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Abstract The development of electric commercial vehicles brought up novel challenges in the design of efficient and reliable air brake systems. The compressor is one of the critical components of the air brake system and is responsible for supplying pressurized air to the brake system. In this study, we aimed to gather essential information regarding the pressure and flow rate requirements for the compressor in the air brake system of electric commercial vehicles. We extensively analyzed the existing air brake systems utilized in conventional commercial vehicles. We examined the performance characteristics of reciprocating compressors traditionally employed in these systems. Recognizing the need for novel compressor designs tailored to electric commercial vehicles, we focused on identifying the specifics such as efficiency, performance characteristics, reliability, and cost of the compressor.

Abstract The use of appropriate loads and regulations is of great importance in weld fatigue assessment of rail on-track maintenance equipment and similar vehicles for optimized design. The regulations and available loads, however, are often generalized for several categories, which proves to be overly conservative for some specific categories of machines. EN (European Norm) and AAR (Association of American Railroads) regulations play a pivotal role in determining the applicable loads and acceptance criteria within this study. The availability of track-induced fatigue load data for the cumulative damage approach in track maintenance machines is often limited. Consequently, the FEA-based validation of rail track maintenance equipment often resorts to the infinite life approach rather than cumulative damage approach for track-induced travel loads, resulting in overly conservative designs.

Abstract During mining material hauling, the chassis frame structure of rear dump trucks is subjected to fatigue loading due to uneven road conditions. This loading often leads to crack propagation in the frame rails, necessitating the determination of stresses in the critical zone during the design stage to ensure structural integrity. In this study, a computer-aided engineering (CAE) methodology is employed to size and select the rectangular profile cross section of the chassis frame rail. A detailed design investigation of the chassis frame is conducted to assess its load resistance, structural flexibility, and weld joint fatigue life under critical stresses arising from combined bending and torsion loads. The optimization process aims to determine the optimal rail size and material thickness, striking a balance between minimizing mass and maximizing structural reliability.

Abstract This article presents the methodical development of a subframe for a novel on-the-road-modular vehicle concept, which was developed for the U-Shift project. The subframe serves as the basis for a modular chassis. This chassis offers the possibility to exchange chassis components by the operator, which means after completion by the manufacturer, and thus to adapt the vehicle to different purposes. According to the applied methodology, the relevant wheel loads are determined and a geometric reference model is created. By defining the relevant load cases, the forces acting on the subframe, and thus the physical boundary conditions, can be determined from the wheel loads. In addition to the wheel loads and the geometric boundary conditions, no other vehicle parameters are required for the development of the subframe. The results of the topology optimization are used to identify areas of the geometric reference model that are not exposed to high loads.

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.

Abstract Being an engineer-to-order (ETO) operating industry, the control cabinet industry faces difficulties in process and workplace optimizations due to changing requirements and lot size one combined with volatile orders. To optimize workplaces for employees, current literature is focusing on ergonomic designs, providing frameworks to analyze workplaces, leaving out the optimal design for productivity. This work thus utilizes a Kano analysis, collecting empirical data to identify essential design requirements for assembly workplaces, incorporating input from switchgear manufacturing employees. The results emphasize the need for a balance between ergonomics and efficiency in workplace design. Surprisingly, few participants agree on the correlation between improved processes and workspaces having a positive impact on their well-being and product quality.

Abstract TOC

Abstract Lateral control is an essential part of driverless mining truck systems. However, the considerable steering lag and poor tracking accuracy limit the development of unmanned mining. In this article, a dynamic preview distance was designed to resist the steering lag. Then the vehicle–road states, which described the real-time lateral and heading errors between the vehicle and the target road, was defined to describe the control strategy more efficiently. In order to trade off the tracking accuracy and stability, the Takagi–Sugeno (TS) fuzzy method was used to adjust the weight matrix of the linear quadratic regulator (LQR) for different vehicle–road states. Based on the actual mine production environment and the TR100 mining truck, experimental results show that the TS-LQR algorithm performed much better than the pure pursuit algorithm.

Abstract Continuous rubber track systems for farming applications are typically designed using multiple iterations on full-scale physical prototypes which is costly and time consuming. The development of numerical design tools could speed up the design process and reduce development costs while improving product performance. In this article, a rigid multibody dynamics (MBD) model of a continuous rubber track system is presented. This article is the first part of a two-part study: Part 1 focuses on the model description and part 2 describes the experimental evaluation of the MBD model. The modeling methodology is based on a track discretization as a set of rigid body elements interconnected by 6 degrees-of-freedom bushing joints. The mathematical formalism and experimental characterization of all critical subsystems such as the roller wheels, tensioner, suspensions, and contact models are also presented.

Abstract Nylon polymer with an optimal blend of Kevlar, fiberglass, and high-speed, high temperature (HSHT) Fiberglass offers improved characteristics such as flexural strength, wear resistance, electrical insulation, shock absorption, and a low friction coefficient. For this reason, the polymer composite manufactured by combining HSHT, Kevlar, and fiberglass with nylon as base material will expand the uses of nylon in the aerospace, automotive, and other industrial applications related to ergonomic tools, assembly trays, and so forth. The proposed work was carried out to investigate the continuous fiber reinforcement (CFR) in nylon polymer using a dual extrusion system. Twenty experimental runs were designed using a face-centered central composite design (FCCD) approach to analyze the influence of significant factors such as reinforcement material, infill pattern, and fiber angle on the fabricated specimen as per American Society for Testing Materials (ASTM) standards.

Abstract This article takes the wet multi-disc brake used in mining Isuzu 600P as the research object, establishes a simplified three-dimensional model of its key components through SOLIDWORKS and imports it into ANSYS Workbench to establish the flow field and structure field model of the wet brake. Based on the fluid–solid coupling, the finite element simulation of the temperature field and stress field of the friction pair of the wet brake under different braking pressures, braking initial speeds, and fluid viscosities was carried out, and then the position changes of the friction pairs at high temperature hot spots and high stress points were analyzed to determine the stability of its friction performance. Finally, by comparing the temperature change curves of the same point during the braking process under different braking conditions, the validity of the finite element analysis results is verified.

Abstract Numerous researchers are committed to finding solutions to the path planning problem of intelligence-based vehicles. How to select the appropriate algorithm for path planning has always been the topic of scholars. To analyze the advantages of existing path planning algorithms, the intelligence-based vehicle path planning algorithms are classified into conventional path planning methods, intelligent path planning methods, and reinforcement learning (RL) path planning methods. The currently popular RL path planning techniques are classified into two categories: model based and model free, which are more suitable for complex unknown environments. Model-based learning contains a policy iterative method and value iterative method. Model-free learning contains a time-difference algorithm, Q-learning algorithm, state-action-reward-state-action (SARSA) algorithm, and Monte Carlo (MC) algorithm.

Abstract Three suspension structures including the parallel vertical suspension (PVS), the horizontal parallel suspension (HPS), and the negative stiffness element added into suspension (NSES) of the driver’s seat are proposed to improve the driver’s ride comfort of off-road vehicles. Based on the dynamic models of the PVS, HPS, and NSES established and simulated under the same random excitations of the cab floor, the effect of the design parameters of the proposed models is analyzed, and the design parameters are then optimized to evaluate their isolation performance. The indexes of the root-mean-square (r.m.s) accelerations of the vertical seat direction, pitching seat angle, and rolling seat angle are used as the objective functions. The study results indicate that the dynamic parameters of the PVS, HPS, and NSES greatly affect the driver’s ride comfort while their geometrical dimensions insignificantly affect the driver’s ride comfort.

Abstract The ability to predict the durability of a structure depends on the knowledge of operating loads experienced by the structure. Typically, multi-body dynamics (MBD) models are used to cascade measured wheel loads to hard points. However, in this approach, there are many sources by which errors creep into cascaded forces. Any attempt to reduce sources of such errors is time consuming and costly. In typical program development timelines, it is very difficult to accommodate such model calibration efforts. Commercial load cells exist in the industry to give engineers insight into understanding the complex real-world loading of their structures. A significant limitation to the use of load cells is that the structure needs to be modified to accept the load cell, and not all desired loading degrees of freedom (DOFs) can be measured. One of the innovative solutions to calculate operating loads is to convert the structure itself into its own load transducer.

Abstract The lightweight structure of a semitrailer composite leaf spring is designed and manufactured using glass fiber composite to replace the conventional steel leaf spring. The sliding composite mono leaf spring was designed based on the conventional parabolic spring design theory. The composites product design (CPD) module of CATIA software is used to create the lamination of the composite leaf spring. Using finite element analysis of the position and proportion of ±45° biaxial layer by OptiStruct software, it is found that a certain proportion (nearly 5%) of a ±45° biaxial layer can effectively reduce the shear stress under the condition of keeping the total number of layers fixed. Then, the natural frequency, stiffness, and strength of the composite leaf spring are simulated by the finite element method. Finally, the stiffness, fatigue, and matching of the designed spring are tested by experiments.

Abstract Articulated vehicles form an important part of our society for the transport of goods. Compared to rigid trucks, tractor-trailer combinations can transport huge quantities of load without increasing the axle load. The fifth wheel (FW) acts as a bridge between the tractor and trailer, which can be moved within the range to achieve rated front and rear axle loads. When the FW is moved front, it adversely affects the cab dynamics and cab suspension forces. Compared to the cab pitch and roll, yaw motion increases drastically. The current study tries to address this issue by providing reaction rod links in the rear cab suspension. In this study, a 4×2 tractor with a three-axle semitrailer is considered by keeping the FW at its frontmost position, which is the worst-case scenario for a cab. Three different cases of reaction rod arrangement and its influence on cab dynamics are studied in comparison with a model without reaction rods.

Abstract This research examined tractor operators’ daily vibration exposure A(8) with different input riding parameters, i.e., average speed (m/s) (2.78, 3.89, 5.0), body mass (BM) (kg/m2) (35.3, 32.6, 25.4), and different terrain types (brick, farm, and tar roads). To arrange the systematic sequence of experiments, Taguchi’s L9 orthogonal array has been selected for this study. The signal-to-noise ratio (SNR) is calculated to analyze the overall influence of input parameters over the output parameters. In this study, it is found that A(8) responses exceeded the recommended action value among all the tractor operators according to ISO 2631-1 (1997). The average speeds and various terrain conditions were shown to be the most influential significant variables (p ≤ 0.05), with percentage contributions of 53.71% and 11.53%, respectively.

Abstract Wheel loaders are widely used in construction projects. In order to reduce pollution and energy consumption, major wheel loader manufacturers are developing electric powertrain technology. Our main research goal is to reduce the energy consumption of a pure electric loader. This study is intended to build a vehicle simulation model of a multiple drive motor electric loader. According to the common working conditions and empirical formulas of the loader, the simulation data of the electric loader are calculated. The torque distribution control strategy based on the optimal efficiency of the motor is designed for the multiple drive motor electric loader and is compared with the equal proportion distribution control and the axle load ratio distribution control through simulation analysis. The simulation results show that the proposed torque distribution control strategy based on motor optimal efficiency can reduce energy consumption by 7–12%.

Abstract Vehicle-to-everything (V2X) technology has played an important role in improving the active safety of autonomous vehicles. In order to improve the stability of the autonomous vehicle on the curved road, this article presents a pre-emptive braking control method based on V2X technology. Instead of using the active safety system to try to stabilize the vehicle in case of danger, the pre-emptive braking action is proposed to reduce the vehicle speed in advance to a level that allows safe navigation of the turn to avoid danger. It is assumed that the friction and curvature of the curved road ahead can be obtained through V2X technology. Combined with a linear two degrees of freedom (2-DOF) bicycle model, an optimal control method is adopted to calculate the front and rear wheel steering angles to track the centerline of the curve lane. A more complex vehicle dynamics model established earlier is selected for simulation analysis to verify the proposed control method.

Abstract The riding-comfort of high-speed trains affects the travel experience of passengers, and the lightweight design technology of the carbody increases the flexible vibration and reduces passenger comfort. To this end, a vertical dynamics model of railway vehicles is established to demonstrate the potential of using passive inerter-based suspensions to reduce the flexible vibration of the carbody and improve riding-comfort. According to the characteristics of the inerter component, an appropriate inerter-based suspension is applied to the railway vehicle to reduce low-frequency resonance. The sum of the comfort indexes of the three reference points of the carbody is optimized as the objective function to improve the passenger comfort of the whole vehicle. The results reveal that the inerter-based suspension applied to the primary or secondary suspension has different effects on vehicle vibration.