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When fuel cells fly Emerging hydrogen and fuel-cell-based technologies are being developed for the future replacement of onboard electrical systems in more-electric or all-electric aircraft. Motor controls spin forward Improved power handling and software advances make electrified powertrains more competitive. Multiple controllers adds to EV complexity Model-based design has revolutionized the way products are developed, with design shifting from parts to the whole.

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.

Paving the way for the hydrogen highway Experts at SAE WCX 2022 look beyond EVs to other systems that can garner net-zero capabilities. Electric mobile machines won't abandon hydraulics Bosch Rexroth executive stresses that electrification in off-highway applications must make optimum use of both next-gen electric and hydraulic technology. Aftermarket augments off-highway autonomous efforts Kontron and Intel experts explain how rugged, modular COM Express solutions reduce complexity and allow retrofit of autonomous systems on heavy mobile equipment. Solving the challenges of Megawatt chargers Littelfuse executive details an alternative technique for fast and efficient high-power charging of commercial electric vehicles. Supplier Directory Complete listing of industry suppliers categorized by technology area.

Virtual powertrain development Simulation is critical for efficient product development, but proper tool selection and efficient data management are keys to success. Blue Arc amps up for EV production Shyft Group's EV subsidiary is lighting the path for the electrification of last-mile delivery vehicles as well as mobile charging solutions. Increasing connectivity in construction Jobsites look to overcome challenges posed by mixed fleets and proprietary telematics to achieve "one-dashboard" vision and increased machine utilization.

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.

Perkins bets big on smaller engine The new 2600 Series 13-liter engine for off-highway machines will do more with less thanks to variable geometry turbocharging. BorgWarner targets more- sustainable e-motors System optimization and lifecycle analysis are key to taking heavy rare earths out of next-gen motors for commercial EVs. Enhancing digital platforms with CT data analysis TE Connectivity gains critical insights using Volume Graphics software throughout design, simulation and manufacturing.

Steel sector aids sustainability Volvo Group partners with SSAB on 'green steel' for off-highway machines and with Ovako for access to fossil-free hydrogen. CV autonomy: Picking the 'low-hanging fruit' Increasingly automated commercial vehicles offer challenges and opportunities in simulation, data management and standardization. Developing EV-specific lubes As electric-vehicle technology accelerates, dedicated e-fluids are necessary to maintain proper levels of drivetrain performance. Editorial Real-world emphasis on electric Mahle, Liebherr develop active pre-chamber for hydrogen ICE ABS ramps up commercial-vehicle battery-pack assembly Navistar updates A26 engine, improves FE by 4% Bosch debuts new CV-specific electric motor and inverter Western Star adds 'weight sensitive' 47X to vocational lineup Hyundai CE launches next-gen electric forklift Q&A Mahle's Laurent Art discusses thermal-management challenges, solutions for battery and fuel-cell electric commercial vehicles.

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.

Accelerating truck autonomy Platform-agnostic interfaces, field data analytics and smart diagnostics will help the commercial-vehicle industry reach SAE Level 4 and 5 operations sooner. Upswing in outsourced EV testing As testing for electric commercial-vehicle propulsion systems surges, Drive System Design is rushing to expand its testing capabilities in the U.S. to keep up with the demand. Global emissions regs demand differing engine strategies The best choice in emissions-reducing technology varies for the U.S. versus Europe and elsewhere, a Jacobs expert details. Precision ag aids sustainability Deere expert Deanna Kovar, a 2021 SAE COMVEC keynoter, provides her thoughts on the future of autonomy, computer vision and machine learning, data management and more.

Headliners from Las Vegas Big reveals abounded at the triennial CONEXPO trade show. Following are some of the most notable unveilings from the desert. Cat doubles down on diesel with new C13D platform Deere pursues electric construction machines and charging infrastructure JCB debuts clean-sheet hydrogen combustion engine Volvo CE unveils electric asphalt compactor, announces NA arrival of L350H loader Honda reveals next-gen Autonomous Work Vehicle Deere 3D-prints fuel valves for tractors HP's binder jetting technology and GKN's manufacturing expertise helped John Deere realize its first 3D-printed metal part for mass production. Returning to the SAE presidency for 2023 Setting a "prudently aggressive" mindset in advancing SAE's goals in the mobility ecosystem.

Connectivity takes center stage Telematic links have become the norm, helping fleet owners and operators improve efficiency and letting OEMs predict component failures. More power, less noise, fewer emissions These key attributes drive development of new generators both big and small. TARDEC pursues advanced power generation U.S. Army, GM collaborate on fuel-cell-generated electricity to power the vehicle's propulsion system and onboard electronics, while providing off-vehicle power via an Exportable Power Take-Off unit. Developing an alternative engine concept Ricardo's CryoPower engine leverages two unique combustion techniques for reduced emissions and fuel consumption-liquid nitrogen and split combustion. Long-haul trucking and stationary power generation will be the first beneficiaries of the technologies. Technology time-warp The road to autonomous driving has been under construction for decades, as showcased by SAE's Mobility History Committee at the 2018 WCX in Detroit.

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.

The row about rare earths Rare-earth elements are key to applications as varied as traction motors, catalytic converters, and wind turbines, but high prices and supply shortages have the auto industry grappling with design changes and other alternatives.

'Infernal' combustion no more Continuous improvements to the 130-year-old ICE aim to keep conventional engines ahead of electric drive. Alternative fuels tested at altitude Federal government researchers in Canada tested certain alternative fuels at simulated altitudes and found that they do offer some benefit.

Software's role continues to expand Design teams use different technologies to create new software and link systems together. Emissions regulations and engine complexity With the European Commission announcing a Stage V criteria emissions regulation for off-highway, scheduled to phase-in as earlly as 2019, there will be an end to a brief era of harmonized new-vehicle regulations. Will this affect an already complex engine development process? Evaluating thermal design of construction vehicles CFD simulation is used to evaluate two critical areas that address challenging thermal issues: electronic control units and hot air recirculation.

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.

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.

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.

The big engine that could With the stringent EPA 2015 regulations on large diesel engines for locomotive, marine, and stationary generator applications, the need for NOx reduction via urea SCR catalyst arises given the proven performance of urea SCR. Monitoring hydraulics Component producers and vehicle service providers offer their views of hydraulic diagnostics as the industry moves toward real-time, intelligent health monitoring, predictive failure software algorithms, and wireless notification. Engine management expands from minute movements to full vehicle Electronic controls grow in complexity as engine designers extend their scope to include hydraulics.

High-performance polymers and biofuel compatibility During the material selection process for engine components such as fuel rails, filter housings, and connectors, engineers need to take into account not only the basic tenets of metal-to-plastic conversion, but also the type of fuel and its impact on the performance of the materials.