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Electro-hydraulic actuated systems are widely used in industrial applications due to high torque density, higher speeds and wide bandwidth operation. However, the complexities and the parametric uncertainties of the hydraulic actuated systems pose challenges in establishing analytical mathematical models. Unlike electro-mechanical and pneumatic systems, the nonlinear dynamics due to dead band, hysteresis, nonlinear pressure flow relations, leakages and friction affects the pressure sensitivity and flow gain by altering the system's transient response, which can introduce asymmetric oscillatory behavior and a lag in the system response. The parametric uncertainties make it imperative to have condition monitoring with in-built diagnostics capability. Timely faults detection and isolation can help mitigate catastrophic failures. This paper presents a signal-based fault diagnostic scheme for a gearbox hydraulic actuator leakage detection using the wavelet transform.

In this paper, an optimization method is proposed to improve the efficiency of a transmission equipped electric vehicle (EV) by optimizing gear shift strategy. The idea behind using a transmission for EV is to downsize the motor size and decrease overall energy consumption. The efficiency of an electric motor varies with its operating region (speed/torque) and this plays a crucial role in deciding overall energy consumption of EVs. A lot of work has been done to optimize gear shift strategy of internal combustion engines (ICE) based automatic transmission (AT), and automatic-manual transmissions (AMT), but for EVs this is still a new area. In case of EVs, we have an advantage of regeneration which makes it different from the ICE based vehicles. In order to maximize the efficiency, a heuristic search based algorithm - Genetic Algorithm (GA) is used.

In response to the need for lightweight design in industries, composite materials are increasingly used to replace traditional metal tubes. However, subsurface defects such as voids, delaminations, and microcracks are still remaining common issues in composite pressure tubes. This paper introduces an application of Digital Shearography method in the Non-Destructive Testing (NDT) of high-pressure composite tubes. A new prototype high-pressure composite tube with a working pressure of 1000 psi range is tested using the digital Shearography method. To detect the sub-surface defects, a reference Shearographic phase map is created at 0 psi state, after that the composite tube is pressured using an oil pump, then the second Shearographic phase map is created at the pressured state. By subtracting the two shearographic phase maps created in different pressure state, the sub-surface defects can be identified clearly. The Shearographic NDT result is then compared with CT scan result.

Eaton has been working on technologies for cost effective, reliable and safe Automated Mechanical Transmissions (AMTs) since the mid 1970's. The company has introduced three different systems since the late 1980's, but all three systems were constrained by the lack of precise engine speed control during shifting. With the advent of electronic engine controls the constraint has been removed and precise engine speed control during shifting can be easily accomplished. The result is a simplified system that is powerfully intelligent and fully capable of automatic shifting i.e., the transmission system determines when to shift and executes the shift without any driver inducement across the broad spectrum of truck usage. This paper discusses some of the AMTs available to the truck market, showing how the system benefits both the OEM and the end user.

The increased trend of automatic and automated transmissions across a breadth of applications is one of the market drivers for the development of wet clutch systems. Key product differentiators that drive the use of wet clutches in specific applications are (a) Compactness, (b) Low inertia, (c) Higher energy density, (d) Better NVH characteristics, and (e) Longer wear life. The above-stated product differentiators are dependent on performance of both the clutch cooling system and the friction system for two different operating events, namely engagement and disengagement. During engagement, slip under load between the clutch plates generates heat, which must be carried away by the oil, necessitating a high oil flow demand to all friction surfaces. Failing to achieve this leads to excessive plate temperatures and wear, ultimately resulting in poor performance and reduced clutch life.

Vehicle electrification is being actively expanded into coming generations of passenger and commercial vehicles. This technology trend is helping vehicles to become more energy efficient. For electric vehicle (EV) city bus application, the system designers have been experimenting with a number of options including direct drive and multi-speed gearbox architectures. Direct drive scenario offers simplified drivetrain system, however requires a large and powerful electric motor. Multi-speed transmission system provides an opportunity to reduce motor size and optimize its operating points, but increases complexity from the architecture and controls point of view. This paper provides an overview of several common system layouts and examines their advantages and disadvantages. Vehicle simulation results are presented to compare direct drive vs. multi-speed technology from the gradeability, acceleration and energy consumption points of view.

Downsizing and downspeeding have become accepted strategies to reduce fuel consumption and criteria pollutants for automotive engines. Engine boosting is required to increase specific power density in order to retain acceptable vehicle performance. Single-stage boosting has been sufficient for previous requirements, but as customers and governments mandate lower fuel consumption and reduced emissions, two-stage boosting will be required for downsized and downsped engines in order to maintain performance feel for common class B, C, and D vehicles. A 1.6L-I4 diesel engine model was created, and three different two-stage boosting systems were explored through engine and vehicle level simulation to reflect the industry's current view of the limit of downsizing without degrading combustion efficiency with cylinder volumes below 400 cm₃. Some current engines are already at this size, so downspeeding will become much more important for reducing fuel consumption in the future.

A part-task simulator has been developed which concentrates on the functions related to transmission gear shifting in heavy duty trucks. By avoiding the complexity of full-feature simulators, a simple and cost-effective tool has been produced which allows training of the driver and study of the powertrain in a controlled environment. The components and operation of this new simulator are described, along with present and potential applications.

This paper briefly summarizes the development history of electronic transmission controls in heavy duty highway vehicles. It reviews the function, technology, reliability, and commercial requirements of newly developing controls. Possible new functions beyond the “classical” logic functions are considered for electronic implementation.

This paper describes two of the automated medium duty transmission systems currently under development by Valeo and Eaton, aimed to reduce the burden of operating the clutch (electronically controlled).

This book provides a broad and comprehensive look at hybrid powertrain technologies for commercial vehicles. It begins with the fundamentals of hybrid powertrain systems, government regulations, and driving cycles, then provides design guidelines and key components of hybrid powertrains for commercial vehicles. It was written for vehicle and component engineers and developers, researchers, students, policymakers, and business executives in the commercial vehicle and transportation industries to help them understand the fundamentals of hybrid powertrain technologies and market requirements for commercial vehicles. It is useful for anyone who designs or is interested in hybrid powertrains and their key components. The term ‘commercial vehicle’ applies to everything from light delivery vehicles to class 8 long haul trucks, buses, and coaches. These vehicles are used for a wide range of duties, including transporting goods or people and infrastructure service.