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All around the world, steps are being taken to improve the quality of our environment. Prominent among these are the definition, implementation, and attainment of increasingly stringent emissions regulations for all types of engines, including off-highway diesels. These rigorous regulations have driven use of technologies like after-treatment, advanced air systems, and advanced fuel systems. Fuel dispensed off-highway is routinely and significantly dirtier than fuel from on-highway outlets. Furthermore, fuels used in developing countries can be up to 30 times dirtier than the average fuels in North America. Poor fuel cleanliness, coupled with the higher pressures and performance demands of modern fuel systems, create life challenges greater than encountered with cleaner fuels. This can result in costly disruption of operations, loss of productivity, and customer dissatisfaction in the off-highway market.

Air flow through the passages of a Chrysler LH platform ventilated brake rotor is measured. Modifications to the production rotor's vent inlet geometry are prototyped and measured in addition to the production rotor. Vent passage air flow is compared to existing correlations. The inlet modifications show significantly improved vent air flow, over the production rotor. The result improvement in heat transfer and rotor cooling is reported. These benefits in performance should be attainable at very low increases in production cost.

Catalytic converters have become a viable aftertreatment system for reducing emissions from on-highway diesel engines. This paper addresses the development and production qualification of a catalytic converter. The testing programs that were utilized to qualify the converter system for production included emissions performance, emissions durability, physical durability, and field test programs. This paper reports on the specific tests that were utilized for the emissions performance and emissions durability testing programs. An explanation on the development of an accelerated durability test program is also included. The physical durability section of the paper discusses the development and execution of laboratory bench tests to insure the catalytic converter/muffler maintains acceptable physical integrity.

In order to test and design vehicle systems it is often necessary to develop prototypes. A vehicle's steering system requires a qualitative analysis since it is difficult to quantify and measure subjective quantities such as the “feel” of a steering system. The virtual prototype system (VPS) provides an effective and flexible way of developing and testing the prototypes for qualitative testing. By creating a computer model of a vehicle's steering system using a dynamic simulation package and linking it to a virtual reality vehicle, a designer can drive the virtual prototype vehicle as if he or she were operating an actual vehicle.

This paper presents system identification methods of using both frequency and time domain analyses to estimate system parameters for a nonlinear electrohydraulic (E/H) tractor steering system. The frequency domain method identified parameters of the system using a linear model with a nonlinear gain function. The time domain method identified those parameters using a discrete time expression. A method of multiple models was used to represent the nonlinear system for both frequency and time domain analyses. Simulation and test results showed that the modified identification method could satisfactorily identify the parameters of the nonlinear E/H tractor steering system.

Control system design is one of the most critical issues for implementation of intelligent vehicle systems. Wide ranged fundamental research has been undertaken in this area and the safety issues of the fully automated vehicles are clearly recognized. Study of vehicle performance constrains is essential for a good understanding of this problem. This paper discusses safety issues of heavy-duty vehicles under automatic steering control. It focuses on the analysis of the effect of tire force saturation. Vehicle handling characteristics are also analyzed to improve understanding of the truck dynamics and control tasks. A simple differential brake control is formulated to show its effect of on reducing trailer swing.

Most of the history of systems engineering has been focused on processes for engineering a single complex system. However, most large enterprises design, manufacture, operate, sell, or support not one product but multiple product lines of related but varying systems. They seek to optimize time to market, costs of development and production, leverage of intellectual assets, best use of talented human resources, overall competitiveness, overall profitability and productivity. Optimizing globally across multiple product lines does not follow from treating each system family member as an independently engineered system or product. Traditional systems engineering principles can be generalized to apply to families. This article includes a multi-year case study of the actual use of a generic model-based systems engineering methodology for families, Systematica™, across the embedded electronic systems products of one of the world's largest manufacturers of heavy equipment.

Engineering new technology and products challenges managers to balance design innovation and program risk. To do this, managers need methods to judge future results to avoid program and product disasters. Besides the traditional prediction tools of schedule, simulations and “iron tests”, process control standards (with measurements) can also be applied to the development programs to mitigate risks. This paper briefly discusses the theory and case history behind some new process control methods and standards currently in place at Caterpillar's Electrical & Electronics department. Process standards reviewed in this paper include process mapping, ISO9001, process controls, and process improvement models (e.g. SEI's CMMs.)

The need to accurately measure and record the payload of large off-highway mining trucks was identified by The Broken Hill Proprietary Co. Ltd. (BHP). In response. Caterpillar designed and developed a system to fufill that need. The payload carried by mine haul trucks has a strong influence on production rates and costs. The system developed should enable payloads to be much better controlled than has been previously possible. The system also provides a number of mine management features. The development of the system is described from the concept stage to the production stage. Final production capabilities of the microprocessor based system are described. Payload measurement capabilities, diagnostic capabilities, data storage, and data extraction methods are discussed.

The type of differential used in a vehicle has an important and often-neglected effect on handling performance. This is particularly important in racing applications, such as in IndyCar racing, in which the type of differential chosen depends on the course being raced (superspeedway ovals, short ovals, temporary street courses and permanent road courses). In the present work, we examine the effect of a locked rear differential on oversteer/understeer behavior. Using a linear tire model, it is shown that employing a locked differential adds a constant understeer offset to the steering wheel angle (SWA) -v- lateral acceleration vehicle signature. A computer simulation of steady-state cornering behavior showed that the actual effect is much more complicated, and is strongly influenced by static weight distribution, front/rear roll couple distribution, available traction and the radius of the turn being negotiated.

Neural networks are massively parallel computational models for knowledge representation and information processing. The capabilities of neural networks, namely learning, noise tolerance, adaptivity, and parallel structure make them good candidates for application to a wide range of engineering problems including diagnostics problems. The general approach in developing neural network based diagnostic methods is described through a case study. The development of an acoustic wayside train inspection system using neural networks is described. The study is aimed at developing a neural network based method for detection defective wheels from acoustic measurements. The actual signals recorded when a train passes a wayside station are used to develop a neural network based wheel defect detector and to study its performance. Signal averaging and scoring techniques are developed to improve the performance of the constructed neural inspection system.

This paper describes and discusses a computer model that can be used to predict the hydraulic pump requirements of an excavator necessary to meet the specified productivity levels for a given set of design conditions. The model predicts the hydraulic cylinder flow rates, pressures, and power necessary to sustain a given work cycle. The study compares the results from a simulation of the excavator with actual test data obtained from a test vehicle taken during a typical work cycle.

Smaller locomotives often use mechanical transmissions instead of diesel-electric drive systems typically used in larger locomotives. This paper discusses how Model Based Design was used to develop the complete drive train control system for a 24 ton sugar cane locomotive. A complete MATLAB Simulink machine model was built to fully test and verify the shift control logic, traction control, vehicle speed limiting, and braking control for this locomotive application before it was commissioned. The model included the engine, torque converter, planetary transmission, drive line, and steel on steel driving surface. Simulation was used to debug all control code and test and refine control strategies so that the initial field commissioning in remote Australia was executed very quickly with minimal engineering support required.

Since the advent of P/M technology as a near net shape production process, millions of mechanical components of various shapes and sizes have been produced. Although P/M continues to be one of the fast growing shaping processes, it suffers from the inability to produce intricate geometry's such as internal tapers, threads or recesses perpendicular to pressing direction. In such cases application of machining as a secondary forming operation becomes the preferred alternative. However, machining of P/M parts due to their inherent porosity is known to decrease tool life and increase tool chatter and vibration. Consequently, several attempts have been made to improve the machinability of P/M materials by either addition of machinability enhancing elements such as sulfur, calcium, tellurium, selenium, etc., or by resin impregnation of P/M parts.

During the early 1990s, the Track-Type Tractors Division (TTTD) of Caterpillar Inc. experienced several challenges. The Division faced increasing global competition in the midst of an economic recession. Although intense plant modernization and reorganization occurred in the five previous years, the business unit was not profitable. In 1993, Track-Type Tractors Division instituted its solution -- a change in its culture. Previously, the culture hindered the division’s ability to move forward. This was revealed in a 1992 review detailing the major obstacles inhibiting management from achieving divisional goals. The division leaders recognized that a change in business philosophy, as opposed to further plant modernization, was required to achieve production goals and stay globally competitive.

Environmental concerns have obstructed development of new landfill sites making it essential to efficiently use currently available space. Finite element methods are evaluated for predicting densification by compactors with the intent of eventually optimizing vehicle design with respect to compaction. A geometrically non-linear, plane strain, quasistatic analysis is used to capture the effects of a single rigid wheel. Future work will include multiple wheels and successive passes, three-dimensional simulations, and realistic material characterization.

This paper examines the feasibility of modifying an existing semi-trailer air suspension system to function as an anti-rollover system in addition to its normal suspension operation. The semi-trailer model used is a dynamic, two-dimensional system. The anti-rollover system controller is formulated using projective control theory. All other factors being equal, simulations show that use of the modified suspension system decreases the weight shift when the semi-trailer undergoes lateral acceleration. By decreasing weight shift, the modified suspension system decreases the possibility of rollover.

A prediction model for hand prehensile movements was developed and validated. The model is based on a new approach that blends forward dynamics and a simple parametric control scheme. In the development phase, model parameters were first estimated using a set of hand grasping movement data, and then statistically analyzed. In the validation phase, the model was applied to novel conditions created by varying the subject group and size of the object grasped. The model performance was evaluated by the prediction errors under various novel conditions as compared to the benchmark values with no extrapolation. Analyses of the model parameters led to insights into human movement production and control. The resulting model also offers computational simplicity and efficiency, a much desired attribute for digital applications.

Today’s business climate and economy demand new, innovative strategies from the initial kickoff of research and development - to the mining of ore from the earth - to the final inspection of a finished product in a mid-western factory. From startup companies with two employees to the largest companies, the world faces new and challenging requirements every day. The demands from companies, customers, executives, and shareholders continue to drive for higher outputs with more efficient use of personnel and investments. Fortunately, the rate of technology continues to exponentially accelerate, which allows those at the cutting edge of technology to capitalize. Caterpillar has been a pioneer in advanced technology since its inception and has been developing the foundation for autonomy over the past four decades.

The development of automated guidance for agricultural tractors has addressed several basic and applied issues of agricultural equipment automation. Basic analyses have included the dynamics of steering systems and posture sensors for guidance. Applied issues have evaluated the potential of several commercial sensing systems and a commercial mechanical guidance system. A research platform has been developed based on a Case 7220 Magnum1 2-wheel drive agricultural tractor. An electrohydraulic steering system was used and characterized in support of automated guidance control. Posture sensing methods were developed using GPS, geomagnetic direction sensors (GDS), inertial, and machine vision sensing systems. Sensor fusion of GPS-inertial-machine vision and GPS-GDS-machine vision provided the most flexible and accurate guidance and capable for operation under dynamically changing field conditions.