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Mileage Accumulation Target Identification For AEBS Validation for Medium & Heavy Trucks Considering Real-World Accidents In India2026-26-0036To be published on 01/16/2026
Robust validation of Advanced Driver Assistance Systems (ADAS) considering real-world conditions is a vital for ensuring safety. Mileage accumulation is a one of the validation method for ensuring ADAS system robustness. By subjecting systems to diverse real-world driving environments and edge-case scenarios, engineers can evaluate performance, reliability, and safety under realistic conditions. In accordance with ISO 21448 (SOTIF), known hazardous scenarios are explicitly tested during robustness validation in combination of virtual and physical testing at component, sub system and vehicle level, while unknown hazards may emerge through extended mileage by running vehicles on roads, allowing them to be identified and classified. However, defining a mileage target that ensures comprehensive safety remains a significant engineering challenge. This paper proposes a data-driven approach to define mileage accumulation targets for validating Autonomous Emergency Braking Systems (AEBS
Koralla, Sivaprasad, Ravjani, Amin, Tatikonda, Vijay, GADEKAR, GANESH
Structural analysis and Design optimization of Cylinder Head of Cummins Light duty Engine for Medium Wheelbase (MWB) pick-up truck2026-26-0495To be published on 01/16/2026
This paper presents the design, structural analysis, and risk assessment done by Cummins to evaluate the structural integrity of Light Duty engine cylinder head for a Medium Wheelbase (MWB) pick-up truck. Initially, Cummins used F2.5L (4-cylinder) engine that has 154hp, but rising market demands for more power, fuel efficiency, lower cost and weight, and future emission compliance led to customer requirements for 177hp (Drive New F2.5L, 15% uprate) and 197hp+ (Drive New F3.0L, 22% uprate) from the same base engine. The increase in power requirement possesses challenges on critical components, especially cylinder heads in terms of thermal and structural limits. This paper addresses the challenges and risks in current cylinder head design driven by new power demands, specifically reduced fatigue margins in the water jacket area and increased temperatures on the combustion face under high thermomechanical loads. It explores the design modifications made to the cylinder head design to
Pathak, Arun Jyoti, Adiverekar, Vaidehi, Singh, Rahul, Biyani, Mayur
Electroluminescent Coating Systems for Heavy-Duty Trucks: Advancing Safety and Sustainability through Smart Surface Technology2026-26-0275To be published on 01/16/2026
As the transportation industry pivots towards safer and more sustainable mobility solutions, the role of advanced surface technologies is becoming increasingly critical. This paper presents a novel application of electroluminescent (EL) coating systems in heavy-duty trucks, exploring to enhance safety and environmental impact through lightweight, energy-efficient lighting integration. EL coatings, capable of emitting light uniformly across painted surfaces when electrically activated, offer a transformative alternative to conventional lighting systems and reflective materials. In the context of heavy-duty trucks, these systems can significantly improve visibility under low-light and adverse weather conditions, thereby reducing the risk of road accidents. Furthermore, illumination achieved without bulky fixtures and without interface gaps contributes to aerodynamic efficiency, fuel economy and reducing carbon emissions. use of this coating system, can optimize tooled up plastic part and
Harel, Samarth Dattatraya, Borse, Manoj
A Noval methodology of compact cooling unit design for Truck applications by using CAE CFD simulation2026-26-0460To be published on 01/16/2026
The implementation of AC unit on truck as compulsory as per government guideline demands the AC supplier to design a compact and modular AC unit within the available package space. The installation of AC unit inside the vehicle helps the driver to drive safely due to better cabin comfort. This will reduce fatigue due to the long driving of the truck drivers. Thereby the safety of the truck and driver will be saved with the implementation. But there are challenges for AC manufactures to design the compact size AC unit. The challenges like performance, durability, cost and less noise to be met as per customer requirement. To overcome the issue of design at the early stage and compact AC unit within small space is possible with the support of simulation software. AE and CFD plays a major role in this regard. So first unit level CAE and CFD analysis conducted to predict the result. AE used for checking the strength of the mounting bracket of cooling unit and CFD used for verifying the air
Parayil, Paulson
Optimization of Battery Mixing Strategies to Enhance Electric Vehicle Performance and Efficiency2026-26-0209To be published on 01/16/2026
Fleet operators increasingly contend with a patchwork of battery‑pack generations that remain electro‑chemically compatible yet differ markedly in capacity, internal resistance and residual life. Conventional “like‑for‑like” replacement policies oblige service providers to retain costly legacy inventories or to install brand‑new packs in ageing vehicles—both scenarios inflating warranty exposure and material waste. Deploying a rational mixing strategy for packs of different vintages therefore offers a compelling path to lower costs and improve sustainability, but industry‑wide guidance is limited and confidence in performance impacts remains low. This paper presents an optimisation‑driven framework that determines when and how heterogeneous packs can be paired at the moment of integration while maintaining vehicle performance targets and minimising life‑cycle cost. The methodology combines: a physics‑based electro‑thermal performance model parameterised for discrete state‑of‑health
Nair, Sandeep R., Ravichandran, Balu Prashanth, Hallberg, Linus
Evaluation of Waste Heat Recovery technology in FCEV on different drive-cycles2026-26-0259To be published on 01/16/2026
Growing global warming and the associated climate change have expedited the need for adoption of carbon-neutral technologies. The transportation sector accounts for ~ 25 % of total carbon emissions. Hydrogen (H2) is widely explored as an alternative for decarbonizing the transport sector. The application of H2 through PEM Fuel Cells is one of the options available for the trucking industry, due to their relatively higher efficiency (~50%) and power density. However, at present the cost of an FCEV truck is considerably higher than its diesel equivalent. Hence, new technologies either enabling cost reduction or efficiency improvement for FCEVs are imperative for their widespread adoption. FCEVs have a system efficiency in the range of 40-60% implying that around half of the input energy is lost to the atmosphere as waste heat. However, recapturing this significant amount of low-grade waste heat into useful work is a challenge. This paper discusses the feasibility of waste heat recovery
P V, NAVANEETH
Optimizing Heavy-Duty Mining Operations with LNG Powertrains: Boosting Efficiency and Minimizing Environmental Impact2026-26-0438To be published on 01/16/2026
Heavy-duty mining is a demanding sector within the trucking industry. Mining companies are assigned coal mine sites, and fleet operators are tasked with efficiently extracting ore within the allotted timeframe. To accomplish this, companies deploy dumper trucks that operate in three shifts daily to transport payloads from the site. As a result, uptime is critical, requiring trucks with exceptionally robust powertrains. The profitability of mining operations depends on the efficient use of these dumper trucks. Fuel consumption in these mines represents a significant portion of total expenses. Using LNG as a fuel can help reduce operational fuel costs, thereby increasing customer profitability. Additionally, employing LNG has the potential to lower the CO2 footprint of mining operations. This paper details the development of a data-driven duty cycle for mining vehicles and the simulation methodology used to accurately size LNG powertrain components, focusing on maintaining uptime and
John, Ann Veena, Pendharkar, Koustubh
Connected Traffic Warnings for Enhanced Commercial Trucking Safety2026-26-0680To be published on 01/16/2026
Commercial trucking forms the backbone of global supply chains, but the consistently high number of truck-related fatalities emphasises the pressing need for enhanced safety systems. Connected safety systems present a significant opportunity to mitigate risks and prevent collisions by providing commercial vehicle operators with real-time hazard alerts. This paper delves into the operational mechanisms and potential benefits of such warning systems within the trucking industry. These systems function by establishing a network of connected vehicles capable of detecting and communicating hazardous situations through a centralised, cloud-based platform. By seamlessly integrating real-time telemetry data from individual trucks with information sourced from third-party providers, weather services, the system gains an understanding of prevailing road conditions. This allows for the identification of potential dangers such as traffic accidents, ongoing road construction or maintenance
Madarla, Manoj, George, Basil, Gangapuram, Siva, Hegde, Subrahmanya, Mukherjee, Shubhobroto, Dixith, Sampreetha, Hegde, Preetham
Mobility Within Mines: Harmonization of Safety requirements for Underground Mining Trucks in India.2026-26-0140To be published on 01/16/2026
The need for energy is ever increasing, though the dependency on renewable energy have increased, it is not sufficient to cater the demand. India is one of fastest developing country which depends on coal 55% for its total energy need. To achieve coal digging & transportation an underground mining vehicle has gained high importance. Underground mine environment is inherently dangerous due to various factors, including explosive and toxic gases, dust, and the potential for collapses. Thereby vehicles running in coal mines requires extreme safety features to safeguard its operator & coal mine workers. In India Directorate General of Mines Safety (DGMS) directing standards & safety provisions for Diesel equipment's working under ground mines. This Paper is providing complete guideline for required safety features for the latest available technology in underground mining trucks. This paper will take you through various standards available globally to insure safety of the operator. Further
Babar, Sagar, Akbar Badusha, A
Analysis of door seal compression and its influence on NVH performance in heavy-duty vehicle2026-26-0339To be published on 01/16/2026
Seals in a truck cabin is one of the major contributors for cabin noise in terms of structure borne as well as air borne noise transfer path. This study emphasizes on the effect of door seal compression prediction and its impact on structure borne NVH in trucks. Vibrations are regarded as quality criteria in the perception of customers. It is necessary to ascertain the contribution of seal stiffness on compression of the seal under closed condition of the door rather than uncompressed conditions. The dynamic stiffness of door seal is calculated by non-linear analysis. The simulations models are constructed using the Mooney - Rivlin theory for both 2D and 3D seals. This encompasses contemplating the relevant seal mounted boundary condition on the body and the door of the vehicle. The stiffness after compression of seal is extracted from this non-linear analysis which is further used to obtain the vibration modes for the doors in the truck cabin. Subsequently, the compressed seal
L, Kavya, Ramanathan, Vijay
Lightweight Cascade Design Using Type IV Cylinders for Efficient Hydrogen Gas Logistics in India2026-26-0485To be published on 01/16/2026
Hydrogen mobility in India faces a key challenge in the form of high transportation and logistics costs, particularly in tier-II and tier-III cities where dedicated pipelines are not yet feasible. Current methods using traditional steel based cascades are heavy, inefficient, and limit payload capacity. This paper presents a novel lightweight cascade system designed to enhance the efficiency of hydrogen gas logistics using Type IV composite cylinders and an aluminium structural frame. The design adheres to PESO (Petroleum and Explosives Safety Organisation) standards and achieves a structural weight reduction of 52%, owing to the use of carbon fibre composite cylinders and aluminium framework. Field level analysis demonstrates that the gas transport efficiency is improved by a factor of 2.5 compared to conventional steel based systems when used in heavy duty trucks. This innovation offers a significant step forward in enabling economically viable hydrogen distribution for mobility
Parasumanna, Ajeet Babu, Muthusamy, Hariprasad, Ammu, VNSU Viswanath, Kola, Immanuel Raju
Drive Cycle Type Identification Using Data Driven Methodologies2026-26-0649To be published on 01/16/2026
Identifying the type of drive cycle is crucial for analyzing customer usage and optimizing vehicle performance and emission control. Methods that rely on geographical location are limited by varying driving conditions at the same location (e.g., heavy traffic during peak hours vs. free-flowing traffic at night). This paper proposes a methodology to identify the type of drive cycle (city, interurban, highway or others) using drive characteristics derived from vehicle data rather than geographical location. Real-world vehicle data from testing trucks is taken, whose drive profiles are already known. Initially, multiple characteristic features of the drive cycle are identified from literature surveys and domain experiences. These features, which can be extracted from basic signal data, include gear shifts, time spent in different driving modes (acceleration, cruise, standstill), velocity distributions, and an 'aggressiveness factor' representing overall driving style. Using ML based
REDDY, MALLANGI PRASHANTH, Gorain, Raju, Ganguly, Gourav
Pre-crash characteristics of Motorised Two Wheelers in Indian Crashes2026-26-0034To be published on 01/16/2026
Motorized two-wheelers (M2Ws) represent the most affected road users in India, account for 45% of all fatalities in road crashes as per government data. Despite this, most research has focused on injury outcomes rather than the events leading up to these crashes. This study addresses the gap by analyzing pre-crash characteristics of M2W incidents using the Road Accident Sampling System-India (RASSI) database, which provides in-depth, scientifically collected crash data from across India. RASSI data was analysed to identify the pre-crash characteristics of M2W crashes such as the road structure, crash configurations, vehicle speeds, and specifically behavioural characteristics of M2W riders. A total of 3862 M2W samples were analysed over the period of 2011-2022 that represent 51,00,211 M2Ws nationally. The results show that although M2Ws have highest involvement in side/angle (‘T-bone’) crashes, Head-on crashes are the most severe crashes for M2Ws with 22% fatalities. The results also
Govardhan, Rohan, Padmanaban, Jeya, Jethwa, Vaishnav
Safer Trucks for India-Smart Tech Fusion2026-26-0031To be published on 01/16/2026
Commercial vehicle sector (especially trucks) has major role in economic growth of a nation. With improving infrastructure, increasing number of trucks on roads, accidents are also increasing. As per RASSI (Road Accident Sampling System India) FY2016-21 database, commercial vehicles are involved in 43% of total accidents on Indian roads. Involvement of trucks (N2 & N3) is 25% over total accidents. Amongst all accident scenarios of N2 &N3, frontal impacts are the most frequent (26%) and causing severe occupant injuries. Today, truck safety development for frontal impact is based on passive safety regulations (viz. front pendulum - AIS029) and basic safety features like seatbelts. In any truck accident, it is challenging rather impossible to manage comprehensive safety only with passive safety systems due to size and weight. Accident prevention becomes imperative in truck safety development due to extremely high energy involved in front impact scenarios. The paper presents unique safety
Joshi, Kedar Shrikant, GADEKAR, GANESH, Date, Atul, Koralla, Sivaprasad
Optimizing Powertrain Performance: A Customer Usage-Centric Approach2026-26-0067To be published on 01/16/2026
The optimization of new generation trucks is crucial for enhancing performance, efficiency, and compliance with regulatory standards. In the conventional product development, the manufacturer often optimises the powertrain to meet the stringent emission which might not account for the customer usage. This study uses the simulation-based approach that integrates customer usage with help of logged vehicle data across various applications, to develop a single engine platform equipped with multiple drivetrain options. Using a data driven approach, real-world usage pattern analysis is conducted to identify key performance metrics required to optimize the driveline components tailored to each application. Additionally, the impact of certification requirements on vehicle performance is examined to ensure compliance while maximizing the benefits of the proposed optimization strategies. The findings of this research will provide valuable insights for manufacturers and fleet operators, enabling
Mohan, Vignesh, Darzi, Mahdi
J1939 Digital AnnexJ1939DA_201402 (Current)12/08/2025
The J1939 Digital Annex The J1939 Digital Annex, introduced in August 2013, offers key J1939 technical data in an Electronic Spreadsheet that can be easily searched, sorted, and adapted to other formats. J1939DA contains all of the SPNs (parameters), PGNs (messages), and other J1939 data previously published in the SAE J1939 top level document. J1939DA also contains all of the SLOTs, Manufacturer ID Codes, NAME Functions, and Preferred Addresses previously published in the SAE J1939 top level and the J1939-71 document. J1939DA contains the complete technical details for all of the SPNs and PGNs previously published in the SAE J1939-71 document. For all other SPNs and PGNs which are published in a document other than SAE J1939-71, J1939DA lists only basic details along with a reference to the document that contains the complete technical details. J1939DA replaces, and expands upon, the 1939 Companion Spreadsheet (CS1939), which was last published through November 2012. The data fields
Truck Bus Control and Communications Network Committee
SAE TOMORRO TODAY BRIEFS - Scaling Software-Defined EV Fleets1351204/24/2025
When it comes to electrifying commercial vehicle fleets, one company offers a transformative modular platform that can drastically reduce the time to market. REE Automotive is a publicly traded company that designs and manufactures advanced software-defined vehicles (SDVs) that are fully electric, capable of autonomy, and compatible with existing fleet management software. The company recently began production on its first medium-duty truck for the US market and has since seen a 230% growth in reservations, indicating strong customer interest and positive feedback. To learn more, Roberto Baldwin, Sustainability Editor, SAE Sustainable Mobility Solutions, recently sat down with Daniel Barel, CEO, and Pete Dow, VP of Engineering, to discuss REE Automotive's revolutionary approach to scaling software-defined commercial EV fleets. For more information on the evolution of sustainability, head on over to sustainablecareers.sae.org. There, you can check out our podcast on the state of NEVI
Hineman, Marcie
SAE TOMORROW TODAY: Electrified Trailers for the Heavy-Duty Truck Market1350403/03/2025
Can the commercial transportation industry move beyond diesel? Yes, and it starts with practical decarbonization that makes trailers smarter, safer, and more efficient. Range Energy is accelerating the electrification of commercial transportation via powered trailers for the heavy-duty truck market. With a solution that can easily hook up to any tow vehicle, Range's powered trailers offer offroad mobile power with an electric propulsion system that slashes fuel consumption and is compatible with dry van and refrigerated trailers. To learn more, we sat down with Ali Javidan, CEO and Founder of Range Energy, to discuss the future of the electrified trailer market, the journey from prototype to scalable commercial success, and the impact of Formula SAE on his personal growth. We'd love to hear from you. Share your comments, questions and ideas for future topics and guests to podcast@sae.org. Don't forget to take a moment to follow SAE Tomorrow Today--a podcast where we discuss emerging
Hineman, Marcie
Improving the Carbon Footprint of Long-Haul Trucks Running on First-Generation Biodiesel2025-01-500701/27/2025
Lowering carbon emissions from road-based transport is required to achieve climate targets. In addition to passenger cars, long-haul trucks contribute more than one-third of on-road generated carbon emissions. Therefore, this sector has great potential to reduce such emissions. Numerous options including electrified drivetrains are possible. Nevertheless, the existing fleet of trucks powered by conventional diesel engines also needs to be addressed. Additionally, a ramp-up of green electricity and charging infrastructure is required to ensure carbon-neutral and reliable transport. Heavy-duty diesel engines are typically suitable for use with first-generation biofuels. However, operational restrictions, such as shorter oil drain intervals are mandatory for users. In the case at hand, the oil change was mandatory after only 30,000 km when pure biodiesel (B100) was used instead of 120,000 km when operating on conventional, mineral oil-based diesel. These boundaries counter efforts to
Rohbogner, Christoph J., Heine, Carsten
SAE TOMORROW TODAY: The Future of Hydrogen Fuel: A Distribution Revolution1349112/10/2024
Jules Verne was ahead of his time--and so is a company inspired by his name that recognizes hydrogen's immense potential as a clean energy solution. Verne develops and commercializes a novel technology to store and distribute hydrogen in its densest form, cryo-compressed. This approach maximizes hydrogen density, addressing the limitations of compressed gas and reducing the cost of dense storage -- which is a game-changer for boosting hydrogen adoption. To learn more, we sat down with Ted McKlveen, Co-founder & CEO, Verne, to discuss the company's breakthrough solution to addressing hydrogen storage and transportation and how it can unlock the widespread adoption of hydrogen energy, particularly in sectors like Class 8 trucking. We'd love to hear from you. Share your comments, questions and ideas for future topics and guests to podcast@sae.org. Don't forget to take a moment to follow SAE Tomorrow Today--a podcast where we discuss emerging technology and trends in mobility with the
Hineman, Marcie
SAE TOMORROW TODAY UNPLUGGED: Entering The Golden Age of Autonomy1349011/27/2024
Could the next 18 months mark the beginning of a golden age in autonomy? In this Unplugged episode of SAE Tomorrow Today, host Grayson Brulte discusses the incoming presidential administration's plans to establish a national framework that could enable autonomy to scale across all 50 states. Key topics include the future of autonomous trucking, the possibility of households combining personally owned AVs with subscription-based robo-taxis, and the liability and regulatory environment surrounding autonomy. Have your own thoughts on this topic? We'd love to hear from you! Share your comments, questions or ideas for future topics with Grayson on Twitter or send them to podcast@sae.org. Follow SAE on LinkedIn, Instagram, Facebook, Twitter, and YouTube. Follow host Grayson Brulte on LinkedIn, Twitter, and Instagram.
Hineman, Marcie
SAE TOMORROW TODAY: Scaling 2 Million Miles in Autonomous Trucking1347709/16/2024
Get ready for COMVEC 2024 with a rewind of Episode 235! We're honored to have Continental as the Executive Leadership sponsor of COMVEC, the leading forum for global experts in the commercial vehicle industry taking place September 10-12 in Schaumburg, IL. Join us as we network, exchange ideas, and get up to date on CV research and technology. Learn more and register now. A traditional Class 8 truck is on the road for a million miles or more over its lifetime. For autonomous trucks, that number could double to two million or more -- and that requires a specialty focus on scalability and safety. Enter Continental Automotive, a multinational automotive parts manufacturer pioneering technologies and services for the sustainable and connected mobility of people and goods. Continental has partnered with Aurora to commercially scale autonomous trucking systems. Together, they recently finalized the completion of the blueprint and design of the future Aurora Driver hardware and fallback
Hineman, Marcie
SAE TOMORROW TODAY: Balancing Fleet Sustainability with Competitiveness1347408/16/2024
As trucking fleets strive to minimize their environmental impact, it's important to balance sustainability with competitiveness. From adhering to new government guidelines to considering alternative fuel sources like battery, electric, and hydrogen, Covenant Logistics carefully factors in evolving requirements for more sustainable solutions, while maintaining their clients' profitability. To learn more, we sat down with we sat down with Matt McLelland, VP of Sustainability and Logistics, to discuss his focus on decarbonizing the class 8 trucking space, improving carbon reporting, the impact of greenwashing, and how he helps clients meet their scope 3 sustainability goals.
Hineman, Marcie
SAE TOMORROW TODAY: Scaling 2 Million Miles in Autonomous Trucking1346807/23/2024
A traditional Class 8 truck is on the road for a million miles or more over its lifetime. For autonomous trucks, that number could double to two million or more--and that requires a specialty focus on scalability and safety. Enter Continental Automotive, a multinational automotive parts manufacturer pioneering technologies and services for the sustainable and connected mobility of people and goods. Continental has partnered with Aurora to commercially scale autonomous trucking systems. Together, they recently finalized the completion of the blueprint and design of the future Aurora Driver hardware and fallback system. To learn more, we sat down with Phil McEwen, Vice President and General Manager, Commercial and Special Vehicles North America, Continental Automotive, to discuss the importance of safety in autonomous trucking technology, the partnership with Aurora, and the future of autonomy. We're also honored to have Continental as the Executive Leadership sponsor of COMVEC, the
Hineman, Marcie
SAE TOMORROW TODAY: Setting the Standard in Autonomous Middle Mile Delivery1345505/20/2024
Autonomous box trucks that can move goods on short-haul B2B routes? It's possible -- and North America's largest grocers, retailers, distributors, and e-commerce platforms are unlocking the benefits. As the leader in autonomous middle mile delivery, Gatik is improving supply chain efficiency with their fleet of medium duty, class 3-7 autonomous box trucks. By moving goods safely and efficiently between distribution centers, fulfillment centers, stores and warehouses, Gatik is optimizing regional distribution networks for major customers like Walmart, Kroger, Loblaw, Tyson Foods, and Pitney Bowes. With operations across multiple markets including Texas, Arkansas and Ontario, Gatik has more than 60 trucks on the road today and operates the largest revenue-generating commercial fleet of autonomous trucks on the continent. To learn more, we sat down with Dr. Adam Campbell, Senior Manager, Safety Innovation and Impact, to discuss the company's safety-first approach to the development and
Hineman, Marcie
Thermal system simulation and modelling for Alternative Fuels in a Heavy Duty Truck2024-26-029601/16/2024
In the current scenario, demand for Alternate energy source is increasing to reduce dependency on presently available fuels. Internal Combustion engines working on multiple fuels developed in which LNG/CNG is a close contender. Cooling system is one of the critical components of an automobile that influences the engine performance and efficiency. Higher heat demands efficient Cooling system. In this paper an approach is defined to arrive at a Cooling system architecture for CNG/LNG fuel. The aim is to finalise a Cooling system package which is simple and Energy efficient. Modelling is done in Thermal simulation software KULI. Detailed study is done on simulation results of air flow and temperatures and correlated with test results.
M S, Vignesh, KIRAN, NALAVADATH, M, VIGNESH
Geometry, Sizing and Optimization of honeycomb structures along with embedded metal inserts on the floor for Truck-Mounted Container Applications2024-26-018601/16/2024
With the rise of worldwide trends towards light weighting and the move towards electric vehicles, it is now more important than ever for the automotive industry to develop and implement lightweight materials that will result in significant weight reduction and product improvements. A great deal of research has been done on how to best combine and configure honeycomb cores with the right face sheets for Truck-Mounted Container Applications. Honeycomb structures possess the ability to bring about superior structural rigidity when the core parameters are selected and optimized based on the automotive application requirements. Through a variety of experimental tests for various combinations of the core parameters, the selection of the critical honeycomb core parameters to efficiently increase the compressive strength and panel rigidity of the entire container assembly has been evaluated and compared in order to determine the most effective combination to produce superior results for
phukan, Prerna, Dave, Rajeev
Crash simulation of palisade security fencing2024-26-028101/16/2024
Palisade fencing can be effectively used for security purposes. For high-security establishments, palisade fences are being used as effective security barriers which can withstand high-speed vehicle impact and maintain a stand-off distance between the vehicle and the environment to be protected. The test setup being costly, the simulation-based approach will help in identifying the performance at the design stage itself. This paper discusses the explicit dynamic finite element analysis of the high-speed truck impact on the palisade fence as per ASTM F2656 standard using RADIOSS solver. Detailed finite element modeling of the fence for simulation is explained using various material models, load, and boundary conditions. Analysis output includes a variation of several parameters with time and some of such parameters include truck velocity, displacement and stress levels during the impact, energy absorption, etc.
Rathore, Gopal Singh, Kumar, Ankit
Digital approach for design of modular, scalable Futuristic Instrument Panel for Commercial Vehicle2024-26-038701/16/2024
Road infrastructure in India is being upgraded at a rapid pace. Quality of life of people has also improved significantly in the last decade. Such trends have significantly impacted design of commercial vehicles and vehicular systems in the country. This paper deals with the design and development of a modern futuristic instrument panel for trucks. Methodology to arrive at product features and solutions which retain their novelty and appeal for a longer term has also been illustrated. Regulatory scenario, modularity, HMI, Perceived Quality, Driver Comforts, evolving technologies, trends and materials are some of the considerations which have discussed in detail. International benchmarks and customer requirement have been analyzed for setting Performance targets. A digital approach for evaluating these considerations evolved during the design and development process has been elaborated in detail. Design verifications methodology has been formulated at digital level and physical
Mhaske, Pramodkumar Chimaji, PALLATH, Ashap, Navsariwala, Prashant, Apte, Sanjay
Effect of Lift Axle suspension design on Heavy Commercial Vehicle Handling performance2024-26-004901/16/2024
The cost of fuels used for automobile are rising in India on account of high global crude oil prices. The fuel cost constitutes major portion of total cost of operation for Heavy commercial vehicles. Hence, the trend is to carry the goods transport through higher payload capacity rigid trucks that offer lower transportation cost per unit of goods transported. This is driving the design of multi-axle heavy trucks that have lift axles. In addition, improved network of highways and road infrastructure is leading to increase in average operating speed of heavy commercial vehicles. It has made increased focus on occupant as well as road safety while designing the heavy trucks. The load carried by lift axles is equivalent to the steered axle or drive axle. Hence, the analysis of lift axle suspension from the point of view of vehicle handling and stability is essential. There are two basic kinds of lift axle designs used in heavy commercial vehicles: caster steered lift axle having single
Vichare, Chaitanya Ashok, Raval, Chetan, Patil, Sudhir
Data-Driven Toe Misalignment Detection in Single-Unit Twin-Axle Trucks2024-26-027801/16/2024
Toe misalignment detection and its correction are important periodic tasks recommended by Original Equipment Manufacturers (OEMs) for Heavy Commercial Road Vehicles (HCRVs) to prevent premature tyre wear and improve fuel economy. Existing misalignment detection methods need skilled professionals to operate sophisticated equipment, while automated methods require additional sensors, which are not readily available in most trucks, making their implementation challenging. This study explores the effectiveness of a data-driven method to detect toe misalignment in single-unit twin-axle trucks with symmetric and asymmetric toe configurations. This method involves continuous monitoring of lateral dynamics variables measurable using sensors present in most trucks making it practically tractable. Ramp steer manoeuvres with a 45◦ steering angle and a rise time of 3 seconds in two directions (clockwise and anticlockwise) for two toe configurations (symmetric and asymmetric) constituted the four
Burande, Kalyani, Grandhe, Roshan, Mukhopadhyay, Arko, Sharma, Mitanshu, Shankar Ram, C S
Digital evaluation of mirror (IRVM & ORVM)2024-26-026401/16/2024
Abstract This paper provides the required projection, mirror locations, contours, and curvature area calculation in the design phase. Similarly, we can also do measurements of the driver's head and eye locations by looking into each mirror. This method can be applied to passenger cars, light & heavy trucks. The required projected area can be calculated by using simulation and modeling software (CATIA), and further projected area of ORVM and IRVM can be fulfilled by modifying the size and shape of the mirror as per the requirements. Rotation and position can be controlled by rays from the manikin's eye to the edge of the ORVM/IRVM and helps control the blind zone. ORVM & IRVM fitment in vehicle is carried out with the help of AIS standards (automotive industrial standards) in INDIA. According to the AIS standards, there are specific measurements as per the class of vehicle. For example: AIS-002 (Part 1) (Rev. 1):2011 Automotive Vehicles - Approval of Devices for Indirect Vision intended
Dias, Francis Anton
Enhanced Development Process for UPDs – Digital Approach2024-26-023901/16/2024
Underrun Protections devices (UPDs) are specially designed barriers fitted to the front, side, or rear of heavy trucks. In case of accidents, these devices prevent small vehicles such as bikes and passenger cars going underneath and thus minimizing the severity of such accident. Design and strength of UPD is such as to absorb the impact energy and minimise deflection to avoid the under run. Compliance to UPD safety regulations provides stringent requirements in terms of device design, dimensions, and its behaviour under loading. Since accuracy of Computer Aided Engineering (CAE) predictions have improved, use of numerical tools like Finite element method (FEM) are extensively used for design, development, optimisation, and performance verification with respect to regulatory requirements. For improved accuracy of prediction of results through FEA, correct representation of sub-systems is very important. One such sub-system in UPDs is bolted connections, which require accurate methods to
Ugale, Dinesh, D, Dileep Kumar, Mohod, Pravin, Khaleelullah, Abdul, Bandru, Shreenu
Lane Change Conflict Analysis of Camera Based Side-view Systems2024-26-001501/16/2024
The recent progress in camera-based technologies has prompted the development of prototype camera-based video systems, intended to replace conventional passenger vehicle mirrors. Given that a significant number of collisions during lane changes stem from drivers being unaware of nearby vehicles, these camera-based systems offer the potential to enhance safety. By affording drivers a broader field of view, they facilitate the detection of potential conflicts. This project was focused on analyzing naturalistic driving data in support of the Federal Motor Vehicle Safety Standard 111 regulatory endeavors. The goal was to assess the effectiveness and safety compatibility of prototype camera-based side-view systems as potential replacements for traditional side-view mirrors. The method employed involved extracting radar data from instances of lane changes conducted by 12 drivers for two pick-up trucks includes 10018 signal-indicated lane changes performed at speeds consistent with highway
Guduri, Balachandar, Llaneras, Robert
ONE DIMENSIONAL (1-D) SIMULATION MODEL FOR RIDE AND COMFORT EVALUATION OF A TWO AXLE TRUCK.2024-26-029901/16/2024
In automotive industry, testing and validation teams are highly dependent on availability of prototype vehicles for testing and evaluation of ride & comfort behavior of vehicles. Special test tracks surfaces are also used (namely Tar road, Belgian random track, Express way and driving over a Cleat) to evaluate the ride & comfort through jury evaluation (subjective evaluation). Ride is largely affected by transmissibility of road excitations to the driver and other occupant's seats, influence of suspension, bushes and tire are the major contributors in the transfer path of vibrations. A configurable 1-D simulation model of a Two Axle Truck is developed for quick evaluation of the ride & comfort behavior which is need of the hour for the testing team in optimizing the number of iterations in physical testing. These simulations will help in understanding the ride & comfort behavior and its sensitivity to changes in the component's characteristics in absence of physical test vehicles. The
SONI, YASH, Bagal, Vikram, GHANWAT, HEMANT, Mullapudi, Dattatreyudu, Chaskar, Mithun
J1939-73 Digital Annex DBCJ1939-73DBC10/11/2023
J1939-73 DBC File - Heavy Duty Diagnostics (DM1, DM2, ...) The SAE J1939-73 DBC file contains decoding rules for converting 'version 4' J1939 diagnostic messages (DM1, DM2, ...) to 'physical values'. This lets you identify issues in e.g. trucks, tractors and buses. DBC is a CAN database format used in most automotive tools.
J1939 Digital Annex DBCJ1939DBC10/11/2023
The SAE J1939 DBC file contains decoding rules for converting raw J1939 data to 'physical values' (Mph, %, etc.). This file lets you easily decode data from heavy duty vehicles (trucks, buses, tractors, etc.). This DBC file download includes: An SAE J1939 DBC file with ~1800+ PGNs and 12000+ SPNs The J1939 Digital Annex Excel file (with additional PGNs/SPNs and description details) One legal license (1 user, 1 PC) matching the DA license DECODE J1939: Convert J1939 data in wide range of software/API tools 1800+ PGNs: The extensive DBC contains 1800+ PGNs and 12000+ SPNs REVIEW FIRST: Use our CAN ID converter to check if your PGNs are covered CROWD INPUT: Benefit from free corrections based on large user base SAVE HOURS: Avoid manually constructing the DBC file from scratch What is a DBC file? A DBC file is a standardized method for storing the "rules" on how to interpret raw CAN bus data. In particular, it contains details on what 'signals' (e.g. RPM, Vehicle Speed, …) are contained
Prediction and Optimization of Noise radiation from a Heavy-Duty Commercial Vehicle Transmission using Statistical Energy Analysis2025-01-005105/05/2023
Heavy Duty (HD) linehaul vehicles are majorly used in transportation of goods and heavy loads between different cities or long distances. Considering the current trend, payload capacity of these heavy-duty trucks are increasing due to constant increase in the load demand. Due to which engine torques of these HD vehicles are increasing which in turn increases the transmission input torque. At higher torque levels, gear excitation also increases and transmission becomes more susceptible towards higher noise radiation. Global vehicle pass-by noise regulations for HD commercial vehicles are becoming more stringent. Historically transmissions have been considered a secondary noise source but with overall HD vehicle noise becoming quieter, the transmission can be more of a significant noise contributor. Hence, noise radiation from the transmission is also an important factor to be considered in the design phase. Gear whine is the major concern for sound radiation from the transmission. The
Rastogi, Sarthak, Milind, T. R.
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
Active Control of Engine Order Noise for Heavy-duty Trucks: Using the Genetic Algorithm for the Optimization of Error Microphone Arrangement2025-01-001305/05/2023
The arrangement of error microphones for a vehicle active noise control (ANC) system is no trivial work, especially for heavy-duty trucks due to the dilemma resulted from the large volume of the cab and the limited number of microphones accepted by most manufacturers in the auto industry. Most ANC developers resort to trial and error, which is not only a heavy workload given the amount of interested working conditions to be test, but also does not guarantee to yield the optimum noise cancellation performance. In this paper, the authors proposed an error microphone selection methodology using a genetic-algorithm (GA) -based mechanism. The target vehicle was a heavy-duty truck with a six-piston diesel engine, and two scenarios were particularly interested, i.e. driver & copilot and driver & one passenger sleeping on the berth. We first arranged eight microphones at different locations in the cab, five on the headrests, two on the B pillars and one at the head position of the sleeping
Wang PhD, Jian, Ling, Zihong, Zhang, Zhe, Cai, DeHua, lv, Xiao, Zhang, Ming, Gao, GuoRan
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
Comprehensive Analysis and Optimization of Door Closing Sound Quality of a Heavy Truck2025-01-006605/05/2023
Based on the objective and subjective experiment and finite element analysis, the influencing factors on the door closing sound quality of a heavy-duty truck is analyzed and optimized. Results show that the loudness and sharpness can be reduced apparently by increasing stiffness and damping of the door. The sound quality can be enhanced by increasing the pressure release area, which can decrease the air resistance of dooring closing. By adding holes on the inner liner and changing the pressure release location, the dooring closing air resistance is reduced from 289 Pa to 181 Pa. In terms of the rebound sound, the sound level is positively relative to the door closing force. Increasing the protrusion height and decreasing the stiffness of the vibration absorber of the handle can improve the rebound sound quality. Optimizing the absorbers on both ends and adding damping material can decrease the loudness by 47.8%, reduce the cavity sound, dismiss the trembling and improve the compact
Wang, Jian, Zhang, Yongshen, Feng, Lei, Xie, Chenhao, Lin, Jiewei, Sun, Changchun
A Methodology to Design the Flow Field of PEM Fuel Cells2023-01-049504/11/2023
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
Aerodynamic Drag of Road Vehicles in Close Lateral Proximity2023-01-095204/11/2023
Aerodynamic interaction between vehicles on a roadway can modify the fuel use and greenhouse gas emissions of the vehicle relative to their performance under isolated, uniform-wind conditions. A comprehensive wind-tunnel study was undertaken to examine changes to the aerodynamic drag experienced by vehicles in close proximity, in adjacent lanes. Wind-load measurements were conducted for two general configurations: 15%-scale testing with light-duty-vehicle (LDV) models, and 6.7%-scale testing with a heavy-duty vehicle (HDV) model. For the LDV study, a DrivAer model was tested with a proximate AeroSUV model or an Ahmed model at lateral distances representing 75%, 100%, and 125% of a typical highway lane spacing, and for longitudinal distances up to 2 vehicle lengths forward and back. Commensurate measurements were conducted for the AeroSUV model with the proximate DrivAer or Ahmed model. For the HDV study, a tractor-trailer model was tested with a single or combination of adjacent-lane
McAuliffe, Brian, Barber, Hali
SAE TOMORROW TODAY: One Step Closer To L4 AV Trucking1338403/09/2023
The most polite driver on the road might soon be an L4 AV truck. Torc Robotics is the first company developing the technology to commercialize fully autonomous semi-trucks in the U.S. for long-haul applications. By running extensive simulations with the best and most experienced truck drivers in the world, Torc's self-driving vehicle software and integration solution is expected to achieve L4 automation by the end of this decade. As an independent subsidiary of Daimler Truck, the Torc system uses an approach called See-Think-Act to calculate the optimal driving decision. By employing veteran truck drivers to reinforce their technology with real world know-how, Torc is truly making the road a safer place. We sat down with Tim Zuercher, VP Engineering - Autonomy at Torc, to discuss the company's mission to reduce highway deaths, enable critical supplies, and help the transportation industry increase fuel economy, uptime, and capacity.
Hineman, Marcie
SECURING CAN NETWORKS IN COMMERCIAL VEHICLES22TOFHP10_0210/01/2022
A CAN transceiver with built-in security functions can avoid the complexity of end-to-end security solutions that are especially hard to implement on CVs. Commercial road vehicles are the backbone of the modern consumer economy. Almost any business from construction, to energy, to online retail at some point relies on the delivery of goods by commercial vehicles, which in turn are becoming increasingly connected both to the external world and to each other via telematics. This enables CV owners to optimize and manage their fleets via platooning for safety and efficiency improvements as well as cost and fuel-consumption reduction to meet the increasingly stringent CO2 emissions requirements necessitated by climate change. However, the increased connectivity brings with it an increase in cyberattack surfaces and CV fleets are prime targets for cybercrime due to the high value of the cargo they carry, and their importance to large businesses and the greater economy. While CV manufacturers
Sivaramakrishnan, Karthik
EDITORIAL: Hiring talent to meet high-tech demands22TOFHP10_0410/01/2022
There's always been competition for engineering talent. But with embedded software becoming ever more critical for subsystems in commercial vehicles and off-highway equipment, nowadays that competition is a whole lot stiffer. Aerospace and process-control industries have been the main competitors for embedded and controls talent in the past, according to Dr. Anupam Gangopadhyay, director of controls and software at Navistar. Despite “new frontiers” that are helping to attract and retain engineers, such as autonomous, connected and electric-vehicle technologies, “a lot of the talent that we were hiring in the past are now interested in things like IoT, cloud computing, natural-language processing and social-networking platforms,” he said during a panel session at SAE COMVEC 2022 in Indianapolis.
Gehm, Ryan
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
Electrification is the future for defense vehicles22TOFHP10_0310/01/2022
Despite infrastructure challenges, electrified and automated military vehicles will save fuel and lives, said Allison's VP of Defense Programs at SAE COMVEC 2022. The M1 Abrams main battle tank developed for the U.S. Army in the late 1970s remains the best tank in the world, according to Allison Transmission's VP of Defense Programs, but it does have an Achilles' heel: It needs 0.7 gallons (2.65 L) of fuel to travel a mile. “You don't have to be an engineer to know that's a problem,” Dana J.H. Pittard said to a ballroom full of engineers during the opening keynote of the SAE COMVEC 2022 conference in Indianapolis. Pittard is not an engineer, but his remarkable real-world experiences make him eminently qualified for his role at Allison. Before entering the commercial sector in 2015, he served in the United States Army as a major general and retired after 34 years of active duty - with assignments that included leading a tank company in Desert Storm and serving as military aide to the
Gehm, Ryan
Evaluating Class 6 Delivery Truck Fuel Economy and Emissions Using Vehicle System Simulations for Conventional and Hybrid Powertrains and Co Optima Fuel Blends2022-01-115609/20/2022
The US Department of Energy’s Co-Optimization of Engine and Fuels Initiative (Co-Optima) investigated how unique properties of bio-blendstocks considered within Co-Optima help address emissions challenges with mixing controlled compression ignition (i.e., conventional diesel combustion) and enable advanced compression ignition modes suitable for implementation in a diesel engine. Additionally, the potential synergies of these Co-Optima technologies in hybrid vehicle applications in the medium- and heavy-duty sector was also investigated. In this work, vehicles system were simulated using the Autonomie software tool for quantifying the benefits of Co-Optima engine technologies for medium-duty trucks. A Class 6 delivery truck with a 6.7 L diesel engine was used for simulations over representative real-world and certification drive cycles with four different powertrains to investigate fuel economy, emissions, and well-to-wheel greenhouse gas performance. Comparisons were made between
Vijayagopal, Ram, Curran, Scott, Deter, Dean, Longman, DOUGLAS
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