Volvo Trucks North America carefully examined the various needs of consumers and then optimized the power system for its 2017 models to improve fuel economy, power performance, and durability while allowing chassis packaging to be more efficient. Major upgrades include the addition of turbocharger technology to the Volvo D13 engine, the integration of I-Shift tiptronic gears to crawl gears, and the application of I-See predictable cruise control systems and integrated exhaust gas reprocessing systems.
Volvo Truck Optimized Power System
With Volvo's improvements to the D11 and D13 engines, the fuel efficiency of the powertrain has increased by 2.2% to 6.5% compared to the previous generation, which will also make Volvo the most efficient product in the North American market. The turbocharged D13 engine is a highly reliable power unit for long-haul vehicles. Turbocharging technology can make full use of the thermal energy in the exhaust gas to convert it into directly useable mechanical energy and increase the power value of 37 kilowatts. This part of the kinetic energy was passed to the engine again, helping to increase fuel efficiency by 6.5%.
The turbocharged version of the D13 engine will be even better if it is paired with a Volvo ultra-high performance XE powertrain kit. Through the automatic speed-reduction technology, the speed of the engine assisted by the XE package in cruise mode is lower than the average value of the trucks currently sold by 300 rpm. The turbocharged version of the D13 can be paired perfectly with the XE transmission with a rear axle ratio of 2.47:1. Car manufacturers claim that in 2015 Volvo sold 27% of its sales vehicles with the XE package.
Volvo's upgrades to the 11-litre D11 engine and the 13-litre D13 engine include a common-rail fuel system that further improves fuel efficiency by finely controlling fuel injection. The improved exhaust gas recirculation flow sensor has a new double-walled casing that reduces condensation and carbon black accumulation in low temperature environments. The low-pressure fuel system uses an optimized injection module that is integrated with the fuel filter housing for greater applicability. The two-speed coolant pump further reduces losses, thereby improving fuel efficiency. After the engine starts, the new throttle can reach the operating temperature faster.
The upgraded version of the D13 engine also uses a new wave piston to help boost the gas compression ratio. The improved flame propagation process reduces the amount of soot and improves cylinder performance. Equipped with Volvo VN, VHD and VAH models, the D13 engine's performance is 2.5% higher than that of the older models.
The 2017 D11 engine has a maximum output of 317 kW (15 kW added), a peak torque of 2100 Nm, and a 2.2% increase in fuel efficiency. D11 engine is suitable for regional LTL distribution environment and is widely used in VN, VNM 430, VNL 430, VAH and VHD models. Volvo Trucks North America expects to start mass production of the 2017 upgraded power system at the end of this year.
The I-Shift manual gearbox adds crawler gear and is very helpful for conditions that require slow start, such as concrete/asphalt construction vehicles, harvesters, dump trucks, heavy trucks, etc. Auxiliary trucks with a total weight of 100 tons successfully started. There are two versions of the I-Shift tiptronic gearbox with crawler gears to choose from: 14 forward gears, including a low-speed crawler (tooth ratio 19.38:1) and an ultra-low crawler (tooth ratio 32.04:1) , The latter with the transmission ratio of 3.58:1 rear axle, making the vehicle speed is only about 1 km / h; 13 forward gear, including a low speed crawling gear (tooth ratio 17.54:1), combined with the total transmission ratio of the rear axle is 22.35 :1.
The upgraded gearbox with 14 forward gears has a transmission ratio ranging from 41.08:1 to 1:1, which is twice the range of the normal I-Shift gearbox. According to the specific application conditions, after assessing whether it needs a very slow driving speed, the I-Shift gearbox can autonomously determine whether to use two crawling gears. The I-Shift manual gearbox with crawler gears and D11, D13 and D16 engines can be used in Volvo VHD, VNX, VNM and VNL models.
In order to improve the durability of the product, the I-Shift manual gearbox has revised the hardware. The upgraded version of the intermediate shaft has accelerated the shifting speed and enhanced the dynamic performance. The extensive gearbox improvements improve shift performance and overall durability. The optimized split synchronizer elements, the engagement sleeves and the main housing are all reinforced. The gearbox software has also been recalibrated to make shift timing more accurate under high load conditions.
I-See predicts that after the upgrade of the circulation system, it can autonomously perceive and adapt to road conditions, helping to improve fuel efficiency; the system stores 4,500 different road conditions. Embedded electronic components continuously monitor operating conditions such as road grade, driving speed, total vehicle weight, engine load, etc., and then evaluate the gear ratio that produces the highest efficiency. Before the vehicle climbs, the system adjusts the gear position to obtain a higher speed, controls the vehicle speed before the downhill slope, and tries to achieve the downhill mountain road without artificial brake condition, and if necessary, utilizes the engine brake.
The I-Shift manual gearbox is an important part of the Volvo XE powertrain package. The addition of crawler gear upgrades enhance vehicle launch performance, improve the low-speed performance of sandstone and mud land surfaces, and help maximize the XE package. The load extends from 36 tons to 50 tons.
Volvo's new integrated exhaust gas aftertreatment system integrates diesel particulate filters, selective catalytic reduction and diesel exhaust gas dosimeters into one unit. The system uses a new copper/zeolite hybrid coating to increase nitrogen oxide conversion at low temperatures and reduce pollution from tail gas emissions. The new structural design results in better thermal performance, smaller package requirements, and lower weight (7.7 kg weight loss compared to traditional, self-contained components), which optimizes fuel efficiency. This design concept provides additional space for the frame rails and increases package flexibility. The new integrated exhaust gas reprocessing system will become the standard configuration for D11 or D13 engine models, and the separate exhaust gas reprocessing system will continue to be used in D16 engine models.
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