Keywords: RLD (Road Load Data), AVL VSM, AVL Route Studio, Duty Cycle, Transmission, Reverse Gear, Durability
The development of transmission systems involves creating duty cycles for bench-level durability evaluations for both forward and reverse gears. For forward gear, vehicles are driven under various real-world conditions over thousands of kilometers, equipped with numerous sensors and components tailored for data collection. In contrast, duty cycles for reverse gear are often based on prior experience or rough estimations due to the lack of clear definition of real world use case.
Reverse gear RLD is particularly scarce, especially for heavy-duty vehicles operating in off-road or mining environments, where specific reverse driving paths are not typically followed. This paper presents a detailed methodology highlighting the importance of reverse gear duty cycles by leveraging virtual RLD simulations on various gradients using tools such as AVL Route Studio and AVL VSM.
By inputting key vehicle parameters into the simulation software, we can accurately generate duty cycles for flat and inclined terrains. This approach significantly reduces development costs, time, and the need for physical testing resources. The paper also outlines the process for generating test schedules using both physical and virtual RLD, and how these simulations can help to simulate real world conditions on test bench at early development phase. An added benefit of this virtual approach is the elimination of fuel consumption and carbon emissions, contributing to sustainability objectives.
The paper further describes the development of a comprehensive vehicle model, incorporating GPS-defined routes, speed limits, real-time traffic data, and driver behavior profiles to replicate real-world driving conditions. Custom reverse gear routes can also be created to meet specific testing standards. This methodology is applicable across all transmission types and is not constrained by geographic limitations or the availability of test vehicles in the early stages of transmission or powertrain development.