Allison, the automatic transmission specialists, is rolling out FuelSense, a fuel-saving solution that automatically adjusts shift schedules, selects neutral and manages vehicle acceleration to maximise transmission fuel economy. Last month, Kenworth became the third OEM to adopt the package. Manlio Alvaro, director of EMEA Marketing, tells just-auto that testing indicates FuelSense has the potential to reduce fuel consumption by up to 20 per cent when compared to the previous generation of Allison Electronic Controls without these fuel saving features.
What is FuelSense?
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FuelSense is an integrated set of software packages and electronic controls that can deliver quantifiable fuel savings of up to 20 per cent. It groups our torque converter-based transmission technology with new software/calibration fuel economy features – EcoCal, Dynamic Shift Sensing, Neutral at Stop and Acceleration Rate Management – to maximise fuel efficiency based on vocation and driving conditions. These features automatically sense when fuel can be saved at each stage of a vehicle’s duty cycle.
How do these new features work?
EcoCal is a defined set of low- and ‘super’ low-speed shift schedules designed to keep engine speed at its optimum point, maintaining superior performance without shift cycling. Dynamic Shift Sensing automatically selects between EcoCal and higher-speed shift schedules based on a vehicle’s actual payload and operating grade. When cruising, it selects the highest gear range possible to minimise engine speed and reduce fuel consumption.
Neutral at Stop reduces or eliminates engine load while the vehicle is stationary, further reducing fuel usage and emissions. It also locks the output to help prevent vehicle roll-back while in neutral.
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By GlobalDataAcceleration Rate Management has five settings, which are selectable by the OEM, and mitigates aggressive driving practices by controlling engine torque based on the vehicle’s grade and load. Performance will be tailored according to the pre-set level of maximum vehicle acceleration rate.
Will FuelSense replace any of your existing technologies?
We took a holistic approach to get the best out of Allison’s 5th Generation Electronic Controls and our transmission architecture. FuelSense enhances previous technologies by adding ultralow shift speeds and introducing new fuel-saving features such as Neutral at Stop.
Is FuelSense available for all Allison transmissions and engine brands?
FuelSense packages require Allison 5th Gen controls and are now available on Allison 1000/2000/3000/4000 Series,TC10 and our family of Torqmatic Series of bus automatics.
How should fleet managers decide which FuelSense package is best for them?
There are three packages available: the basic FuelSense package contains 5th Gen Controls, EcoCal and Dynamic Shift Sensing. FuelSense Plus also includes Neutral at Stop and FuelSense Max adds Acceleration Rate Management – the top-of-the-line package.
Any customer who demands fuel economy in addition to high productivity (number of loads, deliveries, etc.) will benefit from our FuelSense packages. FuelSense Plus is advantageous for applications that require significant idling such as a distribution truck or city bus. For applications where there are significant changes in load during the day, such as a city bus or refuse vehicle FuelSense Max is able to manage vehicle acceleration rate in an empty or lightly loaded condition thus saving fuel.
What evidence do you have to support your claims for FuelSense’s superior fuel efficiency?
Internal testing, simulations and real-world fleet results compared to Allison products without FuelSense validate our fuel-efficiency claims. We have tested with school, city and transit buses, regional tractors, and refuse and distribution fleets. What we have consistently seen is significant savings across these applications. As FuelSense is deployed globally, we will continue to gather customer data and testimonials from fleets worldwide.
How can you be sure FuelSense will generate fuel savings of up to 20 per cent?
FuelSense packages were tested against a baseline – vehicles equipped with Allison 4th Generation Electronic Controls, but without advanced fuel-economy features. Based on testing, simulation results and duty-cycle analysis, we expect to see up to 20 per cent savings in high start/stop duty cycles.
Not every vehicle will achieve that, but we do anticipate that FuelSense will benefit every customer working in fuel-sensitive applications. Exactly how much depends upon the package selected, fleet size, vehicle configuration, powertrain technology, duty cycle, driver and a variety of other variables. The potential savings are significant and can be achieved without compromising overall fleet performance or productivity.
How do FuelSense fuel savings compare to manuals and AMTs?
Our TC10 coupled with the FuelSense Max package has shown to average 5 per cent better fuel economy compared to manuals and AMTs in fleet testing. There are numerous examples from around the world where Allison customers are already experiencing equal or better fuel economy compared with manuals and AMTs in a variety of applications.
What is the value of FuelSense to OEMs?
FuelSense benefits OEMs in much the same way it adds values to fleets – by advancing overarching fuel-economy and emission-reduction efforts. It also allows OEMs to offer a fully-automatic propulsion solution to the most fuel-economy sensitive customers. We are seeing some OEMs using FuelSense to differentiate themselves in this critical area.
When and where will FuelSense be available?
The remainder of this interview is available on just-auto’s QUBE Global light vehicle transmissions and clutches market- forecasts to 2030
