Targeting energy savings: Gates develops truck idle reduction package, accessory drive systems
Gates Corp. has introduced the CabRunner Integrated Power System as part of its new Energy Saving product lineup.
Other Energy Saving products include the Gates E3 Drive and Electro-Mechanical Drive.
The CabRunner IPS for heavy-duty, over-the-road trucks, is essentially an auxiliary power unit designed to power all the truck’s accessories when the truck’s diesel engine is not running. Fuel use and emissions are significantly reduced by eliminating the need to idle the vehicle engine to power air conditioning, heating, lighting and hotel loads during drivers’ downtime.
The CabRunner IPS features a small, liquid-cooled, two-cylinder, 10 hp Kubota Z482 diesel engine. Unlike many APUs where the engine drives a separate generator to provide electrical power, the CabRunner IPS is integrated into the tractor’s existing heating, air conditioning and electrical systems. A reconfigured accessory belt drive system (ABDS) and pulley system design allows either the CabRunner IPS or the truck engine to drive the ABDS, which in turn drives the truck’s alternator, air conditioning and other accessories. On the highway, the truck engine is in control. After driving hours, the CabRunner IPS diesel takes over.
The CabRunner connects into the front engine accessory drive via a flexible shaft. Installation of the CabRunner IPS does not require an additional compressor, alternator or condenser. In this noninvasive installation, the existing accessories are used. The unit also keeps the main truck engine warm for starting in cold weather. The lightweight and compact CabRunner IPS is mounted on a lower frame rail and provides quiet operation with fuel supplied from the tractor’s regular tanks. The unit weighs 385 lb. and measures 25 x 18.5 x 28.5 in.
While the unit is controlled by an in-cab electronic controller, it uses existing dashboard controls for heat, air conditioning, lights, etc. According to Gates, the CabRunner IPS can reduce idling fuel consumption by 60% and greatly reduce emissions of N[O.sub.x] and C[O.sub.2] while idling. A complete installation kit for specific tractor models is being offered. The CabRunner system is an aftermarket installation for the Detroit Diesel Series 60 engine. With an MSRP of $7200 and approximately $1500 for installation, Gates estimated that, depending on fuel prices, payback could be in as little as two years.
The Gates E3 Drive can be used on both cars and trucks either as an OEM or aftermarket installation. The E3 Drive uses a two-speed accessory belt drive system that allows vehicle accessories to operate at a reduced speed while the engine still operates at driving speed.
Accessories such as the air conditioning compressor, alternator and power steering are sized to function properly when the vehicle is idling. They consume more energy at drive speeds than at idle speeds. This not only increases fuel consumption but also decreases the amount of energy available to propel the vehicle, the company said. While drivers will not notice a difference in the vehicle performance, Gates said they will see about a 5% reduction in fuel consumption and C[O.sub.2] emissions with E3 Drive. Lower accessory operating speeds will also result in greater accessory reliability and durability, Gates said.
The E3 Drive will be used on 2007 Saturn Vue, 2007 Chevrolet Malibu and 2008 Saturn Aura, Gates said.
The Electro-Mechanical Drive (EMD) starter-generator belt drive system is a stop/start system that allows the engine to stop when the vehicle is stationary such as at a traffic light, then restarts the engine almost instantaneously. EMD spins the engine to a very high cranking speed enabling a rapid, silent and fuel-efficient start. Both emissions and fuel consumption are reduced with the EMD stop/start operating strategy. Gates said independent studies have shown fuel savings of 6 to 10%, depending on the application and even more in urban traffic conditions.
The EMD system offers the potential to recover braking energy and to use stored electricity to boost acceleration. EMD will give the 2007 Saturn Vue and 2007 Chevrolet Malibu a “mild hybrid” capability.