Browse Topic: Off-highway vehicles and equipment

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Backward Fuzzy Driving Control for 6×4 Off-Road Vehicles2026-01-0148To be published on 04/07/2026
Offroad 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 6x4 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 6x4 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 6x4 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, Sam, Patterson, Albert, Sreenivas PhD, Ramavarapu, Norris, William, Soylemezoglu PhD, Ahmet, Nottage PhD, Dustin
Optimizing Custom Hybrid Solutions for Low-Volume Specialist Equipment2026-01-0479To be published on 04/07/2026
Off-road vehicles are typically powered by diesel engines, sized to cover the highest peak loads in their dutycycles. Such engines can be downsized, using hybridization to supplement engine power for short periods. However, many applications are low-volume and specialized, making it impractical to deploy heavy engineering resources to optimize every 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. It also introduces a simulation tool to benefit OEMs who seek to provide custom low-volume vehicles based on common platforms. The simulation tool is a fast, low-cost, cloud-based software package under development at ZeBeyond, provisionally named "ePop Cloud". It allows many different architectures to be evaluated rapidly at the product planning stage, and can be quickly set up and used by engineers who are not specialists in simulation. An
De Salis, Rupert, Fons, Daniel
Impact of Hydrogen on Methane and Pollutant Emissions over Three-Way Catalysts with Natural Gas–Hydrogen Blends2026-01-0357To be published on 04/07/2026
Natural gas (NG) is a domestically abundant, low-cost fuel with the potential to displace gasoline and diesel fuel in commercial and off-road vehicles. NG engines typically produce lower engine-out pollutant emissions, such as NOx, CO and particulate matter, which could simplify emission control systems. Blending NG with hydrogen (H₂) can improve engine performance and increase combustion efficiency to further reduce engine-out emissions. Additionally, the presence of H2 in the exhaust stream may also facilitate 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
Prikhodko, Vitaly, Wang, Min, Park, Yeonshil, Chen, Hai-Ying, Pihl, Josh
Methodology for generating off-road tracks for powertrain simulation of off-road passenger vehicles2026-01-0275To be published on 04/07/2026
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 an over-dimensioning and high powertrain
Martin, Michael, Winkelheide, Jonas, Hartmann, Lukas, Sturm, Axel, Henze, Roman
Hybrid Prediction Model of Wheel-Traction Force on Soft Soil Based on High-Precision Contact Angle2026-01-0594To be published on 04/07/2026
Traction force plays a critical role in the design of off-road vehicles and the evaluation of terrain trafficability. The accuracy of the traditional Bekker-Wong semi-empirical formula for predicting wheel traction force depends on the precision of parameters such as the entry contact angle, departure contact angle, and maximum stress angle. However, the calculation of these angles is often influenced by multiple empirical factors, which significantly reduces the accuracy of traction force prediction.To improve prediction accuracy, this study proposes a hybrid traction force prediction method that integrates Abaqus simulation with a semi-empirical model. First, a wheel-soil interaction simulation model was established in Abaqus using the FEM-SPH coupling method. Then, computer vision-based image feature extraction techniques were applied to process the simulation result contours, obtaining accurate values for the entry contact angle, departure contact angle, and maximum stress angle
Cao, Ruibin, Wang, Kaidi, Shen, Yanhua, Liu, Zuyang
Clustering-Based Segmentation of Off-Road Vehicle Activity into Productive and Non-Productive States from GPS Data2026-01-0169To be published on 04/07/2026
Accurate identification of Productive and Non-Productive States or Off-Road vehicle duty cycles—comprising working, idle, and transport states—is critical for performance analysis, fuel optimization, and emissions modeling in agriculture machinery and fleet operations. This study explores the application of unsupervised machine learning 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 labeled datasets, making it scalable and adaptable across diverse operational contexts. Clustering algorithms, including K-means and DBSCAN, are 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. Validation against manually annotated datasets demonstrates high accuracy in distinguishing idle, working, and transport phases. The
Maharana, Devi prasad, Gangsar, Purushottam, Dharmadhikari, Nitin, Pandey, Anand Kumar
A Novel Power-Split Hybrid Electric Architecture for Off-Road Tracked Vehicles: Design and Performance Evaluation.2026-01-0258To be published on 04/07/2026
Tracked off-road vehicles operate at low speeds with high tractive effort and frequent skid-steer maneuvers, conditions that push torque and power demand to extremes and exacerbate powertrain efficiency losses. Electrification can improve energy conversion and mobility for such duty cycles. This paper introduces a novel power-split hybrid electric architecture for a tracked vehicle and benchmarks it against three designs: a conventional mechanical driveline, a series hybrid, and a P2 parallel hybrid. To enable fair, architecture-agnostic comparisons, a supervisory controller based on Stochastic Dynamic Programming (SDP) schedules engine operation and power flow across all layouts under representative off-road scenarios, including skid-steer events, with varying terrain and power-demand profiles. Results show higher energy conversion efficiency (lower fuel use) for the proposed power-split architecture, followed by the parallel, then series, and lastly conventional configuration across
Ghate, Atharva, Sundar, Anirudh, Zhu, Qilun, Prucka, Robert, Figueroa-Santos, Miriam, Barron, Morgan, Castanier, Matthew P.
Simulating Cryptographic Primitives in Model Based Systems Engineering Projects2026-01-0083To be published on 04/07/2026
Security has become an increasingly critical concern for large off-road vehicle manufacturers due to the growing threats posed by hackers, heightened awareness around data privacy, the implementation of anti-tamper technologies, and stringent emissions regulations. These pressures necessitate the development of robust security measures that can effectively safeguard vehicle systems while promoting responsible and sustainable innovation. To address these challenges, cybersecurity teams and engineers can leverage tools such as Model-Based Systems Engineering (MBSE), which facilitates the rapid and cost-effective development of comprehensive security mechanisms. This paper explores the application of systems engineering techniques to create a solution for ensuring integrity and authenticity in Controller Area Network (CAN) systems, which are commonly utilized in heavy-duty diesel engines. The deployment of solutions to secure the CAN bus will likely depend on cryptography. However
DiValentin, Maria, Daily, Jeremy
Design and Development of a PWM Generator with Integrated Power Supply for BSVI / BSVII Dosing system2026-01-0365To be published on 04/07/2026
A Direct leap from BSIV to BSVI in 2020 necessitated rapid adaptation by automakers and fuel suppliers. New regulatory standards on engine pollutant emissions have expanded the engine operating conditions subjected to type approval tests, aiming to bridge the gap between regulated and real-driving emissions. The BSVI dosing system, comprising supply and dosing units, is integral to the aftertreatment systems for both on-highway and off-highway applications. This system is crucial for meeting BSVI norms by providing the necessary flow and pressure. Before market introduction, this system must undergo various validation processes. Traditionally, the system relies on a controlled modulated input signal and a closed-loop feedback system developed by manufacturer software. However, this setup was complex, bulky, and requires manual intervention during lab testing validation. To enhance this system, we developed an automated PWM generator with an integrated power supply that dynamically
Chavan, Amit, Rath, Jagannath Prasad, Magar, Vijay, JAHAGIRDAR, RADHIKA
Structural Redesign and Functional Integration of an Electrohydraulic Brake Valve for Enhanced Performance and Manufacturability2026-28-0002To be published on 02/12/2026
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
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
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
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
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
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
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
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
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
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
DPF Passive Regeneration Approach for CEV/TREM-V Off-Highway Applications2026-26-02111/16/2026
With introduction of Diesel Particulate Filter to achieve CEV/TREM V Emission Limits for off-highway segment, there is a requirement of DPF regeneration at defined intervals depending on time of operation and soot loading in DPF. This can be achieved by two methods. First is the frequent regeneration or Active regeneration, wherein fuel is injected before DOC (Diesel Oxidation Catalyst) at specific temperature to burn the soot in the DPF. The second method is the continuous or Passive regeneration, where soot is burnt based on NO2. DPF frequent regeneration (Active Regeneration) requires soot load estimation in DPF over entire engine operation range as well as vehicle operation in different climatic conditions. Frequent regeneration leads to oil dilution and penalty in the fuel consumption. More frequent regeneration promotes the chemical aging of DOC, leading to the poor performance of DOC which results in deteriorating performance of SCR(Selective Catalytic Reduction) situated
Sharma, Rakshit, Garg, Varun, Dhiman, Nitish, Grauenfels, Attila
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
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
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
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.
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
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
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
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
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
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
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
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
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
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
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
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
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
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
Connected Aftermarket Services for Off-Highway Vehicles: Enhancing Fleet Management Through Real-Time Data and Predictive Maintenance2025-28-030711/6/2025
Off-highway vehicles (OHVs) are essential in heavy-duty industries like mining, agriculture, and construction, as equipment availability and efficiency directly affect productivity. In these harsh settings, conventional maintenance plans relying on set intervals frequently result in either early component replacements or unexpected breakdowns. This document presents a Connected Aftermarket Services Platform (CASP) that utilizes real-time data analysis, predictive maintenance techniques, and unified e-commerce functionalities to evolve OHV fleet management into a proactive and smart operation. The suggested system integrates IoT-enabled telematics, cloud-based oversight, and AI-powered diagnostics to gather and assess machine health indicators such as engine load, vibration, oil pressure, and usage trends. Models for predictive maintenance utilize both historical and real-time data to produce advance notifications for component failures and maintenance requirements. Fleet managers get
Vashisht, Shruti
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
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
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
Customer Support – Failure and Warranty Analysis in Off-Highway Vehicles2025-28-030011/6/2025
The reliability and durability of off-highway vehicles are crucial for industries like construction, mining, and agriculture. Failures in such machines not only disrupt operations but can also lead to significant economic losses and safety concerns. Effective failure and warranty analysis processes are essential to improve customer support, minimize downtime, and enhance equipment life cycle. This paper outlines a comprehensive 7-step failure analysis methodology tailored for off-highway vehicles, accompanied by warranty analysis using Weibull, 6MIS, and 12MIS IPTV. It details the process from problem identification through permanent solution implementation, emphasizing tools and techniques necessary for sustainable improvements. The structured approach provides an actionable blueprint for OEMs and service teams to enhance customer satisfaction, support sustainable development goals, and maintain regulatory compliance.
Mulla, Tosif, Thakur, Anil, Tripathi, Ashish
Decarbonizing Off-Highway Vehicles: Fuel Alternatives and Implementation Strategies2025-28-023011/6/2025
Off-Highway Vehicles (OHVs) — including mining trucks, construction machinery, and agricultural equipment — contribute significantly to greenhouse gas (GHG) emissions and local air pollutants due to their dependence on fossil diesel. Achieving sustainable development goals in off-highway sectors requires transitioning toward alternate fuels that can reduce CO₂, NOₓ, and particulate matter (PM) emissions while maintaining performance and reliability. This paper comprehensively evaluates alternate fuels such as biodiesel, renewable diesel, compressed and liquefied natural gas (CNG/LNG), liquefied petroleum gas (LPG), hydrogen, and alcohol-based blends. Using insights from Service Bulletins, fuel standards, and the Worldwide Fuel Charter, it discusses fuel properties, engine compatibility, operational challenges, sustainability impacts, economic feasibility, safety considerations, and regulatory aspects. Case studies of alternate fuel deployment in OHVs illustrate practical challenges and
Mulla, Tosif, Thakur, Anil, Tripathi, Ashish
Virtual Load Sensor Methodology for Structural Verification2025-28-026911/6/2025
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 often necessitate custom load transducers during data collection. However, instrumenting
Zalte, Swapnil Suresh, S Kulkarni, Prasad, Gupta, Shikha, Aundhe, Abhijeet, Darade, Shubham
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