Allison FuelSense fuel-efficient technology saves up to 20% fuel for vehicles

Allison Transmission introduces its new FuelSense fuel-saving technology, and on the basis of ensuring the power performance, optimizes the gear shift law and torque, and maximizes the transmission efficiency according to the actual vehicle load, road gradient and operating conditions. Fuel up to 20%.

The Freightliner Group is the first manufacturer to provide FuelSense technology for the North American mid-market. The M2106 chassis is equipped with an Allison 2000 or 3000 transmission and a Cummins ISB6.7 diesel engine.

The company stated that FuelSense fuel-efficient technologies can be provided to all original equipment manufacturers with Allison 1000/2000/3000 series gearboxes, and the 4000 series is being planned.

Lou Gilbert, Head of North American Markets and Global Brand Development, said: "The 20% improvement in fuel economy is in contrast to Allison's fourth-generation Fuelless fuel-saving technology and full-speed timing shift points. FuelSense Technology Used to save fuel and provide a brief product description to clarify the fuel economy of Allison transmissions for original equipment manufacturers or end-users worldwide."

Allison Transmission
Allison Transmission

The Freightliner Group is the first manufacturer to offer Allison Transmission's new FuelSense fuel economy technology. It carries an Allison 2000 or 3000 transmission and a Cummins ISB6.7 diesel on its M2 106 chassis.

“We generally target the 6th and 7th tier trucks that use the 1000/2000/3000 series. With the improvement of hardware and software, the FuelSense technology was applied to the 4000 series in July. We expect the original equipment manufacturing. In the future, the company will be able to introduce the 4000 series with FuelSense technology. Today, the FuelSense Max technology is already available in the TC10 transmission."

Allison said that the core of FuelSense fuel-efficient technology is a fifth-generation electronic control system that can improve fuel economy for many applications. Compared with the previous generation, its improvements include: multi-level acceleration control systems, and high-precision inclinometers that can optimize the shift process. These control devices can diagnose and predict, maintain performance while predicting maintenance needs, and maximize drive protection.

The system includes economic shift calibration technology to ensure that the engine works in the best speed range. Allison claims that shifting at lower rpm will improve fuel economy, with no shift cycles and guaranteed power. Dynamic shift sensing and economic shift calibration technology work together to automatically switch between economic shift calibration and higher speed power shift programs based on vehicle weight and road gradient. This improved shift sensing technology maximizes fuel savings while maintaining performance.

Another key part of the FuelSense package is the parked automatic neutral with two modes. This technology eliminates engine load while parking and reduces inefficient fuel consumption. When parking, the standard mode locks the power output against back-off, reducing the load. This mode is mainly for trucks with high frequency start and stop conditions.

Allison Company stated that FuelSense's accelerated rate management adopts some preventive measures to avoid the decrease of fuel economy and the decrease of vehicle work efficiency caused by drastic driving. This technology automatically controls engine torque based on vehicle weight and road gradient. Combine with other FuelSense fuel economy technologies to help improve fuel economy.

FuelSense includes three software packages - FuelSense, FuelSense Plus and FuelSense Max. Gilbert said: "The three packages of FuelSense technology can meet our customers' various operating conditions."

The basic FuelSense package includes economic shift calibration and dynamic shift sensing, and the FuelSense Plus software package includes the addition of both automatic parking neutral and acceleration rate management.

"Gravity Die Casting. A permanent mould casting process, where the molten metal is poured from a vessle of ladle into the mould, and cavity fills with no force other than gravity, in a similar manner to the production of sand castings, although filling cn be controlled by tilting the die."

Gravity Die Casting

Sometimes referred to as Permanent Mould, GDC is a repeatable casting process used for non-ferrous alloy parts, typically aluminium, Zinc and Copper Base alloys.

The process differs from HPDC in that Gravity- rather than high pressure- is used to fill the mould with the liquid alloy.

GDC is suited to medium to high volumes products and typically parts are of a heavier sections than HPDC, but thinner sections than sand casting.

There are three key stages in the process.

  1. The heated mould [Die or Tool] is coated with a die release agent. The release agent spray also has a secondary function in that it aids cooling of the mould face after the previous part has been removed from the die.
  2. Molten metal is poured into channels in the tool to allow the material to fill all the extremities of the mould cavity. The metal is either hand poured using steel ladles or dosed using mechanical methods. Typically, there is a mould [down sprue" that allows the alloy to enter the mould cavity from the lower part of the die, reducing the formation of turbulence and subsequent porosity and inclusions in the finished part.
  3. Once the part has cooled sufficiently, the die is opened, either manually or utilising mechanical methods.


  • Good dimensional accuracy
  • Smoother cast surface finish than sand casting
  • Improved mechanical properties compared to sand casting
  • Thinner walls can be cast compared to sand casting
  • Reverse draft internal pockets and forms can be cast in using preformed sand core inserts
  • Steel pins and inserts can be cast in to the part
  • Faster production times compared to other processes.
  • Once the tolling is proven, the product quality is very repeatable.
  • Outsourced Tooling setup costs can be lower than sand casting.

Gravity Casting Parts

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