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SAE J3078 provides test methods and criteria for the evaluation of the operator enclosure environment in earth-moving machinery as defined in ISO 6165. SAE J3078/1 gives the terms and definitions which are used in other parts of SAE J3078. It is applicable to Off-Road Self-Propelled Work Machines as defined in SAE J1116 and tractors and machinery for agriculture and forestry as defined in ANSI/ASAE S390.

Heavy Vehicle Event Data Recorders (HVEDRs) have the ability to capture important data surrounding an event such as a crash or near crash. Efforts by many researchers to analyze the capabilities and performance of these complex systems can be problematic, in part, due to the challenges of obtaining a heavy truck, the necessary space to safely test systems, the inherent unpredictability in testing, and the costs associated with this research. In this paper, a method for simulating vehicle speed sensor (VSS) inputs to HVEDRs to trigger events is introduced and validated. Full-scale instrumented testing is conducted to capture raw VSS signals during steady state and braking conditions. The recorded steady state VSS signals are injected into the HVEDR along with synthesized signals to evaluate the response of the HVEDR. Brake testing VSS signals are similarly captured and injected into the HVEDR to trigger an event record.

Considering the current trend towards the electrification of commercial vehicles, the development of Beam eAxle solutions has become necessary. The utilization of an electric drive unit in heavy-duty solid axle-based commercial vehicles presents unique and demanding challenges. These include the necessity for elevated peak and continuous torque while meeting packaging constraints, structural integrity requirements, and extended service life. One such solution was developed by BorgWarner to address these challenges. This paper offers a comprehensive overview of the design and development process undertaken for this Dual Motor Beam eAxle system. This includes the initial comparison of various eAxle solutions, the specifications of components selected for this design, and the initial results from dyno and vehicle development.

Nowadays, Bismuth (Bi) is being applied as an overlay material for engine bearings instead of Lead (Pb) which is an environmentally harmful material. Bi overlay has already been a solid performer in some automotive engine sectors due to its superior load carrying capacity and good robustness characteristic which are necessary to maintain its longevity during the lifetime of engines. The replacement is also seen on relatively larger size engines, such as Trucks and Off-highway heavy duty applications. Basically, these applications require higher power output than passenger cars, and the expected component lifecycle becomes longer. Though Bi has similar material characteristic to traditional Pb, it becomes challenging for the material alone to satisfy these requirements. Polymer overlay is known for its superior anti-wear performance and longer lifetime due to less adhesion against a steel counterpart than metallic materials (included Bi).

Lithium-ion batteries serve as the main power source for contemporary electric vehicles. Safeguarding these batteries against damage is paramount, as it can trigger accelerated performance deterioration, potential fire hazards, environmental threats, and more. This study explores damage progression of a commercial vehicle lithium-ion battery module containing prismatic cells under indentation crush loading. We employed computational simulations of mechanical loading tests to investigate this behavior. Physical tests involved subjecting modules to low-speed (0.05 m/s) indentations using a V-shaped stainless-steel wedge, under six unique loading conditions. During the tests, force, and voltage change with wedge displacement were monitored. Utilizing experimental insights, we constructed a finite element model, which included key components of the battery module, such as the prismatic cells, steel frames, and various plastic parts.

Bicycle computers record and store global position data that can be useful for forensic investigations. The goal of this study was to estimate the absolute error of the latitude and longitude positions recorded by a common bicycle computer over a wide range of riding conditions. We installed three Garmin Edge 530 computers on the handlebars of a bicycle and acquired 9 hours of static data and 96 hours (2214 km) of dynamic data using three different navigation modes (GPS, GPS+GLONASS, and GPS+Galileo satellite systems) and two geographic locations (Vancouver, BC, Canada and Orange County, CA, USA). We used the principle of error propagation to calculate the absolute error of this device from the relative errors between the three pairs of computers. During the static tests, we found 16 m to 108 m of drift during the first 4 min and 1.4 m to 5.0 m of drift during a subsequent 8 min period. During the dynamic tests, we found a 95th percentile absolute error for this device of ±8.04 m.

This paper investigates the tire-road interaction for tires equipped with two different solid rubber material definitions within a Finite Element Analysis virtual environment, ESI PAMCRASH. A Mixed Service Drive truck tire sized 315/80R22.5 is designed with two different solid rubber material definitions: a legacy hyperelastic solid Mooney-Rivlin material definition and an Ogden hyperelastic solid material definition. The popular Mooney-Rivlin is a material definition for solid rubber simulation that is not built with element elimination and is not easily applicable to thermal applications. The Ogden hyperelastic material definition for rubber simulations allows for element destruction. Therefore, it is of interest and more suited for designing a tire model with wear and thermal capabilities.

Leaf Springs are commonly used as a suspension in heavy commercial vehicles for higher load carrying capacity. The leaf springs connect the vehicle body with road profile through the axle & tire assembly. It provides the relative motion between the vehicle body and road profile to improve the ride & handling performance. The leaf springs are designed to provide linear stiffness and uniform strength characteristics throughout its travel. Leaf springs are generally subjected to dynamic loads which are induced due to different road profiles & driving patterns. Leaf spring design should be robust as any failure in leaf springs will put vehicle safety at risk and cost the vehicle manufacturer their reputation. The design of a leaf spring based on conventional methods predicts the higher stress levels at the leaf spring center clamp location and stress levels gradually reduce from the center to free ends of the leaf spring.

Recent advancements towards autonomous heavy-duty vehicles are directly associated with increased interconnectivity and software driven features. Consequently, rise of this technological trend is bringing forth safety and cybersecurity challenges in form of new threats, hazards and vulnerabilities. As per the recent UN vehicle regulation 155, several risk-based security models and assessment frameworks have been proposed to counter the growing cybersecurity issues, however, the high budgetary cost to develop the tool and train personnel along with high risk of leakage of trade secrets, hinders the automotive manufacturers from adapting these third party solutions. This paper proposes an automated Threat Assessment & Risk Analysis (TARA) framework aligned with the standard requirements, offering an easy to use and fully customizable framework. The proposed framework is tailored specifically for heavy-duty vehicular networks and it demonstrates its effectiveness on a case study.

Wheel hubs with drum brakes of heavy-duty vehicles rarely broke, but some suddenly cracked in the 2000s. The cause of damage was said to be a lack of hub strength. However, the case was suspicious because the hubs were produced according to the design guidelines by the JSAE. In the 1990s, brake shoe-lining materials were changed from asbestos to non-asbestos for people’s health. The brake squeal and abnormal self-lock frequently occurred because of the increased friction coefficient between drum and shoe lining in the case of the leading–trailing type. The mechanical friction coefficient changes with the material and the contact angle, which varies with the wear of shoe lining and the drum temperature. In the previous report, the deformation of the wheel hub under the abnormal self-lock was verified by observing the change of hub attitude in model test equipment.

SAE J115 specifies the relevant ISO standards for application to safety labels for use on off-road work machines as defined in SAE J1116.

Commercial vehicle are exposed to harsh environment conditions like dust, mud, wind, rain, extreme sun and winter throughout. Apart from white goods and other conventional loading these vehicles also used in applications which involve Handling of Dirty Loads, Construction Raw materials, Mining Industry etc. which leads to fast deterioration of Interiors. Also, in most cases drivers are not the owners. Hence due to high cost of Cleaning at dealerships and low Product maintenance awareness amongst Commercial Vehicle Users, on Road Washing & Cleaning by riverside is common practice which leads to early deterioration of Interior trims. This paper deals with the retention of newness of soft trim parts such as headliner, wall trims and carpets. Causes of product deterioration and attributes which influence newness like product appeal, NVH, perceived quality, environmental impact, geometry retention over time etc. have been discussed in detail.

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.

Automotive crash data analysis and reconstruction is vital for ensuring automotive safety. The objective of vehicle crash reconstruction is to determine the vehicle's motion before, during, and after the crash, as well as the impact on occupants in terms of injuries. Simulation approaches, such as PC CrashTM, have been developed to understand pre-crash and post-crash vehicle motion, rather than the crash phase behavior. Over the past few decades, crash phase simulations have utilized vehicle finite element models. While multibody simulation tools are suitable for crash simulations, they often require detailed crash test data to accurately capture vehicle behavior, which is not always readily available. This paper proposes a solution to this limitation by incorporating crash test data from databases, such as NHTSA, Global NCAP, consumer rating reports, and videos, along with a multibody-based approach, to conduct crash phase simulations.

The commercial vehicles market is dominated by manual transmission, due to lower ownership cost. Generally, commercial vehicles are used in large numbers by the fleet owners. The transmission endurance life is very important to a vehicle owner. On the other hand, driver fatigue can be reduced with a smooth gear change process. The gear change process in a manual transmission is carried out with the help of the synchronizer pack. The crucial function of a synchronizer pack in an automotive transmission is to match the speed of the target gear for smooth gear shifting. In a transmission, the loose and the weakest part is the synchronizer ring. The failure of the synchronizer affects smooth gear shifting and it also affects the endurance life of the transmission. The synchronizer ring can fail due to poor structural strength, synchronizer liner wear, synchronizer liner burning, etc.

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The SAE Recommended Practice establishes minimum performance requirements and related uniform laboratory test procedures for evaluating lateral (curb) impact collision resistance of all wheels intended for use on passenger cars and light trucks.