle (truck and trailer)

Methodology ("VECTO") considers:

Engine, driving resistances of whole vehicle (rolling,
aerodynamic), gearbox, most relevant auxiliaries

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VECTO Graphical User Interface (GUI)

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VECTO's modes

VECTO offers a declaration mode, where all

generic data and the test cycle are allocated
automatically as soon as the vehicle class is
defined.
An engineering mode is also offered, where the
user can select and change all input data to allow
recalculation of test data e.g. for model validation.

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VECTO output

In the declaration mode of VECTO fuel

consumption and CO2 emissions are automatically
calculated for all CO2 test cycles allocated to the
vehicle for average payload, full load and empty
driving. Results are given in g/km and g/ton-km
or g/pass-km.
Which of these values will be used in a final
certification process is not decided yet.

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Components and input data

For the following components, relevant input data

for VECTO have to be delivered from standardised
test procedures :
-- Vehicle mass
-- Tires (dimensions and rolling resistance coef)
-- Engine (engine fuel flow map)
-- Transmission (transmission ratios, loss maps for
gear box and axle, default values optional)
-- Aerodynamic drag (Cd x A, for some vehicle
classes generic values can be used)
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Components and generic values

For the following components generic values are

defined, which are allocated by the software VECTO
to the vehicle depending on the vehicle class and
mission profile. :
- Auxiliaries (alternator, air compressor, alternator,
steering pump, cooling fan, Heating Ventilation AC-
HVAC)
- Mass of the standard bodies and trailers
- Vehicle payload (truck) or passengers weight (bus)
- Test cycle
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 VECTO: Programme structure
• Developed initially to cover:
• Delivery trucks (long haul
and regional-city)
• Coaches
• Effort to include city
buses
• Effort to standardize:
• Measurement protocols
for input data generation
• Individual component
simulation models
• Mission profiles and
cycles
• Evaluation / validation
approaches

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Model structure - Four main modules

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Model structure - Four main modules

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Tasks of single modules (1)

In Driving Cycle Pre-processing (M1) the

distance-based driving cycle (mission profile) is
being converted to 1Hz. Time-based cycles are
converted to 1Hz if necessary.

Driver Pre-processing (M2) applies driver

functions to the driving cycle which can't be
considered later in the backwards power calculation
(M3) like Over-speed or Look-Ahead Coasting.

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Tasks of single modules (2)

Power Calculation (M3) is the core of the model.

Here the engine operation points (engine torque
and speed) are calculated for each time step
considering driving resistances and powertrain
losses and auxiliary power demands.

Finally in FC Calculation (M4) the fuel

consumption (FC) is being interpolated from the
stationary FC map and the WHTC correction is
applied.

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 Mission profiles
Trucks Buses and coaches
- Urban delivery - City-bus heavy urban
- Regional delivery - City-bus urban
- Long haul - City-bus suburban
- Construction - Interurban bus
- Municipal utility - Coach

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Rigid and tractors classification
The generic values
are allocated to the
vehicle by VECTO
automatically
depending on the
HDV class in which
the vehicle falls.
Classification, mission
profile or type of use
and identification of
standard bodies for
each type of HDV
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Busses classification

For each class the corresponding test cycles, the

standard body or trailer and the payload are defined as
well as the data relevant for the simulation of the
generic auxiliaries.
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Simulation of engine power

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 Shares of energy consumption
EURO V semitrailer 28 t EURO V city bus
engine brake
2.4%
sum service brakes engine cooling fan
7.5% 0.5%
drivetrain losses alternator
air resistance 6.5% 0.9%
53.8%
auxilliaries
air compressor
5%
2.3%

steering pump
0.7%
A/C compressor
rolling resistance
0.2%
25.2%

Source bus:
Marx, 2011

 Must be included: Shall be included: Should be included

*** Air resistance ** Transmission losses as far as possible:
*** Rolling resistance * Auxiliaries
*** Engine efficiency * Power consumers
 +transmission ratios Climate
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Evaluation of simulation program
- Selected 12 ton truck, measured over various conditions on chassis dyno
- Performed simulations with VECTO
- Verify good correlation between measured and simulated values
- Compared against 3 commercially available simulators
- First sensitivity analysis – uncertainties quantification

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•Fuel consumption over sub-cycle (normalized by measured average
100=measurement)
VECTO Cruise PHEM Autonomie
Urban part 99 96 101 -
Rural part 98 101 96 98

Motorway part 98 101 98 96

10%
Deviation from cumulative measured FC (%)

Cruise

Accuracy target originally set PHEM

5% VECTO
Autonomie

96-98% accuracy with simulation tools

0%
0 2000 4000 6000 8000 10000 12000

-5%

-10%
Time (s)
Urban cycle Rural cycle Motorway cycle

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 Proof of concept activity
- Scope:
- Prove that simulation based monitoring can deliver results that
accurately reflect fuel consumption and performance of modern HDVs
- Verify the validity and soundness of the approach
- Extensive measurements concluded February 2013
- Joint Commission-ACEA activity
Included
• 2 HDVs provided by DAF and Daimler
• Proving ground testing (Iveco’s circuit)
• Chassis dyno testing (JRC)
• On – road / PEMS testing (JRC)
• Engine test bed testing (JRC)

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 Vehicles used
Daimler
OEM DAF

Model Actros CF75

Maximum vehicle weight [kg] 40000 18600

Test mass [kg] 33580 14270

Engine Emission Standard Euro VI Euro V

Rated power [kW] 330 265

Rated Torque [Nm] 220 1050
Displacement [l] 12.8 9.2

Fuel Consumption Map From steady state RPM vs Torque points as measured by manufacturers

Gearbox & Final Drive

As provided by manufacturers
characteristics

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The full report can be found on
DG Clima's website

http://ec.europa.eu/clima/policies/transpo
rt/vehicles/heavy/docs/hdv_co2_certificati
on_en.pdf

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 Report conclusions and follow up
- Simulated fuel consumption was calculated with a range of
±3% from the real world measurements or even less.
- Finalize and validate topics remaining open in the
methodology such as gearbox and driveline efficiency,
auxiliary units power consumption, automatic gear shifting
strategies, mobile air-conditioning simulation for city buses.
- Perform a sensitivity analysis in order to more accurately
quantify the uncertainty of the method for different vehicle
types/categories.
- Investigate the necessary conditions for expanding the
methodology to other HDV categories.

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 Timeline

- VECTO development: on-going

- Dissemination and trials: from 2013 to mid-2016

- Possible legislative proposals: 2015

- Possible first reporting year: 2018

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 Thank you for your attention

- VECTO demonstration will follow

- I will be happy to address your questions
- More info can be found at:
http://ec.europa.eu/clima/policies/transport/vehicles/he
avy
- Contact details:
Dimitrios SAVVIDIS: dimitrios.savvidis@ec.europa.eu

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