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Inside the cell walls The high cost of lithium-ion batteries is a prison that has largely kept electric vehicles off the street; the keys to their release are more effective—but not more expensive—cell chemistries.

Biofuel opportunities and pitfalls Annual growth in biofuels has been strong but is expected to slow in the near future. User interfaces going mainstream Off-highway HMIs use consumer technologies to add functions, simplify tasks. Reducing the environmental impact of hydraulic systems OEMS and their suppliers are creating new hydraulic systems and components, using new fluids and remanufacturing to save energy and reduce the environmental impact of off-highway equipment. Multiple controllers add to EV complexity Model-based design has revolutionized the way products are developed, with design shifting from parts to the whole.

Tackling biodiesel's technical challenges Caterpillar researchers are working to mitigate biodiesel's negative effects on engine components and aftertreatment systems. More for less Telematic systems are offering more features and functions for lower prices. Improving actuation speed and controllability With high-speed hydraulic proportional valves, the performance of existing cam phasing systems can be improved or the actuation mechanisms can be applied directly to engine valve actuation.

Heavy-duty engine design What are the most significant factors influencing the way engine developers approach near-term design and development cycles? Two experts provide their insights from recent programs. Reducing winter range loss for electric trucks Researchers at the Austrian Institute of Technology have developed an air exchange system that's capable of reducing heat load by 37% in real-world tests. Narrower focus, bigger payoff Design teams are targeting focused markets for their commercial electric-vehicle programs to combat challenges like range and infrastructure. Removing complexity for autonomous trucks Narrowing the operating domains for driverless commercial vehicles reduces the requirements of autonomous technology and speeds time to market. Plastics innovations 2019 The 49th annual SPE Automotive Awards highlight the ongoing benefits of lightweight polymers and composites.

Over-the-air affair Remote updating of software and firmware on commercial trucks and off-highway machines is on the rise, not only for maintenance functions but also to add new features like operator-assist technology. Developments in engine-based gensets With demand for generator sets steady and regulatory change settling, suppliers can rationalize their offerings and push improvements in areas like noise abatement and economy. Testing, testing and even more testing The commercial-vehicle market is eager to adopt more ADAS and automated-driving innovations, but before those technologies get to the road they must first pass rigorous testing practices that prove their efficacy. Smart and connected powertrains FPT Tech Day reveals multi-power Cursor X concept, other "4.0 innovations" for hydrogen fuel cell, electric and natural gas propulsion.

Defending the heavy-vehicle cyber domain Cybersecurity experts explained at SAE COMVEC 2021 how they're preparing the next generation of thwarters to protect increasingly electrified, connected and automated trucks. Digitalization of product engineering ESI proposes "sustainable" product development via virtual prototyping to ensure operational safety and comfort for off-highway machines. Developing a next-gen VGT Engineers from Mitsubishi Heavy Industries refine the design of a variable geometry turbocharger for commercial vehicles. Editorial Insightful comments from COMVEC Lidar lets Vermeer automate baling processes Extending a Wankel future on hydrogen fuel Next-gen HMI crucial for ADAS efficacy Altair honors weight-saving innovations A bevy of battery and fuel-cell electric truck reveals Q&A Dr. Philip Stephenson, general manager of the PACCAR Technical Center, hones in on the potential efficacy of E-fuels, commercial-vehicle battery-swapping.

Connectivity continues its advance More OEMs and Tier 1 suppliers are focusing on embedded telematic systems, hoping to displace aftermarket hardware. Tailoring fuel injection to control NOx The next big step to help heavy-duty diesel engines meet stricter emissions regulations involves adapting the fuel-injection system to the combustion needs. Active on safety Crash-avoidance technologies are vital "building blocks" to automate commercial vehicles, implement truck platooning and ultimately achieve zero accidents. Engineering with simulation and data Companies are discovering new simulation techniques, especially optimization; the next step is to combine simulation with sensor data and predictive analytics to create even more robust off-highway equipment.

Next-generation power Additional benefits for commercial customers may drive hybrid technology adoption. Shake and bake: a recipe for testing Vehicles, components endure much in-lab abuse before they enter the commercial-vehicle market. Fuel for thought The performance and emissions of a stationary single-cylinder diesel engine is evaluated using an ethanol blend with diesel and jet fuels.

In search of the perfect burn The simultaneous download pressures on NOx and PM continue to make research into higher injection pressures and alternative combustion solutions such as homogenous-charge compression ignition attractive. One way to stop a train A new self-energizing electrohydraulic brake offers the advantages of hydraulic brake actuation without the disadvantages of a centralized hydraulic power supply. A model combustion: from art to science Analysis tools, advanced hardware provide insight into combustion process, refining the cylinder's 'big bang.' The datalinked vehicle In the fields and on the job site with GPS.

The diesel engine diet Researchers correlate engine performance and durability with the properties of alternative fuels that consist of vegetable oils and animal fats. Looking at a safer future Software, other sensors will augment cameras as safety's role in the off-highway industry takes an upward spiral. Plastics expand their range From high-speed train exterior panels to powertrain components, plastics and composite materials are finding their way into more off-highway applications.

What we have here is a desire to communicate Telematic service and equipment providers are racing to gain market share in what's expected to become a solid long-term market. Sizing up accumulators No other feature of a hydraulic hybrid has more effect on the end performance of the powertrain than the accumulator. modeling helps to provide specific guidance with regard to establishing pre-charge pressure. Beating a path to biodiesel Multiple pathways are being pursued to increase biodiesel use, reduce dependence on petroleum, and improve the environment, but the best route is not yet known.

Simulating air-conditioning performance A computer program developed by Modine Climate Systems and Modelogics helps determine and optimize air-conditioning system performance. Reduced mass haul-truck design concepts Liebherr Mining trucks adopted a reduced structural mass approach to convert unladen weight directly into payload, while simultaneously incorporating state-of-the-art driveline technology. Optimizing a tractor frame for improved cabin NVH To address an aging agricultural workforce and modern ergonomic guidelines, researchers at Doshisha University and Kubota modeled medium- and large-sized agricultural tractors to reduce vibration and noise and increase comfort. Applying 3d-CAD to turbocharger development Ishkawajima-Harima Heavy Industries has developed a 3d-CAD system for turbochargers. satisfying requirements for digital mockup development.

Making sense of engines Heavy-duty equipment is known for its ruggedness in harsh environments, but vehicles are not neglecting their sensitive side. The world's fastest digger gets closer JCB's Dieselmax goes 350 mph and teaches engineers much about engine capability, extreme testing, and program management. The whole system, and nothing but the system Properly implemented, an electrohydraulic system can add a great deal of automatic control, advanced performance, advanced diagnostics, and remote monitoring to a mobile application. Regenerative hydraulics The use of multiple hydraulic pumps can satisfy the needs of various circuits in off-highway equipment. The gas is greener Biofuels promise to help reduce petroleum cinsumption and CO2 emissions, but much of the potential depends on production and infrastructure investments. Material returns Effective use of materials information is important to engineers in development of parts and components.

Lightpipe design According to Breault Research Organization, any off-highway instrument or control that needs illumination is a candidate for a lightpipe to take light from where it is generated to where it is needed. The biodiesel choice Experts from the Natural Biodiesel Board believe it is time to consider alternatives to the current fuel structure. One solution to rising fuel prices is the pursuit of biodiesel fuels. Understanding machining difficulties in gray iron Bosch Braking Systems' engineers look more closely than usual at iron brake rotor samples to give new insights into critical characteristics of the material. Caterpillar mining for customers With commodity prices low, Caterpillar wants to make mining as productive an enterprise as possible for customers.

F-35 manufacturing ergonomics addressed Human-factors simulation from Delmia is playing a key role as Northrop Grumman tools up for work on the Joint Strike Fighter. Keeping it together: design, development, and maintenance It is only in relatively recent years that the full meaning of integrating manufacturing and maintenance as part of the design and development processes has been grasped by the aerospace industry. Exploring the boundaries of our solar system SAE 100 Future look: In addition to helping enable NASA's new vision of taking humans back to the moon and paving the way to Mars and beyond, two robotics space science missions are preparing to explore the outermost and innermost edges of our solar system. What's on the horizon for space SAE 100 Future look: Dramatic changes in the Earth's climate are certain to drive humanity's search for alternative fuel sources.

High hopes or just dreaming? A look at how Asia's aircraft manufacturers are trying to break into new markets to challenge the status quo. Camelina-based biofuel shows advantages in turboprop Researchers within the government of Canada see the need to improve the emissions performance of the Rolls-Royce T56 engine, which despite its age remains a workhorse for its military aircraft fleet.

Cadillac CTS GM's all-new global sports sedan makes no excuses in chassis dynamics, body integrity, powertrain performance, premium materials, and overall craftsmanship. Taking control of hybrids Software must monitor and manage many parameters while coordinating the complex operations of the engine, electric motors, and batteries. LIghter, faster, lower cost Ducati's top engineer brought a "maniacal" approach to developing the 1098 superbike. Diesels' brave new year Lean-NOx catalysts, closed-loop cylinder pressure sensing, and homogenous combustion are making "50-states" diesels a reailty. Behind the curtain AEI takes an in-depth look at how the designers and engineers at General Motors took the company's trio of new crossover SUVs from sketchbook to road. Engineering from everywhere With future growth in car and truck sales coming mainly from emerging markets, companies are realigning their engineering operations accordingly.

Safe and sensitive Sensor fusion is the latest data sharing scheme for improving the performance of safety systems. BMW counts down to 1 Series The company's latest entry in the premium compact segment comes to market with rear-wheel drive, 50:50 weight distribution, and longitudinally mounted engines headlined by a powerful turbodiesel. Chevrolet re-engineers Corvette Although the new C6 is shorter and narrower than its predecessor, engineers wanted "more power, more passion, more precision" for the two-seat sportscar. 2005 Honda Odyssey The completely re-engineered model features new technologies from the inside out related to safety, performance, and entertainment. Chrsyler 300 / Dodge Magnum The "it" vehicles for the 2005 model year feature advanced technologies such as cylinder deactivation to go along with Hemi power and distinctive styling. Ford makes space for family vehicles Volvo donates its P2 platform for the new Ford Five Hundred, Freestyle, and Mercury Montego.

Systems drive safety Engineers are using a holistic approach to design safer vehicles by adding function and integrating multiple subsystems. The gas in greener Biodiesels promise to help reduce petroleum consumption and CO2 emissions, but much of the potential depends on production and infrastructure investment. Good vibrations Instead of excising all noise, vibration, and harshness, engineers are focusing more on making specific sounds and feedback "fit" a vehicle. SAE Commercial Vehicle Congress Preview International Truck and Engine executives head the charge for "positive industry change" at SAE's third Congress for the on- and off-highway communities.

Ultracapacitors charge ahead The limitations of current energy-storage solutions could encourage consideration of these alternative solutions, but more engineering work needs to be done to reduce costs. Technology for all Automotive industry executives expect high-end technologies, once considered only for inclusion in luxury cars, to increasingly make their way into entry- and mid-level vehicles in the very near future. Convergence continues A lot of automotive electronics ground has been covered at the Convergence conferences past, and there's more to come at this year's show in October. Fueling the next generation As hydrogen joins the battle for automotive power with gasoline and diesel, the future could be more choices rather than one winner.