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Currently, inaccuracies in machine tools are often not detected until after they have produced nonconforming parts, causing reworking or scrap. For high-value aerospace parts, a single rejected part is a significant cost. Low-value parts are often inspected less frequently, allowing many nonconforming parts to be produced before the issue is detected, also resulting in high cost. The alternative to relying on part inspection is to run frequent tests on the machine itself, but established calibration and health-check processes take between 20 minutes and several days. Emerging rapid and automated verification (RAV) processes enable machine tools to check their performance automatically in just a few minutes. These RAV processes can be performed frequently throughout the day, allowing machines to operate without human intervention for long periods of time. When an issue is detected, the machine may be able to recalibrate and then continue automatically.

A narrow focus on electrification and elimination of tailpipe emissions is unlikely to achieve decarbonization objectives. Renewable power generation is unlikely to keep up with increased demand for electricity. A focus on tailpipe emissions ignores the significant particulate pollution that “zero emission” vehicles still cause. It is therefore vital that energy efficiency is improved. Active travel is the key to green economic growth, clean cities, and unlocking the energy saving potential of public transport. The Challenges of Vehicle Decarbonization reviews the urgent need to prioritize active travel infrastructure, create compelling mass-market cycling options, and switch to hybrid powertrains and catenary electrification for long-haul heavy trucks. The report also warns of the potential increase in miles travelled with the advent of personal automated vehicles as well as the pitfalls of fossil-fuel derived hydrogen power.

Electric road systems (ERS) enable dynamic charging—the most energy efficient and economical way to decarbonize road vehicles. ERS draw electrical power directly from the grid and enable vehicles with small batteries to operate without the need to stop for charging. The three main technologies (i.e., overhead catenary lines, road-bound conductive tracks, and inductive wireless systems in the road surface) are all technically proven; however, no highway system has been commercialized. Electric Road Systems for Dynamic Charging discusses the technical and economic advantages of dynamic charging and questions the current investment in battery-powered and hydrogen-fueled vehicles. Click here to access the full SAE EDGETM Research Report portfolio.

Most heavy trucks should be fully electric, using a combination of batteries and catenary electrification, but heavy trucks requiring very long unsupported range will need chemical fuels. At the scale of heavy trucks, compressed hydrogen can match the specific energy of diesel, but its energy density is five times lower, limiting range to around 2,000 km. Scaling green hydrogen production and addressing leakage must be priorities. Hydrogen-derived electrofuels—or “e-fuels”—have the potential to scale, and while the economic comparison currently has unknowns, clean air considerations have gained new importance Decarbonized Power Options for Long-haul Commercial Vehicles discusses these energy sources as well as the caveats related to bioenergy usage, and reasons to prefer ethanol or methanol to diesel-type fuels. Click here to access the full SAE EDGETM Research Report portfolio.