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Innovative Aerodynamics for Class 8 Long-Haul Trucks: The SmartTruck Program

The SmartTruck Program, a collaboration between BMI Corporation and PepsiCo/Frito-Lay, is pioneering aerodynamic innovations for Class 8 long-haul trucks. Utilizing advanced CFD technology from aerospace, the program aims to enhance fuel efficiency and reduce drag, potentially saving billions in fuel costs and cutting CO2 emissions significantly. The initiative involves designs, prototypes, and rigorous field testing to achieve its ambitious fuel efficiency performance goals, tailoring technology for the trucking industry’s specific needs.

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Innovative Aerodynamics for Class 8 Long-Haul Trucks: The SmartTruck Program

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  1. The SmartTruck Program Precision computer model of PepsiCo/Frito-Lay ProStar PepsiCo/Frito-Lay has provided 4 tractors and 6 trailers for testing and modification BMI Corporation

  2. SmartTruck OverviewOur Partners Kennedy Space Center

  3. The SmartTruck Program Experience from Aerospace, Racing and Ground Transportation CFD Technology was developed in the Aviation and Aerospace industry Complicated flow fields required advanced analysis methods New tools were developed at NASA and Boeing to assist Aerodynamic Engineers in measuring and optimizing complex airflows AERION FLAPS 25 NAVIER STOKES SOLUTION AOA = 22, M= .2 These same tools are utilized today in motorsports & transportation BMI Corporation & SmartTruck Products

  4. Aerion Super Sonic Business Jet • Activity: • Program Management (COO) • High Speed Design • Low Speed Design • Optimization • Status: • Preliminary Design Complete • Meets Goal Performance • Refinement Continuing • Commercialization BMI Corporation & SmartTruck Products

  5. Boeing MD-80 Winglet • Activity: • High Speed Design • Low Speed Design • Optimization • Status: • Preliminary Design Complete • Meets Performance Goals • Mechanical Design Underway BMI Corporation & SmartTruck Products

  6. Racing Daytona Prototype Indy Car NASCAR Our racing background helps the SmartTruck Team adapt aerospace technology to ground transportation • Our racing background gives the SmartTruck Team the Ability To: • Rapid Prototype • Precision Fabricate • Field/Track Test BMI Corporation & SmartTruck Products

  7. Ford Hydrogen Fuel Cell Concept Car • Activity: • Ford Hybrid Vehicle • 1 Yr. Aero Development Program • Status: • Aero Goals Met ( Exceeded) • Attractive, Practical Design BMI Corporation & SmartTruck Products

  8. Bright Automotive Plug-In Hybrid Van BRIGHT Automotive Release 2.1 Analysis Full Navier Stokes, SA Turbulence Model Grid size 24,000,000 Cells Rotating Wheels, Moving Road 70 MPH, Sea Level BMI Corporation & SmartTruck Products

  9. CFD Model BMI Corporation & SmartTruck Products

  10. Tractor Underside BMI Corporation & SmartTruck Products

  11. Trailer Suspension BMI Corporation & SmartTruck Products

  12. Gridding BMI Corporation & SmartTruck Products

  13. Aerodynamic Assessment and Opportunities • Of all vehicles operating on the road, class 8 long haul trucks would benefit most from low drag designs • Class 8 long haul drive cycle: 80% highway vs. 20% non-highway • Class 8 long haul trucks average 125,000 miles per year (100,000 highway miles) • However, among common vehicles on the road, class 8 long haul trucks have the highest drag • If all 1.3 million long haul trucks operated with Cd = .26, the US would annually: • Save 6.8 billion gallons of diesel • Reduce 75 million tons CO2 • Save $19 billion in fuel costs BMI Corporation & SmartTruck Products

  14. Class 8 Truck Drag Assessment:High Level Drag Assessment of Today’s Best Tractor/Trailer BMI Corporation & SmartTruck Products

  15. Class 8 Truck Drag Assessment: High Level Drag Assessment of Today’s 53’ Dry Van Trailer BMI Corporation & SmartTruck Products

  16. Class 8 Truck Drag Assessment:Detailed Breakdown of a Tractor - Trailer BMI Corporation & SmartTruck Products

  17. Aerodynamic Opportunities 10 MPG 8.3 MPG 6.0 MPG BMI Corporation & SmartTruck Products

  18. Background on SmartTruck:Fuel Efficiency Performance Goals BMI Corporation & SmartTruck Products

  19. SmartTruck Trailer Designs:Overview of the Trailer Challenge – Low Pressure Wake BMI Corporation & SmartTruck Products

  20. Next Steps • Design and Optimization • Tractor Improvements • Blank Sheet Design BMI Corporation & SmartTruck Products

  21. Q & A BMI Corporation & SmartTruck Products

  22. Supplimental Slides BMI Corporation & SmartTruck Products

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