Browse Topic: Trucks

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Development of a Diesel Combustion System for Next‑Generation Heavy‑Duty Engines Using a Synergistic Analysis‑and‑Testing Approach2026-37-0004To be published on 06/09/2026
Regulators and policymakers have introduced increasingly stringent limits on tailpipe CO₂ and pollutant emissions to accelerate the decarbonization of heavy-duty vehicle applications. The development of innovative propulsion technologies — such as advanced combustion systems, low-friction reciprocating components, and improved aftertreatment solutions — combined with hybridization and the adoption of alternative fuels (e.g., biogas, HVO, green hydrogen), represents a key pathway for meeting future emission and GHG targets. In this study, advanced combustion systems were developed for a 13‑liter diesel engine for heavy-duty truck applications, with the objective of complying with forthcoming Euro VII regulations while maximizing thermal efficiency. The combustion system architecture—including open-bowl geometry with high aspect ratio, injector nozzle with wider spray opening angle, and reduced swirl ratio—was optimized using a Machine Learning–algorithm trained on high-fidelity 3D CFD
Belgiorno, Giacomo, Centini, Maria Pia, Pezza, Vincenzo, Cozza, Ivan F., Pesce, Francesco C., Vassallo, Alberto, Colombo, Giovanni, Gallo, Alessandro, Mirzaeian, Mohsen, Borg, Jonathan
Integration of energy consumption simulation in optimal charging planning for battery electric long-haul trucks2026-37-0019To be published on 06/09/2026
Vehicle fleet decarbonization is a key objective for the coming years, with electrification representing the primary pathway to achieving the targets set by the European Union. The share of battery electric trucks in new registrations has been gradually increasing especially in light and medium size trucks. The replacement rate of diesel long-haul trucks with zero emission trucks is still low due to challenges posed by added complexity and limitations of battery charging. Depot overnight charging is not sufficient to cover the energy needs of a truck covering large distances and careful planning of the route using public charging infrastructure is crucial for an optimized route minimizing extra costs and range anxiety. The current work aims to develop a methodology to propose the optimal charging locations for a given route of a battery electric truck based on nearby stations along the route. Our study uses an open-source optimization algorithm for the fixed route vehicle charging
Perdikopoulos, Michail, Doulgeris, Stylianos, Livitsanos, Georgios, Kazakis, Thomas, Mellios, Giorgos, Ntziachristos, Leonidas
Thermal Management of Electric Microtruck Motors2026-01-50264/9/2026
This study investigates the gradeability performance of an L7e-class electric micro truck from both vehicle dynamics and thermal perspectives. A 1D simulation model (Amesim) was developed and validated with multiple test results. Using inputs such as motor characteristics, drivetrain configuration, and vehicle mass, the model analyzed vehicle performance on a 20% gradient, calculating the required torque, achievable motor speed, and corresponding vehicle speed. Furthermore, gradeability limits were evaluated, and the effects of gear ratio and airflow rate around the air-cooled motor on both gradeability and thermal behavior were examined. The findings provide practical insights for improving the powertrain and cooling system design of lightweight electric vehicles. The results showed that selecting an appropriate gear ratio can enable the motor to operate more efficiently under demanding driving conditions. A 20% increase in the gear ratio was found to delay motor heating by up to 10
Turan, Azim, Kantaroğlu, Hasan Hüseyin, Akbaba, Mahir, Kasım, Recep Faruk, Yarar, Göktuğ
Novel Air System for 300 kW Heavy Duty Fuel Cell2026-01-04344/7/2026
Hydrogen fuel cell powered vehicles for heavy duty trucking are a promising path for reducing future vehicle emissions due to their reduced mass for storage and faster refueling compared to battery electric trucks. These benefits come at the cost of increased system complexity stemming from the fact that fuel cells generate electricity through a chemical reaction which must be tightly controlled. The air handling system delivers the proper amount of air (oxygen) to react with fuel (hydrogen) in the fuel cell to produce power. Air delivery requires significant power and is the largest parasitic loss for a 300 kW fuel cell. Today’s systems use an electric motor driving an air compressor to supply pressurized air to the fuel cell stack. By operating at elevated pressure levels, fuel cells can achieve higher power density, which is important for vehicle powertrains. In addition to parasitic power loss, hydrogen fuel cell systems often have reliability issues associated with the air
Reich, Evan, Swartzlander, Matthew, Wine, Jonathan, McCarthy, Jr., James, Miller, Eric, Akhtar, Saad, Reddy, Sharan, Lawy, TJ
Accelerating Electrification through Modular Propulsion: GM’S Strategy for BEV and BET Platforms2026-01-04104/7/2026
General Motors (GM) continues to advance its electrification strategy through the development of scalable Battery Electric Vehicle (BEV) and Battery Electric Truck (BET) platforms. This paper highlights GM’s latest BEV and BET products that leverage shared Drive Unit (DU), Rechargeable Energy Storage System (RESS), and integrated power electronic (IPE) components across multiple vehicle programs. By adopting a modular and commonized propulsion architecture, GM achieves significant benefits in manufacturing efficiency, cost optimization, speed to market, and product flexibility. The shared DU, RESS, and IPE components are engineered to meet diverse performance requirements while maintaining high standards of energy efficiency, thermal management, and durability. This approach enables rapid deployment of electrified solutions across various segments, from passenger vehicles to full-size trucks, without compromising on capability or customer experience. The paper outlines the technical
Liu, Jinming, Sevel, Kris, Anwar, Mohammad, Oury, Andrew, Welchko, Brian, Gagas, Brent
Energy Efficiency Analysis of U-Haul Truck and Trailer Systems: Impact of Tongue Weight and Load Variations2026-01-04664/7/2026
The demand for improved energy efficiency in real-world vehicle operations continues to grow with technology enhancement. When transporting large cargo loads with passenger pickup trucks and rental trailers, the interaction between vehicle payload, towing configuration, and fuel consumption becomes a key factor in overall system efficiency. Understanding how towing configurations and trailer loading influence fuel consumption and vehicle performance is critical for both consumer guidance and vehicle system design. This study investigates the energy efficiency of U-Haul truck and trailer systems, with a particular focus on the influence of trailer tongue weight. U-Haul truck and trailer simulation models were developed using AVL Vehicle Simulation Model (VSM) software, with an F-350 engine brake-specific fuel consumption (BSFC) map integrated to represent realistic engine performance. Two configurations with equal payload were evaluated: (1) a U-Haul truck alone, and (2) a U-Haul truck
Wang, Gang, Kathadi, Mohammad, Yang, William, Chen, Yan
Multi-Physics Topology Optimization and Neural Network–Based Design of Experiments for Lightweight Automotive Cast Components2026-01-05104/7/2026
This paper presents a hybrid optimization framework that integrates Multi-Physics Topology Optimization (MPTO) with a Neural Network–surrogated Design of Experiments (NN-DOE) to enable lightweight structural design while satisfying crashworthiness, durability, and noise, vibration, and harshness (NVH) requirements under practical casting and packaging constraints. In the proposed MPTO formulation, crash and durability performances are incorporated through equivalent static compliance measures, while NVH performance is assessed using a frequency-domain dynamic stiffness metric, allowing consistent evaluation of trade-offs among competing design requirements. The framework is first demonstrated using a mass-produced passenger-car lower control arm (LCA) as a benchmark component. In this application, MPTO achieves weight reduction under multi-physics objectives by removing non-load-bearing material. Results show that single-discipline optimization produces unbalanced topologies, while
Kim, Hyosig, Senkowski, Andres, Gona, Kiran, Saroha, Lalit, Boraiah, Mahesh
The Stellantis North America Aero-Acoustic Wind Tunnel Upgrade2026-01-06094/7/2026
The Stellantis North America Aero-Acoustic Wind Tunnel (AAWT) has been upgraded with a cutting-edge 5-belt Moving Ground Plane (MGP) system, featuring an 8.5-meter center belt and four Wheel Spinning Unit (WSU) belts with advanced coatings for durability and visibility. The expanded 9.4-meter turntable enables ±90° yaw and supports vehicles with wheelbases from 1800 mm to 4500 mm and weights up to 5000 kg, accommodating the full Stellantis North America product range. The original 2-stage boundary layer control system was retained, with new tertiary slots added for improved flow quality. A high-stiffness, six-component Horiba balance with integrated calibration weights and tractive force measurement ensures accurate and precise measurements. Facility enhancements include a 550 m2 building addition for equipment and vehicle prep, a dedicated compressor container for clean air supply, and a vehicle underbody wash booth for efficient cleaning. Commissioning confirmed that flow quality
Lounsberry, Todd, Ladouceur, Brent, Fadler, Gregory
Application of Reliability Growth Methods in Conjunction with Design for Reliability Framework to Validate Heavy Truck Design2026-01-01374/7/2026
Why field campaigns in the automotive industry have been going up over the years despite the strong development of technical knowledge, computational design tools and techniques to secure higher reliability standards since early stages of development phases? Uncertainties created by product complexity have been a factor that affects the ability of the manufacturers to prevent design failures before the product launch. Another factor is the shorter product development time, less test time to validate the product means that the new design will not have enough exposure to the real truck application and so some failures may not be able to be detected during the project. To deal effectively with uncertainties this study shows an application of reliability growth techniques in conjunction with DfR- Design for Reliability framework to validate the truck design in the customer application. The Crow - AMSAA method is applied to measure the reliability growth of the complete vehicle in various
Coitinho, Marcos
Physics-Based Simulation for Sustainable Fuels Part 2.1: Inter-Ring Pressure Measurements and 2D/3D Ring Dynamics Analysis across Multiple Engine Platforms – Light Vehicle2026-01-02814/7/2026
The growing demand for sustainable mobility and transportation is accelerating the adoption of alternative fuels, particularly hydrogen, in internal combustion engines. The first part of this publication series highlights the significance of 2D simulation as a crucial and computationally efficient tool for the precise development of hydrogen Power Cylinder Units. This approach demonstrates predictive capability proofed through engine tests, achieving a reduction in lube oil consumption by 5 g/h during high-load operations, alongside a 28% decrease in blow-by and an 11% reduction in hydrogen flow to the crankcase. To provide deeper insights into the complexities identified in Part 1, this study employs inter-ring pressure measurements across various engine types and configurations, including light vehicles, heavy-duty trucks, and large-bore applications, covering a broad range of engine displacements from 2 to almost 100 liters. This investigation in Part 2.1 focuses on understanding
Moreira, Rui, Köser, Philipp, Rösch, Hannes, Ehnis, Holger
Model-Based Development of a Heavy-Duty H 2 -ICE and Integrated, Turbogeneration, Electrification, and Supercharging (ITES) System2026-01-04264/7/2026
Changing global economic conditions and efforts to reduce greenhouse gas emissions are driving the need to develop efficient, near-term, alternative propulsion system technologies for heavy-duty vehicles. This study combines a hydrogen internal combustion engine (H2-ICE) with electrically assisted turbocharging, exhaust energy recovery, and mild hybridization to maximize propulsion system efficiency and reduce NOx emissions. To reduce cost and packaging impact of integration of these technologies on an engine, the study presents a model-based development and optimization of an Integrated Turbogeneration, Electrification, and Supercharging (ITES) system that combines the enabling components into a single compact unit. In the first phase of this study, a H2-ICE and aftertreatment concept for a MY2027 7.7L medium heavy-duty on-road engine was developed and evaluated through 1D simulation. The concept was to convert a diesel engine by changing the cylinder head to implement a port fuel
Bustamante, Oscar, Correia Garcia, Bruno, Joshi, Satyum, Franke, Michael
Techno-Economic Evaluation of Electrified Vehicle Options in Drayage Fleets2026-01-04544/7/2026
The electrification of drayage fleets offers potential economic and operational benefits, but the financial viability of electrified vehicles remains sensitive to battery cost, energy price, and fleet usage patterns. While total cost of ownership (TCO) is a useful benchmark, fleet operators and investors are equally concerned with investment performance metrics such as payback period (PB) and Internal Rate of Return (IRR), which better reflect financial risks and investment return timelines. This study develops a unified techno-economic framework that jointly evaluates TCO, PB, and IRR to determine when electrified trucks become cost-effective alternatives to diesel trucks. Building on a previously developed cost modeling tool and using real-world telematics data from a Class 8 drayage fleet at the Port of Savannah, the analysis incorporates projected battery cost trajectories, electricity and diesel price trends, vehicle efficiency improvements, and multiple battery capacities
Sun, Ruixiao, Sujan, Vivek, Goulet, Nathan, Wang, Qixing
Agile Safety Case Assessments for Autonomous Vehicle Fleets2026-01-05214/7/2026
Rapidly upcoming deployment of autonomous vehicles (AVs), including robotaxis and trucks, has intensified the need for rigorous safety assessment of complex AI-driven systems. While considerable effort has been invested in constructing safety cases for AVs, systematic approaches for evaluating these safety cases remain underdeveloped. This paper presents a three-stage methodology for assessing AV safety cases. A process for assessing argumentation is presented that involves traceability to pre-reviewed and peer-reviewed safety cases such as the Open Autonomy Safety Case (OASC). Next, we present a structured process for evaluating the quality of evidence supporting these arguments. We applied this methodology to evaluate safety cases from multiple AV developers, enabling iterative refinement throughout the development lifecycle. Our agile approach supports efficient assessments by establishing clear traceability to industry standards and enabling early identification of potential gaps
Wagner, Michael
Physics-Based Simulation for Sustainable Fuels Part 2.2: Inter-Ring Pressure Measurements and 2D/3D Ring Dynamics Analysis across Multiple Engine Platforms – Heavy Duty and Large Bore2026-01-02804/7/2026
The growing demand for sustainable mobility and transportation is accelerating the adoption of alternative fuels, particularly hydrogen, in internal combustion engines. The first part of this publication series highlights the significance of 2D simulation as a crucial and computationally efficient tool for the precise development of hydrogen Power Cylinder Units. This approach demonstrates predictive capability proofed through engine tests, achieving a reduction in lube oil consumption by 5 g/h during high-load operations, alongside a 28% decrease in blow-by and an 11% reduction in hydrogen flow to the crankcase. To provide deeper insights into the complexities identified in Part 1, this study employs inter-ring pressure measurements across various engine types and configurations, including light vehicles, heavy-duty trucks, and large-bore applications, covering a broad range of engine displacements from 2 to almost 100 liters. Part 2.1 focuses on understanding the cyclic variations
Köser, Philipp, Moreira, Rui
Camera Monitor System Soiling Correlation for a Class-8 Truck Using Lattice Boltzmann Method2026-01-05964/7/2026
As Camera Monitoring Systems (CMS) become an integrated part of the driving experience for current automotive and heavy vehicles, keeping the CMS clean from water, dirt, sand, snow and ice is a main focus of the design process in order to avoid safety issues due to obscured visibility. On-road soiling prevention becomes an important feature when designing the camera and sensor systems. Computational Fluid Dynamics (CFD) analysis can be used to facilitate the design process, to provide important information of the cause of the problems and design mitigation mechanism to prevent the visibility issues. Most of existing work focusses on automotive applications. This paper is targeted for heavy vehicle application. Road tests were performed in Alaska by the testing department. Results from the road test were compared to CFD simulation. This comparison showed a good agreement between CFD and road testing, based on the qualitative soiling deposition patterns, rivulet formation and dispersed
He, Wei, Dasarathan, Devaraj, Linden, Tom, Park, Jeongbin
Optimization Method for Vehicle Shape to Drastically Reduce Aerodynamic Drag in Heavy-Duty Vehicles2026-01-06034/7/2026
Since air drag is proportional to the square of the speed, it is expected that reducing air drag will significantly improve fuel efficiency for on-highway trucks and buses, which are often driven at high speeds. Therefore, the purpose of this study is to propose an optimization method for vehicle shape to drastically reduce aerodynamic drag in heavy-duty vehicles. Using NSGA-II, one of a genetic algorithm, the overall vehicle shape was optimized with drag coefficient (CD) and lift coefficient (CL) values as objective functions and design variables as parameters in a total of 13 locations. Among the Pareto solutions, an 86% reduction in CD was achieved compared to the base shape when the CD value was the lowest. Since the CL value remains low with this shape, it can be seen that driving stability does not deteriorate. Among the design variables in optimization, it was confirmed that the corner radius of the vehicle side was particularly effective in reducing the CD value. In addition
Kawano, Daisuke
Energy Management Strategy for Hybrid Mining Trucks Based on Global SOC Planning and Neural Network Optimal Control2026-01-04464/7/2026
Hybrid mining trucks, as core equipment for mine transportation, face high energy consumption and significant fluctuations in power demand during cyclic operations due to prolonged exposure to demanding operating conditions characterized by heavy loads and variable working conditions. To address the issues of high energy consumption and significant fluctuations in power demand during the cyclic operation of mining trucks, this paper proposes a hybrid mining truck energy management strategy based on global SOC (State of Charge) planning and neural network optimization control. First, a powertrain model was developed for a typical operating cycle of a hybrid mining truck, and its accuracy was validated by comparing it with experimental data. Using dynamic programming algorithms to plan the SOC for single-cycle operations provides a rational reference for energy allocation across different operational phases of mining trucks during a single cycle. Next, using the powerful nonlinear
Yang, Jianyu, Zhao, Zhiguo, Chen, Huiyong, Li, Tao, Zhuang, Wenyu, Shen, Peihong, Tang, Peng
Energy-Efficient Predictive Cruise Control in Heavy-Duty Electric Trucks with Optimization of the Penalty Factor as a Function of Payload2026-01-00424/7/2026
Heavy-duty Class 8 battery electric trucks not only offer the potential to significantly reduce greenhouse gas (GHG) emissions compared to conventional diesel trucks but can also provide significant savings in fuel costs. To further enhance energy and freight efficiency, Predictive Cruise Control (PCC) algorithms can be developed that generate optimal acceleration profiles for the vehicle by minimizing a cost function which combines both energy consumption and deviation from the desired velocity. A critical component of the cost function is the penalty factor, which governs the tradeoff between energy use and travel time, which are two conflicting objectives in freight logistics. Selecting an appropriate penalty factor is essential, as freight deliveries are time sensitive, but minimizing energy consumption remains a priority. Moreover, variations in payload significantly affect vehicle dynamics and energy usage, making it critical to adapt the penalty factor to different payload
Safder, Ahmad Hussain, Villani, Manfredi, Wang, Eric, Khuntia, Satvik, Nelson, James, Meijer, Maarten, Ahmed, Qadeer
Quantifying the Impact of Towing on BEV Energy Use: Instrumented On Road Testing and Chassis Dynamometer Reproduction2026-01-04314/7/2026
Electrification is rapidly entering all vehicle classes, including light- and heavy-duty trucks designed for heavy towing capabilities. Still, the quantitative impact of towing on battery-electric vehicle (BEV) energy use and range remains under-characterized. We conducted controlled towing tests with a Ford F-150 Lightning using two trailers of different sizes and varying payloads to isolate aerodynamic and mass effects and to span the full range of towable payloads within the vehicle’s rated capacity. The vehicle was instrumented at the CAN bus level, capturing motor power, torque, speed, and related internal signals from different control modules. On-road testing consisted of repeated back-and-forth passes on level, straight road segments at set speeds focusing on highway operation, where aerodynamic drag is stronger and real-world towing use cases occur. From these data, we extracted road load equations and dynamometer coefficients for each trailer combination, then reproduced
Timermans Ladero, Inigo
Sideslip Angle Estimation for Mining Trucks Based on Real-Time Cornering Stiffness Identification2026-01-06184/7/2026
High-precision estimation of key vehicle–road state parameters is crucial for ensuring the accurate and safe control of mining trucks (MT), as well as for reliable trajectory tracking. Among these parameters, the vehicle sideslip angle is particularly critical for assessing and predicting lateral stability. However, its direct measurement is challenging, and its estimation typically depends on an accurate characterization of tire cornering stiffness. For MT, large variations in loading conditions (from empty to fully loaded) pose significant challenges to sideslip angle estimation due to the resulting nonlinearity and variability of tire cornering stiffness. To address this issue, a novel joint estimation framework integrating the Moving Horizon Estimation (MHE) and Square-Root Cubature Kalman Filter (SCKF) is proposed to simultaneously achieve high-precision estimation of both tire cornering stiffness for each tire and vehicle sideslip angle. In this framework, the cornering stiffness
Xia, Xue, Shen, Peihong, Jiao, Leqi, Li, Tao, Chen, Huiyong, Zhao, Kun, Jiao, Leqi, Zhao, Zhiguo
Dual Battery Pack System for Multi-Voltage Electric Vehicle Operation2026-01-03924/7/2026
Electric Vehicles (EV) have become a major focus in the automotive industry. This paper introduces a propulsion system design, which supports the Wide Torque Band (WTB) concept to boost the power density of PM (permanent magnet) motors in EV Trucks resulting in performance, efficiency, and cost benefits. A selectable 400V/800V battery system has been developed to support the WTB concept and enhance the power density of permanent-magnet motors in electric vehicles. The RESS comprises two 400V battery packs that can be charged at 400V in parallel or at 800V in series via a DC fast-charging (DCFC) connection. In this study, an 800V driving mode was additionally implemented. A prototype battery management system (BMS) along with existing production voltage, current and temperature measurement block hardware are applied to perform mode switching, safety, and cell balancing. The success of this dual pack hardware enables high voltage dynamometer testing of a new 800V DU (Drive Unit) and
Zhu, Yongjie, Lee, Chunhao, Gopalakrishnan, Suresh, Namuduri, Chandra
Experimental Evaluation of After-Treatment Solutions for Heavy-Duty Natural Gas Vehicles to Meet Future CNVII Regulations2026-01-03764/7/2026
The heavy-duty truck market in China has seen a significant increase in the adoption of natural gas-powered engines over the past two years. Simultaneously, the anticipated release of the China VII emissions regulation proposal by the end of 2025 is expected to impose stricter emissions limits on all heavy-duty engines, including new particulate number (PN10) thresholds analogous to those in the Euro 7 regulation. While tailpipe oxides of nitrogen (NOx) and methane (CH4) emissions from natural gas engines can be mitigated through tighter lambda control and adjustments to catalyst volume and precious metal (PGM) loading, addressing NOx and particulate number (PN) emissions necessitate more advanced after-treatment solutions. Although natural gas combustion is virtually soot-free, the entrainment of lubricating oil into the combustion chamber, especially during cold-start conditions, poses a challenge, leading to potential exceedance of the proposed future China VII limits. Additionally
Gao, Jiahui, Besch, Marc, Ding, Ning, He, Suhao, Zhao, Yuxin, Yixiao, Li, Shen, Ye
Look-Ahead Information based Predictive Cruise Controller for Energy Efficient Powertrain Operation of Heavy-Duty Electric Trucks2026-01-00394/7/2026
Heavy-duty electric trucks represent a growing innovation in the transport and logistics sector, aiming to reduce emissions and reliance on fossil fuels. A major challenge with battery electric trucks is the long recharging time which takes significantly longer than refueling conventional diesel trucks. This limitation highlights the importance of optimizing powertrain operations to reduce energy losses and maximize efficiency. One effective approach is implementing optimal speed control through a predictive cruise controller. By anticipating road conditions, traffic, and elevation changes, the predictive cruise controller can adjust the truck’s speed in real time to minimize energy consumption, enhancing the range and reducing the need for frequent charging. Many problem formulations for electric trucks focus primarily on minimizing the energy required at the wheels, often overlooking the impact of powertrain efficiencies. This simplification neglects critical factors such as the
Safder, Ahmad Hussain, Villani, Manfredi, Khuntia, Satvik, Nelson, James, Meijer, Maarten, Ahmed, Qadeer
Investigation of the Blockage Phenomenon in Closed Wall Wind Tunnels during the Testing of Bluff Automotive Bodies with Small Wakes in Yawed Configurations2026-01-06074/7/2026
The difficulties of testing a bluff automotive body of sufficient scale to match the on-road vehicle Reynolds number in a closed wall wind tunnel has led to many approaches being taken to adjust the resulting data for the inherent interference effects. But it has been difficult to experimentally analyze the effects that are occurring on and around the vehicle when these blockage interferences are taking place. The present study is an extension of earlier works by the authors and similarly to those studies uses the computational fluid dynamics analysis of five bodies that generate small wakes to examine the interference phenomena in solid wall wind tunnels. This focuses on the effects on the pressures, and forces experienced by the vehicle model when it is in yawed conditions up to 20 degrees. This is accomplished by executing a series of CFD configurations with varying sized cross sections from approximately 0.4% to 14% blockage enabling an approximation of free air conditions as
Gleason, Mark, Riegel, Eugen
Protection of Megawatt-Scale DC Fast Charging Infrastructure for Heavy-Duty Vehicles: Ultra-Fast DC Breaker Development, Testing, and Future Roadmap2026-01-04004/7/2026
Direct Current (DC) fast charging enables supply of megawatt (MW) scale DC power to the large battery systems of Heavy-Duty Electric Vehicles (HDEVs), such as electric trucks, buses, ferry and construction machinery. This contrasts with Alternating Current (AC) charging, which is limited by the capacity of the On-Board Charger (OBC) that converts AC to DC to charge the battery. In DC fast charging, however, the Electric Vehicle Supply Equipment (EVSE) delivers DC power directly to the HDEVs, bypassing the OBC. The feasibility of fast DC charging has been driven by advancements in semiconductor technology offering higher voltage and current handling capabilities as well as improvements in battery energy density. Ongoing research indicates continued growth in both semiconductor power handling and battery storage capacity, further strengthening the case for fast DC charging. Key benefits include significantly higher charging efficiency, drastically reduced charging times, and lower driver
Rahman, Md Rakib-Ur, Dobrzynski, Daniel
BorgWarner to supply integrated drive and generator for EREV trucks26AUTP04_114/1/2026
BorgWarner revealed an integrated drive and generator module optimized for range-extended trucks and large SUVs, a technology many see as the predominant electrified strategy for utility vehicles with the headwinds currently facing the BEV market. The company already has a contract with what it calls a major American automaker to build the model beginning in 2029 for a series of range-extended vehicles.
Clonts, Chris
Analysis and Determination the Time to Rollover of Tractor Semi-Trailer Vehicle Based on Multi-body System Analysis and Newton–Euler Equations02-19-03-00133/27/2026
This article aims to determine the time to rollover (TTR) of a tractor semi-trailer vehicle (TSTV). It uses a full dynamics model for assessment, specifically applying multi-body system analysis and Newton–Euler Equations with a nonlinear tire model. The model is applied to investigate velocities ranging from 40 km/h to 80 km/h and magnitude of steering angles ranging from 12.5° to 300°. The times at which the Load Transfer Ratio (LTR), Roll Safety Factor (RSF), and lateral acceleration reach their maximum values are evaluated. The survey results demonstrate the impact of velocity and steering wheel angle on the time it takes for the LTR, RSF, and lateral acceleration to reach their maximum values. The time interval between the RSF reaching 1 and the LTR reaching 1 range from 0.144 s to 0.655 s. Similarly, the time it takes for the tractor body’s lateral acceleration to peak and the LTR to reach 1 varies between 0.228 s and 1.555 s. Additionally, the time interval from when the semi
Hung, Ta Tuan, Khanh, Duong Ngoc
Anti-Rollover Strategy for Six-Axis Semi-Trailer Based on Lateral Force Balance02-19-04-00242/24/2026
To address the rollover risk of six-axle semi-trailers due to their large mass, high center of gravity, and multi-axle articulation, a lateral force balance anti-rollover strategy based on the Ackermann steering principle is proposed. By establishing the wheel angle constraint equations for the full-wheel steering system of the six-axle semi-trailer, a rigid-body dynamic model considering the articulation characteristics is developed. The key control and observation parameters are included in the wheel angles, center of gravity lateral offset, yaw angular velocity, sideslip angle, and lateral load transfer rate. An SMC-PID joint controller is designed, in which the third axle steering angle of the tractor is optimized by the SMC controller, and the trailer’s three-axle steering angle tracking control is achieved by the PID controller. The nonlinear accumulation of centrifugal force and dynamic load transfer under high-speed emergency lane change conditions is suppressed by a
Zhang, Qiyuan, Zhang, Lei, Liao, Shengkun, Sun, Jinxu, He, Jing
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
Measurement of Light Truck Tire Operating Deflection Shapes Using Scanning Doppler Laser Vibrometry: Issues and Insights10-10-02-00102/10/2026
As internal combustion engines are replaced by quieter electric motors in ground vehicles, noise and vibration sources aside from the powertrain have become relatively more important. This is especially true of tires. Measurement of the dynamic vibratory characteristics of tires is critical to understanding their influence on the noise and vibration performance of vehicles, both outside the vehicle body and inside of it. In this work, the normal modes and operating deflection shapes of a Yokohama Geolander A/T light truck tire are measured using traditional modal analysis techniques as well as a non-contact Scanning Laser Doppler Vibrometry (SLDV) approach. Boundary conditions including free, fixed, loaded, and rotating are implemented to the tire and investigated. Rotating conditions are accomplished in a physical chassis dynamometer environment, with the measured tire mounted on the front axle of a Chevrolet Silverado 1500 pickup truck. Modes of vibration and associated natural
Bastiaan, Jennifer M., Chauda, Gaurav, Baqersad, Javad, Gupta, Arjun, Dhami, Kevalya
Understanding Prevailing Physics in Automotive Aerodynamics Applications—Detached Eddy Simulation vs Reynolds-Averaged Navier–Stokes Approach02-19-04-00232/6/2026
This study presents a structured approach to the aerodynamic evaluation of commercial heavy-duty vehicles by categorizing the underlying flow physics into three primary phenomena: pressure-induced separation, geometry-induced separation, and flow diffusion. Furthermore, the study gives insights into the benefits of Detached Eddy Simulations (DES) over traditional Reynolds-Averaged Navier–Stokes (RANS) approaches by analyzing the flow behavior in cases that correspond to these phenomena. Fundamental insights on pressure and geometry-induced separation were developed through simulations of flow over a sphere and a rectangular cylinder at a Reynolds number of 2.8 × 106. Additionally, flow diffusion was investigated using a coaxial jet interacting with surrounding fluid at a Reynolds number of 2.1 × 104. These cases were analyzed using three turbulence modeling techniques: k-ε, k-ω SST, and DES. To demonstrate the practical relevance of these phenomena, a comprehensive aerodynamic
Sankar, Hari, Holay, Sarang, Ikeda, Masami, Singh, Ramanand
Improving Semi-Truck Torque Overlay Steering Systems to Boost On-Center Performance: Hardware Design Investigation02-19-02-00122/4/2026
In class 8 semi-trucks, the hydraulic steering gear and torque overlay system are critical components affecting the steering feel design and vehicle control. Transitioning from traditional hydraulic gears to hydraulic gears with torque overlay steering (TOS) systems for increased enhancement of driver comfort is beneficial but has also resulted in drawbacks for on-center steer feel, especially at high vehicle speeds (60+ km/h). This article evaluates the impact of three design mechanisms within hydraulic steering gears of a TOS system that have shown improvement in on-center performance for traditional hydraulic gears. The study compares a standard assembly of TOS, i.e., baseline, and a design-optimized ideal prototype, to evaluate the effectiveness of the three design mechanisms: valve curve performance, on-center friction, and torsion bar stiffness. The two samples underwent high-speed vehicle testing to gather driver feedback and assess potential enhancements to the on-center
Bari, Praful Rajendra, Chaudhuri, Nilankan
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
A proactive approach to hydraulic health in Class 8 trucks26TOFHP02_072/1/2026
For any fleet or logistics manager, the specter of a downed Class 8 truck is a constant concern. The costs aren't just in parts and labor; they're in lost productivity, missed deadlines and potential damage to your reputation. While many factors can sideline a heavy-duty vehicle, one of the most persistent and costly culprits is hydraulic system failure. These failures often trace back to a single, preventable issue: contamination.
Lapierre, Luc
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
Accelerating down the road to AUTONOMY26TOFHP02_022/1/2026
Commercial success of the autonomous truck may be closer than we think. The last half decade has brought the best of times and worst of times for the commercial autonomous truck sector. While some perceived pillars of this technology have fallen, others have continued to carry the weight of bringing driverless trucks closer to commercialization. Consolidation was inevitable given the volume of speculative investment that brought a tidal wave of capital to various startups. Even so, some industry experts and Wall Street investors wondered if the autonomous truck sector might collapse entirely.
Wolfe, Matt
Steering Control Systems - Heavy TrucksJ2425_202601 (Current)1/27/2026
This SAE Recommended Practice describes a laboratory test procedure and requirements for evaluating the characteristics of heavy-truck steering control systems under simulated driver impact conditions, as well as driver entry/egress conditions. The test procedure employs a torso-shaped body block that is impacted against the steering wheel.
Truck Crashworthiness Committee
Pre-Crash Characteristics of Motorized Two-Wheeler Crashes on Indian Roads2026-26-00341/16/2026
India has emerged as the world’s largest market for motorized two-wheelers (M2Ws) in 2024, reflecting their deep integration into the country’s transportation fabric. However, M2Ws are also a highly vulnerable road user category as according to the Ministry of Road Transport and Highways (MoRTH), the fatality share of M2W riders rose alarmingly from 27% in 2011 to 44% in 2022, underlining the urgency of understanding the circumstances that lead to such crashes. This study aims to investigate the pre-crash behavior and crash-phase characteristics of M2Ws using data from the Road Accident Sampling System – India (RASSI), the country’s only in-depth crash investigation database. The analysis covers 3,632 M2Ws involved in 3,307 crash samples from 2011 to 2022, representing approximately 5 million M2Ws nationally. Key variables examined include crash configuration, collision partner, road type, pre-event movement, travel speed, and human contributing factors. The study finds that straight
Govardhan, Rohan, Padmanaban, Jeya, Jethwa, Vaishnav
Safer Trucks for India: Smart Tech Fusion2026-26-00311/16/2026
Commercial vehicle sector (especially trucks) has a major role in economic growth of a nation. With improving infrastructure, increasing number of trucks on roads, accidents are also increasing. As per RASSI (Road Accident Sampling System India) FY2016-23 database, commercial vehicles are involved in 42% of total accidents on Indian roads. Involvement of trucks (N2 & N3) is over 25% of total accidents. Amongst all accident scenarios of N2 &N3, frontal impacts are the most frequent (26%) and causing severe occupant injuries. Today, truck safety development for frontal impact is based on passive safety regulations (viz. front pendulum – AIS029) and basic safety features like seatbelts. In any truck accident, it is challenging rather impossible to manage comprehensive safety only with passive safety systems due to size and weight. Accident prevention becomes imperative in truck safety development due to extremely high energy involved in front impact scenarios. The paper presents a unique
Joshi, Kedar Shrikant, Gadekar, Ganesh, Date, Atul, Koralla, Sivaprasad
Optimizing Powertrain Performance a Customer Usage-Centric Approach2026-26-00671/16/2026
The US trucking industry heavily relies on the diesel powertrain, and the transition towards zero-emission vehicles, such as battery electric vehicles (BEV) and fuel cell electric vehicles (FCEV), is happening at a slow pace. This makes it difficult for truck manufacturers to meet the Phase 3 Greenhouse Gas standards, which mandate substantial emissions reductions across commercial vehicle classes beginning of 2027. This challenging situation compels manufacturers to further optimize the powertrain to meet stringent emissions requirements, which might not account for customer application specifics may not translate to a better total cost of ownership (TCO) for the customer. This study uses a simulation-based approach to connect customer applications and regulatory categories across various sectors. The goal is to develop a methodology that helps identify the overlap between optimizing for customer applications vs optimizing to meet regulations. To use a data-driven approach, a real
Mohan, Vignesh, Darzi, Mahdi
Drive Cycle Type Identification Using Data Driven Methodologies2026-26-06491/16/2026
Identifying the type of drive cycle is crucial for analyzing customer usage, optimizing vehicle performance and emission control. Methods that rely on geographical location for drive cycle identification are limited by varying driving conditions at the same location (e.g. heavy traffic during peak hours vs. free-flowing traffic at night). This paper proposes a methodology to identify the type of drive cycle (city, interurban, highway or hybrid) using drive characteristics derived from vehicle data rather than geographical location. Real-world vehicle data from testing trucks is taken, whose drive profiles are already known. Initially, multiple characteristic features of the drive cycle are identified from literature surveys and domain experience. These features, which can be extracted from basic signal data, include gear shifts, time spent in different driving modes (acceleration, cruise, standstill), velocity distributions, and an 'aggressiveness factor' representing overall driving
Reddy, Mallangi Prashanth, Gorain, Raju, Ganguly, Gourav
Analysis of Door Seal Compression and its Influence on NVH Performance in Heavy-Duty Vehicle2026-26-03391/16/2026
This study focuses on the effect of door seal compression prediction and its impact on structure borne NVH in trucks. Customer perception of vibrations are envisaged as quality criteria. It is necessary to determine the contribution of seal stiffness due to seal compression under closed condition of the door rather than considering stiffness of the door seal under uncompressed conditions. The dynamic stiffness of door seal is determined from analysis of non-linear type. The simulations are built using the Mooney - Rivlin model. The parameters influencing the compression of door seals in both two – dimension and three – dimension, are identified from the analysis. This involves contemplating the appropriate seal mounted boundary condition on the body and the door of the vehicle. The stiffness after compression of seal is extracted from this non-linear analysis which is further used to obtain the vibration modes for the doors in the truck cabin. As a part of next step, the compressed
L, Kavya, Ramanathan, Vijay
Mobility Within Mines: Harmonization of Safety Requirements for Underground Mining Trucks in India2026-26-01401/16/2026
The need for energy is ever increasing, though the dependency on renewable energy have increased, it is not sufficient to cater the demand. India is one of fastest developing country which depends on coal 55% for its total energy need. To achieve coal digging & transportation an underground mining vehicle has gained high importance. Underground mine environment is inherently dangerous due to various factors, including explosive and toxic gases, dust, and the potential for collapses. Thereby vehicles running in coal mines requires extreme safety features to safeguard its operator & coal mine workers. In India the Directorate General of Mines Safety (DGMS) under Government of India circulates notification to Manager of Coal and Metalliferous Mines & OEM, concerned about the minimum safety evaluations to be taken care for the mining trucks. It has been observed that there are significant inconsistencies in design practices for mining vehicles, with the presence of multiple, unverified
Babar, Sagar, Akbar Badusha, A
Mileage Accumulation Target Identification for Autonomous Emergency Braking System Validation for Medium & Heavy Trucks Considering Real-World Accidents in India2026-26-00361/16/2026
Robust validation of Advanced Driver Assistance Systems (ADAS) considering real-world conditions is a vital for ensuring safety. Mileage accumulation is a one of the validation method for ensuring ADAS system robustness. By subjecting systems to diverse real-world driving environments and edge-case scenarios, engineers can evaluate performance, reliability, and safety under realistic conditions. In accordance with ISO 21448 (SOTIF), known hazardous scenarios are explicitly tested during robustness validation in combination of virtual and physical testing at component, sub system and vehicle level, while unknown hazards may emerge through extended mileage by running vehicles on roads, allowing them to be identified and classified. However, defining a mileage target that ensures comprehensive safety remains a significant engineering challenge. This paper proposes a data-driven approach to define mileage accumulation targets for validating Autonomous Emergency Braking Systems (AEBS
Koralla, Sivaprasad, Ravjani, Amin, Tatikonda, Vijay, Gadekar, Ganesh
Auto Braking System for Preventing Commercial Vehicle Overloading2026-26-00321/16/2026
Overloading in vehicles, particularly trucks and city buses, poses a critical challenge in India, contributing to increased traffic accidents, economic losses, and infrastructural damage. This issue stems from excessive loads that compromise vehicle stability, reduce braking efficiency, accelerate tire wear, and heighten the risk of catastrophic failures. To address this, we propose an intelligent overloading control and warning system that integrates load-sensing technology with real-time corrective measures. The system employs precision load sensors (e.g., air below deflection monitoring via pressure sensors) to measure vehicle weight dynamically. When the load exceeds predefined thresholds, the system triggers a multi-stage response: 1 Visual/Audio Warning – Alerts the driver to take corrective action. 2 Braking Intervention – If ignored, the braking applied, immobilizing the vehicle until the load is reduced. Experimental validation involved ten iterative tests to map deflection-to
Raj, Amritesh, Pujari, Sachin, Londhe, Mahesh, Shirke, Sumeet, Shinde, Akshay
Electroluminescent Coating Systems for Heavy-Duty Trucks: Advancing Safety and Sustainability through Smart Surface Technology2026-26-02751/16/2026
As the transportation industry pivots towards safer and more sustainable mobility solutions, the role of advanced surface technologies is becoming increasingly critical. This paper presents a novel application of electroluminescent (EL) coating systems in heavy-duty trucks, exploring their potential to enhance vehicular safety and reduce environmental impact through lightweight, energy-efficient lighting integration. Electroluminescent coatings, capable of emitting light uniformly across painted surfaces when electrically activated, offer a transformative alternative to conventional external lighting and reflective materials. In the context of heavy-duty trucks, these systems can significantly improve visibility under low-light and adverse weather conditions, thereby reducing the risk of road accidents. Furthermore, the uniform illumination achieved without bulky fixtures contributes to aerodynamic efficiency, supporting fuel economy and reducing carbon emissions. use of this coating
Harel, Samarth Dattatraya, Borse, Manoj, L, Kavya
Design and Development of a Lightweight Aluminium Cascade System for Type IV COPVs for Stationary and Mobile Applications2026-26-04851/16/2026
The global push for clean energy has made hydrogen a central element in decarbonizing transport, industrial processes, and energy systems. Effective hydrogen storage and distribution are critical to supporting this transition, and type IV Composite Overwrapped Pressure Vessels (COPVs) have emerged as the preferred solution due to their lightweight, high pressure capacity, hydrogen embrittlement and corrosion resistance. However, the cascade infrastructure used to house and transport these vessels has lagged behind in innovation. Steel-based cascades, while strong, are heavy prone to corrosion, and unsuitable for mobile deployment. This paper introduces a custom designed aluminium cascade system offering a 65% weight reduction while maintaining structural integrity and safety. Designed for mobile use, the system features modularity, better damping, and enhanced corrosion protection. The paper outlines design methodology, material selection, fabrication process, and comparative
Parasumanna, Ajeet Babu, Muthusamy, Hariprasad, Ammu, Vnsu Viswanath, Kola, Immanuel Raju
Structural Analysis and Design Optimization of Cylinder Head of Cummins Light Duty Engine for Medium Wheelbase (MWB) Pick-Up Truck2026-26-04951/16/2026
This paper presents the design, structural analysis, structural test validation and risk assessment done by Cummins to evaluate the structural integrity of Light Duty engine cylinder head for a Medium Wheelbase (MWB) pick-up truck. Initially, Cummins used the 2.5L and 3.0L (4-cylinder) engines that have standard power ratings based on existing requirements, but rising market demands for more power, fuel efficiency, lower cost and weight, and future emission compliance led to customer requirements for 15% uprate for 2.5L and 22% uprate for 3.0L from the same base engine. The increase in power requirement possesses challenges on critical components, especially cylinder heads in terms of thermal and structural limits. Multiple analysis led design iterations were performed using cutting edge CAE software such as Ansys, Dassault Systems fe-safe, and PTC Creo to ensure the structural integrity of the cylinder head under high thermal and mechanical loads, and to keep design margins within
Pathak, Arun Jyoti, Adiverekar, Vaidehi, Singh, Rahul, Biyani, Mayur
Waste Heat Recovery Evaluation in FCEV Truck on Different Drive-Cycles2026-26-02591/16/2026
Growing global warming and the associated climate change have expedited the need for adoption of carbon-neutral technologies. The transportation sector accounts for ~ 25 % of total carbon emissions. Hydrogen (H2) is widely explored as an alternative for decarbonizing the transport sector. The application of H2 through PEM Fuel Cells is one of the available technologies for the trucking industry, due to their relatively higher efficiency (~50%) and power density. However, at present the cost of an FCEV truck is considerably higher than its diesel equivalent. Hence, new technologies either enabling cost reduction or efficiency improvement for FCEVs are imperative for their widespread adoption. FCEVs have a system efficiency around 40-60% implying that around half of the input energy is lost to the environment as waste heat. However, recapturing this significant amount of waste heat into useful work is a challenge. This paper discusses the feasibility of waste heat recovery (WHR
P V, Navaneeth
Performance Evaluation and Optimization of Engine Brake System using Chassis Dynamometer2026-26-05111/16/2026
Engine braking is a deceleration technique that leverages the internal friction and pumping losses within the engine. By closing the throttle and potentially selecting a lower gear, the engine creates a retarding force that slows the vehicle. This practice contributes to better fuel economy, decreased brake system load, and improved vehicle handling in specific driving scenarios, such as steep declines or slippery road surfaces. To alleviate stress on their primary braking systems and prevent overheating, heavy vehicles frequently incorporate engine-based braking. While older trucks relied on simple exhaust brakes with a butterfly valve to restrict exhaust flow, these had limited impact. Hence contemporary heavy vehicles almost exclusively use more advanced engine braking technologies. Traditionally, our heavy-duty vehicles use Exhaust brake system to elevate the braking performance on hilly terrains. Hence an improved sample of Engine brake was developed for enhanced braking
M, Vipin Prakash, Rajappan, Dinesh Kumar, R, Suresh, N, Gopi Kannan
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