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Gear Shift Pattern Optimization for Best Fuel Economy, Performance and Emissions

Chidhanand S.
Mahindra & Mahindra, Ltd.-Lemuel Paulraj, Saravanan Muthiah
  • Technical Paper
  • 2020-01-1280
To be published on 2020-04-14 by SAE International in United States
As the FTP-75 drive cycle does not have a prescribed gear shift pattern, automotive OEMs have the flexibility to design. Conventionally, gear shift pattern was formulated based on trial and error method, typically with 10 to 12 iterations on chassis dynamometer. It was a time consuming (i.e. ~ 3 to 4 months) and expensive process. This approach led to declaring poor fuel economy (FE). A simulation procedure was required to generate a gear shift pattern that gives optimal trade-off amongst conflicting objectives (FE, performance and emissions). As a result, a simulation tool was developed in MATLAB to generate an optimum gear shift pattern. Three different SUV/UV models were used as test vehicles in this study. Chassis dyno testing was conducted, and data was collected using the base and optimized gear shift patterns. Dyno test results with optimized gear shift pattern showed FE improvement of ~ 4 to 5% while retaining the NOx margin well above engineering targets. This labeling FE improvement method did not require any hardware or software changes, thus, involved no additional expense.…
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Development and demonstration of a class 6 range-extended electric vehicle for commercial pickup and delivery operation

Cummins Inc.-John Kresse, Ke Li, Jesse Dalton
National Renewable Energy Laboratory-Matthew A. Jeffers, Eric Miller, Kenneth Kelly
  • Technical Paper
  • 2020-01-0848
To be published on 2020-04-14 by SAE International in United States
Range-extended hybrids are an attractive option for medium- and heavy-duty (M/HD) commercial vehicle fleets because they offer the efficiency of an electrified powertrain and accessories with the range of a conventional diesel powertrain. The vehicle essentially operates as if it was purely electric for most trips, while ensuring that all commercial routes can be completed in any weather conditions or geographic terrain. Fuel use and point-source emissions can be significantly reduced, and in some cases eliminated, as many shorter routes can be fully electrified with this architecture. Under a U.S. Department of Energy award for M/HD Vehicle Powertrain Electrification, Cummins has developed a plug-in hybrid electric (PHEV) class 6 truck with a range-extending engine designed for pickup and delivery application. The National Renewable Energy Laboratory (NREL) assisted by developing a representative work day drive cycle for class 6 operation and adapting it to enable track testing. A novel, automated driving system was developed and utilized by Southwest Research Institute (SwRI) to improve the repeatability of vehicle track testing used to quantify vehicle energy consumption. Cummins…
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Heavy Vehicles Kinematics of Automatic Emergency Braking Test Track Scenarios

NHTSA-Devin Elsasser
Transportation Research Center Inc.-M. Kamel Salaani, Christopher Boday
  • Technical Paper
  • 2020-01-0995
To be published on 2020-04-14 by SAE International in United States
This paper presents the test track scenario design and analysis used to estimate the performances of heavy vehicles equipped with forward collision warning and automatic emergency braking systems in rear-end crash scenarios. The first part of this design and analysis study was to develop parameters for brake inputs in test track scenarios simulating a driver that has insufficiently applied the brakes to avoid a rear-end collision. In the second part of this study, the deceleration limits imposed by heavy vehicles mechanics and brake systems are used to estimate automatic emergency braking performance benefits with respect to minimum stopping distance requirements set by Federal Motor Vehicle Safety Standards. The results of this study were used to complete the test track procedures and show that all heavy vehicles meeting regulatory stopping distance requirements have the braking capacity to demonstrate rear-end crash avoidance improvements in the developed tests.
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NHTSA's 2018 Heavy Vehicle Automatic Emergency Braking Test Track Research Results

NHTSA-Devin Elsasser
Transportation Research Center Inc.-M. Kamel Salaani, Christopher Boday
  • Technical Paper
  • 2020-01-1001
To be published on 2020-04-14 by SAE International in United States
This paper presents National Highway Traffic Safety Administration’s 2017 and 2018 test track research results with heavy vehicles equipped with forward collision warning and automatic emergency braking systems. Newly developed objective test procedures were used to perform and collect performance data with three single-unit trucks equipped with the crash avoidance systems. The results of this research show that the test procedures are applicable to many heavy vehicles and indicate that performance improvements in heavy vehicles equipped with these safety systems can be objectively measured.
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A Novel Prediction Algorithm for Heavy Vehicles System Rollover Risk Based on Failure Probability Analysis and SVM Empirical Model

China Automotive Technology and Reseach Center Co.,Ltd-Zhenfeng Wang, Fei Li, Xinyu Wang
Harbin Institute of Technology-Zheng Wang
  • Technical Paper
  • 2020-01-0701
To be published on 2020-04-14 by SAE International in United States
The study of heavy vehicles rollover prediction, especially in algorithm-based heavy vehicles active safety control for improving road handling, is a challenging task for the heavy vehicle industry. Due to the high fatality rate caused by vehicle rollover, how to precisely and effectively predict rollover of heavy vehicles become a hot topic in both academia and industry. Due to the strong non-linear characteristics of Human-Vehicle-Road interaction and the uncertainty of modeling, the traditional deterministic method cannot meet the requirement of accurate prediction of rollover hazard of heavy vehicles. To deal with the above issues, a probability method of uncertainty is applied to the design of dynamic rollover prediction algorithm for heavy vehicles, and a novel algorithm for heavy vehicle rollover hazard prediction based on the combined empirical model of reliability index and failure probability is proposed. In addition, a classification model of heavy vehicles based on support vector machine (SVM) is established, and Monte Carlo method is used to calculate the failure probability of rollover limit state of heavy vehicles. The fishhook, double lane change…
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Kalman Filter Slope Measurement Method Based on Improved Genetic Algorithm- Back Propagation

Wuhan University of Technology-Haoyu Wang, Donghua Guo, Gangfeng Tan, Zhenyu Wang, Ming Li, Yifeng Jiang, Meng Ye, Kailang Chen
  • Technical Paper
  • 2020-01-0897
To be published on 2020-04-14 by SAE International in United States
How to improve the measurement accuracy of road grade is the key content of the research on the speed warning of commercial vehicles in mountainous roads. If there is a large measurement error, the obtained speed threshold will be biased, posing a safety hazard. Conventional measuring instruments such as accelerometers and gyroscopes generally have noise fluctuation interference or time accumulation error, resulting in large measurement errors. In response to this situation, the Kalman filter method is often used for filtering to reduce the interference of unwanted signals, thereby improving the accuracy of the slope measurement. However, the Kalman filtering method is limited by the estimation error of various parameters, and the filtering effect is difficult to meet the project research requirements. In this paper, the acceleration of vehicle gravity, running speed and acceleration of parallel slope are used as auxiliary measurement parameters to improve the measurement method of mountain road slope. Based on the Kalman model, genetic algorithm (GA) and BP neural network are used to carry out the innovation , covariance matrix and the…
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Engine mount design & failure analysis in commercial vehicle and a correlation between virtual & physical validation.

VE Commercial Vehicles Ltd.-Mahendra Parwal
VE Commercial Vehicles, Ltd.-Arushi Dev
  • Technical Paper
  • 2020-01-0491
To be published on 2020-04-14 by SAE International in United States
Vehicle life and performance is affected by many factors when in use. The most influential being the vibrations generated especially when the vehicle is in motion. These vibrations are directly experienced by the driver, whose performance goes down, if under continuous influence of these vibrations. This increases the fatigue and greatly reduces the return on investment done by the customer. There are two major sources of vibrations, the engine and the road on which the vehicle moves. To prevent such issues engine mounts are used in vehicles, which may seem simple but perform a critical role, of providing comfort to the driver. Therefore it becomes important that thoroughly designed and examined mounts are being used in the vehicle. This paper focuses on the parameters and methodology to be followed for design and validation of an engine mount used in heavy duty vehicles. Case study has been presented to show the failure cases in an engine mount, especially the separation of rubber and metal bonding. Importance of surface pre-treatments to have better bonding has been discussed…
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Development of Intercooler Hose for Future Engine

Hino Motors, Ltd.-Ryoji Kodama, Takahiro Onishi
  • Technical Paper
  • 2020-01-0236
To be published on 2020-04-14 by SAE International in United States
Turbocharged diesel engines with an intercooler are widely used in modern heavy-duty commercial vehicles to achieve both cost performance and durability. These engines have low CO2 emissions due to their high thermal efficiency, and are essential to the movement of people and goods. Given the high compression ratio and supercharging requirements of diesel engines, further improvements in thermal efficiency require enhancing the performance of existing intercooler hoses. Intercooler hoses made of fluororubber (FKM) and silicone rubber (VMQ) have high heat resistance and durability. However, future diesel engines will be subject to more severe operating conditions. This research identified the deterioration in the mechanical properties of FKM in hot environments as an issue to resolve for intercooler hoses in future engines. Specific improvement efforts focused on the low heat resistance of crosslinking points inside FKM. The current crosslinking method cannot be changed because of its excellent acid resistance. Therefore, the formation of new networks distinct from the crosslinking network was induced, and the improvement in physical properties was confirmed. The gelation of a carbon black reinforcing…
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Chip and Board Level Digital Forensics of Cummins Heavy Vehicle Event Data Recorders

Colorado State University-Jeremy Daily, Duy Van
Delta v Forensic Engrg-Matthew DiSogra
  • Technical Paper
  • 2020-01-1326
To be published on 2020-04-14 by SAE International in United States
Crashes involving Cummins powered heavy vehicle can damage the electronic control modules (ECMs) containing heavy vehicle event data recorder (HVEDR) data. When ECMs are broken and data cannot be extracted using vehicle diagnostics tools, more invasive and low level techniques are needed to forensically preserve and decode HVEDR data. A technique for extracting non-volatile memory contents using non-destructive board level techniques with the available JTAG port. Additional chip level data extraction techniques can also provide access to the data. Once the data is obtained and preserved in a forensically sound manner, the binary record is decoded to reveal typical HVDER data like engine speed, vehicle speed, accelerator pedal position, and other status flag data. The memory contents from the ECM can be written to a surrogate and decoded with traditional maintenance and diagnostic software. The research also shows the diagnostic trouble codes from the ECM are preserved in its as-found state. In other words, the digital forensic technique of extracting memory contents through the JTAG port does not introduce any new fault codes. Cryptographic hashing…
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An Experimental Methodology for Measuring Resistance Forces of Light-Duty Vehicles under Real-World Conditions and the Impact on Fuel Consumption

Aristotle University of Thessaloniki-Dimitrios Komnos, Leonidas Ntziachristos
European Commission Joint Research-Georgios Fontaras, Jelica Pavlovic, Biagio Ciuffo
  • Technical Paper
  • 2020-01-0383
To be published on 2020-04-14 by SAE International in United States
A key element of any vehicle-certification test is the use of representative values for the vehicle resistance forces. In most certification procedures, including the WLTP recently adopted by the EU, the latter is achieved mainly through coast down tests. Subsequently, the resistance values measured are used for setting up the chassis-dyno resistances applied during the laboratory measurements. These reference values are obtained under controlled conditions, while a series of corrections are applied to make the test procedure more repeatable and reproducible. In real driving, the reference road loads are influenced by a series of factors leading to a divergence between the certified fuel consumption values, and the real-world ones. An approach of calculating representative road loads during on-road tests can help to obtain a clearer view of vehicle efficiency and quickly validate the officially declared road loads. This approach is crucial also for validating simulations and achieving better estimates of the actual fuel consumption, a requirement introduced by the new policy adopted in the EU. In this direction, a series of on-road experiments were conducted,…