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Fatigue is a structural failure mode that must be recognized and understood to develop products that meet life cycle durability requirements. In the age of lightweighting, fatigue strength is an important vehicle design requirement as engineers struggle to meet stringent weight constraints without adversely impacting durability. This technical concept course introduces the fatigue failure mode and analysis methods. It explains the physics of material fatigue, including damage accumulation that may progress to product failure over time, and it provides the needed foundation to develop effective fatigue prediction capabilities.

This class will provide the student with the skills, knowledge, and abilities to interpret, analyze and apply HVEDR data in real-world applications. This course has been designed to build on the concepts presented in the SAE course Accessing and Interpreting Heavy Vehicle Event Data Recorders (ID# C1022). Advanced topics will include associating HVEDR data with collision events through timestamps, odometer logs, and data signatures, validating HVEDR speed data using specified vehicle parameters, performing time and distance analyses using HVEDR data, and correlating HVEDR data to physical evidence from the vehicle and roadway.

Billions of dollars have been invested in AV trucking. It is no longer a matter of IF, it is a matter of When, Where, Who and How? This will be the most disruptive event to happen in our supply chains in more than 4 decades. Are you ready to help your company usher in the most disruptive technology? This class will help you prepare and understand what you will need to do to become part of the ecosystem. You will learn how to identify what needs to start, stop, and change for you to adopt, integrate, and scale. Join us to learn the answers to key questions like the following: 1)How will maintenance change in the AV trucking ecosystem?

SAE 2011 High Efficiency IC Engines Symposium - Session 3 - Advanced Diesel Engine Technologies Presenter Andrew Brown, Delphi Corp.

Battery Electric Vehicles and Extended Range Electric Vehicles, like the Chevrolet Volt, can use electrical energy from the Grid to meet the majority of a driver�s transportation needs. This has the positive societal effects of displace petroleum consumption and associated pollutants from combustion on a well to wheels basis, as well as reduced energy costs for the driver. CO2 may also be lower, but this depends upon the nature of the grid energy generation. There is a mix of sources � coal-fired, gas -fired, nuclear or renewables, like hydro, solar, wind or biomass for grid electrical energy. This mix changes by region, and also on the weather and time of day. By monitoring the grid mix and communicating it to drivers (or to their vehicles) in real-time, electrically driven vehicles may be recharged to take advantage of the lowest CO2, and potentially lower cost charging opportunities.

In 1991, Hino Motors, Ltd. (Hino) launched the world's first hybrid city buses in the market. Thereafter, Hino has improved its hybrid vehicle technology and applied it to various commercial vehicles including city buses, sightseeing buses, medium-duty trucks and light-duty trucks. Presenter Shigeru Suzuki , Hino Motors, Ltd Shigeru Suzuki , Hino Motors, Ltd

Today CFD is an important tool for engineers in the automotive industry who model and simulate fluid flow. For the complex field of Underhood Thermal Management, CFD has become a very important tool to engineer the cooling airflow process in the engine bay of vehicles. Presenter Peter Gullberg, Chalmers University of Technology

Our trucks today contain anywhere from XX to XX computers on board, some of these computers have the capability to manage algorithms for the correct operation of up to XX systems. Presenter Jesus Gomez, Daimler Trucks North America LLC

Driver assistance systems (e.g. the emergency brake assist Active Brake Assist2, or ABA2 for short, in the Mercedes-Benz Actros) are becoming increasingly common in heavy-duty commercial vehicles. Due to the close interconnection with drivetrain and suspension control systems, the integration and validation of the functions make the most exacting demands on processes and tools involved in mechatronics development. Presenter Thomas Bardelang, Daimler AG

Several technological advancements have enabled hybrid technology to become a viable option in the commercial truck market. Although hybrid trucks are becoming more mainstream, they are not the right alternative fuel solution for every application. When matched with the right duty cycle, hybrid technology can provide a significant cost savings. Due to these advancements and anticipated benefits, hybrid commercial trucks are forecasted to become a significant part of the commercial truck market. Presenter Glenn Ellis, Hino Motors Sales USA Inc.

These advanced checks have resulted in development of many new diagnostic monitors, of varying types, and a whole new internal software infrastructure to handle tracking, reporting, and self-verification of OBD related items. Due to this amplified complexity and the consequences surrounding a shortfall in meeting regulatory requirements, efficient and thorough validation of the OBD system in the powertrain control software is critical. Hardware-in-the-Loop (HIL) simulation provides the environment in which the needed efficiency and thoroughness for validating the OBD system can be achieved. A HIL simulation environment consisting of engine, aftertreatment, and basic vehicle models can be employed, providing the ability for software developers, calibration engineers, OBD experts, and test engineers to examine and validate both facets of OBD software: diagnostic monitors and diagnostic infrastructure (i.e., fault memory management).

Architecting and integrating commercial hybrid electric vehicles (HEV) is a long and labor intensive process which is unique every time. The challenge intensifies when one attempts to create an HEV capable of engine-off operation. Presenter Benjamin Saltsman, Eaton Corp.

In “Using Turbocharging in New Engine Design” (9:23), engineers from Schaeffler Group USA and McLaren Performance Tech explain what turbocharging is, and what it can do to improve both the power output of an engine and its fuel efficiency. Another engineer from the General Motors Powertrain group talks about how turbocharging was used in the new engine design for the Cadillac CT6. This episode highlights: The lessons learned from when turbocharging was first used to help heavy-duty trucks go uphill The experience acquired from car racing using turbo-charged engines The advantages of using turbo charging to decrease the size of engines without losing power output Also Available in DVD Format To subscribe to a full-season of Spotlight on Design, please contact SAE Corporate Sales: CustomerSales@sae.org or 1-888-875-3976.

Micro-pitting is a fatigue effect that occurs in geared transmission systems due to high contact stress, and monitoring its progression is vital to prevent the eventual failure of the tooth flank. Parameter signature analysis has been successfully used to monitor bending fatigue failure and advanced phases of gear surface fatigue failure such as macro-pitting and scuffing. However, due to modern improvements in steel production the main cause of gear contact fatigue failure can be attributed to surface micro-pitting rather than sub-surface phenomena. Responding to the consequent demand to detect and monitor the progression of micro-pitting, this study experimentally evaluated the development of micro-pitting in spur gears using vibration and oil debris analysis. The paper presents the development of an online health monitoring system for use with back-to-back gear test rigs.

Combustion engines are typically only 20-30% efficient at part-load operating conditions, resulting in poor fuel economy on average. To address this, LiquidPiston has developed an improved thermodynamics cycle, called the High-Efficiency Hybrid Cycle (HEHC), which optimizes each process (stroke) of the engine operation, with the aim of maximizing fuel efficiency. The cycle consists of: 1) a high compression ratio; 2) constant-volume combustion, and 3) over-expansion. At a modest compression ratio of 18:1, this cycle offers an ideal thermodynamic efficiency of 74%. To embody the HEHC cycle, LiquidPiston has developed two very different rotary engine architectures ? called the ?M? and ?X? engines. These rotary engine architectures offer flexibility in executing the thermodynamics cycle, and also result in a very compact package. In this talk, I will present recent results in the development of the LiquidPiston engines. The company is currently testing 20 and 40 HP versions of the ?M?

This technical paper collection covers recent fatigue research, analysis, analytical tools development, and novel applications of fatigue technology in the ground vehicle industry.

This collection of technical papers focuses on state-of-the-art fatigue theory and advanced development in fatigue testing, material behavior under cyclic loading, and fatigue analysis methodology & research in the ground vehicle industry.

This collection of papers focus on state-of-the-art fatigue theory and advanced development in fatigue testing, material behavior under cyclic loading, and fatigue analysis methodology & research in the ground vehicle industry. Studies and discussions on innovative and improved fatigue theory/methods in will be discussed along with and engineering applications of CAE durability analysis.

Abstract Truck platooning comprises a number of trucks equipped with automated lateral and longitudinal vehicle control technology, which allows them to move in tight formation with short following distances. This study is an initial step toward developing an understanding of the occupant injury risks associated with the multiple sequential impacts between truck platoons and roadside safety barriers, regardless of whether the crash is associated with a malfunction of automated control or human operation. Full-scale crash impacts of a tractor-trailer platoon into a concrete bridge guardrail were simulated for a specific Test Level condition according to the Manual for Assessing Safety Hardware (MASH) standards. The model of the bridge barrier was developed based on its drawings, and material properties were assigned according to literature data.

Abstract A kinematic modeling framework was established to predict status (position, displacement, velocity, acceleration, and shape) of a towing vehicle system with different driver inputs. This framework consists of three components: (1) a state space model to decide position and velocity for the vehicle system based on Newton’s second law; (2) an angular acceleration transferring model, which leads to a hypothesis that the each towed unit follows the same path as the towing vehicle; and (3) a polygon model to draw instantaneous polygons to envelop the entire system at any time point.