ANNEX IXSupplementary provisions
ANNEX IX VERIFYING TRUCK AUXILIARY DATA 1. Introduction This Annex describes the provisions regarding the power consumption of auxiliaries for heavy duty vehicles for the purpose of the determination of vehicle specific CO 2 emissions. The power consumption of the following auxiliaries shall be considered within the Vehicle Energy Consumption calculation tool by using technology specific average standard power values: (a) Fan (b) Steering system (c) Electric system (d) Pneumatic system (e) Air Conditioning (AC) system (f) Transmission Power Take Off (PTO) The standard values are integrated in the Vehicle Energy Consumption calculation Tool and automatically used by choosing the corresponding technology. 2. Definitions For the purposes of this Annex the following definitions shall apply: (1) ‘Crankshaft mounted fan’ means a fan installation where the fan is driven in the prolongation of the crankshaft, often by a flange; (2) ‘Belt or transmission driven fan’ means a fan that is installed in a position where additional belt, tension system or transmission is needed; (3) ‘Hydraulic driven fan’ means a fan propelled by hydraulic oil, often installed away from the engine. A hydraulic system with oil system, pump and valves are influencing losses and efficiencies in the system; (4) ‘Electrically driven fan’ means a fan propelled by an electric motor. The efficiency for complete energy conversion, included in/out from battery, is considered; (5) ‘Electronically controlled visco clutch’ means a clutch in which a number of sensor inputs together with SW logic are used to electronically actuate the fluid flow in the visco clutch; (6) ‘Bimetallic controlled visco clutch’ means a clutch in which a bimetallic connection is used to convert a temperature change into mechanical displacement. The mechanical displacement is then working as an actuator for the visco clutch; (7) ‘Discrete step clutch’ means a mechanical device where the grade of actuation can be made in distinct steps only (not continuous variable). (8) ‘On/off clutch’ means a mechanical clutch which is either fully engaged or fully disengaged; (9) ‘Variable displacement pump’ means a device that converts mechanical energy to hydraulic fluid energy. The amount of fluid pumped per revolution of the pump can be varied while the pump is running; (10) ‘Constant displacement pump’ means a device that converts mechanical energy to hydraulic fluid energy. The amount of fluid pumped per revolution of the pump cannot be varied while the pump is running; (11) ‘Electric motor control’ means the use of an electric motor to propel the fan. The electrical machine converts electrical energy into mechanical energy. Power and speed are controlled by conventional technology for electric motors; (12) ‘Fixed displacement pump (default technology)’ means a pump having an internal limitation of the flow rate; (13) ‘Fixed displacement pump with electronic control’ means a pump using an electronic control of the flow rate; (14) ‘Dual displacement pump’ means a pump with two chambers (with the same or different displacement) which can be combined or only one of these is used. It is characterised by an internal limitation of flow rate; (15) ‘Variable displacement pump mech. controlled’ means a pump where the displacement is mechanically controlled internally (internal pressure scales); (16) ‘Variable displacement pump elec. controlled’ means a pump where the displacement is mechanically controlled internally (internal pressure scales). Additionally, the flow rate is elec. controlled by a valve; (17) ‘Electric steering pump’ means a pump using an electric system without fluid; (18) ‘Baseline air compressor’ means a conventional air compressor without any fuel saving technology; (19) ‘Air compressor with Energy Saving System (ESS)’ means a compressor reducing the power consumption during blow off, e.g. by closing intake side, ESS is controlled by system air pressure; (20) ‘Compressor clutch (visco)’ means a disengageable compressor where the clutch is controlled by the system air pressure (no smart strategy), minor losses during disengaged state caused by visco clutch; (21) ‘Compressor clutch (mechanically)’ means a disengageable compressor where the clutch is controlled by the system air pressure (no smart strategy); (22) ‘Air Management System with optimal regeneration (AMS)’ means an electronic air processing unit that combines an electronically controlled air dryer for optimized air regeneration and an air delivery preferred during overrun conditions (requires a clutch or ESS). (23) ‘Light Emitting Diodes (LED)’ mean semiconductor devices that emit visible light when an electrical current passes through them. (24) ‘Air conditioning system’ means a system consisting of a refrigerant circuit with compressor and heat exchangers to cool down the interior of a truck cab or bus body. (25) ‘Power take-off (PTO)’ means a device on a transmission or an engine to which an auxiliary driven device, e.g., a hydraulic pump, can be connected; a power take-off is usually optional; (26) ‘Power take-off drive mechanism’ means a device in a transmission that allows the installation of a power take-off (PTO); (27) ‘Tooth clutch’ means a (manoeuvrable) clutch where torque is transferred mainly by normal forces between mating teeth. A tooth clutch can either be engaged or disengaged. It is operated in load-free conditions only (e.g. at gear shifts in a manual transmission); (28) ‘Synchroniser’ means a type of tooth clutch where a friction device is used to equalise the speeds of the rotating parts to be engaged; (29) ‘Multi-disc clutch’ means a clutch where several friction linings are arranged in parallel whereby all friction pairs get the same pressing force. Multi-disc clutches are compact and can be engaged and disengaged under load. They may be designed as dry or wet clutches; (30) ‘Sliding wheel’ means a gearwheel used as shift element where the shifting is realized by moving the gearwheel on its shaft into or out of the gear mesh of the mating gear. 3. Determination of technology specific average standard power values 3.1 Fan For the fan power the standard values shown in Table 1 shall be used depending on mission profile and technology: Table 1 Mechanical power demand of the fan Fan drive cluster Fan control Fan power consumption [W] Long haul Regional delivery Urban delivery Municipal utility Construction Crankshaft mounted Electronically controlled visco clutch 618 671 516 566 1 037 Bimetallic controlled visco clutch 818 871 676 766 1 277 Discrete step clutch 668 721 616 616 1 157 On/off cluch 718 771 666 666 1 237 Belt driven or driven via transmission Electronic controlled visco clutch 989 1 044 833 933 1 478 Bimetallic controlled visco clutch 1 189 1 244 993 1 133 1 718 Discrete step clutch 1 039 1 094 983 983 1 598 On/off cluch 1 089 1 144 1 033 1 033 1 678 Hydraulically driven Variable displacement pump 938 1 155 832 917 1 872 Constant displacement pump 1 200 1 400 1 000 1 100 2 300 Electrically driven Electronically 700 800 600 600 1 400 If a new technology within a fan drive cluster (e.g. crankshaft mounted) cannot be found in the list the highest power values within that cluster shall be taken. If a new technology cannot be found in any cluster the values of the worst technology at all shall be taken (hydraulic driven constant displacement pump) 3.2 Steering System For the steering pump power the standard values [W] shown in Table 2 shall be used depending on the application in combination with correction factors: Table 2 Mechanical power demand of steering pump Identification of vehicle configuration Steering power consumption P [W] Number of axles Axle configuration Chassis configuration Technically permissible maximum laden mass (tons) Vehicle class Long haul Regional delivery Urban delivery Municipal utility Construction U+F B S U+F B S U+F B S U+F B S U+F B S 2 4 × 2 Rigid + (Tractor) 7,5 t - 10 t 1 240 20 20 220 20 30 Rigid + (Tractor) > 10 t - 12 t 2 340 30 0 290 30 20 260 20 30 Rigid + (Tractor) > 12 t - 16 t 3 310 30 30 280 30 40 Rigid > 16 t 4 510 100 0 490 40 40 430 30 50 Tractor > 16 t 5 600 120 0 540 90 40 480 80 60 4 × 4 Rigid 7,5 - 16 t 6 — Rigid > 16 t 7 — Tractor > 16 t 8 — 3 6 × 2/2-4 Rigid all 9 600 120 0 490 60 40 430 30 50 Tractor all 10 450 120 0 440 90 40 6 × 4 Rigid all 11 600 120 0 490 60 40 430 30 50 640 50 80 Tractor all 12 450 120 0 440 90 40 640 50 80 6 × 6 Rigid all 13 — Tractor all 14 4 8 × 2 Rigid all 15 — 8 × 4 Rigid all 16 640 50 80 8 × 6/8 × 8 Rigid all 17 — where: U = Unloaded – pumping oil without steering pressure demand F = Friction – friction in the pump B = Banking – steer correction due to banking of the road or side wind S = Steering – steer pump power demand due to cornering and manoeuvring To consider the effect of different technologies, technology depending scaling factors as shown in Table 3 and Table 4 shall be applied. Table 3 Scaling factors depending on technology Factor c1 depending on technology Technology c 1,U + F c 1,B c 1,S Fixed displacement 1 1 1 Fixed displacement with electronical control 0,95 1 1 Dual displacement 0,85 0,85 0,85 Variable displacement, mech. controlled 0,75 0,75 0,75 Variable displacement, elec. controlled 0,6 0,6 0,6 Electric 0 1,5/η alt 1/η alt with η alt = alternator efficiency = const. = 0,7 If a new technology is not listed, the technology ‘fixed displacement’ shall be considered in the Vehicle Energy Consumption calculation Tool. Table 4 Scaling factor depending on number of steered axles Factor c2 depending on number of steered axles Number of steered axles Long haul Regional delivery Urban delivery Municipal utility Construction c 2,U+F c 2,B c 2,S c 2,U+F c 2,B c 2,S c 2,U+F c 2,B c 2,S c 2,U+F c 2,B c 2,S c 2,U+F c 2,B c 2,S 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 0,7 0,7 1,0 0,7 0,7 1,0 0,7 0,7 1,0 0,7 0,7 1,0 0,7 0,7 3 1 0,5 0,5 1,0 0,5 0,5 1,0 0,5 0,5 1,0 0,5 0,5 1,0 0,5 0,5 4 1,0 0,5 0,5 1,0 0,5 0,5 1,0 0,5 0,5 1,0 0,5 0,5 1,0 0,5 0,5 The final power demand is calculated by: If different technologies are used for multi-steered axles, the mean values of the corresponding factors c1 shall be used. The final power demand is calculated by: P tot = Σ i (P U + F * mean(c 1,U +F ) * (c 2i,U + F )) + Σ i (P B * mean(c 1,B ) * (c 2i,B )) + Σ i (P S * mean(c 1,S ) * (c 2i,S )) where: P tot = Total power demand [W] P = Power demand [W] c 1 = Correction factor depending on technology c 2 = Correction factor depending on number of steered axles U+F = Unloaded + friction [-] B = Banking [-] S = Steering [-] i = Number of steered axles [-] 3.3 Electric system For the electric system power the standard values [W] as shown in Table 5 shall be used depending on the application and technology in combination with the alternator efficiencies: Table 5 Electrical power demand of electric system Technologies influencing electric power consumption Electric power consumption [W] Long haul Regional delivery Urban delivery Municipal utility Construction Standard technology electric power [W] 1 200 1 000 1 000 1 000 1 000 LED main front headlights – 50 – 50 – 50 – 50 – 50 To derive the mechanical power, an alternator technology dependent efficiency factor as shown in Table 6 shall be applied. Table 6 Alternator efficiency factor Alternator (power conversion) technologies Generic efficiency values for specific technologies Efficiency η alt Long haul Regional delivery Urban delivery Municipal utility Construction Standard alternator 0,7 0,7 0,7 0,7 0,7 If the technology used in the vehicle is not listed, the technology ‘standard alternator’ shall be considered in the Vehicle Energy Consumption calculation Tool. The final power demand is calculated by: where: P tot = Total power demand [W] P el = Electrical power demand [W] η alt = Alternator efficiency [-] 3.4 Pneumatic system For pneumatic systems working with over pressure the standard power values [W] as shown in Table 7 shall be used depending on application and technology. Table 7 Mechanical power demand of pneumatic systems (over pressure) Size of air supply Technology Long Haul Regional Delivery Urban Delivery Municipal Utility Construction Pmean Pmean Pmean Pmean Pmean [W] [W] [W] [W] [W] small displ. ≤ 250 cm 3 1 cyl./2 cyl. Baseline 1 400 1 300 1 200 1 200 1 300 + ESS – 500 – 500 – 400 – 400 – 500 + visco clutch – 600 – 600 – 500 – 500 – 600 + mech. clutch – 800 – 700 – 550 – 550 – 700 + AMS – 400 – 400 – 300 – 300 – 400 medium 250 cm 3 < displ. ≤ 500 cm 3 1 cyl./2 cyl. 1-stage Baseline 1 600 1 400 1 350 1 350 1 500 + ESS – 600 – 500 – 450 – 450 – 600 + visco clutch – 750 – 600 – 550 – 550 – 750 + mech. clutch – 1 000 – 850 – 800 – 800 – 900 + AMS – 400 – 200 – 200 – 200 – 400 medium 250 cm 3 < displ. ≤ 500 cm 3 1 cyl./2 cyl. 2-stage Baseline 2 100 1 750 1 700 1 700 2 100 + ESS – 1 000 – 700 – 700 – 700 – 1 100 + visco clutch – 1 100 – 900 – 900 – 900 – 1 200 + mech. clutch – 1 400 – 1 100 – 1 100 – 1 100 – 1 300 + AMS – 400 – 200 – 200 – 200 – 500 large displ. > 500 cm 3 1 cyl./2 cyl. 1-stage/2-stage Baseline 4 300 3 600 3 500 3 500 4 100 + ESS – 2 700 – 2 300 – 2 300 – 2 300 – 2 600 + visco clutch – 3 000 – 2 500 – 2 500 – 2 500 – 2 900 + mech. clutch – 3 500 – 2 800 – 2 800 – 2 800 – 3 200 + AMS – 500 – 300 – 200 – 200 – 500 For pneumatic systems working with vacuum (negative pressure) the standard power values [W] as shown in Table 8 shall be used. Table 8 Mechanical power demand of pneumatic systems (vacuum pressure) Long Haul Regional Delivery Urban Delivery Municipal Utility Construction Pmean Pmean Pmean Pmean Pmean [W] [W] [W] [W] [W] Vacuum pump 190 160 130 130 130 Fuel saving technologies can be considered by subtracting the corresponding power demand from the power demand of the baseline compressor. The following combinations of technologies are not considered: (a) ESS and clutches (b) Visco clutch and mechanical clutch In case of a two-stage compressor, the displacement of the first stage shall be used to describe the size of the air compressor system 3.5 Air Conditioning system For vehicles having an air conditioning system, the standard values [W] as shown in Table 9 shall be used depending on the application. Table 9 Mechanical power demand of AC system Identification of vehicle configuration AC power consumption [W] Number of axles Axle configuration Chassis configuration Technically permissible maximum laden mass (tons) Vehicle class Long haul Regional delivery Urban delivery Municipal utility Construction 2 4×2 Rigid + (Tractor) 7,5 t - 10 t 1 150 150 Rigid + (Tractor) > 10 t - 12 t 2 200 200 150 Rigid + (Tractor) > 12 t - 16 t 3 200 150 Rigid > 16 t 4 350 200 300 Tractor > 16 t 5 350 200 4×4 Rigid 7,5 - 16 t 6 — Rigid > 16 t 7 — Tractor > 16 t 8 — 3 6×2/2-4 Rigid all 9 350 200 300 Tractor all 10 350 200 6×4 Rigid all 11 350 200 300 200 Tractor all 12 350 200 200 6×6 Rigid all 13 — Tractor all 14 4 8×2 Rigid all 15 — 8×4 Rigid all 16 200 8×6/8×8 Rigid all 17 — 3.6 Transmission Power Take-Off (PTO) For vehicles with PTO and/or PTO drive mechanism installed on the transmission, the power consumption shall be considered by determined standard values. The corresponding standard values represent these power losses in usual drive mode when the PTO is switched off/disengaged. Application related power consumptions at engaged PTO are added by the Vehicle Energy Consumption calculation Tool and are not described in the following. Table 10 Mechanical power demand of switched off/disengaged power take-off Design variants regarding power losses (in comparison to a transmission without PTO and / or PTO drive mechanism) Additional drag loss relevant parts PTO incl. drive mechanism only PTO drive mechanism Shafts / gear wheels Other elements Power loss [W] Power loss [W] only one engaged gearwheel positioned above the specified oil level (no additional gearmesh) — — 0 only the drive shaft of the PTO tooth clutch (incl. synchroniser) or sliding gearwheel 50 50 only the drive shaft of the PTO multi-disc clutch 1 000 1 000 only the drive shaft of the PTO multi-disc clutch and oil pump 2 000 2 000 drive shaft and/or up to 2 engaged gearwheels tooth clutch (incl. synchroniser) or sliding gearwheel 300 300 drive shaft and/or up to 2 engaged gearwheels multi-disc clutch 1 500 1 500 drive shaft and/or up to 2 engaged gearwheels multi-disc clutch and oil pump 3 000 3 000 drive shaft and/or more than 2 engaged gearwheels tooth clutch (incl. synchroniser) or sliding gearwheel 600 600 drive shaft and/or more than 2 engaged gearwheels multi-disc clutch 2 000 2 000 drive shaft and/or more than 2 engaged gearwheels multi-disc clutch and oil pump 4 000 4 000