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The hydraulic retarder is the most stabilized auxiliary braking system [1-2] of heavy-duty vehicles. When the hydraulic retarder is working during auxiliary braking, all of the braking energy is transferred into the thermal energy of the transmission medium of the working wheel. Theoretically, the residual heat-sinking capability of the engine could be used to cool down the transmission medium of the hydraulic retarder, in order to ensure the proper functioning of the hydraulic retarder. Never the less, the hydraulic retarder is always placed at the tailing head of the gearbox, far from the engine, long cooling circuits, which increases the risky leakage risk of the transmission medium. What's more, the development trend of heavy load and high speed vehicle directs the significant increase in the thermal load of the hydraulic retarder, which even higher than the engine power.

To prevent braking recession, heavy commercial vehicles are often equipped with fluid auxiliary braking devices, such as hydraulic retarder. Hydraulic retarder can convert the vehicle’s kinetic energy to the fluid heat energy, which can enormously alleviate the main brake’s workload. The traditional hydraulic retarder can provide enough braking torque but has a delay during the braking. In this paper, a new type of magnetorheological fluid (MR fluid) hydraulic retarder is introduced by replacing the traditional fluid with magnetorheological fluid because of its linear braking torque and quick response. By changing the magnetic field intensity, it is easier to control the braking torque than the traditional hydraulic retarder. The rise of magnetorheological fluid temperature during the braking period will reduce the hydraulic retarder’s performance.

Mountain road winding and bumpy, traffic accidents caused by speeding frequently happened, mainly concentrated on curves. The present curve warning system research are based on Charge-coupled Device, but the existing obstacles, weather , driving at night and road conditions directly affect the accuracy and applicability. The research is of predictability to identify the curves based on the geographic information and can told the driver road information and safety speed ahead of the road according to the commercial vehicle characteristic of load, and the characteristics of the mass center to reduce the incidence of accidents. In this paper, the main research contents include: to estimate forward bend curvature through the node classification method based on the digital map.

Vehicle hydraulic retarders are applied in heavy-duty trucks and buses as an auxiliary braking device. In traditional cooling systems of hydraulic retarders, the working fluid is introduced into the heat exchanger to transfer heat to the cooling liquid in circulation, whose heat is then dissipated by the engine cooling system. This prevents the waste heat of the working fluid from being used effectively. In hydraulic retarder cooling system based on the Organic Rankine Cycle, the organic working fluid first transfers heat with the hydraulic retarder working fluid in Rankine cycle, and then outputs power through expansion machine. It can both reduce heat load of the engine cooling system, and enhance thermal stability of the hydraulic retarder while recovering and utilizing braking energy. First of all, according to the target vehicle model, hydraulic retarder cooling system model based on Rankine cycle is established.

With the continuous increasing requirements of commercial vehicle weight and speed on highway transportation, conventional friction brake is difficult to meet the braking performance. To ensure the driving safety of the vehicle in the hilly region, the eddy current retarder (ECR) has been widely used due to its fast response, lower prices and convenient installation. ECR brakes the vehicle through the electromagnetic force generated by the current, and converted vehicle mechanical energy into heat through magnetic field. Air cooling structure is often used in the traditional ECR and cooling performance is limited, which causes low braking torque, thermal recession, and low reliability and so on. The water jacket has been equipped outside the eddy current region in this study, and the electric ECR is cooled through the water circulating in the circuit, which prolongs its working time.

The hydraulic retarder is an auxiliary braking device used for commercial vehicle in a long slope brake, and its transmission oil generates a lot of heat in its working process. If the heat of transmission doesn’t go through a reasonable management, it will seriously affect the braking performance of hydraulic retarder. To cool down the transmission oil, it will aggravates the load of the engine cooling system, and the long cooling path sometimes causes heat exchange not timely. When the Rankine cycle is used for cooling the hydraulic retarder transmission oil in virtue of its good heat transfer performance in phase change process, it can make the transmission oil temperature controlled more stable. In this new system, the setting parameters of the Evaporate-condensate system will affect the stability of the transmission oil temperature in the hydraulic retarder inlet and the energy recovery efficiency of the system.

The hydraulic retarder is an auxiliary braking device generally equipped on commercial vehicles. Its oil temperature change influences the brake performance of hydraulic retarder. The Organic Rankine Cycle (ORC) is a good means to recover exhausted heat. Moreover, it can cool oil and stably control oil temperature with the help of heat absorption related with evaporation. Comprehensively considering the heat-producing characteristics of hydraulic retarder and the temperature control demand, the aimed boundary conditions are determined. Also the changing rules about the working medium flow rate are obtained. In this work, the heat-producing properties of hydraulic retarder under different conditions and the oil external circulating performance is firstly analyzed. By researching the system’s adaptation to the limiting conditions, the aimed temperature to control is prescribed.

The hydraulic retarder is an important auxiliary braking device. With merits such as its high braking torque, smooth braking, low noise, long service life and small size, it is widely used on modern commercial vehicles. Transmission fluid of traditional hydraulic retarder is cooled by engine cooling system, which exhausts the heat directly and need additional energy consumption for the thermal management component. On account of the working characteristics of hydraulic retarder, this study designs a set of waste heat recovery system based on the Organic Rankine Cycle (ORC). Under the premise of ensuring stable performance of hydraulic retarder, waste heat energy in transmission fluid is recycled to supplement energy requirements for cooling system. First of all, a principle model, which is scaled down according to D300 retarder`s thermal power generation ration of 1:100, is established. Then through theoretical calculations, components' structural parameters of the ORC are determined.

The cooling system with two fans is generally driven by electrical motors in the small cars. Compared with the traditional cars, heavy duty trucks have the larger heat dissipation power of cooling system. The motors power consumption of dual fans will be larger and the two electrical motors will occupy a large space in the engine cabin. Hydrostatic drive refers to the cooling fan is driven by hydraulic motor, but it has the low transmission efficiency. According to the engine water temperature value and the actual working status of the hydraulic system, the actual speed of cooling fan can be controlled by the computer, which guarantees the normal working water temperature of the engine. Hydrostatic drive is generally applied to heavy vehicles, engineering machinery and excavators as driving source of cooling fan which contains the advantages of large output power, overload protection, continuous speed regulation and flexible space arrangements.

It’s not easy to start the engine in winter, especially in frigid highlands, because the low temperature increases the fuel’s viscosity, decreasing the lubricating oil flow ability and the storage performance of battery. Current electrical heating method can improve the engine starting performance in low temperature condition, but this method adds an external power to the engine, leading to the engine cannot maintain an efficient energy utilization. A warming device using the solar energy is designed to conserve the energy during the daytime, and directly warm up the engine at the time when the engine turns off for a long time, especially during the night. A solar collector installed on the top of the vehicle is used to convert the solar energy to the thermal energy, which is then transferred to the heat accumulator that contain the phase-change medium which can increase the heat storage performance.

Due to the increase of mining production and rising labor costs, manufacturers of construction and mining equipment are engaged in developing large tonnage mining truck with good dynamic performance and high transport efficiency. This paper focuses on the improvement of the dynamic performance of a 52t off-highway dump truck. According to the characteristics of its operating cycle, electric auxiliary drive system is installed in the front axle aiming at improving the utilization rate of ground adhesion. The new all-wheel drive hybrid electric system makes it possible for dump truck transports at a higher velocity. Both the conventional dump truck model and the new all-wheel drive hybrid truck model are built based on the AVL-Cruise platform. Meanwhile, under the premise of enough dynamic performance, fuel consumption can be minimized by collaborative optimization in Isight.

This paper presents a novel application of hydraulic electromagnetic energy-regenerative shock absorber (HESA) into commercial vehicle suspension system and vehicle road performance are simulated by the evaluating indexes (e.g. root-mean-square values of vertical acceleration of sprung mass, dynamic tire-ground contact force, suspension deflection and harvested power; maximum values of pitch angle and roll angle). Firstly, the configuration and working principle of HESA are introduced. Then, the damping characteristics of HESA and the seven-degrees-of-freedom vehicle dynamics were modeled respectively before deriving the dynamic characteristics of a vehicle equipped with HESA. The control current is fixed at 7A to match the similar damping effect of traditional damper on the basis of energy conversion method of nonlinear shock absorber.

When driving in mountainous areas, vehicles often encounter long downhill sections. Due to the large mass of bus and the drum brake with poor heat dissipation effect, it is easy for bus to produce braking thermal decay in long downhill section, which makes the vehicle out of control and causes safety accidents. The braking methods of parallel hybrid electric bus include drum braking, engine braking and regenerative braking, whose torque models are established in this paper. The coasting test in Trucksim is used to verify the correctness of the engine braking torque model. Based on coupling braking torque curve with vehicle speed in different gradient, the stable speed is determined and the shift strategy is proposed. The temperature rise model of brake drum is established to analyze the temperature change of brake drum during long downhill. Then, according to the ramp data of G22 freeway, the above models are simulated.

The development of high precision flow divider/combiner valves has received considerable attention by the authors over the past decade. Several different valve designs for division and combination of flow have been designed which display small flow dividing/combining error (1-2%) when compared to conventional designs (2-10%). Recent studies have improved upon the design in order to reduce cost, weight and complexity of the valve. This paper will present the latest of the authors research into the development of a high precision, autoregulated flow divider/combiner valve with an integral shuttle valve. The autoregulator extends the operating range of the integrated flow divider/combiner valve (for errors less than 2 %) to 10-50 lpm compared to 30-50 lpm for the unregulated valve.

In order to obtain the comprehensive evaluation of thermal management system for the retarder, the complete driveline thermal management model is built. The characteristic parameters for the thermal management system are determined and the hydromechanical characteristics for the retarder are fixed by the rig test. On the basis of the same whole vehicle driving cycle, comparing to the traditional mechanical-drive system, the independent-drive system makes the working temperature of the heat source more stable. Meanwhile the parasitic power caused by the radiator fan is decreased markedly on the condition that the heat reject requirement of the heat source is satisfied.

The basic principle of wavelet transform is presented and the method of wavelet theory is used in vibration signal analysis of vehicle in this paper. The vibration signals which generated in the locations such as cab floor, engine, transmission, band spring and frame under the usual work condition are measured by the vibration test system. The vibration signals are decomposed with the principle of wavelet decomposition at level six, and eigenvectors of signal energy are gained. According to the correlation coefficient of eigenvectors of signal energy distribution, two signals correlativity is determined. It could be an effective method that identificate the main vibration source.

The mountain roads are curved and complicated, with undulating terrain and large distance between charging stations. Compared with traditional powered vehicles, in addition to safety issues, pure electric vehicles also need to deal with the driving range issue. At present, the relevant researches on automobile driving in mountainous areas mainly focus on the driving safety of traditional fuel oil vehicles when going uphill and downhill, while there are few researches on the driving planning of pure electric commercial vehicles on curved slope road. This paper presents a speed planning method for pure electric commercial vehicles based on vehicle-road collaboration technology. First, establish the vehicle dynamics model, analyze the vehicle dynamics characteristics when passing the downhill curve, calculate the safe speed range of the vehicle when passing the downhill curve, and establish the safe speed model of the downhill curve.

When dump trucks unload dusty materials, dust particles with a diameter of 1 to 75 microns slide out of the dump body and float into the air. Dust particles naturally settle down spending a few hours, which causes air pollution. People who work in this environment daily suffer serious physical harm. To study the movement of dust particles during the unloading process, a scaled-down model is used to simulate the process of dump truck unloading gravel, and a high frame rate camera is used to record the movement trajectory of dust particles during the unloading process. In this paper, by observing the movement process of unloading dust particles by dump trucks, based on the principle of dynamics, a mathematical model describing the unloading of dust particles in the dump body and a mathematical model of the diffusion of dust particles in the air are established. Take the small gravel sampled at the construction site as an example of the experiment.

With the development of highway transportation and automobile industry technology, highway truck overload phenomenon occurs frequently, which poses a danger to road safety and personnel life safety. So it is very important to identify the overload phenomenon. Traditionally, static detection is adopted for overload identification, which has low efficiency. Aiming at this phenomenon, a dynamic overload identification method is proposed. Firstly, the coupled road excitation model of vehicle speed and speed bump is established, and then the 4-DOF vehicle model of half car is established. At the same time, considering that the double input vibration of the front and rear wheels will be coupled when vehicle passes through the speed bump, the model is decoupled. Then, the vertical trajectory of the body in the front axle position is obtained by Carsim software simulation.

The hydraulic retarder, which is an auxiliary brake device for enhancing traffic safety, has been widely used in kinds of heavy commercial vehicles. When the vehicle equipped with the retarder is traveling in non-braking state, the transmission loss would be caused because of the stirring air between working wheels of the rotor and the stator no matter if the retarder connects in parallel or in series with the transmission [1]. This paper introduces an elaborate hydraulic retarder air-friction reduction system (AFRS) which consists of a vacuum generating module and pneumatic control module. AFRS works to reduce the air friction by decreasing the gas density between working wheels when the retarder is in non-braking state. The pneumatic control model of hydraulic retarder is built first. Then various driving conditions are considered to verify the performance of the AFRS. The stability of the AFRS is analyzed based on the complete driveline model.