Browse Topic: Off-highway vehicles and equipment

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Machine Learning based Off-Road Vehicle Turn identification using Vehicle & GPS Parameters2025-28-0344To be published on 11/06/2025
Identification of different types of turns during field operation of off-road vehicles is critical in the overall vehicle development as it is helpful in identifying & optimizing machine performance, correct duty cycle, fuel economy, stability analysis, accurate path planning, customer usage pattern & designing the critical components, etc. In this study, a machine learning (ML) based methodology has been developed to detect the off-road vehicle turns using vehicle & GPS parameters. Three most common types of off-road vehicles turn conditions e.g., Straight line, Bulb turn, and Three-Point turn have been considered. Different vehicle parameters (like latitude & longitude, compass bearing, yaw rate, vehicle speed, swash plate angle, engine speed, percent load at vehicle speed, raise lower front & PTO channels) generated during field test have been used here. These vehicle parameters are further processed, analyzed and used in ML learning model building. Four ML models e.g., SVM, K-NN
Gangsar, Purushottam
Development of Door Impact Loads Using Frugal use of "Pedal Force Sensor"2025-28-0283To be published on 11/06/2025
The first step in designing or analyzing any structure is to understand “right” set of loads. Typically, off-road vehicles have many access doors for service/getting into cab etc. Design of these doors and their latches involve a knowledge of the closing loads when the door is shut mostly with an impact of varying magnitudes. In scenarios of these impact events, where there is sudden change of velocity within few milliseconds, produces high magnitude of loads on structures. One common way of estimating these loads using hand calculations involves evaluating the rate-of-change-of-momentum. However, this calculation needs “duration of impact”, and it is seldom known/difficult to estimate. Failing to capture duration of impact event will change load magnitudes drastically, e.g. load gets doubled if time-of-impact gets reduced from 0.2 to 0.1 seconds and subsequently fatigue life of the components in “Door-closing-event” gets reduce by ~7 times. For these problems, structures are usually
Valkunde, Sangram, Ghate, Amit, Gagare, Kiran
Cooling System Design Approach for Off-Road Vehicles Using 3D CFD and 1D Tools2025-28-0260To be published on 11/06/2025
The average product development cycle spans 3-5 years, involving extensive virtual and physical testing of the machine. Advances in simulation tools have significantly enhanced our ability to identify product solutions early in the design phase. Tools like 1D KULI and Creo Flow simulations offer faster solutions in less time, thereby accelerating the product development cycle. Cooling systems are crucial components of off-highway hybrid vehicles, directly affecting engine efficiency and overall machine functionality. An optimized cooling system ensures the engine operates within safe temperature ranges, preventing overheating and potential damage. Thus, designing an effective cooling system is a vital aspect of machine engineering. 3D Computational Fluid Dynamics (CFD) simulations are essential for evaluating cooling system performance. These high-fidelity simulations provide detailed insights into fluid flow and heat transfer, enabling engineers to predict and enhance cooling
Ukey, Snehal, Tirumala, Bhaskar, Nukala, Ramakrishna
Off-Highway Vehicles for Sustainable Development and Empowerment: Innovation and Technology.- Diagnosis2025-28-0301To be published on 11/06/2025
Off-highway vehicles (OHVs) play a crucial role in industries such as agriculture, construction, and mining, contributing to sustainable development and economic empowerment. Ensuring their optimal performance requires a robust customer support system focused on efficient diagnosis and resolution of technical issues. This paper explores the importance of advanced diagnostic techniques in OHVs, emphasizing innovation and technology-driven approaches to minimize downtime and enhance productivity. The evolution of diagnostic tools, from traditional manual inspections to AI-powered predictive maintenance, has transformed customer support in the OHV sector. The integration of telematics, IoT-enabled sensors, and cloud-based analytics allows real-time monitoring of vehicle health, enabling proactive maintenance and reducing unexpected failures. Additionally, remote diagnostics and augmented reality (AR)-assisted troubleshooting empower field technicians with real-time insights, improving
Mulla, Tosif, Thakur, Anil, Tripathi, Ashish
Cybersecurity: Applying Threat Modeling to Sensor-Control Architectures in Autonomous Off-Highway Vehicles2025-28-0316To be published on 11/06/2025
The increasing autonomy and connectivity of off-highway vehicles—such as tractors, harvesters, and construction equipment—introduce new cybersecurity challenges, particularly within the sensor-to-control data flow that governs real-time decision-making and actuation. These architectures comprise a mix of embedded sensors, electronic control units (ECUs), communication buses (e.g., CAN, Ethernet), and actuators, all of which are susceptible to cyber-physical threats that can compromise safety, performance, and reliability. This paper proposes a systematic application of threat modeling, using the STRIDE framework, to assess and mitigate risks in sensor-control systems specific to autonomous off-highway machinery. It provides a practical methodology for identifying trust boundaries, constructing Data Flow Diagrams (DFDs), and mapping threats such as spoofing of GNSS/GPS inputs, CAN message injection, sensor data tampering, and control logic manipulation. By contextualizing threat
Kotal, Amit
Use of the Sound-intensity Method to Identify Acoustic Leakages from Off Highway Machine Cab2025-28-0267To be published on 11/06/2025
The operator station or “cab” in off Highway equipment plays a critical role to provide a comfortable environment for the operator. The cab interfaces with several elements of the off-highway equipment which can create gaps and openings. These openings have the potential for acoustic energy leakage, ultimately increasing sound within the cab. During machine operation, noise generated around the cab conducts inside through these leakages resulting in increased sound levels. Acoustic leakages are among the key noise transfer paths responsible for noise inside the cab. Therefore, before considering noise control treatments it is best to first identify and minimize any leakages from joints, corners, and pass-throughs to achieve required cab noise reduction. In this effort the sound intensity technique is used to detect the acoustic leakages in cab. The commercial test system is used for measuring the sound intensity field over objects. For the cab, an acoustic source is used inside the cab
Pawar, Sachin M., Mandke, Devendra, Fapal, Anand, Cone, Kerry
Off-Highway Vehicles for Sustainable Development and Empowerment: Innovation and Technology2025-28-0230To be published on 11/06/2025
The growing demand for sustainable solutions in the off-highway vehicle sector has driven innovation in alternative fuels, significantly contributing to environmental conservation and economic empowerment. Off-highway vehicles, including construction equipment, agricultural machinery, and mining trucks, are traditionally powered by diesel engines, which contribute to greenhouse gas emissions and environmental degradation. Transitioning to alternative fuels such as biodiesel, hydrogen, compressed natural gas (CNG), liquefied natural gas (LNG), and electrification presents a viable solution to reduce the carbon footprint and promote sustainable development. This paper explores the advancements in alternative fuel technologies and their impact on the off-highway vehicle industry. It highlights how biofuels and hydrogen fuel cells are reducing dependency on fossil fuels, while electrification and hybrid powertrains are enhancing efficiency and lowering emissions. The integration of these
Mulla, Tosif, Thakur, Anil, Tripathi, Ashish
Functional Safety of Electric or Hybrid Off-Highway Vehicles - An Embedded Software Viewpoint2025-28-0217To be published on 11/06/2025
To provide growing needs of food, clothing and infrastructure for growing population of the world, off-highway vehicles such as those in construction, agriculture and commercial landscaping are moving towards electrification for enhanced precision, productivity, efficiency and sustainability. It has also paved way to adopt autonomy of these vehicles to address challenges like skilled labour shortage for timely and efficient execution. Despite the tremendous advantages of electrification, be it through completely replacing engine in vehicles or efficiency improvements using hybrid architecture for powertrain and auxiliary power demands, safety remains a significant challenge and critical requirement for off-highway electric vehicles. This paper explains the concept and importance of functional safety in electric off-highway vehicles, and shows how the different standards like ISO 26262, ISO 25119, ISO 13849 being utilized to achieve state of the art in functional safety for different
Mujumdar, Chaitanya Gajanan, Bachhav, Kiran, Deshpande, Chinmay
PTO Clutch Hydraulic Performance Evaluation Methodology Development & Correlation2025-28-0295To be published on 11/06/2025
This paper presents an analysis methodology developed to understand the impact of pressure spikes in off-highway applications, particularly during PTO (Power Take-Off) clutch engagement. These pressure spikes can adversely affect hydraulic subsystem components such as seals, gaskets, and valve operations. Assessing hydraulic system performance through physical trials can be cumbersome, resulting in longer development times and increased costs. To address this, a methodology was developed in a virtual environment to evaluate hydraulic system performance. The virtual method outlined in this paper is created in a 1D environment using an analytical approach to replicate the transient behavior of the system. The hydraulic system primarily includes a relief valve, solenoid valves, a pump, and a clutch. An analytical model was developed for the hydraulic system components with the right fidelity to accurately capture the transient behavior and magnitudes of pressure spikes. This methodology
Memane, Nilesh, Kumar, Suneel, Veerkar, Vikrant
Electric fan arrangement and performance predictions of an off-highway cooling system2025-28-0241To be published on 11/06/2025
Traditionally, off-highway vehicles like tractors and construction machinery have been using either hydraulic or viscous or fixed fan to meet the cooling demands of the diesel engine. These fans draw power from the engine, affecting fuel consumption and contributing to noise levels that impact operator comfort. Recently, the use of electric fans in off-highway applications has increased due to their energy efficiency, lower noise, and flexible design. Electric fans can be used to cool various components, such as radiators and condensers, and can be positioned for optimal performance. They are easy to select from established supplier catalogs based on application requirements like machine voltage, fan size, and type. This study examines different fan arrangements in relation to coolers and the engine, using pusher and puller types, and multiple electrical fans based on cooler zones to enhance cooling system performance without altering cooler size or specifications. A mathematical flow
Durairaj, Renganathan, Dewangan, Nitin, Anand, Ketan, Bhujbale, Sagar
Off-Highway Electrification: A Case Study Beyond Propulsion and Emission2025-28-0223To be published on 11/06/2025
To provide needs of food, clothing and infrastructure for growing population of the world, off-highway vehicles such as those in construction, agriculture and commercial landscaping are moving towards electrification for enhanced precision, productivity, efficiency and sustainability. It has also paved way to adopt autonomy of these vehicles to address challenges like skilled labor shortage for timely and efficient execution. There are many challenges and opportunities of electrification in off-highway domain, be it through completely replacing engine in vehicles or efficiency improvements using hybrid architecture for powertrain and auxiliary power demands, electrification being key enabler precision and speed of the complex operations, automation of complex operation. This paper explains the need of electrification in electric off-highway vehicles and shows how the electrification solves the current challenges faced by off-highway heroes like farmers, construction site owners and
Deshpande, Chinmay Vasudev, Mujumdar, Chaitanya, Bachhav, Kiran
Isolation of Engine Vibrations from 3 Cylinder Engines on Off-Highway Machines2025-28-0292To be published on 11/06/2025
The BS4 regulation for emission required several changes on engines as well as design and development of new auxiliary systems. These changes affected the engine dynamic behavior and ultimately noise and vibration in engine. These changes are validated for various operating conditions on engine test cell in a controlled environment where engine is mounted on test cell with dyno. Further, this engine is used in various equipment application and needs to be validated for noise and vibration performance. Three-cylinder engines have inherent imbalance forces, hence it is extremely critical to select the proper engine isolators to reduce the vibrations and noise. This paper covers the methods used for verification of engine isolation performance. NVH tests are conducted for integration of three-cylinder engine with roadbuilding machine. An analytical model is developed to identify rigid body modes and mount transmissibility. Results from this analytical model were verified with a physical
Pawar, Sachin M., Mandke, Devendra Laxmikant, KASABE, SANDEEP, Jadhav, Vijay
Challenges & approaches for Cost modelling in off highway electric vehicles2025-28-0212To be published on 11/06/2025
The electrification of off-highway vehicles presents a complex landscape of challenges, particularly in the realm of cost engineering for motors. These challenges stem from technological complexities, use of specialty materials and processes, economics of scale, and operational factors, each requiring careful consideration to ensure accurate and efficient cost modeling. The lack of standardized cost data for specialty materials poses a significant barrier to accurate cost engineering. Furthermore, the cost of key materials and components, such as electrical steel and permanent magnets, can fluctuate due to supply chain disruptions, material shortages, introducing uncertainty into cost projections. The economies of scale play a crucial role in cost engineering for off-highway electrification. Many off-highway vehicles are produced in lower volumes compared to on-road vehicles, which can result in higher unit costs for electric motors and other. In this paper, we delve into the primary
Chauhan, Shiv, Padalkar, Bhaskar
Customer Support- Failure and Warranty analysis in Off highway vehicles2025-28-0300To be published on 11/06/2025
Off-highway vehicles (OHVs) play a crucial role in industries such as construction, agriculture, and mining, contributing significantly to global infrastructure and economic development. However, ensuring their reliability and performance requires robust customer support, particularly in failure analysis and warranty management. This paper explores innovative approaches to diagnosing failures, optimizing warranty policies, and leveraging technology to enhance customer support for OHVs. Failure analysis involves systematic root cause identification to prevent recurring issues, minimize downtime, and improve product durability. Advanced diagnostic tools, predictive maintenance strategies, and telematics integration have revolutionized how failures are detected and addressed. By utilizing IoT-enabled sensors and AI-driven analytics, manufacturers can proactively monitor vehicle health, reducing unplanned failures and enhancing service efficiency. Warranty analysis is equally critical
Mulla, Tosif, Thakur, Anil, Tripathi, Ashish
Challenges in Transitioning from 400V to 800V Off-Highway Power Electronics2025-28-0281To be published on 11/06/2025
Electrification applications are increasingly moving towards higher voltage systems to enable greater power delivery and faster battery charging. This trend is particularly evident in the shift from 400V to 800V systems, which offers several benefits and poses unique technical challenges. Higher voltage systems reduce current flow, minimizing energy losses and improving overall efficiency. This is crucial for applications like electric vehicles and off-highway machinery, where efficient power management is essential. One of the primary benefits of increasing the DC link voltage beyond the 400V is the ability to support higher power levels Additionally, higher voltage systems can reduce the size and weight of power components, contributing to more compact and lightweight designs. However, transitioning to 800V systems introduces several technical challenges in power electronics design. Key components such as power components (IGBT , MOSFET etc) must be optimized to handle higher
Hatkar, Chetan Manohar, Pipaliya, Akash
Virtual load sensor methodology for structural verification2025-28-0269To be published on 11/06/2025
Authors - Swapnil Zalte, Prasad Kulkarni, Abhijeet Aundhe, Shikha Gupta, Shubham Darade Large off-highway vehicles, such as combine harvesters, corn heads, and hinged drapers, are complex machines comprised of multiple interacting subsystems. Consequently, capturing the load path through full vehicle finite element modeling poses significant challenges and can be computationally intensive during the design development process. We primarily employ two structural analysis approaches based on the availability of load inputs: • Full Frame Finite Element Model Setup • Subsystem Finite Element Model Setup Just like virtual verification, physical verification can also be performed at both the full vehicle and subsystem levels. The most critical input for both physical and virtual structural verification is load data. Traditionally, we acquire structural loads induced by ground excitations using wheel force transducers. For subsystem finite element models, interface loads are essential, which
Zalte, Swapnil Suresh, S Kulkarni, Prasad, Gupta, Shikha, Aundhe, Abhijeet, Darade, Shubham
Hybrid Safety Framework for Autonomous Off-Highway Vehicles2025-28-0325To be published on 11/06/2025
The evolution of Autonomous off-highway vehicles (OHVs) has transformed mining, construction, and agriculture industries largely by increasing vehicles efficiency and safety. These vehicles operate in high dust, uneven terrain, and potential communication failure environments where vehicle safety is challenged. To guarantee vehicle safety in such situations, a robust architecture that combines AI-driven perception, fail-safe mechanisms, and conformance to many ISO standards is required. In unstructured environments, AI-driven perception, decision-making, and fail-safe mechanisms are not fully addressed by traditional safety standards like ISO26262 (road vehicles), ISO19014 (earth-moving machinery),ISO12100(Safety of machinery) and ISO25119 (agriculture). These standards mainly concentrate on the reliability of mechanical and electric/electronic systems. Additionally, emerging standards such as ISO21448 (SOTIF) used to detect and mitigate unsafe AI outputs, and ISO8800(AI safety) which
Muthusamy, Sugantha
Machine Learning Model for Predicting Transient Jerk Behavior in Knuckle Boom Loaders2025-28-0332To be published on 11/06/2025
The knuckle boom loader machine experiences a significant issue where rapidly retracting the joystick to the neutral (0) position causes the machine's legs to lift momentarily. This unintended lifting occurs when the joystick is moved back quickly, while gradual movements do not trigger this effect. Addressing this problem is crucial for enhancing both safety and operational efficiency. The primary objective of this project is to develop a machine learning model to predict jerk based on joystick movements. This prediction will aid in creating a model predictive controller (MPC) that suggests optimal joystick positions, thereby reducing unintended lifting. To simulate the knuckle boom loader's response to joystick inputs, a high-fidelity Simulink model developed using Simscape Multibody was utilized. Data were collected through a Design of Experiments (DOE), logging key parameters such as head side pressure, jerk, jerk rate, and lift levels across various joystick positions. The input
Kamaraj, Keerthi Vallarasu
Integrating Self Hydraulic Jacks Under the Chassis for off-Road vehicles, and Utility Task Vehicles2025-28-0264To be published on 11/06/2025
Imagine a futuristic vehicle chassis, sleek, low-slung, and aerodynamic, constructed from advanced materials like high-strength alloys or carbon fiber composites. Underneath this captivating structure, a sophisticated system of self-hydraulic jacks is seamlessly integrated. These jacks, situated adjacent to the four shock absorber mounts, are designed to lift the chassis at the tire areas, ensuring efficient underbody maintenance and quick, safe emergency lifts. The design incorporates an intuitive control system with strategically placed buttons for driver convenience. Whether positioned alongside the steering wheel, integrated near the infotainment display, or mounted within the driver-side door, these controls blend technology and practicality. Integrating Self Hydraulic Jacks Under the Chassis:- • Adjacent to each shock absorber mounting point, a self-hydraulic jack is integrated into the chassis design. Designed to be unobtrusive when not in use, these jacks are built into
Gogula, Venkateswarlu
Environmental Factors and Off-Highway Vehicle Safety2025-28-0322To be published on 11/06/2025
Off Highway vehicles recreation has rapidly expanded across the globe hence it is important to consider the safety of off-highway vehicles which is significantly influenced by various environmental factors, which can pose unique challenges and risks. it is important to make sure that the entire vehicle operates safely and reliably even in the toughest conditions. This paper investigates the impact of environmental conditions on the safety and performance of off-highway vehicles, such as construction equipment, agricultural machinery, and mining vehicles. By examining factors such as terrain, weather conditions, visibility, and natural obstacles, the study aims to identify key hazards and propose strategies to mitigate them. The paper explores how advanced technologies, including digital twins and predictive analytics, can be leveraged to enhance safety measures and improve vehicle resilience in diverse environmental settings. Through comprehensive case studies and empirical data, we
Mogal, Masthanvali, Chennamalla, Chandra Shekar
Mechanical Boom Vibration Mitigation using Active Force Control2025-28-0345To be published on 11/06/2025
In off-highway vehicles, an undesirable vibration in a mechanical structure is a well-known problem. Such vibrations are discomforting in humans and can even lead to serious health issues related to orthopedics. Passive vibration attenuation approaches are popular in engineering practice but rely heavily on vehicle structural changes. Moreover, such approaches are known to be less effective on low frequency vibrations. In the last decade or so, there has been significant technological advancement in actuators as well as sensing mechanisms. This has enabled us to realize active vibration control as an important tool in managing excessive vibration levels. It is noteworthy that a typical active vibration control assumption is that the controlled structure maintains its dynamic properties throughout the control procedure. This simplifies linear-time invariant (LTI) model-based control design approaches. We note that in certain applications, such as gantry cranes, spraying mechanical booms
Patil, Bhagyesh, Bawankar, Shubham
Ensuring Functional Safety and SOTIF Analysis for Autonomous Off-Highway Vehicles: Addressing Risks in Complex Systems2025-28-0315To be published on 11/06/2025
The growing complexity of electronic systems and the rise of autonomous (driverless) vehicles in the off-highway industry emphasise the need for safer Electronic/Electrical (E/E) systems. In this paper, we present our approach to performing a comprehensive Functional Safety (FuSa) analysis and extending the scope to the application of Safety of the Intended Functionality (SOTIF) principles for off-highway vehicles. We apply FuSa to ensure that systems operate safely, by minimising risk through safety measures. This involves assessing risks based on potential hazards and deriving safety requirements in accordance with ISO 19014 and IEC 61508. Autonomous operation involves significant safety challenges. Thus, further analysis is needed to ensure the perception system functions safely and as intended in all scenarios. In the absence of a dedicated SOTIF standard for off-highway vehicles, we adapt ISO 21448 from the automotive industry for this analysis, as it is regarded as state-of-the
Kumar, Amrendra, Bagalwadi, Saurabh
Impact of Cooling Airflow and Its Path on Underhood Cooling in Farm Tractors2025-28-0280To be published on 11/06/2025
To ensure the effective operation of engine cooling systems in agricultural tractors, several critical parameters must be considered, including grille opening area and location, grille resistance, front-end blockage, fan speed, and coolant flow rate. While grille design has been moderately explored for highway vehicles, research specific to grille configuration in agricultural tractors remains limited. This study investigates the influence of grille location, grille resistance - modeled using porous inertial and viscous resistance coefficients - front-end blockage, fan RPM, and coolant flow rate on radiator top tank temperature (TTT) using Computational Fluid Dynamics (CFD). The analysis is conducted in two phases: first, the effects of grille opening area and location, grille resistance, and front-end blockage are evaluated under fixed fan speed and coolant flow rate; second, an orthogonal array design of experiments is employed to rank the influence of grille opening area, fan RPM
Subramani, Sridharan, Baskar, Subramaniyan, Gopinathan, Nagarajan
Connected Aftermarket Services for Off-Highway Vehicles: Enhancing Fleet Management Through Real-Time Data and Predictive Maintenance2025-28-0307To be published on 11/06/2025
Off-highway vehicles (OHVs) are critical to industries such as construction, agriculture, and mining, where they often operate in challenging environments requiring constant maintenance and repair. This paper presents a connected platform designed to enhance customer support and fleet management by integrating real-time data monitoring, predictive maintenance, and e-commerce capabilities. Through IoT-enabled sensors, cloud computing, and data analytics, the system continuously collects and analyzes vehicle performance data, providing fleet owners with actionable insights for efficient resource allocation and maintenance scheduling. The platform offers automated alerts for part replacements, tracking of repair history, and optimization recommendations based on vehicle condition. By integrating e-commerce for aftermarket parts and services, fleet managers can easily purchase and manage the inventory required for their operations. This connected system not only improves operational
Vashisht, Shruti
Onboard Exhaust Capture and Carbon Sequestration for Off-Highway Vehicles: A Sustainable Approach to Emission Reduction2025-28-0215To be published on 11/06/2025
Off-highway vehicles (OHVs) operating in sectors like mining, construction, and agriculture play a significant role in greenhouse gas (GHG) emissions, especially carbon dioxide (CO₂) and nitrogen oxides (NOx). Despite progress in alternative fuel technologies, diesel-powered OHVs continue to prevail because of their strong torque and reliability. This paper suggests an onboard exhaust capture and carbon sequestration system designed to be incorporated into diesel OHVs to temporarily contain and utilize emissions, thereby lessening their environmental impact. The system employs nano-porous filters and solid-state carbon absorption materials to selectively trap CO₂ and NOx directly from the exhaust flow. The gathered CO₂ is then subjected to compression and temporary storage, with possible uses for conversion into carbon-based fuel additives or direct sequestration in industrial applications. Unlike conventional catalytic converters that only diminish NOx emissions, this system provides
Vashisht, Shruti
Adaptive Terrain Morphing Chassis for Off-Highway Vehicles: Enhancing Fuel Efficiency Through Dynamic Structural Adaptation2025-28-0342To be published on 11/06/2025
Off-highway vehicles (OHVs) frequently encounter difficult terrains such as swamps, deserts, and rocky landscapes, which can lead to increased fuel usage due to elevated rolling resistance and irregular surfaces. This paper suggests an adaptive terrain morphing chassis that actively modifies its structure to enhance fuel efficiency and vehicle performance. Employing soft robotics concepts and hydraulic morphing materials, the chassis can vary its height, width, and track shape in accordance with real-time terrain evaluations. These modifications assist in lowering rolling resistance, boosting traction, and improving stability. For instance, the chassis may expand in marshy regions for better weight distribution or reduce in height in rocky environments for enhanced stability. Key features consist of: Real-time terrain evaluation using sensors to modify chassis configurations. Hydraulic actuators and adaptive polymers that change the vehicle’s structure for peak performance. Fuel
Vashisht, Shruti
Road Simulation Techniques for Reproducing Off-Road Vehicle Behavior2025-32-003111/03/2025
A road simulator reproduction method was developed to reproduce the off-road conditions of utility vehicles in a laboratory setting. Off-road running behavior can be reproduced by considering the effects of inertial forces from jump landings owing to uneven terrain and slow-speed navigation. However, extremely low-frequency components and behaviors, including inertial forces from jumps, vehicle acceleration and deceleration, are difficult to reproduce with a normal road simulator in the limited test space of a laboratory. Therefore, it is common practice to intentionally remove input components below 1 Hz. Alternatively, inertial forces can be reproduced by adding a restraining device to the sprung mass of the vehicle along the wheel-axle inputs. Therefore, the former method excludes extremely low- frequency components, whereas the effects between actuators, which increase the test complexity and time required, should be canceled in latter method. Furthermore, the restraining device on
Miyasaka, Takahiro, Shimizu, Ryota
Noise Mitigation Techniques Off-Highway Vehicle HVAC Unit2025-28-037810/30/2025
Noise generated by a vehicle’s HVAC (Heating, Ventilation, and Air Conditioning) system can significantly affect passenger comfort and the overall driving experience. One of the main causes of this noise is resonance, which happens when the operating speed of rotating parts, such as fans or compressors, matches the natural frequency of the ducts or housing. This leads to unwanted noise inside the cabin. A Campbell diagram provides a systematic approach to identifying and analyzing resonance issues. By plotting natural frequencies of system components against their operating speeds, Test engineers can determine the specific points where resonance occurs. Once these points are known, design changes can be made to avoid them—for example, adjusting the blower speed, modifying duct stiffness, or adding damping materials such as foam. In our study, resonance was observed in the HVAC duct at a specific blower speed on the Campbell diagram. To address this, we opted to optimize the duct design
Trivedi, Arpita, Kumar, Ravi, Madaan, Ashish, Shrivastava, Pawan
SAE Truck & Off-Highway Engineering: October 202525TOFHP1010/09/2025
Lifelike simulation accelerates middle-mile autonomy The Gatik Arena platform integrates NVIDIA Cosmos models to create closed-loop, ultra-realistic digital environments that address real-world limitations. JCB heads to the front line The United States Marine Corps enlists the JCB 4CX backhoe loader as its latest recruit. Rethinking vehicle controls Smarter control architectures including CAN- and LIN-based multiplexing can elevate operational efficiency, customization and end-user experience. Editorial COMVEC covers the tech landscape Grease innovation adapts to meet new demands of heavy equipment Deutronic DC/DC converter streamlines off-highway electrification The economics of lightweighting in heavy-duty vehicles Monarch unveils AI vehicle platform ZM Trucks plants its flag in North America, pushes ahead with electric ZM8 Class 4/5 truck Product Briefs SPOTLIGHTS: Connectors; Hydraulics and Flow Control Q&A AVL addresses path to greater hybridization
Rethinking VEHICLE CONTROLS25TOFHP10_0310/01/2025
Smarter control architectures including CAN- and LIN-based multiplexing can elevate operational efficiency, customization and end-user experience. From long-haul Class 8 trucks navigating cross-country routes to articulated dump trucks operating deep in a mining pit, the need for smarter, more reliable and more efficient control systems has never been more critical. Across both on- and off-highway commercial vehicle segments, OEMs are re-evaluating how operators interact with machines - and how those systems can be made more robust, flexible and digitally connected. Suppliers have responded to this industry-wide shift with new solutions that reduce complexity, improve durability and help customers future-proof their vehicle architectures. For example, Eaton's latest advancement is the E33 Sealed Multiplexed (MUX) Rocker Switch Module (eSM) - a sealed, modular switch solution that replaces traditional electromechanical designs with a multiplexed digital interface. Combined with Eaton's
Ortega, Carlos
Grease innovation adapts to meet new demands of heavy equipment25TOFHP10_0510/01/2025
In the commercial and off-highway sectors, equipment reliability isn't just a maintenance target but a business imperative. Whether it's a long-haul truck on the interstate or a dozer working through dust and rock, these machines operate in some of the most demanding environments on Earth. And while engine design and fuel choice often dominate conversations about performance, the role of grease is just as critical, particularly as equipment is pushed harder and longer under more variable conditions. Over the last decade, heavy-duty grease development has undergone a quiet evolution. Performance expectations have risen sharply. So have the environmental and regulatory considerations that influence formulation decisions.
Kumar, Anoop
Q&A25TOFHP10_1110/01/2025
The powertrain landscape of the future is sure to be a mix that includes clean diesel engines and other ICE options running alternative fuels. Zero-emissions technology such as battery-electric also will play a greater role in certain applications - despite the policy headwinds it currently faces in the U.S. “Eventually we have to decarbonize the heavy-duty industry,” Thomas Howell, segment lead for conventional powertrain, AVL in the U.S., told Truck & Off-Highway Engineering. A promising “best of both worlds” technology could be hybrid-electric. But as with BEVs, its impact will depend greatly on finding the right applications for it, Howell said. Read on for more of his thoughts on the hybridization of commercial vehicles.
Gehm, Ryan
Monarch unveils AI vehicle platform25TOFHP10_0810/01/2025
Before Monarch existed in 2015, its cofounders CTO Zachary Omohundro and CEO Praveen Penmetsa traveled to India to assemble two electric and connected tractors they had shipped over in crates. They went to a local village and had a plan to deploy the vehicles. “We had a text messaging-based reservation system that the villagers ended up saying, ‘Nope, we're not going to use that at all,’” Omohundro told Truck & Off-Highway Engineering. Instead, the local farmers wanted to work through a local man who knew how to operate tractors. So, they pivoted.
Baldwin, Roberto
EDITORIAL: COMVEC covers the tech landscape25TOFHP10_0410/01/2025
This year's SAE COMVEC conference held in mid-September in Schaumburg, Illinois, was focused around the theme “Shaping the Future Together” by embracing advancement, empowerment and exploration in the commercial and off-highway vehicle industries. Workforce and technology topics ranged from skills gaps to powertrain development and software-defined vehicles (SDVs) to AI deployment - a thread that ran through many of the conference's sessions. Following are a few of the salient points made by industry experts at the annual engineering event:
Gehm, Ryan
Deutronic DC/DC converter streamlines off-highway electrification25TOFHP10_0610/01/2025
Thanks to the continued growth of electrified machines in the off-highway segment, DC/DC converters are rapidly becoming a crucial component in the supply chain for numerous OEMs for a wide array of applications. Deutronic recently unveiled a new line of DC/DC converters intended for the mass electrification needs of today's off-highway commercial vehicles. The converter's design is said to be durable and compact with high power density that also offers protection from environmental factors such as vibration, shock, and high temperatures. Deutronic's DVCHx3 converter also provides an interlock function, as well as short-circuit, overtemperature and no-load/self-protection features.
Wolfe, Matt
The economics of lightweighting in heavy-duty vehicles25TOFHP10_0710/01/2025
Like those in many other industries, truck and off-highway vehicle manufacturers face the challenge of producing quality components and maintaining productive processes while also generating a better bottom line. Improving employee training, simplifying complex operations and implementing better workflows can all help generate efficiencies. While not a new concept, lightweighting - in this case, reducing the weight of parts through the substitution of traditional steel with high-strength, thinner steels - can also be a viable answer to a better vehicle. As a rule of thumb, when manufacturers double the strength of the material through lightweighting, it is possible to reduce the weight of the part by one-third. That weight reduction can then lower the cost per part for greater profitability per piece of equipment and greater annual savings.
Gugel, Mick
ZM Trucks plants its flag in North America, pushes ahead with electric ZM8 Class 4/5 truck25TOFHP10_0910/01/2025
To say 2025 has been a bumpy ride for North American electric vehicle OEMs would be an understatement not heard since Jack Swigert informed Houston that Apollo 13 was experiencing a problem. However, despite a tariff tug of war, EPA upheaval and continually changing tax incentives, OEMs are pushing ahead with plans to electrify the commercial truck segment. In late August, ZM Trucks celebrated the grand opening of its U.S. headquarters and assembly facility in Fontana, California. Truck & Off-Highway Engineering was in attendance for the opening ceremony, which included the U.S. debut of the ZM8 Class 4/5 truck.
Wolfe, Matt
Ensuring Safe Control of Automated/Autonomous Ground Vehicles2025-01-043609/16/2025
Automated, telerobotic, and autonomous off road vehicles present unique safety concerns for their users, both military and civilian, due to their complexity and their extensive use of open source software. This is particularly true when personnel are intermingled with vehicles as is common during many operations. This paper presents a unique approach to providing true functional safety while permitting the developers of the automated/telerobotic/autonomous hardware and software to rapidly implement changes and improvements.
Underhill, Mark, Delecki, Rich, Sullivan, Denis O.
Towards Effective SCR System Optimization: A 3D-CFD and Experimental Study Enabling Faster Deposit Formation Risk Assessment2025-24-008709/07/2025
Selective Catalytic Reduction (SCR) is a key technology for reducing nitrogen oxides (NOx) emissions in diesel engines. In this process, a urea-water solution (UWS) is injected upstream of the catalyst to generate ammonia, which reacts with NOx to form nitrogen. However, liquid urea can adhere to system walls, undergoing secondary reactions that lead to the formation of solid deposits. These deposits must be minimized to ensure the long-term durability and efficiency of the system. Computer-Aided Engineering (CAE) simulations play a crucial role in optimizing SCR performance during the design phase. However, accurately predicting deposit formation requires detailed chemical modelling, which is computationally expensive and introduces uncertainties related to reaction mechanisms definition. To address this challenge, simplified CAE approaches are needed to assess deposit formation risks while maintaining computational efficiency. This study presents an improved Deposit Risk Index (DRI
Bianco, Andrea, Prestifilippo, Mattia, Robino, Cristina, Petrafesa, Giovanni, Postrioti, Lucio, Buitoni, Giacomo
SAE TOMORROW TODAY - Powering A Cleaner Commercial Vehicle Industry1353208/29/2025
From battery-electric trucks to hydrogen fuel cell vehicles, the company behind Kenworth, Peterbilt, and DAF is leading the charge toward zero-emissions. PACCAR is a global technology leader in the design, manufacture, and customer support of premium light-, medium- and heavy-duty trucks. The company is also actively investing in zero-emission technologies, positioning itself as a leader in the transition to cleaner commercial vehicles. To learn more, we sat down with Dr. Philip Stephenson, General Manager, PACCAR Technical Center and Executive Chair of this year's COMVEC, the annual commercial vehicle engineering conference hosted by SAE International. Listen in for an engaging discussion on PACCAR's approach to battery-electric trucks, hydrogen fuel cell vehicles, and charging infrastructure partnerships. And if you enjoyed this conversation, register now for COMVEC and join us as we bring together industry leaders, engineers, and innovators to discuss the latest advancements in on
Patterson, Lori
Optimizing Hybrid Powertrains for Off-Highway Vehicles02-18-03-002408/23/2025
This article details the development of a plug-in hybrid electric powertrain system for a wheel loader. The work included both computer modeling and fired engine testing. A methodical approach was utilized, which included identifying system requirements, an architecture study, component sizing, and cost analysis. After the optimal system was designed, the engine and hybrid motor were installed in a powertrain test cell and evaluated over an in-use duty cycle. A bespoke utility factor, relevant for wheel loader operation, was developed to enable realistic fuel economy and emissions weighting between charge depleting and charge sustaining operation. Finally, an exhaust heater was used to ensure rapid warmup of the aftertreatment system. Compared to an internal combustion engine–only baseline, the hybrid powertrain system resulted in a 48% reduction in CO2 and an 84% reduction in NOX emissions when operated over an 8-h shift, with daily recharging.
Bachu, Pruthvi, Michlberger, Alexander, Meruva, Prathik, Bitsis, Daniel Christopher
SAE Truck & Off-Highway Engineering: August 202525TOFHP0808/14/2025
A model of design efficiency How Cummins used modeling and other advanced design software to create its most efficient engines yet. Solving problems and seeking big ideas PACCAR's Phil Stephenson previews SAE COMVEC 2025 and offers insights into powertrain diversification, the role of AI, a software-defined future and the importance of people. Refurbishing high-voltage batteries for electric trucks Mercedes-Benz Trucks employs "like-new" reworked batteries to expand its spare parts portfolio and to inform future battery designs that are more sustainable. Editorial Hydrogen's humming in power generation Bosch invested in large-scale metal 3D printing Schaeffler optimizes rolling bearings for hydraulic and axle drives Natural gas infrastructure is scaling fast for HD fleets Cummins powers up the S17 genset SAE J3400/2 update brings quicker NACS charging Workhorse's W56 is the people's champ of electrified work vans Komatsu logs a new timber machine Product Briefs SPOTLIGHTS: Power
Solving problems and seeking big ideas25TOFHP08_0208/01/2025
PACCAR's Phil Stephenson previews SAE COMVEC 2025 and offers insights into powertrain diversification, the role of AI, a software-defined future and the importance of people. Advancing technology to solve challenges involving regulation, compliance, autonomy, electrification, combustion engines and other areas is an obvious focus of SAE International's flagship gathering for the commercial vehicle and off-highway industries, COMVEC 2025 (https://comvec.sae.org/). But advancing people, which is vital to navigating this challenging environment, is a particular focal point for this year's engineering event being held near Chicago in September. Workforce development is just as critical as technology development, stresses Phil Stephenson, general manager of PACCAR Technical Center, where he leads a team of engineers, technicians, mechanics, scientists and business leaders. Stephenson is serving as the executive chair of SAE COMVEC 2025, which carries the theme “Advancement, Empowerment
Gehm, Ryan
Komatsu logs a new timber machine25TOFHP08_1108/01/2025
Komatsu has announced a new swing machine designed to move large quantities of timber in log loader and millyard environments. The TimberPro TN785D is Komatsu's most powerful and highest capacity machine to date. According to Komatsu, it was built with proven components and new features to meet the demand of high productivity swing applications. “TimberPro has designed this machine to excel in high demand millyard applications where lift capacity, reach combined with stability and hydraulic response are key to maximizing productivity,” said Nathan Repp, product manager for Forest Products at Komatsu. “We understand the real-world demands our customers face in these environments, and the TN785D was designed to meet those needs.”
Wolfe, Matt
Design and Analysis of Passive Controlled Plastic Hinge in Two-Post Rollover Protective Structure for Off-Highway Motor Grader Equipment02-19-01-000107/23/2025
Rollover protective structures (ROPS) that absorb energy during vehicle rollovers play a crucial role in providing integrated passive safety for operators restrained by seat belts. These protective structures, integrated into the vehicle frame, are designed to absorb high-impact energy and deform in a controlled manner without intruding into the occupant’s safe zone. This research focuses on the detailed analytical design procedure and performance evaluation criteria of the two-post open ROPS used on motor graders against lateral loads. An experimental test on a standard tubular square hollow section (SHS) column subjected to lateral load has demonstrated a significant correlation between the post-yield behavior of plastic hinge development and energy absorption, compared with results from various formulations adopted in finite element analysis (FEA). To reduce design iteration time and the cost of physical destructive testing, the complete equipment experimental setup is virtually
J., Avinash
A New Electrified Planetary Gear Set - The Cost- and Fuel-Efficient Alternative to Continuously Variable Transmissions2025-01-030907/02/2025
In order to mitigate the effects of climate change, the global transport sector, one of the largest emitters of CO2, needs to drastically reduce its emissions. Although hybridization and electrification are becoming increasingly popular as a solution for a variety of applications, their use in two- and three-wheelers, as well as in recreational and powersports vehicles, remains limited due to their high costs and complexity compared to conventional drivetrains with continuously variable transmissions (CVTs). Despite their affordability and simplicity, CVTs suffer from low mechanical efficiency, with transmission losses ranging from 20–50 %, highlighting a significant opportunity for improvement. In response to these limitations, this study presents the development and experimental evaluation of an electrified planetary gear set (ePGS) in a lightweight off-road vehicle. It is designed to overcome the efficiency limitations of CVTs while maintaining high driving comfort and low system
Jakoby, Moritz, Engels, Michael, Fahrbach, Timm, Andert, Jakob
SAE Truck & Off-Highway Engineering: June 202525TOFHP0606/12/2025
Developing next-gen diesels to last decades John Deere's newest combustion engines are designed to accommodate alternative fuels and evolving technologies as requirements demand. New Volvo D13 VGT utilizes 24V architecture Volvo Trucks North America launches the all-new VNR with standard D13 VGT engine and announces an upcoming CARB-24 Omnibus compliant engine variant. Next reman up: The role of engine remanufacturing While new sustainability efforts aim to curb the carbon footprint of the commercial vehicle industry, old methods continue to be among the most effective. Challenges and opportunities for electrifying machines The switch to electrified off-highway vehicles can help reduce reliance on hydraulic components that decrease system efficiency via parasitic losses. Editorial Tech - and tariffs - top of mind at tradeshows ACT Expo 2025: Battery experts fret tariffs, encourage specific designs How HVAC systems can adapt to the needs of electric off-highway vehicles Clarios brings
Multi-Objective Robust Optimization for a Parallel Link Steering System: A Six Sigma and Monte Carlo Approach2025-01-503606/03/2025
The steering system is one of the most important assemblies for the vehicle. It allows the vehicle to steer according to the driver’s intention. For an ideal steering system, the steering angle for the wheel on the left and right side should obey the Ackman equation. To achieve this goal, the optimization method is usually initiated to determine the coordinates of the hard points for the steering system. However, the location of hard points varies due to the manufacturing error of the components and wear caused by friction during their working life. To decrease the influence of geometry parameter error, and system mass, and improve the robust performance of the steering system, the optimization based on Six Sigma and Monte Carlo approach is used to optimize the steering system for an off-road vehicle. At last, the effect is proved by the comparison of other methods. The maximum error of the steering angle is decreased from 7.78° to 2.14°, while the mass of the steering system is
Peng, Dengzhi, Deng, Chao, Zhou, Bingbing, Zhang, Zhenhua
Challenges and opportunities for electrifying machines25TOFHP06_0406/01/2025
The switch to electrified off-highway vehicles can help reduce reliance on hydraulic components that decrease system efficiency via parasitic losses. The off-highway machine industry is embracing new technologies to optimize operations, specifically regarding electric and hybrid off-highway equipment. The electric off-highway equipment market is poised for growth, with an expected 12.5% compound annual growth rate (CAGR) from 2025-2034, reaching over $17 billion, according to Market Research Future. These off-highway vehicles operate on tough terrain and require unprecedented amounts of power for long duty cycles. Diesel engines have always been the conventional application for this kind of work, but now hybrid and electric vehicles are starting to gain traction thanks to new innovations and more investment. While the implications of replacing traditional combustion engines with hybrid or electric counterparts can be intimidating, learning the challenges and opportunities each option
Liu, Zifan
How HVAC systems can adapt to the needs of electric off-highway vehicles25TOFHP06_0706/01/2025
The sustainability trend continues to grow in the off-highway sector. Wherever possible, manufacturers rely on electric vehicles to contribute to climate protection goals. Therefore, heating and cooling solutions need to fit these given circumstances. Eliminating the traditional waste heat from the combustion engine requires new strategies for temperature regulation, for the cabin as well as for the battery. The aim is to efficiently control all thermally relevant areas in the vehicle.
Touzet, Adrien
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