Abstract
One of the primary concerns in the automotive industry is energy saving, protecting the global environment and fuel consumption reduction. The main purpose of this study is to develop optimal supplementary parts for reduction of aerodynamic force of highway tractor and trailer combinations to reduce aerodynamic drag, without negatively affecting the usefulness or profitability of the vehicles. In this article, the possibility to improve the aerodynamic performance for boosting fuel economy of trucks is studied by optimal designing of supplementary devices. That will be carried out by using integrated computational fluid dynamic and genetic algorithm for simulation and geometry optimization of applied devices. Also, simulation results are verified by experimental results in wind tunnel. For this purpose, effects of various supplementary devices and configuration are added to space between cabin and cargo compartment to stabilize the vortex and decrease the drag resistance force. Finally, the geometry of appended device with considering the installation and packing conditions is optimized by using a genetic algorithm. Through the analysis of airflow contours and optimization procedure, results indicate that using two plates at the sidewalls of the gap with optimized length and installation angle can reach the maximum reduction of drag force and fuel consumption by 20 and 10%, respectively.
Keywords
Introduction
In recent years, with the continuous increasing of road transportation, fuel prices, and emissions, the aerodynamic styling of heavy truck becomes an important issue development of truck Cab, which is one of the main targets for truck manufacturers. In order to evaluate the vehicle aerodynamic performance, wind tunnel and finite element method (FEM) are utilized by manufactures. Wind tunnels are used to simulate air (fluid) flows over vehicles, which is in contact (friction) with the surrounding environment.1–4 Given the high cost and required equipment for the wind tunnel, the alternative simulation method based on FEM is applied to check the vehicles aerodynamics performance (Figure 1).5,6
Pressure flow around vehicle in wind tunnel.
As shown in Figure 2, aerodynamic forces include Drag, Lift, Lateral force, Rolling Moment, Pitching Moment, and Yawing Moment. These forces are effective in fuel economy, emissions, vehicle controllability, and noise-vibration-harshness (NVH).
Aerodynamic forces.
The drag force is the dominating resistance force, which acts on commercial vehicles and trucks in highway. Drag force at high speeds is one the main resistance force that increases fuel consumption significantly. Increasing speed from 55 to 65 mph, for example, increases drag by about 40%, resulting in a 10 to 15% increase in fuel consumption.7,8 Drag reduction techniques are mainly divided into two categories; design optimal body shape in manufacturing process, which is usually in conflict with body structure and style parameters. Adding supplementary parts such as Front Fairing, Side Fairing, Rear Fairing, Roof Reflector, Corner blades, Gap seal, forebody, Back blade, and Base Flap that are illustrated in Figure 3.
Adding supplementary parts for drag force reduction.
Heavy vehicles because of their large frontal area and bluff shapes are aerodynamically inefficient and take up to 65% of fuel to overcome drag. As mentioned by Hsu and Davis,
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it is estimated that with a drag reduction of about 40%, 10,000 USD/year/vehicle can be saved. Because of the high cost of development and required testing for any changes in sample model in the wind tunnel. So, before production, original sample FEM is utilized to analyze the influence of aerodynamic parameters and finding optimal body shape. In the case of trailers and trucks, the cab shape has huge impact on the formation of airflow around the body and creation of vortices (Figures 4 and 5). Therefore, proper design of the cabin can significantly affect the drag reduction. Previous studies10,11 investigated the effects of different types of roof deflectors, side deflectors, and chassis fairings on vehicle aerodynamic improvements. Mazyan
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analyzed the effect of applying drag reducing devices on a sedan, sports utility vehicle (SUV), and a tractor-trailer model to improve the fuel consumption of the vehicle. They used computational fluid dynamic (CFD) to analyze the percent drag reduction due to the use of different drag reducing devices. Ortega et al.
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employed a full-scale wind tunnel to investigate the changes in the drag coefficient that arise from the installation of supplementary devices for class 8 heavy vehicles. They obtained a better understanding of how different devices affect the performance of other devices installed simultaneously.
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Singh et al.
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could reach drag reduction of up to 18% by implementation of base flaps in heavy and road vehicles. Håkansson and Lenngren
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presented devices for Volvo FH trailer. Their results demonstrate that fuel Aerodynamic trailer devices have a great potential of reducing drag compared with the tractor. Also, they showed that Side skirts and Frame extension have a large potential to prevent turbulence and vortices in these regions.
Effects of cab shape and height upon the drag coefficient. Effects of wind screen height and angle on air flow over cab roof.

In commercial vehicles such as trailers and trucks, drag force can be reduced by adding supplementary parts. Figure 6 demonstrates the overall effects of each regions role on vehicle drag coefficient. Also, it can be found the main supplementary parts on drag reduction, such as Roof Reflector, Corner blades, Gap seal, forebody, Skirt, Front Fairing, Back blade, and Base Flap.
Percentage of drag coefficient regions on a tractor-trailer truck.
Previous studies7,15 demonstrated that in commercial vehicles, total reduction of drag coefficient results in 12% improvement in fuel economy. Average mileages of trailers over a year is about 10,000 mile, which with considering 35 l/100 km fuel consumption rate, it consumes 56,000 l (12,300 gallon) per year. By reducing the drag coefficient reduction, about 12% of fuel consumption reduces, which is equivalent to 4000 pound for a year. Beside that with reduction of drag force, vehicles emissions and NVH reduces significantly. Kassim and Filippone 16 used various aerodynamic retrofitting techniques to reduce heavy vehicle drag and fuel consumption. They numerically simulated realistic on-road operations to represent the effectiveness of these retrofits on various vehicle weights and driving cycles. Their results demonstrated that fuel economy improvement could be achieved from less than 1% to almost 9% annual mileage. Englar 17 studied the effect of the gap between the tractor and trailer. He used a generic truck model for wind tunnel tests. Hyams et al. 18 investigated unsteady aerodynamic flows affecting the fuel economy of Class 8 trucks by numerical solutions of the unsteady Reynolds-averaged Navier–Stokes equations using a parallel implicit flow solver have been given to investigate unsteady aerodynamic flows affecting the fuel economy of Class 8 trucks. Comparison of their numerical results with experimental shows that with increasing yaw angle, the accuracy decreases, whilst excellent agreement with experimental data was obtained for the 0° yaw angle while the 10° case had good agreement.
In this research, a comprehensive CFD study are conducted to investigate the influences of supplementary parts on drag reduction of trucks. For this purpose, geometry of main add-on parts are optimized by using genetic algorithm (GA) to reduce fuel consumption, emission, and NVH. The results of the current study provide optimal supplementary parts usage for improvement of heavy vehicle aerodynamic characteristics.
Modeling and simulation
Governing fluid equations
Two-dimensional equations governing laminate viscous incompressible flows including dimensionless momentum equation are as follows:
In this article, the equations are solved by using pressure-based method in external flows. Vector representation of the governing equations is as follows:
Vehicle longitudinal model
In order to develop longitudinal vehicle dynamics, a force balancing along the vehicle longitudinal axis yields:
Relationship between changes in drag and changes in fuel consumption are presented as
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:
In this article, Volvo truck FH12 specification and dimension is considered for the modeling (Figure 7). As well as the large dimensions of the complete trailer model, the governing equations will go up, which result in complication and time consuming of FEM. Because of the symmetry of the vehicle, half of the vehicle is modeled to reduce required time for procedure simulation (Figure 8).
Complete vehicle model. Half-car model. Trailer model in virtual.


In order to simulate the aerodynamic behavior vehicle, as shown in Figure 9, CFD analysis of proposed model is carried out in virtual wind tunnel. Then boundary conditions are defined as Figure 10. The boundary conditions of the trailer model in 1 atm and 25℃ and steady state are defined. Boundary condition for input air is considered only as air velocity and pressure of output air intends to be zero. Also, surrounded wind tunnel walls are considered non-slip and trailer body proposed to be no friction surface. Finally, trailer meshed model is illustrated in Figure 11. Boundary conditions for CFD analysis of the trailer are presented in Table 1.
Boundary condition. Wind tunnel and trailer mesh model. Boundary condition specifications.

Optimization
In order to minimize the drag force with considering the shape and layout of add-on parts, a constrained optimization procedure are developed based on GA. For this purpose, as shown in Figure 12, the length (L) and angle (θ) of the sidewall (supplementary part) are considered as variables to minimize drag force while its layout and variables range are assumed as a constraint function. GAs are adaptive heuristic search algorithm based on the evolutionary ideas of natural selection and genetics. As such, they represent an intelligent exploitation of a random search used to solve optimization problems. GA operates on a population of individuals (potential solutions), each of which is an encoded string (chromosome), containing the decision variables (genes). After an initial population is randomly generated, the algorithm evolves the through three operators:
Selection which equates to survival of the fittest in the defined range of variables; Crossover which represents mating between individuals to produce new population; Mutation which introduces random modifications to avoid local minimums. Ga procedure.

Parameters and variables amount and range.
In this article, the optimization problem of vehicle aerodynamic force is examined by variation of the truck sidewall geometry change. For this purpose, the length and angle of the side wall (supplementary part) as variables are optimized by GA to minimize drag force and prevent fluid separation by considering its layout and installation. The optimal selection of parameters for drag force minimization is then formulated as a constrained optimization problem as follows20,21:
Some of the optimization parameters are shown.

Results
Validation
To validate the simulation, obtained results in this article are compared with experimental and test results. 22 In other words, due to high costs of optimization procedure in experimental and test procedures, several FEM simulation is utilized and optimized, then based on best solution, sample model is developed and tested. The accuracy of developed model depends on geometry, element, and material. In aerodynamic models, boundary conditions and fluid parameters should be determined properly.
Stenvall
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compared the aerodynamic performance (drag force and coefficient) for various trailers (Volvo, Scania, Mercedes, Renault, DAF). Figure 14 demonstrates the resistance force increase relative to the speed. It is obvious that Volvo FH driven at summer has the best performance at high speeds, because of the combination of low wind speeds, low air density, and a proper aerodynamic shape.
Force increase relative to the resistance at 5 km/h.
22

Also in Stenvall, 22 experimental aerodynamic coefficient for various trailers based on various parameters are calculated in Table 2. These results are used for comparison with simulation and optimization results of Volvo trailer body.
Because of that, the tests for trucks FH12 was carried out without the cargo in the wind tunnel, so for comparison, the simulation results with experimental one, trailer body for FEM analysis is modeled without cargo. Simulation model is presented in Figure 15 and air density and wind speed are considered 1.294 kg/m3 and 23.6 m/s.
Pressure counter and air flow around FH12 model.
Simulation results in Figure 15 presents drag force as 2672 N. In comparison with actual one (2300 N) in Stenvall, 22 it is 9% more, which is due to simplification of the model curves.
Optimal structure for drag reduction
As shown in Figure 6, one of the main add-on parts in reduction of drag force are front fairing and filler plates installed on the gap between the cargo compartment and cab.
Gap between cab and container
The gap between cab and cargo filled by three method. In the first method, as shown in Figure 16(a), plates are installed on the sidewalls of cabin transversely. In the second method, two side plates are used to stabilize the vortex of air through the gap between the cargo compartment and the cab (Figure 16(b)). Figure 16(c) illustrates the third configuration that one plate mounted in the center of gap transversely. In this method, air vortexes are stabilized, which reduces drag force and improves aerodynamic performance.
Various configuration of filler plates installed on the gap between the cargo compartment and cab: (a) Two plates at side walls; (b) two plates at center; (c) one plate at center.
Front fairings
As shown in Figure 17, this device is installed on around cargo compartment front surface. It deflects airflow and prevents flow separation, which causes reduction of drag force. Figure 18 illustrates pressure counter and airflow velocity around trailer.
Trailer model with front fairings. Pressure counter and airflow velocity around trailer with front fairings.

Efficiency of various add-on devices on drag reduction
Calculation example of aerodynamic resistance assuming constant rolling resistances. 22
It is fairing obvious that installation of two plates at gap sidewalls provide the most efficiency between various configurations in drag reduction. In other words, the optimal device among studied add-on devices is two filler plates installed on the gap sidewalls between the cargo compartment and cab. Therefore, in the optimization procedure, its geometry optimizes by using GA.
Geometry optimization of supplementary part
Effects of various add-on devices on drag force.
Optimization results.

Solution convergence in GA iterations.

Child generation for 20 initial population.
Table 5 presents the optimization results for 50 iterations and selected solutions are with various length and angles are determined for each case.
Result demonstrates that GA with considering packaging and installations constraints determines the best optimal solution of device geometry. It demonstrates that the best angle and length are 10.52° and 0.74 m, which results in 0.88% drag reduction (force 45.8 N reduces). Figure 21 depicts the airflow and velocity counter around the trailer with optimized sidewall device mounted on the trailer Volvo FH12.
Airflow and velocity counter around trailer.
Fuel tank blade
In this article, we develop a blade for fuel tank to reduce the drag and fuel consumption. Simulation results for velocity streamline around fuel tank and vehicle with blade is shown in Figure 22. Also, the drag force and coefficient for with and without fuel tank blade are presented in Table 6.
Velocity streamline with fuel tank blade. Effects of fuel tank blade and optimization on drag.
It is obvious that with addition an optimized orib blade of fuel tank, drag coeffiecient and force reduce about 0.3% and 0.5%, respectively.
Fuel consumption and emissions
In this section, fuel consumption are compared in two cases; optimized supplementary parts and initial one. As shown in Figure 23 by optimizing the supplementary parts, fuel rate over a traveled path reduces significantly by 20%. Fuel consumption reduction decreases the emissions and the cost of energy. Overall, fuel consumption rate and mileages of trailers are considered to be 40 l/km and 10,000 km per year.23,24 According to these assumptions, 800 l fuel can be saved in each trailer, which results in a significant reduction of emissions and costs in transportation system.
Engine operation and fuel rate comparision in two cases.
Conclusion
Fuel consumption is always one of the key issues in the truck design, which significantly effects on emissions and costs. Therefore, the primary objective of this article is to design and optimize the drag force reduction devices, which has the main role in improving fuel efficiency and emissions. For this purpose, a trailer with optimized appended devices was developed and effects of each of them on the reduction of drag force investigated. At the first step, in order to verify the proposed model and simulation, enhanced results for the basic model were compared with the experimental data in wind tunnel. 22 Then main add-on devices effects on improving aerodynamic performance compared. Results indicated that the installation of two plates at gap sidewalls provide the most efficiency in drag and fuel consumption reduction. Finally, to minimize the drag force, the geometry of plates at the sidewalls optimized by GA with considering the installation and packing constraints, which results in obtaining the optimal length and angle of installation. Findings showed that with installation, the optimized plates at the side of the gap between cabin and cargo compartment, drag force reduces about 20%, which, it can reduce fuel consumption about 4 to 10% over a year. Also, it was shown that with using all optimal supplementary devices, fuel rate reduces about 800 l for each trailer in a year, which can cause a significant emission and energy cost reduction in the transportation system.
Footnotes
Declaration of conflicting interests
The author(s) declared no potential conflicts of interest with respect to the research, authorship, and/or publication of this article.
Funding
The author(s) received no financial support for the research, authorship, and/or publication of this article.
