Reducing Fuel Consumption and Greenhouse Gas Emissions of Medium- and Heavy-Duty Vehicles, Phase Two Final Report (2020) / Chapter Skim
Currently Skimming:
11 Manufacturing Considerations
11 Manufacturing Considerations
Pages 277-289
The Chapter Skim interface presents what we've algorithmically identified as the most significant single chunk of text within every page in the chapter.
Select key terms on the right to highlight them within pages of the chapter.
From page 277... ...
The approach of this report for manufacturing considerations will focus primarily on the emerging technologies for the latter part of the next decade that may have significant influence over fuel consumption reduction. As stated in Chapter 12, several technologies with strong fuel consumption improvement potential also carry the burdens of high current and projected manufacturing costs, posing challenging pathways through the stages of low volume growth and rational consumer choice to reach the volumes necessary to achieve improved, acceptable cost effectiveness.
|
From page 278... ...
11.2 ADVANCED MANUFACTURING TECHNOLOGIES CONSIDERED There are many advanced manufacturing technologies presently under development, and with the increasing capabilities in advanced computational methodologies, greater application of more accurate and representative mathematical models and simulations, and a broader global collaborative approach many more will be generated before the Phase III regulations are in effect. To cover every known advanced manufacturing technology would be exhaustive, so this report will only highlight a few of those that currently appear to have highly relevant potential for this report's primary directions.
|
From page 279... ...
Additive manufacturing is advancing quickly in the medical and dental fields, from creation of dental implants and prosthetic devices to 3D printing of life-like human tissue.1 In the industrial sectors, the leading usages of additive manufacturing are in aerospace, where low-volume complex, lightweight structures that must operate in harsh environments and intricate manufacturing jigs and fixtures can be produced faster and better than by conventional methods. Successively more challenging applications are expanding in the aerospace industry, such as gas turbine engine blades under development by Siemens2 and CFM International's LEAP engine fuel nozzles (Figure 11-1)
|
From page 280... ...
Chapter 4 details the progress and prognosis for engine thermal efficiency improvements, recognized as one of the most significant factors in vehicle fuel consumption. Thermodynamic cycle losses in the form of heat transfer to coolant and exhaust have eluded rapid improvement for decades, partly because of limitations in the way engine parts need to be designed to be economically manufactured by traditional, predominantly subtractive manufacturing processes.
|
From page 281... ...
generation WHR system from Cummins utilizes a low–global warming potential refrigerant that transfers exhaust heat energy to a mechanical turbine expander made by Cummins Turbo Technologies, shown in Figure 11-3. The complex WHR turbine expander rotor and blade geometries could be candidates for additive manufacturing processing, as are the turbocharger compressor and turbine wheels in the conventional turbochargers, and can be considered an extension of what the aerospace industry is doing for gas turbine engine blades to achieve higher-performance geometries with materials impractical for conventional manufacturing processes.
|
From page 282... ...
In this context, the priority directions to reduce transportation industry fuel consumption should identify from the thousands of parts and tools used in a vehicle which ones are the highest-yield target opportunities, and the output of the ever-improving additive manufacturing modeling and simulation tools should identify which materials, processes, and equipment would
|
From page 283... ...
should strongly pursue cross-agency coordination of projects and priorities to accelerate the prime additive manufacturing technologies for benefiting fuel consumption improvement. Finding: Additive manufacturing technologies appear to offer opportunities for improving the ROI of high-effect fuel-consumption-improving technologies, such as hybrids, WHR, and mass reduction.
|
From page 284... ...
Returning to the premise stated in the introduction to this chapter, the priority areas for greater manufacturing technology emphasis are those that would reduce the most fuel consumption if penetration rates can be increased, 6 See http://www.autonews.com/article/20160229/OEM06/302299967/gms-sharks-hunt-for-innovations (accessed December 20, 2019)
|
From page 285... ...
For example, in this arena, employing thermal fluids and solids enhanced with nanoscale particles may provide an opportunity to improve heat transfer from the exhaust to the organic Rankine cycle expander. Another attractive emerging manufacturing technology utilizing nanoparticle technology is in catalyzed exhaust aftertreatment systems.
|
From page 286... ...
11.2.4 Conclusion Manufacturing innovation has been shown to offer strong potential for improving the cost and effectiveness of product technologies in general, and this chapter has highlighted only a sampling of those emerging and rapidly expanding technologies that presently appear capable of markedly improving the cost of some of the highestpotential fuel consumption reduction technologies, thereby improving their natural penetration rate increase in the nation's fleets. It should be pointed out that, given the long time between this report and Phase III rulemaking, the trajectories for these technologies are not easily projected, and the emergence of additional new manufacturing innovations will undoubtedly occur.
|
From page 287... ...
Recommendation 11-4: The status and, if necessary, mid-course correction of the national advanced manufacturing strategy, as it applies to enabling fuel consumption improvement, should be included within the interim review recommended in Chapter 2 of this report. Recommendation 11-5: NHTSA and EPA, through their representation in or coordination with the relevant entities within the Department of Commerce, the Department of Energy, and the Office of Science and Technology Policy, should prioritize development and application of additive manufacturing, materials joining processes, nanostructured materials, and other yet-to-be-identified promising manufacturing innovations on those parts and systems that offer the greatest potential for fuel consumption and GHG reduction.
|
From page 288... ...
With respect to changes to the powertrain for reducing fuel consumption, the study found, for example, that reducing friction calls for "tighter machining, balancing, assembly tolerances, and bearing specifications, which all have a potential to increase manufacturing cost." The report also noted that standardized engine features can enable manufacturing flexibility, such as engines with varying numbers of identical in-line cylinders being manufactured on the same line as are V-6 and V-8 engines. The report identified this as a major trend among original equipment manufacturers.
|
From page 289... ...
2015. Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges.
|
Key Terms
This material may be derived from roughly machine-read images, and so is provided only to facilitate research.
More
information on Chapter Skim is available.