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MAN shows TGX parallel diesel hybrid truck concept, previews CNG in TGM trucks at IAA; gearbox cooperation with Scania

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MANs TGX hybrid concept at IAA. Click to enlarge.

At the IAA, MAN (part of the Volkswagen Group) presented a concept diesel-electric parallel hybrid version of its long-haul TGX truck. (MAN showed the Metropolis research truck, a range-extended electric refuse collection truck developed in collaboration with Benteler Engineering Services for use in the city, at IAA 2012, earlier post.) Also at IAA, MAN gave a preview of the CNG technology in trucks with a TGM distributor chassis; the CNG trucks are due in the market in 2016. (MAN has an established line of CNG-powered buses.)

TGX Hybrid. The MAN TGX concept hybrid will be driven by a parallel hybrid system, supplied by a 440 hp (328 kW) diesel engine and an electric motor with 130 kW drive power. The electric motor acts as an alternator when coasting and braking. A MAN TipMatic gearbox transfers power to the rear axle.

MAN TGX
The current TGX offers a range of Euro 6 6-cylinder engines: the D20 and D26 with 360 to 480 hp as well as the new D38 with 520, 560 or 640 hp.
Common Rail injection reduces the generation of particles, while exhaust-gas recirculation (EGR) reduces NOx. The two-stage turbocharging optimizes engine tuning in the Euro 6 version. This improves the exhaust gas values across a wide speed range.
The low-temperature cooling system with its own dedicated circuit makes charge-air cooling more effective in the Euro 6 version. Due to the increased heat input through the EGR and the two-stage turbocharging, the charge air needs to be re-cooled to a greater extent.
The electronic TopTorque torque enhancer function allows the engines powertrain manager to make 200 N·m more torque available in the two top gears 11 and 12.

The recovered energy is stored in a Li-ion battery with a capacity of about 3.8 kWh. The TGX hybrid uses this energy to increase torque for the diesel engine on gradients. The diesel engine can therefore be driven in the most economical engine speed range and the additional torque avoids downshifts on hills, thereby saving fuel.

The hybrid concept in the TGX is designed to optimize the TCO (total cost of ownership). The focus here is on fuel savings as a result of fewer gearshifts and recovering kinetic energy when braking and driving downhill. Tests show that this design has the potential to save around 8% of fuel, corresponding to a CO2 reduction at the same level.

As the electric motor serves only to assist the diesel engine, the system is lean and saves weight, with the hybrid components in the system weighing around 400 kg (882 lbs). For this reason, MAN has focused the range of functions on fuel savings alone, as a system that allows a heavy truck to travel short distances using electric power alone would by contrast be technologically more complex, and the battery would be significantly heavier, larger and more expensive.

MAN is presenting the TGX hybrid concept at the IAA to show the advantages of the hybrid drive in long-distance transport for operators and the environment. We are looking forward to discussions with our international customers.

—Heinz-Jrgen Lw, Sales & Marketing Chair at MAN Truck & Bus

A short video, produced by Benteler, of the Metropolis range-extended electric refuse truck, showing it in operation as well as providing an overview of the drive system and components.

For the presentation of the TGX Hybrid, MAN noted that different hybrid concepts are required due to the very different drive requirements for buses and trucks in city, in long-distance transport, and in special vehicles. As examples, the city bus uses a series diesel-electric hybrid; the Metropolis research vehicle is targeted for tasks in the city; and the TGX Hybrid is targeted for long-haul applications.

TGM CNG. The 18-tonner is driven by a 6.9-liter six-cylinder CNG engine with 280 hp (209 kW) and is equipped with a 12-speed MAN TipMatic gearbox. The Euro 6 turbo engine has a maximum torque of 1150 N·m (848 lb-ft), providing the same tractive force as a diesel engine of this performance class.

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MAN TGM CNG. Click to enlarge.

The tank at the IAA exhibit holds 140 kg of natural gas, which is stored in eight compact aluminium tanks with carbon coating. Steel tanks able to hold up to 140 kg natural gas are also available. This tank capacity allows 18-tonners to cover some 400 km (49 miles) in distributor urban transport and around 700 km (435 miles) on secondary roads.

CNG trucks are therefore not only of interest to municipalities with gas-powered bus fleets and their own filling stations, MAN noted. The economic advantage of CNG vehicles is that the fuel costs are around 2035% lower than those of a diesel vehicle, depending on the application.

In addition, the TGM with CNG drive is up to 3 dB quieter in interior noise and accelerated drive-by.

CNG vehicles are particularly suitable for tasks in cities and usage in the early morning or late in the evening, for which there are particular noise restrictions. CNG trucks can be used for food and coolant transportation in the distribution segment, parcel services and as retail delivery trucks. The use of municipal vehicles for waste collection is typical in the industry. As a manufacturer of CNG vehicles, MAN can build on more than 40 years of experience and has sold more than 8,000 natural gas buses, chassis and natural gas engines for energy generation in this time. The five-door articulated city bus Lions City GL CNG is Bus of the Year 2015.

MAN and Scania begin gearbox cooperation. Separately, MAN and Scania announced that they, as separate brands within the Volkswagen Group, will be cooperating on vehicle gearboxes in the future. As part of this collaboration, from 2016 Scanias gearbox hardware will be gradually implemented in TGS and TGX series MAN vehicles. MAN will develop the gearbox software for the optimal gear changing strategy. Testing of the first prototype vehicles has already begun.

The aim is also to develop the subsequent generation of the current Scania gearbox portfolio together. The details of the cooperation are currently being drawn up. ZF Friedrichshafen also remains a supplier for MANs trucks and buses.

It means that Scania and MAN will be using a collectively developed, innovative gearbox concept in their vehicles in the future. Our aim with this cooperation is for components which set global benchmarks for commercial vehicle technology to emerge. That's why we want to cooperate on development projects with Scania in future too, provided that these do not impact upon their respective brands.

—Anders Nielsen, CEO MAN Truck & Bus AG

MAN and Scania will remain separate brands in line with Volkswagens multi-brand strategy, with sales and service activities also following this principle. This project is a major step forward in the collaboration carried out by the commercial vehicle alliance which consists of MAN, Scania and Volkswagen Commercial Vehicles. The alliance enables the companies to exchange their know-how as much as possible and make immediate use of the synergies of the collaboration.

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