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Putting electrification to work For fleets, going green is a high priority-but making green is an even higher one. A move to 'more electric' engines Researchers detail a motor control design for the fuel system of a more electric aero engine, focusing on the necessary safety and reliability aspects. 2012-13 Hybrid Vehicles Guide A quick reference to the latest production HEVs and their key specifications.

Why Volt? After 48 months' development, the 2011 Chevrolet Volt has enetered series production. The pioneering "E-REV" is as important to the mobility industry as it is to GM. Creating the heart of Volt GM's battery requirements meant creating new state-of-the-art in-vehicle engery storage - and doing it in less than four years. Top GM and supplier engineers reveal how they did it. Engineering with maniacal focus A dedicated, cohesive team and a conservative engineering approach put this innovative vehicle into production at moon-shot speed. A unique electrified transaxle Hybrid or not? Definitions aside, what really matters is GM wisely leveraged its next-generation Two Mode propulsion technology to give Volt greater overall efficiency. Sweating the body details Extensive wind-tunnel work gave Volt a shape that's slicker than it looks. But engineers aren't happy with the curb weight.

Fuel cells for auxiliary power OEM and supplier researchers explore the benefits of utilizing solid-oxide fuel-cell APUs to help meet heavy-duty truck anti-idling requirements. Safer EV batteries could enter the crush zone ARPA-e targets "robust" batteries that not only bear loads but also absorb crash-impact energy to save weight.

Advances for off-highway engine design As manufacturers continue to drive out cost and meet a worldwide patchwork of regulatory frameworks, the tools for developing those engines are advancing. From showcase prototypes to advanced analytical techniques, suppliers are helping the cause. Military vehicles battle for autonomy at lower cost Engineers are adding sensors, more powerful micros and faster networks as they automate tasks and pave the way to autonomy. Heavy duty lightweighting Optimization of tractor-trailer systems and component design helps to reduce overall vehicle mass, a key strategy in improving fuel economy and meeting upcoming Phase 2 GHG regulations. Navistar's SuperTruck II explores composites, WiFi to cut weight Methane state of mind New Holland ramps up its focus on alternative fuels, showcasing a methane-powered concept tractor that trims emissions, operating costs.

No shortage of challenges Supply chain struggles join perennial challenges for Cummins' off-highway business, namely meeting shifting global emissions standards and satisfying emerging technology trends. Batteries not the only route to EV efficiency Allison CTO stresses efficiency and safety of propulsion units also are critical to reducing cost, improving performance and ultimately winning over customers. Batteries go underground A Saft expert evaluates various Li-ion chemistries and strategies - battery swapping vs. fast charging - for electric mining vehicles. Platooning: an evolving pathway to full autonomy Human-guided convoys can provide real-world benefits sooner than individual driverless trucks, but safety and operational issues still need to be resolved to optimize platoon configurations. Supplier Directory Complete listing of industry suppliers categorized by technology area.

Executive Viewpoints Industry leaders offer their insights on the state of the heavy-duty on- and off-highway industries in this annual series of opinion pieces. The executives share their views on the most pressing technologies and trends shaping their business and the industry moving forward. Alternative power and connectivity top of mind Using power dense flywheel hybrid technology to cut fuel consumption of OH equipment IoT connections transform manufacturing, vehicle validation Annual Product Guide Supplier Directory Complete listing of industry suppliers categorized by technology area.

Big future for e-axles, advanced motors Top transmission engineers claim driveline electrification will transform everything from all-wheel drive to Class 8 tractor-trailers. Big data's benefits keep a-comin' Gigabytes of data are being collected and increasingly mined to improve field operations, maintenance and even vehicle design. Transformative times Despite a challenging climate, technology development progresses - as does the sharing of innovative ideas - virtually. Editorial Zeroing in on zero emissions Softing envisions secure, reliable predictive maintenance Reconstructing accidents in the ADAS age Paving the way to improved truck fuel efficiency Nikola looks to accelerate production, hydrogen infrastructure Mecalac designs unique-pivoting swing loader Q&A' Horiba's Joshua Israel discusses complex regulatory landscape's impact on commercial-vehicle development and shift to electrification.

Predicting mobility in military operational scenarios U.S. Army leads a seven-year, multinational effort to develop new off-road vehicle mobility analysis methodology. Hitting the gas on hydrogen tech OEMs and global suppliers still are betting big on hydrogen propulsion as a solution for decarbonizing the heavy-duty trucking industry. BEV truck manufacturers charge ahead Several companies announced new product offerings and prototypes of BEVs at the NTEA Work Truck Week in Indianapolis. Editorial Maintaining EV chargers yet another challenge Precision tech the 'backbone' to CNH's digital strategy Purdue prototypes new EV fast-charge cable 3DEO unveils metal 3D-printing platform for mass production Paccar launches new 18-speed automated transmissions Lightning's eChassis targets commercial EVs Quantron launches 12-m battery-electric bus; fuel-cell variant to follow Q&A Chemours' Christina Spalding shares insights on the commercial-vehicle industry's shift to R-1234yf HVAC refrigerant.

Executive Viewpoints Off-highway industry executives write about some of the challenges and trends facing the industry over the next 20 years, and the innovation that will be required to stay competitive and sustainable. Annual product guide A product roundup showcasing the newest and most innovative supplier technologies in a variety of areas such as Powertrain & Energy, Electronics, Hydraulics, Materials, Testing & Simulation, Body and Chassis, and Interiors.

Off-highway engines advance beyond Tier 4 With Tier 4 Final/Stage IV needs met, engine OEMs direct their focus and competitive energies toward optimizing competitive solutions. At the same time, they need to keep a weather eye out for future regulations, which many expect. Autonomous vehicle challenges span many fields Many of the challenges faced by military and commercial design teams are similar. Racket busters With a quiet cab at the top of many tractor buyers' wish lists, agricultural equipment manufacturers are pursuing every opportunity possible to shed decibels.

Rotary SI/CI combustion engines: A thing of the future? The internal combustion engine enjoys widespread use as an inexpensive and reliable power conversion system. While piston engines date back 150 years, various alternative engine architectures and cycles have been considered. Aftertreatment comes with challenging diagnosis Diagnosing engine and aftertreatment systems is forcing design teams to look at new ways to diagnose problems over long vehicle lifetimes. Taking on NVH reduction techniques A look at the enhanced durability benefits obtained by changing the polymer composition, manufacturing methods, and design optimization of a powertrain mount for an off-highway vehicle.

Hydraulics still in control of off-highway needs Engineers continue to master electronic controllers and software to help systems manage engine speeds and boost efficiency, to the ultimate benefit of both OEMs and end-users. Off-highway calibration challenges-big and complex As the final set of Tier 4 regulations kick in for engines greater than 750 hp (560 kW), calibration efforts must contend with complex engine and aftertreatment systems. Engine manufacturers and service providers deal with this complexity, but does it need to be so? DEF delivery modelling for SCR systems Researchers characterize a 0-D model of a urea delivery module, oriented to model-based control and to the simulation of the system response to fault injections finalized to diagnosis validation.

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.

Digital engineering for Tier 4 With the final phase-in of the U.S. EPA Tier 4 emissions standard set to take effect by 2015, off-highway engine developers are accelerating product introductions. Design challenges remain for manufacturers even after the final phase-in while CAE software providers improve technology.

Easy to control Designers grab a range of technologies to create controls that are simpler for operators to use. Designing quiet off-highway equipment OEMs and suppliers are using new materials and innovative designs to reduce NVH for both vehicle operators and the environment. Using FEA in off-highway design The process of considering weld redundancy in virtual simulation is a complex way of ensuring that weldment design is robust enough to prevail over accidental weld redundancy that might occur during manufacturing. Efficient and effective leadership Frank O. Klegon, a 30-year SAE member and former product development VP at Chrysler, begins term as chief elective officer of SAE International. Making battlefield targets disappear The use of 'smart' special materials has the potential to radically alter the way military platforms are defended, and used.

Safety steps up Electronic controls let suppliers improve safety without sacrificing reliability.

Tier 4 for large bore Engineers show that a pre-turbine aftertreatment system offers clear and distinct benefits in terms of compact, cost-effective emissions reductions. Programmed for safety and reliability The software that adds features and functions is becoming more reliable as standards and new techniques transform design processes. Electrohydraulics improve with new lift-control strategy Fuel consumption, torque delivery, and emissions can all be improved through flexible control of the valve timing, duration, and lift.

Perking up fatigue analysis with simulation Using CAE simulation tools for fatigue and durability offers advantages to off-highway equipment engineers as they have grown in capability.

Cold metal transfer process picks up heat CMT, with its unique characteristics, is a process that was designed particularly for welding of thin materials while achieving high quality standards.

A 'defensive' approach Oshkosh Corp. is providing executive leadership for this year's SAE Commercial Vehicle Engineering Congress, placing more emphasis on the military and defense businesses, and how those activities align with the commercial vehicle industry. Hybrid and mighty Having gained popularity un the automotive sector, many suppliers of hybrid drives are engineering their battery-electric offerings for the off-highway market. Customers, in turn, are experiencing major gains in efficiency and economy. Finding off-highway's top model Modeling, simulation advances help engineers get complex design to market quickly. Roll your own Technological advances into autonomously controlled vehicles facilitate road trains and troop support.