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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.

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.

Tippers used for transporting blue metal, construction and mining material is designed with different types of load body to suit the material being carried, capacity and its application. These load bodies are constructed with high strength material to withstand forces under various operating conditions. Structural strength verification of load body using FEM is conducted, by modelling forces due to payload as a pressure function on the panels of the load body. The spatial variation of pressure is typically assumed. In discrete element method (DEM) granular payload material such as gravel, wet or dry sand, coal etc., can be modelled by accounting its flow and interaction with structure of load body for prediction of force/pressure distribution. In this paper, coupled FE-DEM is used for determining pressure distribution on loading surfaces of a tipper body structure of a heavy commercial vehicle during loading, unloading and transportation.

Abstract This study underscores the benefits of refining the intralogistics process for small- to medium-sized manufacturing businesses (SMEs) in the engineer-to-order (ETO) sector, which relies heavily on manual tasks. Based on industrial visits and primary data from six SMEs, a new intralogistics concept and process was formulated. This approach enhances the value-added time of manufacturing workers while also facilitating complete digital integration as well as improving transparency and traceability. A practical application of this method in a company lead to cutting its lead time by roughly 11.3%. Additionally, improved oversight pinpointed excess inventory, resulting in advantages such as reduced capital needs and storage requirements. Anticipated future enhancements include better efficiency from more experienced warehouse staff and streamlined picking methods. Further, digital advancements hold promise for cost reductions in administrative and supportive roles.

The mechanization of crops causes problems in soil structure as it causes compaction. Compaction can be severe depending on the type of tire adopted in the field. Producers are concerned with selecting wheelsets that harm the soil less and remembering to save resources when buying agricultural tires. Agricultural tires are more expensive than road tires, and truck tires can be an alternative for producers to save money. The present study evaluated the interaction between wheelset and ground in a fixed tire testing unit, comparing the impact of different tire models on bare ground. The 6 treatments performed consisted of 3 tire models (p1: road radial, composed of double wheelset - 2×275/80r22.5; p2: agricultural radial - 600/50r22.5; and p3: agricultural diagonal - 600/50-22.5) versus two contact surfaces, one rigid and the other with bare agricultural soil. Seven response variables were used to apply Regression analysis and descriptive statistics.

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.

This SAE Recommended Practice establishes a uniform test procedure for evaluating performance of operator enclosure pressurization systems for construction, general-purpose industrial, agricultural, forestry, and specialized mining machinery as categorized in SAE J1116 for off-road, self-propelled work machines.

The transportation industry has been scrutinized for its contribution towards the global greenhouse gas emissions over the years. While the automotive sector has been regulated by strict emission legislation globally, the emissions from marine transportation have been largely neglected. However, during the past decade, the international maritime organization focused on ways to lower the emission intensity of the marine sector by introducing several legislations. This sets limits on the emissions of different oxides of carbon, nitrogen and sulphur, which are emitted in large amounts from heavy fuel oil (HFO) combustion (the primary fuel for the marine sector). A 40% and 70% reduction per transport work compared to the levels of 2008 is set as target for CO2 emission for 2030 and 2050, respectively. To meet these targets, commonly, methanol, as a low-carbon fuel, and ammonia, as a zero-carbon fuel, are considered.

The scope of this SAE Standard is the definition of the functional, environmental, and life cycle test requirements for electrically operated backup alarm devices primarily intended for use on off-road, self-propelled work machines as defined by SAE J1116 (limited to categories of (1) construction, and (2) general purpose industrial).

Materials play a key role in our day to day life and have shaped the industrial revolution to a great extent. Right selection of material for meeting a particular objective is the key to success in today’s world where the cost as well as sustainability of any equipment or a system have assumed greater significance than ever before. In automotive industry, materials have a definitive role as far as the mobility and safety is concerned. Materials that can absorb the required energy or impact can be manufactured through different manufacturing as well as metallurgical processes which involves appropriate heat treatment and bringing correct chemical compositions etc. However, they can also be formed by simpler methods such as combining certain materials together in the form of layered combinations to form light weight composites.

This SAE Recommended Practice establishes uniform Installation Parameters for desiccant Air Dryers for vehicles with compressed air systems.

This SAE Standard incorporates driving cycles that produce fuel consumption data relating to Urban, Suburban, and Interstate driving patterns and is intended to be used to determine the relative fuel economy among vehicles and driving patterns under warmed-up conditions on test tracks, suitable roads, or chassis dynamometers.1

This paper presents a comprehensive investigation aimed to assess the effect of tire inflation pressure on the fuel consumption of a typical 4×4 off-road vehicle over unprepared soft terrains. For this purpose, a fourteen-degrees-of-freedom (14-DOF) full parametrized vehicle model is employed and numerically simulated in MATLAB/Simulink™ environment. This model is intended to consider all the rotational dynamics and compliances of all-wheel-drivetrain aggregates using SimDriveline™ toolbox including engine, transmission, differentials, shafts and wheels. Numerous simulations are carried out to examine both the tractive efficiency and fuel consumption considering all power losses in transmission, terrains and tire slippage over different operating conditions such as terrain’s mechanical properties, tire weight distribution and drivetrain configurations (open or locked center differential).

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.

In marine or stationary engines, consistent engine performance must be guaranteed for long-haul operations. A dual-fuel combustion strategy was used to reduce the emissions of particulates and nitrogen oxides in marine engines. However, in this case, the combustion stability was highly affected by environmental factors. To ensure consistent engine performance, the in-cylinder pressure measured by piezoelectric pressure sensors is generally measured to analyze combustion characteristics. However, the vulnerability to thermal drift and breakage of sensors leads to additional maintenance costs. Therefore, an indirect measurement via a reconstruction model of the in-cylinder pressure from engine block vibrations was developed. The in-cylinder pressure variation is directly related to the block vibration; however, numerous noise sources exist (such as, valve impact, piston slap, and air flowage).

Mixture formation in a hydrogen-fueled heavy-duty engine with direct injection and a nearly-quiescent top-hat combustion chamber was investigated using laser-induced fluorescence imaging, with 1,4-difluorobenzene serving as a fluorescent tracer seeded into hydrogen. The engine was motored at 1200 rpm, 1.0 bar intake pressure, and 335 K intake temperature. An outward opening medium-pressure hollow-cone injector was operated at two different injection pressures and five different injection timings from early injection during the intake stroke to late injection towards the end of compression stroke. Fuel fumigation upstream of the intake provided a well-mixed reference case for image calibration. This paper presents the evolution of in-cylinder equivalence ratio distribution evaluated during the injection event itself for the cylinder-axis plane and during the compression stroke at different positions of the light sheet within the swirl plane.

Unfavorable climates, fatigue, safety & deprived sleep of driver’s leads to use of AC system for their quick thermal comfort during night with engine ON. This scenario is very critical from a human’s safety & vehicle functionality point of view. This also consumes an additional 10-15% of fuel requirements in AC running conditions. So, to address the social problems of driver’s sleep and pollution-free environment by reducing the use of fossil fuels, there is a need for alternative techniques for air cooling which work during engine OFF condition. Various alternative options for air cooling have been reviewed. Accordingly, the packaging flexibility of phase change material (PCM) technology makes it easy to implement, yet effective usage of large quantity stored PCM, needs optimization. This paper proposes a design of a hybrid air conditioning system for sleeper commercial vehicles using a combined conventional compression and phase change material.

To meet stringent emission norms and commercial vehicle customer demands, the selection of an after-treatment system (ATS) plays a considerable role. Therefore, the selected ATS should substantially reduce nitrogen oxide emission by proper decomposition of ammonia and particulate matter without significantly increasing the thermal stress on DPF. Though the BS-VI after-treatment architecture is derived from EURO-VI, only a certain level of technology for the vehicle operating conditions in India can be implemented. However, numerous vehicle operating condition challenges in the Indian market must be explicated. Correspondingly, it should be addressed with a robust durability validation methodology to enhance the ATS product performance in challenging environments. This paper discusses SCR catalysts emission performance and ammonia decomposition durability validation methodology for commercial vehicles.

This specification sheet establishes requirements for a high collapse pressure configuration filter element of a specific configuration with a minimum filtration ratio of 75 for particles larger than 7 µm when designed and tested in accordance with SAE J2321 and this specification sheet.

In response to the national policy of energy conservation and emission reduction, more technologies that can improve the thermal efficiency of engines are gradually applied. Among them, EGR technology has high cost -performance in energy conservation，emission reduction and improving the thermal efficiency of engines. EGR technology redirects a portion of exhaust gas into the engine intake, mixes it with fresh air, and then re-burns it in the engine combustion chamber. Because of the mixture of high temperature exhaust gas and fresh air, if the temperature of the mixture is lower than the dew point temperature of condensate water, condensate water will be precipitated. Excessive condensate water will make the engine combustion worse, and even cause engine misfire. Based on a 1.5L low pressure EGR system engine, this paper studies the factors affecting the condensate generation and combustion stability.