Browse Topic: Off-highway vehicles and equipment

Items (1,257)

Development of the Mild Hybrid System for Off-Road Machinery

2024-32-006704/18/2025

In recent years, the importance of achieving carbon neutrality has been highlighted in response to the escalating severity of climate change. In the leading automobile market, the share of electric vehicles is gradually expanding, especially in passenger car sector. However, it is not same in commercial vehicle sector. In the off-road machinery market, as with electrification in commercial vehicles, the factors such as the need to install charging infrastructure and the requirement for large batteries to expand operating duration are significant challenge to full electrification. As one of the realistic solutions toward carbon neutrality for off-road machines, methods to utilize both internal combustion engines (ICE) and their applied products are being reconsidered. Under the circumstances, we have developed a mild-hybrid (MH) system for small off-road machinery. This system adopts a 48V power supply in order to minimize size of the system offers as a “Drop-in” package solution. This

Koyama, Kazuaki, Kimura, Ryota, Nagamori, Yuko, Horita, Tatsuhiko, Nosaka, Kento

Wheel Analysis Process Considering Bolt Torque Sequencing for Assembly and Disassembly

2024-26-029001/16/2024

This paper is centered on developing a methodology to simulate actual physics of the assembly and disassembly process for rear wheel components of the tractor / off highway vehicle. The components, cast wheel and sleeves, are having interference fit and are assembled through sequential bolt torquing. Effect of different torque values, torque sequence pattern and number of torquing cycles on the structural integrity of the components after assembly is studied in this process. The methodology also encompasses evaluation of residual strains during the assembly and then subsequent disassembly process of sleeves and cast wheel, while reckoning different non-linear material models for nodular and gray cast iron. The process predicts the loosening behavior of the bolts during assembly process and eventually helps to find optimum bolt torquing pattern with minimum preload loss. These are valuable inputs for factory as well as end customers to reduce number of retorquing cycles. Strain pattern

NASALAPURKAR, ANIRUDDHA P., Erisman, Phil, Mali, Kailash

Structural development and improvement of SCR Assembly design for Exhaust After Treatment System of a Construction Equipment off highway Vehicle

2024-26-009101/16/2024

Construction equipment off highway vehicles are heavy industry vehicles that run on diesel engines. To meet the CEV BS-IV emission norms, these engines have the Exhaust After Treatment System (EATS) which includes two primary subassemblies, i.e., a Diesel Oxidation Catalyst (DOC) subassembly to reduce the HC and CO emissions and a Selective catalytic Reduction (SCR) subassembly to reduce NOx emissions. Because of the excessive vibrations in the engine and continuous heavy-duty usage of the Construction equipment, structural failures leading to excess pollution and consequential functional failure are reported in the field. Hence, understanding the effect of engine vibrations and proposing a cost-effective solution is paramount in designing the EATS system including the SCR assembly. A field-testing failure of BS-IV CEV SCR assembly has been taken in consideration for this study. Several use-cases were simulated for the baseline design using real world acceleration data and Frequency

Rahman, Shahzer, Chakraborty, Abhirup, Perumal, Solairaj, Redkar, Dinesh, Usulamarthi, Ramwarun, Singh, Rajendra

Implications of Off-road Automation for On-road Automated Driving Systems

EPR2023029

12/12/2023

Automated vehicles, in the form we see today, started off-road. Ideas, technologies, and engineers came from agriculture, aerospace, and other off-road domains. While there are cases when only on-road experience will provide the necessary learning to advance automated driving systems, there is much relevant activity in off-road domains that receives less attention. Implications of Off-road Automation for On-road Automated Driving Systems argues that one way to accelerate on-road ADS development is to look at similar experiences off-road. There are plenty of people who see this connection, but there is no formalized system for exchanging knowledge. Click here to access the full SAE EDGETM Research Report portfolio.

A Methodology to Design the Flow Field of PEM Fuel Cells

2023-01-0495

04/11/2023

Proton Exchange Fuel Cells (PEMFCs) are considered one of the most prominent technologies to decarbonize the transportation sector, with emphasis on long-haul/long-range trucks, off-highway, maritime and railway. The flow field of reactants is dictated by the layout of machined channels in the bipolar plates, and several established designs (e.g., parallel channels, single/multi-pass serpentine) coexist both in research and industry. In this context, the flow behavior at cathode embodies multiple complexities, namely an accurate control of the inlet/outlet humidity for optimal membrane hydration, pressure losses, water removal at high current density, and the limitation of laminar regime. However, a robust methodology is missing to compare and quantify such aspects among the candidate designs, resulting in a variety of configurations in use with no justification of the specific choice. This contrasts with the large operational differences, especially regarding the pressure loss

Corda, Giuseppe, Cucurachi, Antonio, Diana, Martino, Fontanesi, Stefano, D'Adamo, Alessandro

Tire-Soil Interaction Simulation Using Finite Element Method to Investigate Their Deformation and Sinkage

2023-01-5001

01/03/2023

Abstract This research investigates the tire deformation and sandy soil sinkage on the performance of off-road vehicles. Tire deformation and soil sinkage were simulated with the Finite Element Method (FEM) using ANSYS Workbench 2020 R2 and validated using actual results taken from a previous work of tire size (235/70 R15) under four different tire inflation pressures (50, 100, 150, and 200 kPa) and three soil densities varying from loose, medium dense, and high dense sand. The optimum tire inflation pressures were obtained under various soil densities to achieve flotation pressure of the tires on the soil to generate good performance and accomplish the off-road vehicle missions.

Adel Mohamed, Mahmoud, Elhussieny, Sayed, Emam, Mohamed Ali, Abd Elhafiz, Mohamed M.

Tire-Soil Interaction Simulation Using Finite Element Method to Investigate Their Deformation and Sinkage

2023-01-5001-TEST-REC01/03/2023

Adel Mohamed, Mahmoud, Elhussieny, Sayed, Emam, Mohamed Ali, Abd Elhafiz, Mohamed M.

Numerical Approach to Define Hot Shut Down Strategy for Vehicle Underhood Thermal Management

2022-28-043011/09/2022

At the early phase of vehicle architecture development, thermal management is of extreme importance. Every vehicle needed to be validated for different duty cycles based on the vehicle users usage pattern and geographical load conditions. Numerical analysis place critical role in identifying critical thermal issues for different system and subsystems well in advance before physical validation. Hot shut down is one of the thermal soak phenomena that plays major role in various thermal robustness point of view and that creates the need of computational fluid dynamics (CFD) to provide rapid concepting and safe virtual testing environment, that save huge amount of physical testing of the vehicle. The condition becomes worst for the off road vehicle design when cooling fan moves all the time and keep the underhood compartment cool even when the vehicle operation is stationary, however the underhood compartment becomes very warm as soon as hot shut down appears in the machine. This paper

Dewangan, Nitin, Ukey, Snehal

Airflow and Thermal Management of Off-Road Vehicle Cabin

2022-28-045111/09/2022

Heating, ventilation and air conditioning systems play a crucial role in our day-to-day activities. With rise in global warming, leading to climate change, HVAC unit is the need of the hour. With average temperatures on the rise, it is quite imperative that the unit provides better thermal comfort to the passengers. Off-road vehicles like tractor, is also no exclusion. Tractor drivers have to experience adverse weather conditions out in the open field. Thus it is quite fundamental that sufficient airflow reaches every point inside the driver cabin, ensuring proper cool-down. To ensure proper distribution of airflow inside the cabin, optimization of HVAC unit needs to be properly carried out. The present study shows how an HVAC of an off-road vehicle is properly optimized with the help of Computational Fluid Dynamics. STAR-CCM+ v2021.2.1 is used as solver for the simulation. Airflow and cool-down simulation of inside cabin is also carried out in both initial and optimized design. The

Singh, Shobit Kumar

Automotive RADAR Sensor Modeling with Multi-scale Electromagnetic Field Solvers

2022-01-008103/29/2022

RADAR Sensors are going to be an integral part of autonomous vehicles. One of the main objectives of these sensors in autonomous vehicles is to get the doppler range profile for surrounding traffic. In this paper, we use a similar RADAR for ground speed sensing in the off-highway scenario. There are several challenges in integrating the RADAR sensor with vehicles such as sensor position from ground, location on vehicle, electromagnetic interference with other electronic devices, enclosure design etc. Ground conditions and properties are also critical in the off-highway scenario for speed sensing. We propose to use the physics based electromagnetic field solvers to understand and mitigate some of these challenges and speed up the design. Electromagnetic field solvers tend to scale poorly with distance of propagation, especially in 3D modeling. The computational cost increases dramatically, when wave propagation over multiple wavelengths is desired with FEM type solvers due to

Badgujar, Swapnil Eknathrao

Real-world Emissions from 10 Tier 4F Off-road Construction Equipment

2022-01-069803/29/2022

Off-road equipment has been considered one of the most significant sources of nitrogen oxides (NOx) and particulate matter (PM) both nationally and within California. Although emission standards have been increasingly more stringent over the past decade, there is still more lag between the implementation of the standards for off-road equipment compared to similar standards for on-road vehicles. Developing emissions factors and emissions inventories for off-road equipment has inherently been more challenging than for on-road vehicles. Off-road engines are typically certified through engine dynamometer tests which may not be representative of engine operation under real-world conditions. Current Tier 4F off-road diesel engines are equipped with diesel particulate filters (DPFs) to meet the PM standards for 2007 and newer engines, and selective catalytic reduction (SCR) systems to meet the NOx standards. While there are extensive data on the effectiveness of DPF and SCR systems over

Zhu, Hanwei, Scora, George, Karavalakis, Georgios, Johnson, Kent, Russell, Robert, Durbin, Tom

Performance and activity Characteristics of Zero Emission Battery-Electric Cargo Handling Equipment at a Port Terminal

2022-01-069903/29/2022

Off-road equipment makes some of the most important contributions to the emissions inventory for both urban pollutants and greenhouse gases. Reducing the emissions contribution from these sources has been a focus of regulations and incentive programs over the past few years. The number of plug-in and electric vehicle/equipment models in the medium-duty and heavy-duty off-road categories have significantly expanded in recent years. A growing number of fleets are deploying or are interested in deploying electric vehicles such as port-related equipment, transit buses, school buses, trucks, and other off-road equipment. Reliable operational and performance data on electric vehicles/equipment is needed with the rapid growth and use of electric vehicles/equipment to provide insights on their performance and to support the ongoing research into the future deployment of this equipment. The objective of this study is to collect and analyze activity data from zero emission port-related equipment

Frederickson, Chas, Durbin, Tom, Li, Chengguo, Scora, George, Jung, Heejung, Huang, Eddy

Tire-Soil interaction Simulation using FEM to investigate their Deformation and Sinkage

2022-01-033403/29/2022

This research investigates the tire deformation and sandy soil sinkage on performance of off-road vehicles. Tire deformation and soil sinkage have been simulated by FEM and validated using tire size (235/70 R15) under four different tire inflation pressures (50, 100, 150 and 200 kPa) and three soil density changing from loose, medium and high dense sand. Different relations that clarify the change in tire deflection by changing tire load, tire inflation pressure and soil density. The optimum tire inflation pressures were obtained under various soil densities. When moving on terrains of medium and high strength, tire inflation can be adjusted to a value equal to or higher than its flotation pressure, this will generate good performance and accomplishing the off- road vehicle missions.

Adel, Mahmoud, Emam, Mohamed Ali, Elhussieny, Sayed, Abd elhafiz, Mohamed

Electric hybrid system Architecture & Functional component selection criteria for application based Off-Highway segment

2022-01-081503/29/2022

Hybridization continues to be growing trend in vehicular applications. Current study shows a holistic system approach for the design & integration of the powertrain in Off-Highway tractor applications. It includes study & benchmarking of system architecture of an all-electric and diesel-electric drive systems as per application requirement. Further comprehensive study was done on functional components for an electric powertrain, which includes electric drives, batteries & controllers. Selection & design of these components was studied & component selection approach was developed for typical Off-Highway tractor application. Current study was divided into three parts. 1. Study of different Off-Highway tractor applications & selection of all-electric, series & parallel hybrid architectures as per application requirement. For Parallel hybrid configuration, Comprehensive approach was developed for selection & optimization. 2. An optimum hybrid configuration selected for off-highway

Nain, Ajay

Hybrid Validation Model for System Level Test

2022-01-094203/29/2022

Hybrid model mainly use HIL (Hardware in Loop) and SIL (Software in Loop) test environment combinations for validation at system level test. Universal Implement ISO Stick-Match is device to show customer compatibility to ISOBUS implements to off highway vehicle. In the market we have many third party implements and it’s very difficult to validate all implements on vehicle. This ISO stick-match can be used to perform automatic switching on and off implements sections, automatically adjust the output rate for the implement, data storage etc. This paper mainly presents hybrid validation model for system level test using universal implement ISO stick- match functionality. Hybrid model includes use of vehicle controller simulation interface with universal implement ISO stick- match. Hybrid model could be utilized to run Automotive Electronic Foundation (AEF) conformance test. This also enable us to perform end to end validation activity for a machine which will be useful from safety. We can

Suryawanshi, Archana Ashok, Labade, Chetan

High-Porosity Honeycomb Substrate with Thin-Wall and High Cell Density using for SCR Coating to Meet Worldwide Tighter Emission Regulations

2022-01-066703/29/2022

Selective Catalyst Reduction (SCR) made of cordierite honeycomb substrate is generally used as a DeNOx catalyst for diesel engines exhaust in both on-road and commercial off-highway vehicles to meet today’s worldwide emission regulations. Worldwide NOx emission regulations will become more strict, as represented by CARB2027 and EuroⅦ. Technologies which can achieve further lower NOx emissions are required. Recently, several technologies, like increased SCR catalyst loading amount on honeycomb substrates, and additional SCR catalyst volume in positions closer to the engine are being considered to achieve ultra-low NOx emissions. However, undesirable pressure drop increase and enlarging after treatment systems will be caused by adopting these technologies. Therefore, optimization of the material and honeycomb cell structure for SCR is inevitable to achieve ultra-low NOx emissions while minimizing any system drawbacks. Since the SCR catalyst generally being used in the market today is

Ido, Yuya, Kinoshita, Koji, Saito, Chika, Hirose, Shogo, Toyoshima, Hideyuki, Ohara, Etsuji, Honda, Takahiro, Kaneda, Atsushi, Wells, Alexander, Vogt, Claus Dieter

Off-Highway Machine Fuel Performance Prediction Through Engine Data Analytics

2021-26-031909/22/2021

Field performance of a machine is conventionally analyzed using tools of virtual validation such as physics-based simulations models. Machine performance test data is typically not incorporated for machine performance evaluation using these tools. The present work aims to demonstrate use of Data Analytics as a tool to analyze this data for predictive purpose. It aims at establishing numerical relationships of engineering interest within the data, which would otherwise be complex if done only using physics-based models. Engine operation data spanning over three months, comprising of more than sixty channels, of an off-highway machine is used for model development. Machine fuel burn rate is chosen as the dependent variable. Several independent variables such as Ambient temperature, Engine speed, Charge air pressure are chosen based on their correlation with the dependent variable and upon engineering interest. Linear regression models are developed which show good fit and correlation

Bandekar, Ameya, Dharmadhikari, Nitin

A Holistic Approach of Developing New High Strength Cast Iron for Weight Optimization

2021-26-024409/22/2021

Cast Iron is being used in various Industries like Automotive, Agriculture, Construction etc., for many decades. Metal casting processes have its unique advantages like ease of heavy weight castings, intricate shapes, higher productivity. Commercially viable (low cost) etc., using wide range of materials like Gray cast iron, Spheroidal cast iron, Malleable cast iron ,cast steel etc., Cast iron have an excellent properties like high dampening capacity, higher thermal conductivity, wear resistance required by many critical applications. These unique combinations will be chosen to serve the purposes both functionally and commercially. However, in last one-decade automotive and agriculture industries are facing issue of fuel economy which directly influenced by the weight of the vehicle. For off-road vehicle like tractors, One of the major contributor in vehicle weight is cast iron. Many material grades and strengthening mechanisms are recently being evolved to optimize the cast iron

Gunalan, Magendran, Anandeswaran, V.A

Multiphase Flow Simulation of the Oil Splashing During the Actuated Stage of an Innovative Axle Dry Braking System

2021-01-123809/21/2021

This paper proposes the CFD simulation of the oil splashing within the discs’ chamber of a novel concept for axle dry braking system in off-highway vehicles. The system completely removes the lubricating oil from the discs’ chamber during the not-engaged configuration of the friction plates and it quickly restore it at the beginning of the braking stage when the discs’ cooling becomes crucial, thus ensuring a significant reduction of the power losses. The CFD analysis of the real component is performed to predict the efficiency of the system in terms of both the time needed to replenish the discs’ chamber when brake is actuated and the hydraulic torque exerted by the splashing of the oil. The entire three-dimensional geometry of the domain is accurately discretized and the multi-phase flow nature is addressed by means of the volume of fluid approach. Moreover, the two equation realizable k-epsilon model is adopted to describe the turbulent characteristic of the flow under actual

Muzzioli, Gabriele, Milani, Massimo, Rinaldi, Pier Paolo, Stefani, Matteo, Storchi, Gabriele, Montorsi, Luca

Noise prediction method development for crop feed mechanism

2021-01-107208/31/2021

Off highway vehicles face challenges in terms of noise levels during the operating conditions due to the existence of many dynamic subsystems intended to perform the primary functions. Reducing the overall noise levels are extremely important to provide a quiet environment for the operator and higher productivity. Noise source ranking is a common practice used across the industry to identify the top noise sources. It is important to characterize the top noise sources and work on them to improve the noise performance through further design modifications. Dynamic loads are important to characterize the acoustic behavior of the system. It’s hard to measure the vibration loads and almost impossible to measure acoustic loads in the operational conditions. In such scenarios, test based TPA is used to calculate the vibration and acoustic loads. This paper describes how the analysis methodology is developed for characterization of a crop feed mechanism. Test based TPA method is used to

Dasabai, Balavardhan Reddy, Bogue, Bradley

Combination Pelvic and Upper Torso Operator and Occupant Restraint Systems for Off-Road Work Machines

J2292_202108 (Current)

08/12/2021

This SAE Recommended Practice establishes minimum performance and test requirements for combination pelvic and upper torso occupant restraint systems provided for off-road self-propelled work machines.

HFTC4, Operator Seating and Ride

Performance Test for Windshield Defrosting Systems for Off-Road, Self-Propelled Work Machines

J1535_202108 (Current)08/02/2021

This SAE Standard establishes uniform test procedures for the defrosting systems of off-road, self-propelled work machines used in construction, general purpose industrial, agricultural, and forestry machinery as referenced in table one of this document. It includes tests that can be conducted with uniform test equipment in commercially available laboratory facilities, as well as in an appropriate outdoor environment.

HFTC6, Operator Accommodation

Diesel in distress

SAE-MA-0465606/10/2021

The global chip shortage undercuts surging demand for Cummins’ diesel engines in markets that have rebounded rapidly from 2020’s low point.

Gehm, Ryan

Sound Measurement—Off-Road Self-Propelled Work Machines Operator-Work Cycle

J1166_202103 (Current)

03/22/2021

This SAE Standard sets forth the procedures to be used in measuring sound levels and determining the time weighted sound level at the operator's station(s) of specified off-road self-propelled work machines. This document applies to the following work machines which have operator stations as specified in SAE J1116: • Crawler Loader • Grader • Log Skidder • Wheel Loader • Crawler Tractor with Dozer • Pipelayer • Dumper • Wheel Tractor with Dozer • Trencher • Tractor Scraper • Backhoe • Sweeper • Roller/Compactor • Hydraulic Excavator • Pad Foot Wheel Compactor with Dozer • Excavator and Wheel Feller-Buncher The instrumentation requirements and specific work cycles for these machines are described. The method used to calculate the time weighted average sound level at the operator station(s) is specified for Leq(5), or optional exchange rates, during continuous operation in a work cycle representing continuous medium to heavy work. The work cycles provide a repeatable reproduceable means

OPTC3, Lighting and Sound Committee

Sound Measurement—Off-Road Self-Propelled Work Machines Operator-Work Cycle

J1166_202103-TEST-REC (Historical)03/22/2021

OPTC3, Lighting and Sound Committee

Principles and Process for Developing Icons for Electronic Displays

J3113_202103 (Current)

03/10/2021

SAE J3113 provides principles and a process for developing icons for use in electronic displays related to off-road work machines as stated defined in SAE J1116. Following the process ensures that icons are derived from ISO-registered graphical symbols or ISO-compliant non-registered graphical symbols.

HFTC2, Machine Displays and Symbols