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Power
& Mobility
8/9/2018
Improving Military Ground Vehicle Fuel Efficiency
through the Identification of More Fuel Efficient
Gear Oils (FEGOs) – Development of a Stationary
Axle Efficiency Test Stand and Test ProcedureAllen S. Comfort
Adam BrandtSteven Thrush
DISTRIBUTION STATEMENT A. Approved for public release; distribution unlimited.
Power &
Mobility
8/9/2018 DISTRIBUTION STATEMENT A. Approved for public release; distribution unlimited.
Running Out of Fuel Is No Fun
Power &
Mobility
8/9/2018 DISTRIBUTION STATEMENT A. Approved for public release; distribution unlimited.
How Can We Reduce Fuel Usage?
• Design more efficient engines and powertrains
• Recover waste energy (e.g., regenerative braking)
• Improve aerodynamics
• Reduce weight of vehicles
• Use low rolling resistance tires
• …
How about changing your oil?
The only way to reduce fuel usage of legacy vehicles without expensive retrofitting!
Past project:
Fuel efficient engine oil: 1.5 – 4%Fuel efficient transmission fluid: 0.5 – 1%
Fuel efficient gear oil (FEGO): 1.0 – 2.0%
Synthetic Multi-Purpose Lubricant (SMPL)
Power &
MobilityAxle Efficiency Losses
8/9/2018 DISTRIBUTION STATEMENT A. Approved for public release; distribution unlimited.
Power &
Mobility
8/9/2018 DISTRIBUTION STATEMENT A. Approved for public release; distribution unlimited.
Gear Oil Nomenclature
Example:
75W - 90
Winter Grade: Acts
like a 75 grade in cold temperatures
Summer Grade: Acts
like a 90 grade in hot
temperatures
Current military standard gear oils:• 75W-90
• 80W-90• 85W-140
Power &
Mobility
8/9/2018 DISTRIBUTION STATEMENT A. Approved for public release; distribution unlimited.
Vehicle Fuel Consumption Testing
SAE J1321 Fuel Consumption Test Procedure - Type II
Power &
Mobility
8/9/2018 DISTRIBUTION STATEMENT A. Approved for public release; distribution unlimited.
Axle Efficiency – Test Stand Concept
• Lower qualification test costs
• Modular
• Excellent repeatability
• High precision and discrimination
Power &
Mobility
8/9/2018 DISTRIBUTION STATEMENT A. Approved for public release; distribution unlimited.
Completed Axle Efficiency Test Stand
Temperature Control• Two possible
procedures
1. Allow the axle to obtain its own steady-state temperature
2. Control the temperature to a set valuea. Based on vehicle data a
temperature of 175°F was chosen
Power &
Mobility
8/9/2018 DISTRIBUTION STATEMENT A. Approved for public release; distribution unlimited.
Efficiency Test Development -MTV Drive Cycle Replication
Approximate Vehicle Velocity
Pinion Input Speed (rpm)
Pinion Input
Torque
Pinion Input
Power
88.5 km/h(55 mph)
3207
141 Nm(104 lbft)
47 kW(64 hp)
56 km/h(35 mph)
2033
91 Nm(67 lbft)
19 kW(26 hp)
48 km/h(30 mph)
1723
89 Nm(66 lbft)
16 kW(22 hp)
40 km/h(25 mph)
1469
73 Nm(54 lbft)
11 kW(15 hp)
32 km/h(20 mph)
1157
61 Nm(45 lbft)
7 kW(10 hp)
24 km/h(15 mph)
86561 Nm
(45 lbft)
6 kW(7 hp)
16 km/h(10 mph)
68476 Nm
(56 lbft)
5 kW(7 hp)
8 km/h(5 mph)
294108 Nm
(80 lbft)
3 kW(5 hp) *Gear Oil Temperature: 175°F
90.00
90.50
91.00
91.50
92.00
92.50
93.00
93.50
94.00
94.50
95.00
Trans_05r Trans_10r Trans_15r Trans_20r Trans_25r Trans_30r Trans_35r Trans_55r
Eff
icie
ncy
, [%
]
Step
Average Efficiency, per Test Run
75W140 R1
75W140 R2
75W140 R3
75W140 R4
75W140 R5
80W90 R1
80W90 R2
80W90 R3
80W90 R4
80W90 R5
75W90 R4
75W90 R5
75W90 R6
75W90 R7
75W90 R8
%𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 =𝑃𝑜𝑤𝑒𝑟𝑂𝑢𝑡𝑃𝑜𝑤𝑒𝑟𝐼𝑛
∗ 100
Power &
Mobility
8/9/2018 DISTRIBUTION STATEMENT A. Approved for public release; distribution unlimited.
Efficiency Test Development -Efficiency Mapping
MTV Axle Efficiency Map – 80W-90 MTV Axle Efficiency Map – 75W-90 MTV Axle Efficiency Map – 75W-140
Power &
Mobility
8/9/2018 DISTRIBUTION STATEMENT A. Approved for public release; distribution unlimited.
Efficiency Test Development -Proposed Federal Test Method (FTM)
Test StepApproximate Vehicle Speed
Pinion Input Speed (rpm)
Pinion Input
Torque
Pinion Input
Power
FTM_25_45040 km/h(25 mph)
1469610 Nm
(450 lbft)94 kW
(126 hp)
FTM_35_25056 km/h(35 mph)
2033338 Nm
(250 lbft)72 kW(97 hp)
FTM_25_32540 km/h(25 mph)
1469440 Nm
(325 lbft)68 kW(91 hp)
FTM_45_17572 km/h(45 mph)
2600237 Nm
(175 lbft)65 kW(87 hp)
FTM_15_40024 km/h(15 mph)
865542 Nm
(400 lbft)49 kW(66 hp)
FTM_55_10488 km/h(55 mph)
3207141 Nm
(104 lbft)47 kW(64 hp)
FTM_35_6756 km/h(35 mph)
203391 Nm
(67 lbft)19 kW(25 hp)
FTM_25_5440 km/h(25 mph)
146973 Nm(54 lbft)
11 kW(15 hp)
FTM_15_4524 km/h(15 mph)
86561 Nm
(45 lbft)6 kW(8 hp)
FTM_5_808 km/h(5 mph)
294108 Nm(80 lbft)
3 kW(4 hp)
1
3
2
4
5
9 8 7
6
10
1
2
3
4
5
6
7
8
9
10
Power &
Mobility
8/9/2018 DISTRIBUTION STATEMENT A. Approved for public release; distribution unlimited.
Efficiency Test Development -Proposed FTM Results 75W-90 versus 80W-90
90.00
90.50
91.00
91.50
92.00
92.50
93.00
93.50
94.00
94.50
95.00
95.50
96.00
96.50
97.00
97.50
98.00
Eff
icie
ncy
, [%
]
Step
Average Efficiency, per Test Run
80W90 R1
80W90 R2
80W90 R3
80W90 R4
80W90 R5
80W90 R6
75W90 R1
75W90 R2
75W90 R3
75W90 R4
75W90 R5
75W90 R6
MTV Efficiency Results - Proposed Final Test Points 75W-90
-1.50%
-1.30%
-1.10%
-0.90%
-0.70%
-0.50%
-0.30%
-0.10%
0.10%
0.30%
0.50%
0.70%
0.90%
1.10%
1.30%
1.50%
Eff
icie
ncy
Im
pro
ve
me
nt
Test Step
75W-90 Efficiency Improvement
Power &
Mobility
8/9/2018 DISTRIBUTION STATEMENT A. Approved for public release; distribution unlimited.
Efficiency Test Development -Proposed FTM Results 75W-140 versus 80W-90
90.00
90.50
91.00
91.50
92.00
92.50
93.00
93.50
94.00
94.50
95.00
95.50
96.00
96.50
97.00
97.50
98.00
Effi
cie
ncy
, [%
]
Step
Average Efficiency, per Test Run
80W90 R1
80W90 R2
80W90 R3
80W90 R4
80W90 R5
75W140 R1
75W140 R2
75W140 R3
75W140 R4
75W140 R5
-1.50%
-1.30%
-1.10%
-0.90%
-0.70%
-0.50%
-0.30%
-0.10%
0.10%
0.30%
0.50%
0.70%
0.90%
1.10%
1.30%
1.50%
Eff
icie
ncy
Im
pro
ve
me
nt
Test Step
75W-140 Efficiency Improvement
MTV Efficiency Results - Proposed Final Test Points 75W-140
Power &
Mobility
8/9/2018 DISTRIBUTION STATEMENT A. Approved for public release; distribution unlimited.
Efficiency Test Development -Proposed FTM Results for LTV
-1.50%
-1.30%
-1.10%
-0.90%
-0.70%
-0.50%
-0.30%
-0.10%
0.10%
0.30%
0.50%
0.70%
0.90%
1.10%
1.30%
1.50%
Eff
icie
ncy
Im
pro
ve
me
nt
Test Step
75W90 - Efficiency Improvement
-1.50%
-1.30%
-1.10%
-0.90%
-0.70%
-0.50%
-0.30%
-0.10%
0.10%
0.30%
0.50%
0.70%
0.90%
1.10%
1.30%
1.50%
Effi
cie
ncy
Imp
rove
me
nt
Test Step
75W140 - Efficiency Improvement
LTV Efficiency Results - 75W-90 LTV Efficiency Results - 75W-140
2040
57
11
16
23
16 26
3
8
= Quasi-Stribeck Number (rpm/torque)
Power &
Mobility
8/9/2018 DISTRIBUTION STATEMENT A. Approved for public release; distribution unlimited.
Efficiency Test Development -Temperature Control Revisited
MTV Axle Lubricant Temperature with
Fixed Cooling Rate – 80W-90 vs. 75W-90
MTV Axle Lubricant Efficiency with Fixed
Cooling Rate – 80W-90 vs. 75W-90
Power &
Mobility
8/9/2018 DISTRIBUTION STATEMENT A. Approved for public release; distribution unlimited.
Efficiency Test Development -Temperature Control Revisited
MTV Axle Lubricant Temperature with
Fixed Cooling Rate – 80W-90 vs. 75W-140
MTV Axle Lubricant Efficiency with Fixed
Cooling Rate – 80W-90 vs. 75W-140
Power &
Mobility
8/9/2018 DISTRIBUTION STATEMENT A. Approved for public release; distribution unlimited.
Summary and Conclusion
• An axle efficiency test stand was designed and built using axles from light and medium tactical vehicles
• The test stand was used to develop efficiency maps of a standard 80W-90, and fuel efficient 75W-90, and 75W-140 gear oils
• A test procedure was developed and the efficiency results correlated well with results from vehicle fuel consumption testing
• A fuel efficient 75W-90 provided efficiency benefits over the entire range of operating conditions tested compared to 80W-90
• Investigation of efficiency and temperature response under conditions of fixed cooling rate targets demonstrated that lower power operating points require a lower operating temperature for more realistic efficiency results (e.g., 140°F vs. 175°F)
• Final step to implementation as a Federal Test Method will be to finalize a method to distill the efficiency results down to a single number (or small set) that can be used for qualification