Browse Topic: Drivetrains

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Electromagnetic compatibility (EMC) analysis for e-motors and controllers of electric two-wheelers.2024-26-009801/16/2024
The Indian government has been promoting electric vehicles through various policy initiatives, such as offering incentives and subsidies to EV manufacturers and consumers, establishing charging infrastructure across the country, and setting ambitious targets for EV adoption. These measures aim to reduce the dependence on imported fossil fuels, mitigate air pollution, and promote sustainable mobility. As a result, the demand for electric vehicles across India is steadily increasing, and the country is emerging as a lucrative market for EVs globally. An electronically commuted brushless DC (BLDC) motor usually functions for traction in electric 2-wheelers. Electric vehicles need to comply with electromagnetic compatibility (EMC) requirements. During the EMC compliance of electric two-wheelers, it is certain that the BLDC motor and its controller play an important role. This paper presents the BLDC motor and controller’s Radiated Immunity (RI) and Radiated Emission (RE) performance at
Pawar, Sneha Ravindra, Desai, Manoj Madhukar
Technical Paper
Application of blocked force methodology to an electrified beam axle from a medium-duty truck in vehicle and in a dynamometer test cell2025-01-005405/05/2023
The recent shift in propulsion choice away from internal combustion engines has increased the relevance of sound and vibration from electric motors and gearboxes. Electrified beam axles require different metrics from conventional beam axles for noise and vibration because they have multiple sources of vibration energy, including an electric motor and sometimes multiple reduction gearsets. They also require different metrics from electric drive units because they have stiff suspension connections and lack significant isolation. Blocked force is a good candidate because it can completely characterize the vibration energy transmitted into a receiver and is especially useful because it is theoretically independent of the vehicle-side structure. While the blocked force methodology is not new, its application to beam axles is relatively unexplored in the literature. This paper demonstrates a case study of blocked force measurement of an electrified beam axle from a battery electric medium
Shaw, Matthew D, Grimmer, Michael J
Technical Paper
Directivity driven simulation methodology for efficient Acoustic Encapsulation2025-01-004805/05/2023
Noise Reduction at the source level is critical to achieve the overall vehicle level interior targets. This method presents a novel approach that integrates directivity analysis with simulation techniques to optimize acoustic encapsulation design for automotive sound sources to achieve the targeted radiation levels. The foundation for this methodology is to measure the angular distribution of sound pressure levels around the noise source so called Directivity, at every frequency of interest and determine the most effective Acoustic encapsulation to achieve the targeted sound radiation. Accurate measurement of directivity in physical testing with fine angular resolutions can be complex and expensive, this study utilizes numerical simulation techniques using FEA to mitigate the challenges in mid frequency range. The scope of the study is focused on mid frequency sound pressure levels between 500-2000 Hz, which are determined to be significant contributors to overall DU noise. The first
KALUVAKOTA, SRIKANTH, Ghaisas, Nikhil, Pilz, Fernando
Technical Paper
Gear noise analysis using CTPA on a full vehicle with a rear axled differential2025-01-010305/05/2023
In this paper, an in-situ Component Transfer Path Analysis (CTPA) is conducted on a full vehicle with a Rear Axle Differential. The in-situ computation is performed with both the directly measured Frequency Response Functions (FRF) and as well as a computation using the Virtual Point Transformation (VPT). These two computations produce different blocked forces. To assess their accuracy, we exploit the principle that blocked forces should be independent of the vehicle's dynamic properties. Hence, to validate the blocked forces obtained, we modified the vehicle’s subframe by adding extra masses and conducted a "transfer validation." Here we validate if the blocked forces from the original setup can predict the vibrations in the modified configuration well, testing the accuracy of both predictions.
de Klerk PhD, Dennis, Singh, Vinod
Technical Paper
Hybrid 3D Sound Intensity and Simulation for Optimizing Acoustic Output of Truck Rear Axles2025-01-010505/05/2023
This study presents a novel methodology for optimizing the acoustic performance of rotating machinery by combining scattered 3D sound intensity data with numerical simulations, focusing on the rear axle of a truck. Using Scan&Paint 3D, sound intensity data is rapidly acquired over a large spatial area with the assistance of a 3D sound intensity probe and infrared stereo camera. The experimental data is then integrated into far-field radiation simulations, enabling detailed analysis of the acoustic behavior and accurate predictions of far-field sound radiation. This hybrid approach offers a significant advantage for assessing complex acoustic sources, allowing for quick and reliable evaluation of noise mitigation solutions. While the current application focuses on the truck's rear axle far-field radiation, the same method can be extended to predict in-cabin sound pressure, providing a versatile solution for many industrial problems.
Fernandez Comesana, Daniel, Vael, Georges, Robin, Xavier, Orselli, Joseph, Schmal, Jared
Technical Paper
eAxles gain TRACTION22TOFHP10_0110/01/2022
OEMs are developing and testing axles with integrated electric powertrains to electrify trucks of all sizes. Development of electrified drivelines is rapidly ramping up at OEMs and Tier 1 suppliers. With a wide variety of vehicles suddenly in need of electrified drivelines capable of matching or surpassing the capabilities of the existing ICE powertrains, suppliers are providing an array of solutions to meet customer needs. For the electrification of light- and medium-duty trucks, one of the technologies rapidly gaining interest is electric axle or eAxle. An eAxle is a traditional axle housing and differential incorporating an electric motor, an inverter and a thermal-management system. Most eAxles also are equipped with a multi-speed transmission for high- and low-torque demands. While the basic concept is similar across the industry, suppliers are taking varying approaches to put these axles on the roads depending on their target vehicle segment, required power output and desired
Wolfe, Matt
Magazine Article
Effect of Normalizing Heat Treatment on Improvement in Durability and Reliability of Lift Axle Tube of Commercial Vehicle2022-01-024603/29/2022
Lift axles of commercial vehicles are deployed to handle increased payload. These axles of Commercial vehicles are made of low alloy carbon steel materials. Lift axles are designed in hollow condition for weight reduction opportunity. Two types of tube materials are used for the manufacturing of lift axles. These are either Cold Drawn Seamless (CDS) tubes or Hot Finished Seamless (HFS) tube material. The vanadium micro-alloyed steel grade, 20MnV6 is an excellent choice for the manufacturing of lift axles. The 20MnV6 has favorable mechanical properties for lift axles and also offers good weldability. However, lift axles made of 20MnV6 when manufactured in hot-finished condition, shows significant scatter in terms of durability performance. This requires further heat treatment to be deployed for reducing the scatter in the durability performance and thus increasing the reliability of the lift axles. This study was undertaken to develop the heat treatment process for the 20MnV6 lift Axle
Das, Tarpan, Chauhan, Shiv, Varatharajan, Senthilkumaran, More, Hemant
Technical Paper
Validating the design of CV axle for BAJA SAE ATV2022-01-077803/29/2022
Abstract— Axle transmits power from the gearbox to the wheels. There are primarily two reasons for reducing the Axles diameter in the case of a bipod CV joint namely, to avoid overdesigning and less articulation angle. As the ATV goes in a bump/ droop, a driveshaft with a larger diameter would hit the walls of the CV joint which creates hindrance in its articulation. And, if the driveshaft is overdesigned, it will add unnecessary weight and effort to the power train which would decrease the overall performance of the vehicle. We have reduced the diameter of the axle using real-time testing data by taking the help of various machines to validate that component not failing under the given load conditions; research work is divided into 3 phases of Data collection, Axle design, and validation. Total 3 test rigs were set up for Data collection and validation, combined with axial design, material selection, heat treatment, and CAE validation. Whereas efficiency of Powertrain (CVT) is also
Bhardwaj, Vasu, Dayal, Neelesh, Saini, Rakesh
Technical Paper
Model Based Evaluation of Parallel Hybrid Concepts for a Scooter for Reduced Fuel Consumption and Emissions2022-01-080803/29/2022
IC engines are most efficient when they operate steadily in specific zones which cannot be attained in real driving conditions. Hybrids tackle this issue and improve drivetrain efficiency. Though they are used in cars and commercial vehicles they do not find application in small two wheelers especially scooters which constitute the majority of the market in several Asian Countries. The reasons are cost of implementation and need to have a suitable design. Integrating an electric motor with a conventional scooter drivetrain while retaining the base engine and the CVT is a cost effective proposition which is the motivation behind this work. Such a development will need accounting for the behavior of the belt driven CVT. In this paper a comparison between two parallel hybrid layouts has been made with the base 110cc scooter powertrain. A map based engine model and a physics based CVT model were developed and validated to simulate the base drive-train on the WMTC drive-cycle. A rule based
Mathivanan, Arulkumaran, Elango, Pradeev, Kakani, Raghav, Das, Himadri B, Ramesh, A
Technical Paper
Application Guide for Aerospace Hydraulic MotorsARP4940A (Current)11/09/2021
This SAE Aerospace Recommended Practice (ARP) is an application guide for fixed and variable displacement hydraulic motors. It provides details of the characteristics of fixed and variable displacement hydraulic motors, architectures, circuit designs, controls, and typical applications. The applications include airborne and defense vehicles with emphasis on high performance applications.
A-6C4 Power Sources Committee
Recommended Practice
Steering Control Systems - Heavy TrucksJ2425_202111 (Current)11/09/2021
This SAE Recommended Practice describes a laboratory test procedure and requirements for evaluating the characteristics of heavy-truck steering control systems under simulated driver impact conditions, as well as driver entry/egress conditions. The test procedure employs a torso-shaped body block that is impacted against the steering wheel.
Truck Crashworthiness Committee
Recommended Practice
Front Axle Kingpin Bush - Evaluation of Wear Rate in Operating Conditions2021-26-047309/22/2021
In automobiles, front axle assembly is a main load bearing member and houses steering linkages. Front axle assembly has two main parts viz. axle beam and axle arm, interconnected by a kingpin. This kingpin allows the rotation of axle arm during steering events. To avoid metal to metal contact between axle arm and kingpin, bushes are housed on the top and bottom half of the axle arm & in axle beam. Due to radial load and steering rotation, as a weak member, bushes will wear out faster. This affects the proper functioning of steering mechanism. Hence, the bushes need to be evaluated prior to its implementation in vehicle. In general, bushes are evaluated using Pin-On-Disc test as a comparative study, but it does not simulate exact boundary conditions as in vehicle. Next option is vehicle level validation but leads to more lead time and testing cost. Hence, as an optimized solution, the same vehicle operating conditions can be replicated in component level testing. Considering the
Bakthavachalam, Sathish Kumar, N, Gopi Kannan, Narasimman, Obuli Karthikeyan, R, Suresh
Technical Paper
Frictional Power Loss Distribution of Automotive Axles- Experimental Evaluation and Analysis2021-26-048309/22/2021
With more stringent emission and Co2 norms (e.g. CAFÉ, RDE), it has become extremely important for all OEMs to push their boundary and make vehicle & powertrain more and more efficient. Frictional power loss of automotive axles is major source of losses which reduce the vehicle fuel economy and increase Co2 emissions. To make axles with low frictional power loss consumption, it is first important to understand the distribution of the frictional power i.e. where the energy goes and how it is distributed in the subcomponents of axles. This paper presents the main area of frictional power loss distribution inside an automotive axle of passenger car. For experimental evaluation one frictional torque measurement test rig was prepared and axle power loss was measured by stripping down one by one component to understand the distribution of frictional losses. For this study two different size of axles were compared to understand the impact of bearing size and gear size on power loss
Ahuja, Vishal, Singh, Charanjit, Singh, Parampreet, Gummadi, Gopakishore
Technical Paper
Regulatory Norms and effect on transmission component validation2021-26-046009/22/2021
With the advent of BS VI regulations, automotive manufacturers are required to innovate the powertrains, fuel systems, exhaust and its after treatment systems to meet the regulatory requirements. The exhaust regulations can be met either by reducing the exhaust gases being generated by the engine (attacking the source) or by treating the exhaust gases in after treatment devices. The choice of the opted system varies with the manufacturer. The after-treatment devices such as catalytic converters are generally mounted in the engine compartment to take advantage of high temperature of exhaust gases to yield the reactions. Such an arrangement imposes a lot of thermal load on the peripheral components such as gearshift cables, bearings, oil seals, driveshafts etc. Thermal shields or thermal sleeve are used to address thermal issue and to protect transmission components. System level validation test requirement of transmission need to be re-visited to considering change in environmental
Tongaonkar, Yogesh Manohar, Patel, Hiral, Tendulkar, Vishveshvar, Bhosale, Vikas, halingale, Amol
Technical Paper
Analysis of Torque Waveforms in Two-Cylinder Engines for Ultralight Aircraft Propulsion Operating on 0W-8 and 0W-16 Oils at High Thermal Loads Using the Diamond-Like Carbon Composite Coating03-15-01-000507/28/2021
Piston internal combustion engines used in the propulsion of ultralight aircraft are characterized by special operating conditions, especially an increased engine oil temperature. Most of the engines intended for the drive of the propeller drivetrain are air cooled. Failure to introduce an additional cooling agent so as to absorb and remove heat from the running engine makes the average lubricating oil temperature rise to about 140°C in the pistohn ring part. With such a thermal load, changes in the moments of resistance to motion of the engine are difficult to determine in the conditions of engine tests due to difficulties in temperature stabilization. The performance of aircraft engines requires taking into account many variables that are difficult to determine, which may affect changes in the moment of resistance to movement of the engine, especially when using oils of low dynamic viscosity. The experimental tests on the engine dynamometer undertaken in the article are to fill the
Wróblewski, Piotr
Journal Article
Universal Joint End Yoke Connection (Earwork)J2301_202101 (Current)01/07/2021
This document specified the main dimensions and tolerances which affect interchangeability between end yoke earwork for the most common North American-used universal joints. Dimensions and tolerances of the mating universal joints are left to the discretion of the universal joint manufacturers. The term “earwork” refers to the configuration and geometry defining end yoke connections directly provided for universal joint cross attachment of drivelines. Earwork for certain styles of universal joint connections and flange connections have for a long time been proprietary to certain manufacturers. Over years of usage, proprietary rights have expired and the industry, as a whole, has used these earworks as standard. In an effort to tabulate some of the long-established practices, the following SAE Recommended Practice has been compiled. Manufacturers do from time to time, as the need arises, change tolerances or fits to better enhance component performance. This document has been prepared
Drivetrain Standards Committee
Recommended Practice
Universal Joint End Yoke Connection (Earwork)J2301_202101-TEST-REC (Historical)01/07/2021
This document specified the main dimensions and tolerances which affect interchangeability between end yoke earwork for the most common North American-used universal joints. Dimensions and tolerances of the mating universal joints are left to the discretion of the universal joint manufacturers. The term “earwork” refers to the configuration and geometry defining end yoke connections directly provided for universal joint cross attachment of drivelines. Earwork for certain styles of universal joint connections and flange connections have for a long time been proprietary to certain manufacturers. Over years of usage, proprietary rights have expired and the industry, as a whole, has used these earworks as standard. In an effort to tabulate some of the long-established practices, the following SAE Recommended Practice has been compiled. Manufacturers do from time to time, as the need arises, change tolerances or fits to better enhance component performance. This document has been prepared
Drivetrain Standards Committee
Recommended Practice
Electric-Powered WarshipTBMG-3823912/01/2020
GE's Power Conversion Business Warwickshire, UK +44 (0) 1788 563386
Magazine Article
Torque Limiters 101: Benefits, Types, and ComparisonsTBMG-3783710/01/2020
Modern machines can be simple — a single element translating a rotary-to-linear motion. They can also be complex — a collection of interacting mechanisms operating in a multi-dimensional plane. The commonality of these mechanisms is the element of motion that is predictable with a known torque or force and velocity.
Magazine Article
Directional Vehicle Control by Steering the Third Axle to Provide Redundancy for Steer-by-Wire Systems and Highly Autonomous Vehicles02-13-03-001509/25/2020
A way of providing steering redundancy for highly autonomous vehicles or vehicles equipped with steer-by-wire systems by steering the rear axle for directional control of the vehicle has been previously proposed. In this study, we further investigate and improve on that concept and validate it through simulation and experimental testing on a vehicle. Consequently, we show that in the case of failure of primary front axle steering system, the vehicle controller steering command (in the case of autonomous driving) or the driver’s steering command (in the case of a steer-by-wire system) can be mathematically manipulated to generate a steering input at the rear axle, which results in the same yaw rate response as if the vehicle was steered from the front, and thus providing a way to control the vehicle should a failure occur in the primary steering system.
Nhila, Amine, Williams, Dan E.
Journal Article
Top transmission engineers project big future for e-axles, advanced motors20AUTP08_0907/01/2020
A panel of high-ranking transmission and driveline engineers projected outsized adoption for electric-axle (e-axle) technology, as well as significant expansion of other driveline-electrification strategies now being adopted for new or near-future production vehicles. The engineering executives participated in a recent webinar in SAE's Leadership Roundtable series, a virtual event replacing the in-person program planned for April's SAE WCX 2020 conference that was cancelled because of the COVID-19 outbreak. Most of the panel agreed that hybrid and other electrification strategies such as e-axles are the transition from internal combustion-based drivetrains to volume production and sales of battery electric vehicles (BEVs). “Long-term, BEV is going to be the better answer,” conceded Michael Solt, global head, transmission, driveline and axle at FCA USA LLC. But the EV solution - and when volume adoption happens - “depends on which market you're in,” he added.
Visnic, Bill
Magazine Article
Multi-domain NVH Model for the Complete Electro-mechanical Power Unit2020-01-158406/03/2020
Multi-domain NVH Model for the Complete Electro-mechanical Power Unit Yashwant Kolluru, Rolando Doelling eBike Department Robert Bosch GmbH Kusterdingen, Germany yashwant.kolluru@de.bosch.com rolando.doelling@de.bosch.com Lars Hedrich Institute of Informatics Goethe University Frankfurt Frankfurt, Germany hedrich@em.informatik.uni-frankfurt.de Acoustics and vibrations are amongst the foremost indicators in perceiving the quality of power units. Analyzing these factors is vital to improve the performances of electro-mechanical systems. This paper deals with development of a generic simulation method enabling the multi-domain vibro-acoustic modelling for the drive trains. Excitation's for these systems majorly arise from the electric motor and mechanical gears. The paper initially depicts a flexible gear model for gear whining, which are generated for reasons like gear tooth bending. The forces generated from gear mesh (lumped parameter model) to gear components (multi-body model and
Kolluru, Yashwant, Doelling, Rolando, Hedrich, Lars
Technical Paper
Measurement Location Optimization of Component TPA Method for Road Noise2020-01-158106/03/2020
In this paper, an investigation on the application of a non-intrusive on-site component Transfer Path Analysis (TPA) method is presented together with the comparison with a previously performed direct blocked forces method. The latter is the more common method to determine interface forces between active and passive parts of an assembly. Force transducers are placed between the investigated structure and a rigid measurement rig. The presented comparison shows an investigated whether the faster and cheaper TPA method was able to produce relevant results. The TPA method used in this work calculated the force component contributions, without disassembly of the interfaces, through the local stiffness of multiple indicator positions per interface combined with operational measurement. The method is based on the application of an inverse-matrix model. This approach was applied to a vehicle road noise investigation carried out on a roller bench at three different roller speeds. A rough
de Boer, Onno, Iturbe, Javier, Gagliardini, Laurent, Bragado Pérez, Beatriz
Technical Paper
Numerical Analysis of the Influences of Wear on the Vibrations of Power Units2020-01-150606/03/2020
Numerical Analysis of the Influences of Wear on the Vibrations of Power Units Yashwant Kolluru, Rolando Doelling eBike Department Robert Bosch GmbH Kusterdingen, Germany yashwant.kolluru@de.bosch.com rolando.doelling@de.bosch.com Lars Hedrich Institute of Informatics Goethe University Frankfurt Frankfurt, Germany hedrich@em.informatik.uni-frankfurt.de The prime factor, which influences vibrations of electro-mechanical drives, is wear at the components. This paper discusses the numerical methods developed for abrasion, vibration calculations and the coupling between wear and NVH models of drive unit. Wear is a complex process and understanding it is essential for vibro-acoustics. The paper initially depicts finite element static model used for wear calculations. The special subroutines developed, aids in coupling the wear equations, various contact and friction formulations to the numerical model. The vibration domain model initially, focuses on calculations of mechanical excitation's
Kolluru, Yashwant, Doelling, Rolando, Hedrich, Lars
Technical Paper
Modeling and Analysis of a Heavy Vehicle with Self-Steering Axle02-13-01-000304/21/2020
Commercial vehicles often incorporate self-steering axles to meet the axle load requirements while providing improved maneuverability, reduced off-tracking, and reduced tire and pavement wear. Market forces promote the design of more efficient self-steering axle products with reduced weight and more features. Manufacturers also work to differentiate their products through unique designs and new concepts. Traditional design methods for self-steering axles include empirical and trial-and-error methods to set the steering mechanism design parameters based on known design baselines and prior experience. For innovative new concepts that are too far from the traditional designs, it is desirable to have alternative ways for evaluating the expected performance. This article introduces a reduced-order model that allows the rapid analysis of the steering dynamic behavior of self-steering axles. The model combines a pendulum-like lateral stiffness model with the axle steering dynamics which are
Delorenzis, Damon, Ayalew, Beshah
Journal Article
Research on Control Strategy Optimization for Shifting Process of Pure Electric Vehicle Based on Multi-Objective Genetic Algorithm2020-01-097104/14/2020
With more and more countries proposing timetables for stopping selling of fuel vehicles, China has also issued a “dual-slope” policy. As electric vehicles are the most promising new energy vehicle, which is worth researching. The integration and control of the motor and gearbox have gradually become a hot research topic due to low cost with better performance. This paper takes an electric vehicle equipped with permanent magnet synchronous motor and two-gear automatic transmission without synchronizer and clutch as the research object. Through the action of the motor, gearbox and shift actuator in the shifting process, the whole vehicle dynamics is modeled in each stage of shifting, a method for determining a short-term driving style intensity factor for decision shifting is proposed, three evaluation indexes of the shift quality of electric vehicle are put forward, the control parameters affecting the shift quality are analyzed, and the mathematical relationship between the shift
Lei, Yulong, Zhang, Jingxu, Fu, Yao, Jia, Fuchun, Wang, Binyu
Technical Paper
An Interval Analysis and Optimization Method for Generated Axial Force of Automotive Drive Shaft Systems2020-01-091804/14/2020
To study the generated axial force (GAF) of the drive shaft system more accurately and effectively, this paper introduces the interval uncertainty into the research focusing on the GAF. Firstly, an interval uncertainty model for calculating the GAF is proposed based on the Chebyshev polynomials and an analytical model of the GAF. The input torque, the articulation angle, the rotation angle of the drive shaft system, the pitch circle radius (PCR) of the tripod joint and the friction coefficient are regarded as interval variables. Secondly, the upper and lower bounds of the proposed GAF model under interval uncertainty parameters are calculated quickly with the vertex method. Then the interval uncertainty optimization of the GAF under uncertainty parameters is performed. The upper bound of the response interval of the GAF is taken as the optimization object. Finally, the proposed model is verified by experiments, while the interval uncertainty analysis and optimization of the GAF are
Feng, Huayuan, Rakheja, Subhash
Technical Paper
Research on Fractal Friction Model between Balls and Arc Raceways inside a Ball Joint2020-01-109304/14/2020
During the operation of the ball joint, its service life and transmission efficiency are affected by the internal friction. Taking the ball joint as the research object, based on fractal theory, the friction between the steel ball and the raceway inside the ball joint of an automotive drive shaft system is studied in this paper. During the analysis, the friction between the steel ball and the arc raceway is regarded as the friction between a sphere and an arc raceway surface. In order to describe the friction state more accurately, this paper proposes a correction coefficient to modify the distribution function of contact asperities in the plane, and obtains the distribution function of contact asperities between the sphere and the arc raceway surface. The correction coefficient is related to the load, the size parameters and the material parameters of the steel ball and the raceway. Then based on the modified distribution function, the fractal models of the friction coefficient, the
Feng, Huayuan, Li, XiHua
Technical Paper
Development of New Hybrid Transaxle for Mid-Size Sports Utility Vehicles2020-01-085004/14/2020
Toyota has developed a new Hybrid (HV) transaxle P810 for Mid-Size SUVs to improve fuel efficiency and power performance. The transaxle was developed based on Toyota's new development strategy - Toyota New Global Architecture (TNGA). By adopting technologies to shorten overall length of the transaxle, installation into the same engine compartment of Mid-Size sedans have been realized while also improving the motor output. This paper will introduce technologies regarding the new mount structure for shortening overall length, and furthermore, noise reduction related to this mount structure.
Nobuyasu, Seitaro, Iwata, Shigetsugu, Nishigaya, Masabumi, Hagino, Yoshiteru, Ito, Masatoshi, Aihara, Hiroshi
Technical Paper
John Deere Power Systems expands lineup, introduces new 13.6- and 18-liter enginesSAE-MA-0434403/11/2020
Driven by customer feedback, Deere claims clean-sheet designs for the new engines with improved performance, serviceability and integration.
Shuttleworth, Jennifer
Magazine Article
Bollinger Motors showcases second-gen Class-3 EV prototypes19AUTP11_1611/01/2019
Bollinger Motors recently unveiled its second-generation Class-3 EV prototypes. The start-up, based in Ferndale, Michigan, revealed the latest beta of its B1 SUV and B2 truck prototypes, highlighting the amount of in-house engineering and design. As a Class 3 (GVWR 10,001 to 14,000 lb.) vehicle, the Bollinger Motors truck and SUV are in the same classification as a Ford F-350 or Ram/Chevy 3500 truck. “This is the only all-electric Class 3 truck with off-road capability,” founder and CEO Robert Bollinger said of the B2. “Our beta version vehicles look very much like the original alpha prototype vehicle that debuted in 2017, but almost every component on our B1 SUV and B2 truck prototypes is different,” said Karl Hacken, Bollinger Motors chief engineer. The four-door B1 and B2 are identical from the C-pillar forward, with the B2 truck's 139-in wheelbase stretching 20 inches longer than the SUV. Both aluminum-bodied prototypes feature a vehicle-length 16×14-in pass-through enabled by
Buchholz, Kami
Magazine Article
Towed Vehicle Drivetrain Test Procedure Passenger Cars, Vans, and Light-Duty TrucksJ1144_201910 (Current)10/28/2019
This SAE Recommended Practice provides a means for evaluating the drivetrain of the passenger car, van, or light-duty truck being towed under a variety of road conditions. The towing equipment used is explained in SAE J1142. NOTE—For the purpose of this document, the drivetrain refers to the combination of a specific transmission (make, model, size, type), a specific differential assembly (make, model, size, type), and a specific driveline, if required.
Motor Vehicle Council
Recommended Practice
Setting Preload in Heavy-Duty Wheel BearingsJ2535_201910 (Current)10/07/2019
This SAE Recommended Practice applies to the four primary, large volume applications in the class 7-8 heavy-duty market place, as specified in SAE J1842: a “N” trailer axle b “R” powered rear axle c “FF / FG” nonpowered front axle d “P” trailer axle This document applies to on-highway applications. It is not applicable to those applications that exceed the GAWR ratings or the load line restrictions listed in columns “A,” “B,” and “C” of Table 1. Load lines are measured from the inboard bearing cup backface as shown in 3.4. This document establishes preload force values only. The methodology to obtain these force values must be determined by the fastener supplier and/or axle assembler. This document reviews the bearing system. It is NOT intended to prescribe (new or existing) axle and/or hub manufacturers’ ratings and/or specifications.
Truck and Bus Wheel Committee
Recommended Practice
ERRATUM03-11-01-0004.110/07/2019
Barday, Denis, Fossier, Charlotte, Changenet, Christophe, Ville, Fabrice, Berier, Vincent
Journal Article
GKN spreads premium propshaft tech to quiet pickup cabins19AUTP10_1110/01/2019
It may seem a long way in engineering and NVH terms from premium European cars such as Audi's A5 and A7 to light duty trucks, but GKN Automotive has bridged that gap with its latest lightweight all-wheel drive (AWD) modular propshaft. Many pickups suffer a significant amount of unwanted NVH emanating from the front propshaft, with its two universal or CV joints and an interconnecting shaft positioned below and close to the passenger cabin. But now GKN Automotive has “re-characterized” its premium car driveline system to an entirely different vehicle category. “With a traditional truck front propshaft, the level of noise entering the cabin is perceived as a drone,” explained Michael Miller, GKN's propshaft product technology manager. “We've worked on applications of our new technology where the cabin NVH levels have been dramatically reduced. Positive results stem from the combination of joints used in our lightweight modular front propshaft.”
Birch, Stuart
Magazine Article
Modelling and Control of a Novel Clutchless Multiple-Speed Transmission for Electric Vehicles2019-24-006309/09/2019
Conventional electric vehicles adopt either single-speed transmissions or direct drive architecture in order to reduce cost, losses and mass. However, the integration of optimized multiple-speed transmissions is considered as a feasible method to enhance EVs performances, (i.e. top speed, acceleration and grade climbing), improving powertrain efficiency, saving battery energy and reducing customer costs. Perfectly in line with these objectives, this paper presents a patented fully integrated electric traction system, as scalable solution for electrifying light duty passenger and commercial vehicles (1.5-4.2 tons), with a focus on minibuses (<20 seats). The adoption of high-speed motor coupled to multiple-speed transmission offers the possibility of a relevant efficiency improvement, a 50% volume reduction with respect to a traditional transmission, superior output torque and power density. The proposed clutchless four-speed transmission is specifically conceived and designed to have
Malafronte, Ludovica, Grandone, Mauro, Lega, Alberto, Pennese, Michele, Pianese, Cesare
Technical Paper
THE LIMITATIONS OF THE UNIVERSAL JOINT08001406/25/2019
VANDERBEEK, H.
Technical Paper
Kinematic Analysis and Simulation of the Double Roller Tripod Joint2019-01-152606/05/2019
The kinematic model of the double roller tripod joint is established in order to analyze its kinematic characteristics and provide theoretical basis for its application and improvement. By means of spatial coordinate transformation, the translational and rotational motion equations of the rollers relative to the tracks and trunnions, the motion equation of the center of the tripod and the equations of the input/output angular displacement error and bending angle are derived. The motion simulation of the double roller tripod universal joint was carried out in ADAMS so as to verify the established kinematic model. The results show that the rollers of the double roller tripod joint only have periodic translational motions relative to the tracks while the rollers have both periodic translational and rotational motions relative to the trunnions. The tripod’s center does the circular motion on the tripod plane with the angular velocity 3 times of the input angular velocity. The input/output
Qiu, Yinyuan, Shangguan, Wen-Bin
Technical Paper
New Half Shaft Bench Test Methodology for NVH Characterization2019-01-155806/05/2019
The main purpose of this paper is to develop a reliable bench test to understand the vibratory behavior of the half shafts under applied torque comparable to an idle condition. In some cases, the half shaft path is a major factor influencing the idle vibration in the vehicle. At idle condition vehicle vibrations are caused by engine excitation and then they pass through different paths to the body structure. Half shaft manufacturers generally characterize shaft joints for their frictional behavior and typically there is no data for vibration characteristics of the half shaft under idle conditions. However, for predictive risk management, the vibratory behavior of the half shaft needs to be identified. This can be achieved from measured frequency response functions under preloaded test conditions. This bench test enables manufacturers to conduct comprehensive design of experiments on the impact of powertrain vibration input while transmitting through the half shaft into the vehicle
Siavoshani, Saeed, Vesikar, Prasad Balkrishna, Yuan, Wei, Abbas, Ahmad, Sturla, Francisco Antonio
Technical Paper
Integrated Multi-Physics Simulation for Full-Vehicle Low Frequency NVH Optimization in HEVs2019-01-145506/05/2019
The recent automotive industry trend towards electrification has created new challenges for NVH engineers. These challenges stem from new powertrain architectures and their complex interactions, the governing control strategies which aim to optimize energy management, and new unmasked sources of excitation. Additionally, vehicle manufacturers are attempting to reduce hardware testing in order to rapidly satisfy increasing production demand and to minimize its costs. Hence, to meet the above-mentioned challenges up front in the development process of Hybrid Electrical Vehicles (HEVs) while balancing competing design objectives of drivability, durability and NVH, a simulation-led design and optimization is required. NVH problems are often the result of mechanisms that originate through complex interactions between different physical domains (flow, electromagnetic, structural/mechanical, control logic, etc.) and the assembly of individual components into a complete system. Therefore
Gomez, Llorenc Foraste, Zeman, Jonathan, Liu, Jack
Technical Paper
Heavy-Duty Aerodynamic Testing for CO 2 Certification: A Methodology Comparison2019-01-064904/02/2019
Aerodynamic drag testing is a key component of the CO2 certification schemes for heavy-duty vehicles around the world. This paper presents and compares the regulatory approaches for measuring the drag coefficient of heavy-duty vehicles in Europe, which uses a constant-speed test, and in the United States and Canada, which use a coastdown test. Two European trucks and one North American truck were tested using the constant-speed and coastdown methods. When corrected to zero yaw angle, a difference of up to 12% was observed in the measured drag coefficients from the US coastdown procedure and the EU constant-speed test. The differences in the measured drag coefficient can be attributed, among others, to the assumptions in the speed-dependence of the tire rolling resistance and axle spin losses, the data post-processing required by each methodology, unaccounted frictional losses in the transmission, the behavior of the automated manual transmission during the coastdown run, and the yaw
Rodriguez, J. Felipe, Delgado, Oscar, Demirgok, Berk, Baki, Cem, Besch, Marc, Thiruvengadam, Arvind, Rexeis, Martin, Röck, Martin
Technical Paper
Experimental Investigation of Sliding on Tripod Constant Velocity Joints2019-01-501703/13/2019
An automotive transverse transmission is articulated by mechanisms called constant velocity joints (CVJ). The joint allows the suspension to move freely. Its frictional behavior is not well known. However, the CVJ functional analysis makes it possible to identify important mechanical losses due to the friction of component elements. This article will focus on tripod side. An analysis of its behavior by designing and constructing a rig in order to qualify the sliding inside of the tulip between tracks and rollers has been initiated. Thanks to three-dimensional (3D) printing and sport camera a new approach was established.
Ripard, Valentin, Ville, Fabrice, Cavoret, Jérôme, Ruzek, Michal, Charles, Pierre, Diaby, Moussa
Technical Paper
ABS Exciter Ring Location StandardizationJ1730_201902 (Historical)02/11/2019
This SAE Recommended Practice establishes the Antilock Brake System [ABS] sensor interface and envelope dimensions for standardizing the location of the ABS rings mounted on the inner end of spoke wheels, hubs and hub-rotor assemblies on the following axle designations. a FF b FL c FC d FH e L f R g U h W j N k P
Truck and Bus Wheel Committee
Recommended Practice
Optimizing Steering Column Layout and UJ Phase Angle to Enhance Vehicle Dynamics Performance2019-01-501002/05/2019
Vehicle dynamics is one of the most important vehicle attributes. It is classified into three domains, the longitudinal, vertical, and lateral dynamics. This paper focuses on optimizing the lateral vehicle dynamics which is driven by the straight ahead controllability and cornering controllability of the vehicle. One of the important parameters that dictates these sub-attributes is the steering ratio. Therefore, designing the right steering ratio is critical to meet the vehicle “specific” targets. Significant amount of work has been done by many researchers on variable steering ratio by implementing variable gear ratio (VGR) rack, active steering, and steer-by-wire systems. This paper discusses the methodology and considerations to optimize the steering ratio for a constant gear ratio rack by optimizing the steering column layout, viz., orientation and the phase angle in universal joints. A detailed analysis of steering system layout is done to optimize the steering ratio to enhance
Puvvula, Praneeth, Ravuri, Susheel, Dubal, Ajit, Salunkhe, Swapnil
Technical Paper
Drivetrain Analysis and Optimization of a Two-Speed Class-4 Electric Delivery Truck2019-01-500101/18/2019
The development, analysis, and comparison of battery electric class-4 medium-duty trucks equipped with three possible powertrain layouts, namely, direct drive, single-speed gearbox, and two-speed transmission options, are discussed in this paper. The problem definition is included and the performance evaluation criteria for the proposed truck architectures are defined, namely, acceleration time, top speed, and efficiency. Designs of four new traction motors are proposed and their benefits compared for use in medium-duty electric trucks (e-trucks). The procedure for gear-ratio range selection is outlined, the ranges of gear ratios for the single-speed gearbox and two-speed transmission powertrains being calculated for each of the proposed electric traction motors. The simulation and gear-ratio optimization tasks for the e-trucks are formulated. The energy consumption of the e-truck with the three possible powertrain combinations is minimized over the six driving cycles. The most
Morozov, Alexei, Humphries, Kieran, Rahman, Tanvir, Zou, Ting, Angeles, Jorge
Technical Paper
Development of 2 Speed Automatic Transmission for Battery Electric Two Wheelers2019-26-010901/09/2019
Improving vehicle performance in terms of both torque and power is a strong customer need in both conventional and electric vehicles. In this work, different two speed automatic transmission (AT) concepts are developed to improve the energy efficiency and performance of battery electric two wheelers. Developed transmission systems are simple, compact and cost effective and results in relatively high energy efficiency of an electric motor. The unique shift control strategy ensures motor to operate at higher efficiency zones to minimize the overall energy consumption. Virtual simulations of electric vehicle were carried out for different driving conditions and optimal transmission ratios were determined. Mechanical behaviors such as gear shift characteristics, linear and angular velocities, inertial forces of each components are analyzed by using Multi body dynamics simulation. Forces predicted here are further used for durability studies of these components. The developed system
Satyanarayana, PS, Ayyappath, Prajod, Jaiswal, Animesh, Iyer, Ramkumar, Charantimath, Siddalingesh
Journal Article
Design and Development of a Retrofit Solution for Converting a Conventional LCV into Parallel Hybrid Electric Vehicle2019-26-011701/09/2019
In today’s scenario, the emission norms are getting stringent day by day due to an increased level of pollution. The world is shifting towards low carbon footprint which made it necessary to adopt efficient technologies with fewer emissions. The hybridization of vehicles has resulted in improved efficiency with lower emissions which can fulfil the near future emission norms. Retrofitting of hybrid components into a conventional IC engine vehicle is so far the best way to achieve better performance both economically and technologically. This research is primarily focused on the design and development of a novel retrofit solution of P3x architecture for the light commercial vehicle. This retrofit solution is different from other hybrid solutions in terms of powertrain. It contains an innovative add-on powertrain along with the existing powertrain. This additional powertrain consists of a pair of helical gears followed by a chain and sprocket as a coupler for traction motor. The newly
Kumar, Ravindra, Kaundinya, Ashwin Subramanian, Shah, Ravindra, Ghugal, Swapnil, Kale, Jyoti Ganesh, Thorat, Vivek, Barik, Saroj, Shinde, Sanket
Technical Paper
Electric Vehicle with Multi-Speed Transmission: A Review on Performances and Complexities08-07-02-001112/04/2018
Electric vehicles (EVs) with multi-speed transmission offer improved performances compared to those with single speed transmission system in terms of top speed, fast acceleration, or gradeability along with driving range. In this study, relevant literature is extensively analyzed to explore the performances and associated complexities with multi-speed automatic manual/mechanical transmission (AMT) system in EVs. In EV powertrain, the only torque generator component is electric motor, which is not equally efficient throughout wider speed range. To the other end, vehicles need to run at different speeds in diverse driving conditions. The study shows that multi-speed transmission system enables efficient operation of electric motor by choosing an appropriate gear at different driving torque-speed demands and thus contributes to achieve desired vehicle performances at minimum energy consumption. To demonstrate the differences, both dynamic and economic performances with multi-gear system
Ahssan, Md Ragib, Ektesabi, Mehran Motamed, Gorji, Saman Asghari
Journal Article
Analysis of Rotational Vibration Mechanism of Camshaft at High Engine Speed in Engines with In-Line Four-Cylinder DOHC Configuration2018-32-007210/30/2018
In engines having an inline four cylinder DOHC configuration, the rotational vibrations of camshaft increase at high engine speeds above 10000 rpm, causing an increase of tension in the cam chain. It is therefore difficult to realize an optimum designing of a cam chain system when the durability has to be taken into considerations. Using the simulation we analyzed in this research how the rotational vibrations and tension increase at high engine speeds in an inline four cylinder DOHC engine. As its consequent, it is understood that the increases of rotational vibrations and tension caused by the resonance of the spring mass vibration system in which the cam chain serves as springs and the camshafts as the equivalent masses. Also it is found out that the vibration system is of a unique non-linear type in which the resonance of the fourth order frequency is also excited by the crankshaft torque fluctuations of the second order frequency. Furthermore, it is uncovered that the natural
Hatakeyama, Ryoh, Niino, Tadashi
Technical Paper
Millers Oils tackles EV lubrication challenges18AUTP10_0910/01/2018
Although electric vehicles (EVs) often are extolled as “low-maintenance” alternatives to conventional internal-combustion (IC) propulsion and its brew of critical fluids that require routine maintenance, EV drivetrains also rely on proper lubrication-and in many senses pose performance challenges at least equal to those of IC drivetrains. Not the least of electric drivetrains' unique stresses on lubrication: electric motors can deliver maximum torque at zero rpm.
Birch, Stuart
Magazine Article
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