Browse Topic: Off-highway vehicles and equipment

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Tobolski, Sue
Safety Monitor for Off-Road Planning with Uncertainty Bounded Bekker Costs2026-01-01414/7/2026
Reliable off-road autonomy requires operational constraints so that behavior stays predictable and safe when soil strength is uncertain. This paper presents a runtime assurance safety monitor that collaborates with any planner and uses a Bekker-based cost model with bounded uncertainty. The monitor builds an upper confidence traversal cost from a lightweight pressure sinkage model identified in field tests and checks each planned motion against two limits: maximum sinkage and rollover margin. If the risk of crossing either limit is too high, the monitor switches to a certified fallback that reduces vehicle speed, increases standoff from soft ground, or stops on firmer soil. This separation lets the planner focus on efficiency while the monitor keeps the vehicle within clear safety limits on board. Wheel geometry, wheel load estimate, and a soil raster serve as inputs, which tie safety directly to vehicle design and let the monitor set clear limits on speed, curvature, and stopping at
Naik, Akshay, Norris, William, Sreenivas, Ramavarapu S., Soylemezoglu, Ahmet, Nottage, Dustin S., Patterson, Albert
Vault-Induced Pitchover Crash Testing of a Recreational Off-Highway Vehicle (ROV)2026-01-05464/7/2026
Vehicle pitchover crashes can result in very severe accelerations and forces. Literature and test data available on pitchover crashes is sparse. This paper presents the results of a full-scale pitchover/rollover crash test using an instrumented vehicle in a controlled and documented off-road environment. The test vehicle was driven to the launch point by an off-board operator using remote steering and throttle controls. The test vehicle then experienced an airborne phase during which forward pitching occurred, followed by a front-to-ground impact which induced additional pitchover motion. Then, following the initial front and rear impacts, the vehicle transitioned from a pitchover to rollover motion before coming to rest. The resulting vehicle motion, vehicle damage markings, and ground markings were documented with various slow motion and real time camera views. The test vehicle was instrumented with accelerometers, rotation rate sensors, and other sensors, the results of which
Warner, Mark, Warner, Wyatt, Swensen, Grant, Perl, Mark
Impact of Hydrogen on Methane and Pollutant Emissions over Three-Way Catalysts with Natural Gas–Hydrogen Blends2026-01-03574/7/2026
Blending natural gas (NG) with hydrogen (H₂) can improve combustion and engine performance while potentially facilitating the catalytic conversion of methane and other pollutants, resulting in cleaner tailpipe emissions. This study evaluates the impact of H2 on the conversion of methane, CO, and NOx emissions on a commercial three-way catalyst (TWC) in a flow reactor using synthetic gas mixtures that simulate stoichiometric engine exhausts with NG or NG+H₂ combustion. The work examines whether, and how, the additional amount of H₂ in the exhaust stream affects the conversion efficiency of methane and other pollutants. Experiments were conducted with both degreened and aged catalysts under controlled conditions, systematically varying temperature, the air-to-fuel equivalence ratio (λ), and λ modulation. Test conditions covered λ values from 0.996 to 1.000 to represent nominally stoichiometric engine operation with different λ modulation amplitudes, as well as a range of temperatures to
Prikhodko, Vitaly, Wang, Min, Park, Yeonshil, Chen, Hai-Ying, Pihl, Josh
Optimizing Custom Hybrid Solutions for Low-Volume Specialist Equipment2026-01-04794/7/2026
Off-road vehicles are typically powered by diesel engines, sized to cover the highest peak loads in their dutycycles. Such applications can be designed with downsized engines, using hybridization to supplement engine power with electrical power for short periods. However, many applications are low-volume and specialized, making it impractical to deploy heavy engineering resources to optimize each one. For this reason, manufacturers tend to produce maid-of-all-work vehicles to cover every situation. This paper demonstrates the benefits of custom hybridization for specialist applications, and addresses the lack of accessible software tools for evaluating such opportunities. Analysis is applied with a fast, low-cost, Concept-based software tool named “ePOP Concept”, suited to original equipment manufacturers (OEMs) who seek to provide custom low-volume vehicles. It allows many different powertrain architectures to be evaluated rapidly at the product planning stage, and can be quickly set
De Salis, Rupert, Fons, Daniel
Backward Fuzzy Driving Control for 6×4 Off-Road Vehicles2026-01-01484/7/2026
Off-road autonomous vehicle systems must be able to operate across unstructured and variable terrain while avoiding obstacles. This presents significant challenges in vehicle and control system design, especially for less conventional platforms such as 6×4 vehicles. While forward driving autonomy has developed and matured in recent years, effective reverse navigation remains an under-explored area of vehicle co-design. Reversing 6×4 vehicles have limited rear steering authority, an extended wheelbase, and asymmetric traction, which introduce complex dynamics into any control system that is used. To address this need, a robust and experimentally validated fuzzy logic control architecture for 6×4 reverse navigation was developed during the course of this project. This architecture incorporates both near-field and long-range path data with adaptive outputs controlling steering and velocity based on a rule base that covers the whole vehicle state space. This method has low computational
Dekhterman, Samuel R., Sreenivas, Ramavarapu S., Norris, William R., Patterson, Albert E., Soylemezoglu, Ahmet, Nottage, Dustin
Methodology for Generating Off-Road Tracks for Powertrain Simulation of Off-Road Passenger Vehicles2026-01-02754/7/2026
For off-road driving, particularly on steep grades and over barriers, the engine torque is a key design criterion of off-road vehicles. In conventional powertrains with combustion engines, mechanical all-wheel-drive systems combined with differential locks are used to distribute the torque demand between the front and the rear axle based on wheel-specific traction. With the growing market share of electric powertrains, off-road applications are becoming increasingly relevant for electric passenger cars. In comparison to conventional powertrains, electric all-wheel-drive configurations do not have a mechanical torque transfer between the two axles. If one axle experiences low traction, the second axle can rely on its own torque capability only. Transfer of unused torque of the slipping axle to the other one is not possible. The challenge, therefore, is to specify the right torque requirements for each axle for off-road driving while avoiding over-dimensioning and high powertrain costs
Martin, Michael, Winkelheide, Jonas, Hartmann, Lukas, Sturm, Axel, Henze, Roman
Integrated DBSCAN-Based Segmentation of Tractor Activity into Productive and Non-Productive States from GPS Data2026-01-01694/7/2026
Accurate identification of Productive and Non-Productive States or tractor duty cycles—comprising working, idle, and transport states—is critical for performance analysis, fuel optimization, and emissions modeling in agriculture machinery and fleet monitoring. This study explores the application of integrated unsupervised machine learning (ML) techniques to classify duty cycles using GPS-derived parameters such as speed, location variance, and temporal patterns. Unlike supervised approaches, the proposed method does not rely on several labeled engine and vehicle parameters, making it scalable and adaptable across diverse operational contexts. Clustering algorithm DBSCAN (Density-Based Spatial Clustering of Applications with Noise) in integration with hybrid rule-based and a road feature is employed to segment GPS data into distinct behavioral states. Feature engineering focuses on extracting motion signatures and spatial-temporal features that correlate with operational modes
Maharana, Devi prasad, Gangsar, Purushottam, Dharmadhikari, Nitin, Pandey, Anand Kumar
Classification, Nomenclature, and Specification Definitions for Directional Drilling Tracking EquipmentJ2520_202602 (Current)2/18/2026
This SAE Standard applies to directional drilling electronics and tracking equipment of the following types: Tracking transmitter Tracking receiver Telemetry device Remote display This type of tracking equipment is typically used with horizontal earthboring machines as defined in SAE J2022.
MTC9, Trenching and Horizontal Earthboring Machines
Structural Redesign and Functional Integration of an Electrohydraulic Brake Valve for Enhanced Performance and Manufacturability2026-28-00022/12/2026
The Electrohydraulic Brake Valve (EBV) is a vital component in full-power brake systems for heavy-duty and off-highway vehicles, providing precise hydraulic pressure modulation through electrical control. Traditionally, EBV housings are manufactured using bar-machined components, which offer durability but contribute significantly to the overall weight and cost of the assembly. In response to increasing demands for lightweight and cost-effective solutions, this study presents a targeted design optimization of the EBV housing. The redesigned housing adopts a casting-based geometry, integrates sensor ports for pressure monitoring, and includes a nameplate mounting provision for customer identification. Material substitution and structural simplification were employed to enhance manufacturability and performance. Finite Element Analysis (FEA) was used to validate the mechanical integrity of the new design under operational conditions. The optimized EBV assembly achieved a weight reduction
R, Thangarajan
SAE Truck & Off-Highway Engineering: February 202626TOFHP022/12/2026
AI influence on ICE design Experts offer their outlook on the future of heavy-duty internal combustion engines, and of course artificial intelligence will play a role. Accelerating down the road to autonomy Commercial success of the autonomous truck may be closer than we think. Digital tech a Las Vegas headliner With the rise of AI and other new digital technologies on the horizon, ACT Expo 2026 will be a crucial intersection for industry leaders to map out the route ahead. Editorial CONEXPO debuts - from micro to massive Rolls-Royce pursues pure methanol for marine engines Integrated architectures reshape the mobile-hydraulic ecosystem A proactive approach to hydraulic health in Class 8 trucks Precast concrete bases pave the way for rapid EV charger deployment CONEXPO 2026: Volvo CE to reveal new articulated hauler and short-swing, compact and wheeled excavators Product Briefs SPOTLIGHTS: Imaging/Cameras; Simulation/Analysis Software Q&A Bosch Rexroth: Hydraulics remain relevant in
EDITORIAL: CONEXPO debuts - from micro to massive26TOFHP02_042/1/2026
Visitors to Las Vegas are down. According to a year-to-date summary released by the Las Vegas Convention and Visitors Authority, the number of people who visited the desert city through November 2025 was down 7.4% compared to 2024. Convention attendance was also lower in 2025 compared to the previous year. Many outlets report that a big reason for the drop is fewer international tourists - particularly from Canada - due to U.S. trade policies. The word from some fellow journalists who attended CES in early January is that this trend is continuing into 2026. Jack Roberts of Heavy-Duty Trucking wrote, “I've never seen the city as empty and listless as it was during my time there this year… And the show floor at CES - while still crowded - was noticeably less jam-packed than past years.”
Gehm, Ryan
Guidelines and Procedures for Horizontal Directional Drilling (HDD) Machine Tracking Equipment OperatorsJ2519_202601 (Current)2/1/2026
These general guidelines and precautions apply to personnel operating directional drilling tracking equipment when used with horizontal directional drilling (HDD) machines as defined in ISO 21467:2023.
MTC9, Trenching and Horizontal Earthboring Machines
Integrated architectures reshape the mobile-hydraulic ecosystem26TOFHP02_062/1/2026
Off-highway equipment operates in an environment defined by extremes - extreme loads, extreme duty cycles, extreme temperatures and extreme expectations. OEMs and fleet operators face mounting pressure to deliver more power, more uptime and more precision from platforms that are becoming increasingly compact, intelligent and complex. Whether the task is hauling, lifting, dumping, clearing or moving materials, the equipment must deliver consistent, reliable performance without compromise. This pressure is reshaping the mobile-hydraulic ecosystem. The industry is steadily shifting away from piecemeal systems and toward integrated, intelligent power architectures that maximize efficiency across the entire vehicle. Leaders in this space, Eaton among them, demonstrate how a system-level approach to PTOs, hydraulic pumps and control valves is enabling a new generation of off-highway innovation.
Bogdan, Corneliu
Digital tech a Las Vegas headliner26TOFHP02_032/1/2026
With the rise of AI and other new digital technologies on the horizon, ACT Expo 2026 will be a crucial intersection for industry leaders to map out the route ahead. Since 2011, ACT Expo has served as a meeting point of technology and business discussions for the commercial vehicle industry. The 2026 show in Las Vegas (www.actexpo.com) is shaping up to be another important waypoint for the industry as it continues to grapple with new technologies, regulations and other significant challenges. This year's agenda program builds on ACT Expo's long-established emphasis on clean transportation and places an increased focus on the digital frontier, including AI, autonomy, connectivity and software-defined vehicles. Truck & Off-Highway Enginering interviewed Erik Neandross, president of the Clean Transportation Solutions group at TRC, about what topics are emerging as the main trends heading into 2026 and what he thinks will be some of the most important themes of the upcoming convention.
Wolfe, Matt
A Complex Road Surface Parameter Estimation Method Based on the Fusion Framework of Visual Classifier and Dynamics Observer10-10-02-00131/16/2026
Special vehicles such as off-road vehicles and planetary rovers frequently operate on complex, unpaved road surfaces with varying mechanical parameters. Inaccurate estimation of these parameters can cause subsidence or rollover. Existing methods either lack proactive perception or high precision. This article proposes a fusion framework integrating a visual classifier and a dynamics observer for stable, accurate estimation of road surface parameters. The visual classifier uses an adaptive segmentation system for unpaved roads, leveraging a large-scale vision model and a lightweight network to classify upcoming road surfaces. The dynamics observer employs an online wheel-–ground interaction model using stress approximation, integrating strong tracking theory into an unscented Kalman filter for real-time parameter estimation. The fusion framework performs integration of the classifier and observer outputs at data, feature, and decision levels. An adaptive fading factor and recursive
Zhang, Chenhao, Xia, Guang, Zhang, Yang, Zhou, Dayang, Shi, Qin
AI-Powered Intelligent Cognitive Lens for Driver Monitoring for Safe Transportation and Increased Fleet Efficiency Abstract2026-26-06341/16/2026
The rapid evolution of intelligent transportation systems has made drivers’ attentiveness and adherence to safety protocols more critical than ever. Traditional monitoring solutions often lack the adaptability to detect subtle behavioral changes in real time. This paper presents an advanced AI-powered Driver Monitoring System designed to continuously assess driver behavior, fatigue, distractions, and emotional state across various driving conditions. By providing real-time alerts and insights to vehicle owners, fleet operators, and safety personnel, the system significantly enhances road safety. The system integrates lightweight AI/ML algorithms, image processing techniques, perception models, and rule-based engines to deliver a comprehensive monitoring solution for multiple transportation modes, including automotive, rail, aerospace, and off-highway vehicles. Optimized for edge devices, the models ensure real-time processing with minimal computational overhead. Alerts are communicated
Chikhale, Shraddha, Sing, Sandip, Hivarkar, Umesh, Mardhekar, Amogh
Thermal Management and Engine Calibration Strategies for Enhanced Passive DPF Regeneration in CEV Stage V CI Engines2026-26-01411/16/2026
Meeting the stringent emissions norms of CEV stage V for medium BMEP engines, CI engines present significant challenges. These stringent norms call for a highly efficient DPF. With the increasing demands for high-performance DPFs, the issue of soot accumulation and cleaning presents significant hurdles for DPF longevity. This paper explores the potential of passive DPF regeneration, which leverages naturally occurring exhaust gas conditions to oxidize accumulated soot, offering a promising approach to minimize fuel penalty and system complexity compared to active regeneration methods. The study investigates engine calibration techniques aimed at enhancing passive regeneration performance, emphasizing the optimization of thermal management strategies to sustain DPF temperatures within the passive regeneration range. Furthermore, the paper aims to expand the applicability of passive regeneration across diverse engine loads common in off-highway applications with effective passive
Saxena, Harshit, Gandhi, Naresh, Lokare, Prasad, Shinde, Prashant, Patil, Ajit, Raut, Ashish
Integrating Road Load Data Acquisition and Signal Processing Techniques to Generate Reliable Drive Files for Electrodynamic Shakers in Testing the Exhaust Systems of Off-Highway Applications2026-26-05521/16/2026
Generating a reliable drive file for an electrodynamic (ED) shaker from Road Load Data Acquisition (RLDA) and validating its correlation with real-world conditions through damage and fatigue analysis is crucial for accurate component testing, particularly in complex systems like off-highway exhaust systems. This paper presents a methodology for creating such a drive file and establishing its validity, highlighting the necessity of ED shakers for simulating the intricate dynamic loads experienced by these systems. The process begins with acquiring comprehensive RLDA under representative operational conditions of the off-highway vehicle. Drive files are generated using this data, which records accelerations at important exhaust system mounting locations. Advanced signal processing techniques are employed to condense the raw RLDA into a format suitable for shaker control. To establish proper correlation, the generated drive file is used to excite the exhaust system on an ED shaker
Khaire, Santosh Ramdas, Khaire, Rushikesh, Yadav, Dnyaneshwar
Exploring the Effects of Oil Cooler Deletion on Tractor Engine Operation2026-26-05471/16/2026
An optimal engine lubrication system, encompassing engine oil and an oil cooler, is critical for thermal management and minimizing frictional losses. This system ensures adequate lubrication and cooling of engine components, thereby maintaining optimal performance. This study investigates the implications of oil cooler removal in a 45HP inline engine tractor. Various validation trials were conducted, including high ambient temperature tests under worst-case conditions, high coolant temperature scenarios, and a rigorous tractor killer test. In the latter, the tractor underwent 100 hours of operation on a PTO bench at maximum engine RPMs. Despite an observable increase in lubricant oil temperature during these tests, the tractor did not exhibit any component seizure or failure. The findings aim to determine whether the inclusion of an oil cooler is essential for the engine's operational reliability. This research offers valuable guidance for optimizing hardware selection and cost
Gupta, Deepak, Kumar, Pankaj, Singh, Manjinder, Singh, Gagandeep, Kumar, Munish, Singh, Harpreet, Singh, Maninder
Development of Door Impact Loads Using Pedal Force Sensor and First Principles2026-26-05381/16/2026
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 or getting into cab etc. Design of these doors and their latches involve a knowledge of the loads arising when the door is shut which usually involves 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 ~8 times. For these problems, structures
Valkunde, Sangram, Ghate, Amit, Gagare, Kiran
Evaluation of Methods Used to Determine Vehicle Center of Gravity Height2026-26-05131/16/2026
This paper contains theoretical and experimental studies of the measurement accuracies of two methods commonly used by vehicle industries and other stakeholders to determine vehicle center of gravity (CG) height. The two methods, which both appear in international standards, are the Axle Lift method and the Stable Pendulum method. The Stable Pendulum method requires a dedicated swinging platform mechanism*, but it is generally considered to be more accurate than the Axle Lift method. Both methods rely on equations for computing CG height that are based on static balance models of a vehicle tested at various pitch angles. For each method, the accuracy of the resulting CG height computations is a function of the individual measurements needed in the model equations. The individual measurements needed depend on the method used, but they include weights, angles, and distance measurements. A theoretical error analysis study is presented that provides insight into the accuracy of both
Heydinger, Gary, Zagorski, Scott, Bartholomew, Meredith, Andreatta, Dale
Determining Optimal Suspension & Body in White Mountings to maximize Off-Road Capability of Passenger Vehicles2026-26-00981/16/2026
The automotive market trend is shifting more and more to SUVs and crossovers. This, therefore, means increasing consumer demand for off-road abilities in passenger vehicles. While dedicated off-road platforms provide a path to performance robustness, getting the same level of functionality out of a passenger vehicle with minimal architectural changes proves to be a great feat for engineers. One highly critical performance determinant in the domain of off-road ability is wheel articulation, it requires independent movement capacity of the wheels to keep contact and stability over uneven terrain. Traditional articulations found in passenger car suspensions—created for comfort, packaging, and on-road dynamics—are limited by suspension geometry, damper alignment as well as compliance setup. Damper side loads- were not considered a significant factor in suspension systems that are operating within their original intended design envelope for on-road use. However, when the vehicle is taken
Siddiqui, Arshad, Iqbal, Shoaib, Dwivedi, Sushil
A Comprehensive Strategy for Diesel Particulate Filter Calibration to Address the Diverse Applications of Stage V Construction Equipment Vehicles2026-26-01431/16/2026
The legislation of CEV Stage V emission norms has necessitated advanced Diesel Particulate Filter calibration strategies to ensure optimal performance across diverse construction equipment applications in the Indian market. Considering the various duty cycles of cranes, backhoe loaders, forklifts, compactors, graders, and other equipment, different load conditions and operational environments require a comprehensive strategy to enhance DPF efficiency, minimize regeneration frequency, and maintain compliance with emission standards. The DPF, as an after-treatment system in the exhaust layout, is essential for meeting emission standards, as it effectively traps particulate matter. Regeneration occurs periodically to burn the soot particles trapped inside the DPF through ECU management. Therefore, understanding soot loading and in-brick DPF temperature behavior across various applications is key. This paper explores the challenges in DPF calibration for CEV Stage V and provides a
Mohanty, Subham, Chaudhari, Kuldeepak, Patil, Lalit, Mahajan, Atish, Madhukar, Prahlad
Calibration Strategies to Overcome the Challenges for Naturally Aspirated Off-Highway Engines for TREM V Emissions2026-26-02101/16/2026
The transition to TREM V emission norms presents significant challenges for naturally aspirated (NA) off-highway engines. Off-highway applications like construction and agriculture segments require high load variability and extended duty cycles with increased BMEP resulting in high PM emissions, and increased exhaust temperatures with lower lambda levels. Given the cost-competitive nature of the segment, it also requires designing leaner intake and exhaust system. To overcome above mentioned challenges, holistic calibration strategies need to be adapted during development phase. To meet TREM V emission norms, solutions like advanced combustion, high-pressure fuel injection, EGR (exhaust gas recirculation), and optimized calibration had to be explored along with aftertreatment systems like Diesel Particulate Filters and Diesel oxidation catalysts. Implementation of aftertreatment systems for TREM V pre-dominantly with naturally aspirated engines will result in challenges associated to
Patil, Madhavi M., Ravukutam Sr, Aniketh, Raghu, M Y, Madhukar, Prahlad
Monitoring and Diagnosing Software-Defined Vehicle Architectures2026-26-06771/16/2026
Software-Defined Vehicles (SDV) are fostered through initiatives like SOAFEE and Eclipse SDV promoting the use of cloud-native approaches, distributed workloads and service-oriented architectures (SOA). This means that in these systems each vehicle is connected to the cloud and functions are executed both inside the vehicle and in the cloud. So far, there are no established solutions for monitoring and diagnosing SDVs. In designing these solutions, the cost-sensitive nature of every component inside a vehicle must be considered since it makes it unlikely that significant resources will be provided just for diagnostics. Therefore, conventional data centre monitoring approaches that usually rely on transferring large amounts of data to dedicated servers are not directly applicable in this scenario. To illustrate the challenges in providing new solutions for diagnosing and monitoring SDVs, a SOA that has been defined and studied in research projects is introduced. In this architecture
Böhlen, Boris, Fischer, Diana
Key Parameters for Turbocharger Selection & Experimental Validation for off-Highway Applications2026-26-01041/16/2026
Customers in off-highway industry are increasingly seeking high-performance capabilities for their tractors due to increasing penetration of mechanisation and labour scarcity. One effective solution to achieve enhanced performance is turbocharging of engines, while meeting emission and highly dynamic transient response of tractor field applications. The process of selecting and validating a suitable turbocharger for tractor field application suitability is significantly time and resources consuming activity due to extensive testbed and field trials. This study focuses on the selection of turbocharger for tractor engines through analytical calculations to freeze key parameters like lambda, boost pressure ratio & temperature within boundaries of exhaust temperature and turbo efficiency maps to deliver best field transient performance and fuel consumption. The selected parameters are further validated under real-world transient operating conditions, involving tractors and their implements
Kumar, Harish Kumar, Rawat, Saurabh, Dogra, DaljitSingh, Singh, Sachleen, Singh, Amarinder
Stability Prediction and Anti-Roll Control of Off-Road Vehicle Based on Multi-Objective Optimization2025-01-733012/31/2025
Off-road vehicles need to adapt to harsh road environments and wild driving, so their rollover stability is very important. It is of great significance to predict and control the rollover stability of off-road vehicles based on the vehicle's driving state. This paper adopts a prediction method for off-road vehicle stability based on TTR (Time to Rollover), uses the LQR (Linear Quadratic Regulator) multi-objective optimization control method to perform anti-rollover control. Firstly, in view of the rollover risk of intelligent off-road vehicles under extreme road conditions, a three-degree-of-freedom rollover model of the vehicle is established, and a rollover failure index is proposed. Then, based on the TTR, a rollover failure prediction algorithm is developed. Next, the braking force through LQR controller is determined and the differential braking method is adopted for vehicle anti-roll control. Finally, a simulation platform is built based on CarSim and Simulink to simulate and
Hu, Yutao, Ding, Ronghao, Wu, Dongmei, Wang, Jinxiang, Guan, Jie, Chen, Meng
Predictive Control Applied to Antilock Braking Systems of Heavy Vehicles on Deformable Terrain2025-36-000412/18/2025
Antilock braking systems (ABS) are critical to ensuring vehicle safety, particularly in challenging off-road environments where the braking dynamics is highly complex. This study focuses on the development of an advanced ABS controller for heavy off-road vehicles to improve operational safety and reliability. For this purpose, a Model-based Predictive Control (MPC) is proposed. The predictive capabilities of MPC, which optimize control actions based on system dynamics and constraints, are highlighted as a key aspect of this approach. The controlled system is modeled and simulated using a quarter-car model and a deformable ground model, providing a realistic representation of off-road conditions. Comparative simulations are conducted to evaluate the performance of both controllers, focusing on their effectiveness in maintaining stability and improving braking efficiency.
Sawada, Fernando Satoshi, Santos, Luís Guilherme Cavalcante, Rodrigues, Gustavo Simão, Rossi Lopes, Elias Dias
SAE Truck & Off-Highway Engineering: December 202525TOFHP1212/11/2025
Heavy-Payload Conveyance Paves the Way for Next-Generation Battery ManufacturingTBMG-5427912/1/2025
Battery technology is at the center of global innovation. From electric vehicles and off-highway machinery to consumer electronics and grid storage, demand for high-performing, reliable batteries has never been higher. This acceleration creates pressure on manufacturers to scale production while safeguarding quality and throughput.
EDITORIAL: Off-highway innovators help kick off 202625TOFHP12_0412/1/2025
As I'm wont to do come December, with work well underway on the first issue of the new year, I like to take stock of upcoming venues for innovative product reveals and thought-provoking presentations on emerging trends and technologies. Come the first week of January, that means CES in Las Vegas. Traditional equipment manufacturers have increasingly used the event to demonstrate to the broader public that they not only deal in metal but also the digital realm. For example, earlier this year at CES, John Deere revealed its second-generation tech stack featuring camera pods, Nvidia Orin purpose-built processors and Deere's VPUs (vision processing units), along with four new autonomous machines including the 9RX 640 tractor for open-field ag operations. The company is exhibiting again this coming year.
Gehm, Ryan
Stoneridge Innovation Truck envisions a digital-vision future25TOFHP12_0512/1/2025
Stoneridge displayed its vision for the future of commercial vehicle technology on the SAE COMVEC 2025 exhibit floor. The Innovation Truck showcases the Tier 1 supplier's next-generation vision and driver-assistance technologies designed to enhance driver safety and fleet optimization. Mario Gafencu, product design and evaluation specialist at Stoneridge, gave Truck & Off-Highway Engineering a tech truck walkaround at the event. The first technology Gafencu detailed was the second-generation MirrorEye camera monitor system that's designed to replace the glass mirrors on the sides of a truck.
Gehm, Ryan
Simplifying ELECTRIC DRIVELINES25TOFHP12_0212/1/2025
FEV has a solution to downsize and reduce the complexity of off-highway machines via its electrified planetary gearset architecture. IVT Expo 2025 in Chicago featured a summit where industry professionals presented and discussed the nuts and bolts of the technology that powers the off-highway vehicle industry. Electrification continues to be a centerpiece of these discussions, but OEMs and suppliers are beginning to supply answers to many of the questions that this challenge presents. During the expo, several presentations covered the integration of electric powertrains at the component and architecture level. One presented by Thomas Wellman, chief engineer, drivetrain systems, FEV North America, detailed an EPGS (electrified planetary gear-set) off-highway drivetrain architecture that is modular and scalable for a variety of powertrain configurations.
Wolfe, Matt
Cybersecurity: Applying Threat Modeling to Sensor-Control Architectures in Autonomous Off-Highway Vehicles2025-28-031611/6/2025
The rapid evolution of autonomy in Off-Highway Vehicles (OHVs)—spanning agriculture, mining, and construction—demands robust cybersecurity strategies. Sensor-control systems, the cognitive core of autonomous OHVs, operate in harsh, connectivity-limited environments. This paper presents a structured approach to applying threat modeling to these architectures, ensuring secure-by-design systems that uphold safety, resilience, and operational integrity.
Kotal, Amit
Functional Safety of Electric or Hybrid Off-Highway Vehicles – An Embedded Software Viewpoint2025-28-021711/6/2025
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 a way to adopt autonomy of these vehicles to address challenges like skilled labor shortage for timely and efficient execution. Despite the tremendous advantages of electrification, be it through completely replacing engines 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 different standards like ISO 26262, ISO 25119, ISO 13849 can be utilized to achieve state of the art in functional safety for different off
Mujumdar, Chaitanya Gajanan, Bachhav, Kiran, Deshpande, Chinmay
Off-Highway Electrification: A Case Study beyond Propulsion and Emission2025-28-022311/6/2025
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 labour 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
Hybrid Safety Framework for Autonomous Off-Highway Vehicles2025-28-032511/6/2025
The evolution of Autonomous off-highway vehicles (OHVs) has transformed mining, construction, and agriculture industries by significantly improving efficiency and safety. These vehicles operate in high dust, uneven terrain, and potential communication failures, where 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 and it is replacing withdrawn ISO 15998), ISO12100 (Safety of machinery) and ISO25119 (agriculture), ISO 18497 (safety of highly automated agricultural machinery), and ISO/CD 24882 (cybersecurity for machinery).These standards mainly concentrate on the reliability of mechanical and electric/electronic systems
Muthusamy, Sugantha
Cooling System Design Approach for Off-Road Vehicles Using 3D CFD and 1D Tools2025-28-026011/6/2025
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 Analysis (CFA) offer faster solutions in less time, thereby accelerating the product development cycle. Cooling systems are crucial components of off-highway tractor machines, 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
A Methodology to Develop 25-kWh Battery Pack Model with Its Cooling System for Off-Highway Application2025-28-024011/6/2025
This study presents a methodology to develop a new 25kWh battery pack for off-highway application. Initially an enclosure space is extracted from tractor model maintaining minimum space with adjacent components. Based on available space, various combination of cell form factors and different cell chemistries are evaluated considering operating ambient temperature range (-20 to 45 deg C) and charge/discharge rate 1C. Cylindrical NMC type cell with indirect cooling system fulfils all our technical requirements. However, complete battery pack thermal simulation is carried out for ensuring battery pack safety and limited deterioration with different discharge rate and wider temperature range. The battery pack model contains multiple cells, bricks, and modules with numerous coolant pipes and flow channels. Cell characterization experimental data is used for estimating cell thermal capacity and IR behavior. Battery pack model is tested with different Charge/discharge rates. Five
Nain, Ajay, Lamba, Shamsher, jayagopal, S, dhir, Anish
Electric Fan Arrangement and Cooling System Performance Predictions for Off Highway Vehicles2025-28-024111/6/2025
Traditionally, off-highway vehicles like tractors and construction machinery have relied on hydraulic, viscous, or fixed fans to meet the cooling demands of diesel engines. These fans draw power from the engine, impacting fuel consumption and contributing to noise levels that affect operator comfort. Recently, the adoption of electric fans in off-highway applications has increased due to their energy efficiency, lower noise, and flexible design. Electric fans can cool various components, such as radiators and condensers, and can be positioned for optimal performance. They are easily selected from established supplier catalogs based on application requirements like machine voltage, fan size, and type. This study explores various fan arrangements, including pusher and puller types, and multiple electrical fan banking based on cooler zones to improve cooling system performance without changing cooler size or specifications. A mathematical flow model was developed for both setups: the
Durairaj, Renganathan, Dewangan, Nitin, Anand, Ketan, Bhujbale, Sagar
Integrating Self-Hydraulic Jacks Under the Chassis for Off-Road Vehicles, and Utility Task Vehicles2025-28-026411/6/2025
A futuristic vehicle chassis rendered in precise detail using state-of-the-art CAD software like Blender, Autodesk Alias. The chassis itself is sleek, low-slung, and aerodynamic, constructed from advanced materials such as high-strength alloys or carbon-fibre composites. Its polished, brushed-metal finish not only exudes performance but also emphasizes the refined form and engineered details. Underneath this visually captivating structure, a sophisticated system of self-hydraulic jacks is seamlessly integrated. These jacks are situated adjacent to the four shock absorber mounts. These jacks are designed to lift the chassis specifically at the tyre areas, and the total vehicle, ensuring that underbody maintenance is efficient and that, in critical situations, vital adjustments or emergency lifts can be performed quickly and safely. The design also incorporates an intuitive control system where the necessary buttons are strategically placed to optimize driver convenience. Whether
Gogula, Venkateswarlu
Onboard Exhaust Capture and Carbon Sequestration for Off-Highway Vehicles: A Sustainable Approach to Emission Reduction2025-28-021511/6/2025
Off-highway vehicles (OHVs) in sectors such as mining, construction, and agriculture contribute significantly to global greenhouse gas (GHG) emissions, particularly carbon dioxide (CO₂) and nitrogen oxides (NOₓ). Despite the growth of alternative fuels and electrification, diesel engines remain dominant due to their superior torque, reliability, and adaptability in harsh environments. This paper introduces a novel onboard exhaust capture and carbon sequestration system tailored for diesel-powered OHVs. The system integrates nano-porous filters, solid-state CO₂ adsorbents, and a modular storage unit to selectively capture CO₂ and NOₓ from exhaust gases in real time. Captured CO₂ is then compressed for onboard storage and potential downstream utilization—such as fuel synthesis, carbonation processes, or industrial sequestration. Key innovations include: A dual-function capture mechanism targeting both CO₂ and NOₓ Lightweight thermal-regenerative adsorption materials Integration with
Vashisht, Shruti
Ensuring Functional Safety and SOTIF for Autonomous Off-Highway Vehicles: Addressing Risks in Complex Systems2025-28-031511/6/2025
The increasing complexity of autonomous off-highway vehicles, particularly in mining, demands robust safety assurance for Electronic/Electrical (E/E) systems. This paper presents an integrated framework combining Functional Safety (FuSa) and Safety of the Intended Functionality (SOTIF) to address risks in autonomous haulage systems. FuSa, based on ISO 19014[1] and IEC 61508[2], mitigates hazards from system failures, while SOTIF, adapted from ISO 21448[3] addresses functional insufficiency and misuse in complex operational environments. We propose a comprehensive verification and validation (V&V) strategy that identifies hazardous scenarios, quantifies risks, and ensures acceptable safety levels. By tailoring automotive SOTIF standards to off-highway applications, this approach enhances safety for autonomous vehicles in unstructured, high-risk settings, providing a foundation for future industry standards.
Kumar, Amrendra, Bagalwadi, Saurabh
Challenges and Approaches for Cost Estimation of Motors in Off-Highway Electric Vehicles2025-28-021211/6/2025
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
Self-Healing Biodegradable Composites for Off-Highway Vehicles in Extreme Environments2025-28-021111/6/2025
Off-highway vehicles (OHVs) frequently operate in extreme environments—ranging from arid deserts and frozen tundras to dense forests and abrasive mining zones—where structural wear, impact damage, and environmental stress compromise their material integrity. Frequent repairs and component replacements increase operational costs, downtime, and environmental waste, making durability and sustainability key concerns for next-generation vehicle systems. This paper explores a novel class of self-healing biodegradable composites, inspired by biological systems, to address these challenges. The proposed materials combine bio-based resins, microencapsulated healing agents, and shape-memory polymers (SMPs) to autonomously repair microcracks and surface-level damage when triggered by thermal, UV, or mechanical stimuli. The design draws inspiration from natural self-healing systems such as tree bark and reptile skin, replicating their regenerative behavior to enhance structural resilience in OHVs
Vashisht, Shruti
Machine Learning Model for Predicting Transient Jerk Behavior in Knuckle Boom Loaders2025-28-033211/6/2025
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 momentarily lifting occurs when the joystick is moved back quickly, while gradual movements do not trigger this effect. Addressing this problem is crucial for 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 features for
Kamaraj, Keerthi Vallarasu, Bayyavarapu, Chandu, Gotmare, Akash, Pandey, Prashant
Isolation of Engine Vibrations from 3 Cylinder Engines on Off-Highway Machines2025-28-029211/6/2025
The new Stage 5 emission regulation requires several changes on engines as well as design and development of new auxiliary systems. These changes affected the engine dynamics and NVH characteristics. 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 will be used by other machine forms, hence NVH performance needs to be evaluated for all the applications. Isolation of three-cylinder engines is challenging since it has to deal with inherent imbalance forces while providing the isolation to meet the durability requirements of heavy applications from off highway machines. 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
Pawar, Sachin M., Mandke, Devendra Laxmikant, KASABE, SANDEEP, Jadhav, Vijay
PTO Clutch Hydraulic Performance Evaluation Methodology Development & Correlation2025-28-029511/6/2025
This paper presents an analysis methodology developed to comprehend 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 a simulation methodology to replicate the transient behavior of the dynamic 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 appropriate fidelity to accurately replicate the transient behavior and magnitudes of pressure spikes. This
Memane, Nilesh, Kumar, Suneel, Veerkar, Vikrant
Machine Learning Based off-Road Vehicle Turn Identification Using Vehicle & GPS Parameters2025-28-034411/6/2025
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, analysed and used in ML learning model building. Four ML models e.g., SVM, K-NN
Rai, Rohit, Gangsar, Purushottam, Joseph, Roberts, Malik, Manish, Dutta, Mausum, Fapal, Anand
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