Browse Topic: Trucks

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Introduction to Catesby Aero Research Facility, CARF, the coast-down tunnel proving ground.2026-01-0611To be published on 04/07/2026
This paper reports on the Catesby Aero Research Facility (CARF), which began commercial use in 2019, and provides an overview of the facility and related technologies, particularly details on the vehicle-mounted component force measurement devices. CARF is a proving ground that was renovated from a former railway tunnel approximately 2.74km long and is now covered with high-quality tarmac. The road surface quality was designed to be at least as good as that of SUBARU's proving ground, and the standards were achieved using British construction technology. The course is almost straight, but there is a slight incline. The course specifications are: blockage 40m2, road width 6m (maximum 8.4m), flatness σ<0.5mm, and gradient 0.57%.In particular, compared to outdoor coastdown trucks, its overall length allows for continuous measurement right up to the stop, giving it a significant advantage in repeatability.At the same time, Subaru's newly developed six-component force sensor built into the
Shimoyama, Hiroshi
26M-00552026-01-0603To be published on 04/07/2026
Since air drag is proportional to the square of the speed, it is expected that reducing air drag will significantly improve fuel efficiency for long-distance trucks and buses, which are often driven at high speeds. Therefore, the purpose of this study is to propose a conceptual shape that will dramatically improve the aerodynamic performance of heavy-duty vehicles, assuming that restrictions on overall length will be relaxed in the future. Using NSGA-II, a genetic algorithm, the overall vehicle shape was optimized with the objective functions CD and CL values and design variables as parameters in a total of 13 locations. Among the Pareto solutions, CD = 0.08 was obtained 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, when
Kawano, Daisuke
Camera Monitor System Soiling Correlation for a Class-8 Truck Using Lattice Boltzmann Method2026-01-0596To be published on 04/07/2026
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 these 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. There are many published papers for soiling studies for the automotive application but very limited publication available for heavy trucks, this paper is targeted to fill this space. In these current studies during a design process, road tests were performed in Alaska by the testing department. Correlation was done between those road tests and the CFD analysis, performed in-house. This
He, Wei, Dasarathan, Devaraj, Linden, Tom, Park, Jeongbin
Hydrogen Propulsion for Heavy Commercial vehicle Applications in India : A Quality-Driven Approach from Tata Motors2026-01-0144To be published on 04/07/2026
As the global commercial vehicle sector searches for innovation in propulsion technologies that deliver sustainability and zero tail pipe emissions, hydrogen (H₂) mobility is gaining momentum—especially in heavy duty segments where battery electric drivetrains still face constraints. Tata Motors, recognized in India for its pioneering work in commercial vehicles, has launched an ambitious programme to engineer hydrogen powered solutions custom built for the nation’s heavy trucks and buses that underpin logistics and infrastructure. This paper outlines Tata Motors’ structured approach on ‘Failure mode avoidance’ for a safe and reliable H₂ propulsion, anchored in the ‘Quality by Design’ approach through Design Failure Mode and Effects Analysis (DFMEA) at a very early stage. Every critical vehicle system and sub-system—storage, fuel delivery, control and the propulsion unit itself—is subjected to DFMEA at the concept stage so that potential risks are detected and addressed before vehicle
Giri, Debabrata, Biswas, Kaushik, Saji, Amal
Novel Air System for 300 kW Heavy Duty Fuel Cell2026-01-0434To be published on 04/07/2026
Hydrogen fuel cell powered vehicles for heavy duty trucks is a potential path for reducing heavy duty vehicle emissions in the future. 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 to power an air compressor that supplies oxygen to the fuel cell stack. In addition to parasitic power loss, hydrogen fuel cell systems often have reliability issues associated with the air handling system. Reliability is of significant concern for heavy duty applications (especially long-haul applications). This project aims to improve both the electrical power consumption and reliability of hydrogen fuel cell air handling systems to meet the needs of heavy duty on-highway vehicle applications. The air handling is provided by a twin vortices series (TVS) compressor in addition to adding a
Reich, Evan, Swartzlander, Matthew, Wine, Jonathan, McCarthy, James, Miller, Eric, Akhtar, Saad, Reddy, Sharan, Lawy, TJ
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 Bore2026-01-0280To be published on 04/07/2026
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 5–7 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
Quantifying the Impact of Towing on BEV Energy Use: Instrumented On Road Testing and Chassis Dynamometer Reproduction2026-01-0431To be published on 04/07/2026
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 across the vehicle’s rated towing capacity. The vehicle was instrumented at the CAN bus level to capture motor power, torque, speed, and other related internal signals. 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 equivalent conditions on a four-wheel drive chassis dynamometer
Timermans Ladero, Inigo
Model-based Development of a Heavy-Duty H2-ICE and Integrated, Turbogeneration, Electrification, and Supercharging (ITES) System2026-01-0426To be published on 04/07/2026
Changing global economic conditions and efforts to reduce greenhouse gas emissions to reduce their impact on climate and public health is driving the need to develop alternative technologies to meet the demands of heavy-duty vehicles and increase propulsion system efficiency. This study combines a Hydrogen internal combustion engine (H2-ICE) for its near zero CO2 emissions capability, with electrically assisted turbocharging, exhaust energy recovery, and mild hybridization to maximize propulsion system efficiency in real-world driving. The focus is on model-based integration and optimization of a technology package termed as the Integrated, Turbogeneration, Electrification, and Supercharging (ITES) system to demonstrate its potential for low emissions, high efficiency, and reduced cost will be demonstrated. In a previous 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
Bustamante, Oscar, Correia Garcia, Bruno, Joshi, Satyum, Franke, Michael
Energy-Efficient Predictive Cruise Control in Heavy-Duty Electric Trucks with Optimization of the Penalty Factor as a Function of Payload2026-01-0042To be published on 04/07/2026
Heavy-duty Class 8 battery electric trucks not only offer a significant reduction in greenhouse gas (GHG) emissions compared to conventional diesel trucks but can also provide significant savings in fuel costs. To further enhance the 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 trade-off 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 conditions
Safder, Ahmad Hussain, Villani, Manfredi, Wang, Eric, Khuntia, Satvik, Nelson, James, Meijer, Maarten, Ahmed, Qadeer
Physics-Based Simulation for Sustainable Fuels Part 2.1: Inter-Ring Pressure Measurements and 2D/3D Ring Dynamics Analysis Across Multiple Engine Platforms – Light Vehicle2026-01-0281To be published on 04/07/2026
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 5–7 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, Rösch, Hannes, Ehnis, Holger, Köser, Philipp
Look-ahead Information based Predictive Cruise Controller for Energy Efficient Powertrain Operation of Heavy-Duty Electric Trucks2026-01-0039To be published on 04/07/2026
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
Application of reliability growth techniques in conjunction with DfR framework to validate heavy truck design2026-01-0137To be published on 04/07/2026
Why have the recalls and field campaigns in the automotive industry been going up over the years despite the strong development of technical knowledge, tools and techniques to design products that meet higher reliability standards? One explanation that stands out and is broadly accepted in the industry is related to the challenge to effectively deal with rapid growth of uncertainties in the product development environment brought mainly by the new customers’ demands, stricter safety and emission regulations, shorter project budget and duration. To deliver trucks that meet new market demands with high reliability, the truck industry has been incorporating in their classic product development process a framework of supporting process to ensure that truck components and systems will be designed to meet the reliability requirements, this framework is known as DfR (Design for Reliability). The most recent version of DfR framework was suggested in 2008 by Mettas and encompasses 6 major
Coitinho, Marcos
Inertial Pedal Displacement and Brake Switch Activation in Frontal Crash Events2026-01-0541To be published on 04/07/2026
This paper presents research into the inertial displacement of brake pedals and the subsequent activation of brake light switches during crash events. In certain scenarios—such as multiple-impact crashes or with pre-impact interactions such as curb strikes or sideswipes—inertial forces alone may generate sufficient brake pedal movement to trigger the brake switch, activating the brake lights. Such signals may be recorded by an Event Data Recorder (EDR) or observed by witnesses and mistakenly interpreted as an indication of intentional driver braking. To investigate this phenomenon, HYGE sled tests were performed using brake pedal assemblies and associated components from a Toyota Tacoma pickup truck and a Cadillac DeVille passenger sedan. The assemblies were subjected to acceleration pulses simulating a frontal impact, with high-speed video used to capture brake pedal displacement and brake light activation. The tests demonstrated that inertial loading from a pulse with a delta-V
Duran, Amanda, Walker, James, Barnes, Daniel, Osterhout, Aaron, Clayton, Aidan
Experimental Evaluation of After-treatment Solutions for Heavy-Duty Natural Gas Vehicles to meet future CNVII Regulations2026-01-0376To be published on 04/07/2026
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 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 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, PN emissions from natural
Jiahui, Gao, Marc C, Besch, Ding, Ning, He, Suhao, zhao, Yuxin, Yixiao, Li, Shen, Ye
Multiple-Parameter Joint Estimation for Unmanned Mining Trucks Based on Real-Time Cornering Stiffness Identification2026-01-0618To be published on 04/07/2026
High-precision estimation of key vehicle–road state parameters is essential for accurate and safe vehicle control, as well as for reliable trajectory tracking and path planning. However, the strong nonlinearity of tire forces makes real-time estimation of tire cornering stiffness challenging, and the uncertainty of this parameter significantly limits the performance of conventional estimation methods. To overcome this issue, this study proposes a novel joint estimation framework that integrates the Square-Root Cubature Kalman Filter (SCKF) with Moving Horizon Estimation (MHE). In the proposed approach, the SCKF provides high-accuracy estimation of the vehicle sideslip angle, while the MHE enables real-time identification and updating of tire cornering stiffness using vehicle state information over a short horizon. This establishes a closed-loop joint estimation mechanism between sideslip angle and cornering stiffness. Furthermore, the real-time updated cornering stiffness is
Xia, Xue, Shen, Peihong, Jiao, Leqi, Li, Tao, Chen, Huiyong, Zhao, Kun, Jiao, Leqi, Zhao, Zhiguo
Accelerating Electrification Through Modular Propulsion: GM’s Strategy for BEV and BET Platforms2026-01-0410To be published on 04/07/2026
General Motors 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, 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 rationale behind
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 Variations2026-01-0466To be published on 04/07/2026
The demand for improved energy efficiency in real-world vehicle operations continues to grow with technology enhancement. When transporting large cargos 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, Yang, Allan, Chen, Yan
Protection of Megawatt-Scale DC Charging Infrastructure for Heavy Duty Vehicles: A Review of Current Technologies and Future Roadmap2026-01-0400To be published on 04/07/2026
Abstract Direct Current (DC) fast charging enables the direct delivery of megawatt (MW) scale power to the large battery systems of heavy-duty electric vehicles (EVs), such as trucks, buses, and construction machinery. This contrasts with Alternating Current (AC) charging, which is constrained by the limited capacity of onboard chargers. The feasibility of ultra-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 ultra-fast DC charging. Key benefits include significantly higher charging efficiency, drastically reduced charging times, and lower driver fatigue. However, unlike AC systems, DC charging infrastructure presents unique protection challenges. These challenges arise from the rapid rise of DC fault
Rahman, Md Rakib-Ur, Dobrzynski, Daniel
The Stellantis North America Aero-Acoustic Wind Tunnel Upgrade2026-01-0609To be published on 04/07/2026
The Stellantis North America Aero-Acoustic Wind Tunnel (AAWT), which came into operation in June of 2002, has undergone the significant upgrade of installing a state-of-the-art moving ground plane system. A 5-belt Moving Ground Plane (MGP) has been installed. The center belt measures 8.5m long by 1.1m wide. The new balance is capable of testing all of the Stellantis North America’s vehicles, from small cars to large pickup trucks. Flow quality and other wind tunnel performance parameters were unchanged and remain at previously published specifications, which are on par with the latest industry standards. The new 5-belt rolling road system brings the AAWT to world class capability and it became operational in October 2024.
Lounsberry, Todd, Ladouceur, Brent, Fadler, Gregory
Multi-Physics Topology Optimization and Machine Learning Surrogates for Lightweight Cast Automotive Parts2026-01-0510To be published on 04/07/2026
This paper proposes an integrated optimization framework for lightweight cast vehicle structures by combining Multi-Physics Topology Optimization (MPTO) with machine learning (ML)-driven surrogate modeling. Conventional structural optimization approaches often rely on simplified load cases—such as 3 g inertial loading, frame torsion, or bending—rather than capturing the true complexity of performance-critical conditions like crashworthiness and fatigue durability. As a result, designs optimized for a single criterion frequently degrade in other performance areas, leading to costly redesigns or over-engineered solutions. The proposed methodology introduces MPTO through four structured steps that progressively build design fidelity. Step 1 establishes a baseline primitive topology optimization workflow using a standardized package checklist, ensuring that the design domain, boundary conditions, constraints, and key manufacturing rules are consistently defined as the foundation for
Kim, Hyosig, Senkowski, Andres, Gona, Kiran, Saroha, Lalit, Boraiah, Mahesh
Energy Management Strategy for Hybrid Mining Trucks Based on Global SOC Planning and Neural Network Optimal Control2026-01-0446To be published on 04/07/2026
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
SAE Truck & Off-Highway Engineering: February 202626TOFHP02To be published on 02/12/2026
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
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
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
Optimisation-Driven Framework for Heterogeneous Battery-Pack Mixing in Fleet Applications2026-26-02091/16/2026
Fleet owners often encounter significant logistical and financial problems when dealing with battery packs of different ages and conditions. The standard industry practice is to replace old batteries with identical new ones. This process is inefficient because it costs a lot, creates too much inventory, and eliminates battery packs that are still useful too soon. The problem worsens when manufacturers stop making older battery models, which can force a vehicle to retire early. This paper puts forward a framework for mixing different types of battery packs to deliver the performance needed for a vehicle’s mission. We show how this works in three everyday service situations: 1) Repair, when a single damaged pack needs replacing; 2) Life Extension, where aged packs are combined with newer ones to meet mission range; and 3) Performance Restoration, which uses next-gen packs when the original parts are obsolete. The study shows that a vehicle can complete its required missions by
Nair, Sandeep R., Ravichandran, Balu Prashanth, Hallberg, Linus
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
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
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
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
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
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
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
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
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
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
Advancing Off-Road Autonomy: Comparative Analysis of Manual and AI-Driven Control in Autonomous Trucks2025-36-015212/18/2025
The deployment of autonomous trucks in off-road environments poses significant engineering challenges due to terrain variability and dynamic operating conditions. While recent advancements in perception, planning, and control architectures have improved vehicle autonomy, experimental validations comparing autonomous and manual control particularly regarding propulsion efficiency remain limited. This study addresses this gap by conducting structured field experiments to evaluate the performance of a heavy-duty truck operating in autonomous and manual modes. Tests were performed on a dedicated proving ground using a multi-sensor autonomous system. Key performance indicators included vehicle speed stability, engine speed regulation, and fuel consumption. The results show that autonomous driving achieved a 4.5% reduction in fuel consumption compared to manual operation. This gain is attributed to the system’s ability to maintain lower speed variance and more consistent engine behavior
Paula Silva, Cirilo, Yoshioka, Leopoldo Rideki, Kitani, Edson Caoru, André, Fatec Santo, Silva, Nouriandres Liborio
An AI-Based Embedded Offline Voice Assistant for Commercial Trucks: Enhancing Driver Safety and HMI Design2025-36-007812/18/2025
Commercial vehicle operation faces challenges from driver distraction associated with traditional Human-Machine Interfaces (HMIs) and inconsistent network connectivity, particularly in long-haul scenarios. This paper addresses these issues through the development and presentation of an embedded, offline AI-powered voice assistant. The system is designed to reduce driver distraction and enhance operational efficiency by enabling hands-free control of vehicle functions and access to critical information, irrespective of internet availability. The technical approach involves a three-tier architecture comprising an Android-based In-Vehicle Infotainment (IVI) unit for primary user interaction and voice processing, an Android mobile device acting as a communication bridge and processing hub, and a proprietary OBD-II dongle for CAN bus interfacing. Offline speech recognition is achieved using embedded wake word detection and speech-to-intent engines. A user-centered design methodology
De Oliveira Nelson, Rafael, De Almeida, Lucas Gomes, Arantes Levenhagen, Ivan
Research on Vehicle Routing Optimization for Bulk Waste Shared Collection Model2025-99-036012/17/2025
At present, bulky waste is mainly collected and transported by self-owned vehicles. However, the use of self-owned vehicles for collection has problems, such as high purchase costs and insufficient stability in vehicle configuration, making it difficult to balance the utilization of truck resources and the efficiency of bulky waste collection and transportation. Therefore, this paper proposes a bulky waste collection and transportation model using shared vehicles. Under this model, a scheduling model for shared bulky waste collection and transportation vehicles is designed. The core of the model is to integrate time window constraints and three-dimensional loading constraints. By integrating existing truck resources for scheduling and optimizing the truck scheduling decisions through optimization algorithms, the feasibility and effectiveness of the model are verified through experiments.
Xu, Chen, Ma, Huimin
Tailpipe NOx Emissions Modeling of a Heavy-Duty Diesel Truck Using Deep Learning Methods03-18-08-004812/11/2025
This study develops deep learning (DL) long–short-term memory (LSTM) models to predict tailpipe nitrogen oxides (NOx) emissions using real-driving on-road data from a heavy-duty Class 8 truck. The dataset comprises over 4 million data points collected across 11,000 km of driving under diverse road, weather, and load conditions. The effects of dataset size, model complexity, and input feature set on model performance are investigated, with the largest training dataset containing around 3.5 million data points and the most complex model consisting of over 0.5 million parameters. Results show that a large and diverse training dataset is essential for achieving accurate prediction of both instantaneous and cumulative NOx emissions. Increasing model complexity only enhances model performance to a certain extent, depending on the size of the training dataset. The best-performing model developed in this study achieves an R2 higher than 0.9 for instantaneous NOx emissions and less than a 2
Shahpouri, Saeid, Jiang, Luo, Koch, Charles Robert, Shahbakhti, Mahdi
SAE Truck & Off-Highway Engineering: December 202525TOFHP1212/11/2025
Fuel-Efficient Large-Spacing Truck Platooning in Windy Environments Considering Longitudinal and Lateral Motions2025-99-041912/10/2025
Large-spacing truck platooning offers a balance between operational safety and fuel savings. To enhance its performance in windy environments, this study designs a control system integrating both longitudinal and lateral motions. The longitudinal control module regulates the inter-vehicle spacing within a desired range while generating a fuel-optimal torque profile by minimizing unnecessary decelerations and accelerations. The lateral control module ensures lateral stability and maintains alignment between the trucks to achieve the expected fuel savings. A two-truck platoon is simulated with a 3-sec time gap under varying wind conditions, using experimental data from the on-road cooperative truck platooning trials conducted in Canada. The control system effectively remains spacing errors within the preset safety buffer and limits lateral offsets to 0.07 m, ensuring safe and stable platooning in windy environments. Additionally, the smoother speed profiles and reduced lateral offsets
Jiang, Luo, Shahbakhti, Mahdi
Risk Assessment and Identification of Freight Vehicle Trip Chains2025-99-042112/10/2025
Although the number of trucks is low, their accident rate is high, and the consequences of accidents are severe. This paper is based on GPS data from 100 trucks, with each trip chain defined by a vehicle’s stay time greater than 20 minutes. The kinematic parameters for each trip chain are then extracted, and the entropy weight method is used to calculate the weights of various parameters. A random forest model is applied to select 11 key indicators, including speed and acceleration. The entropy weight-TOPSIS algorithm is used to assess the risk of each trip chain for the trucks. Different combinations of continuous and discontinuous trip chain scenarios are constructed. Finally, support vector machines (SVM) and decision tree methods are used for risk prediction under different trip chain combinations. The results show that the 11 selected key indicators provide an accuracy of 95.74% for describing the sample. In general, the SVM model shows better prediction accuracy than the decision
Huang, Yunhe, Xiong, Zhihua, Li, Jiayu
SAE TOMORROW TODAY - Electrifying Europe?s Heavy-Duty Trucks1354612/5/2025
When it comes to battery electric trucks, is real-world data beating consumer expectations? According to findings from The International Council on Clean Transportation (ICCT), the real-world driving range of heavy duty electric trucks is 10 to 20% better than what is communicated by truck manufacturers. It's an exciting finding -- and one that could propel the decarbonization of freight forward. To learn more, we sat down with Hussein Basma, Senior Researcher at the ICCT, for an eye-opening look at the electrification of Europe's heavy-duty trucking sector. From ambitious regulations to rapid advances in battery technology and charging infrastructure, you'll discover how the EU is driving toward decarbonizing freight -- and what that means for the rest of the world. We'd love to hear from you. Share your comments, questions and ideas for future topics and guests to podcast@sae.org. Don't forget to take a moment to follow SAE Tomorrow Today--a podcast where we discuss emerging
Patterson, Lori
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
Fuel Cell Powered Commercial Vehicles – Solutions of the Next Generation Vehicles2025-01-052511/25/2025
Vehicle manufacturers are to reduce the CO₂ emissions of new trucks dramatically within the next decade. That requires to consider emission-free/neutral vehicles in the fleet mix. Especially for the application of heavy-duty (HD) long haul trucks, fuel cell powered trucks demand a holistic concept for the integration of the entire powertrain, its auxiliaries and the complete vehicle’s energy management. In an internally funded research project, AVL built up a Fuel Cell Technology Demonstrator Truck. This vehicle is not intended to go into series production but to show leading-edge solution to challenges these vehicles are facing today. Due to the length restrictions of semi-trailer trucks in Europe, packaging into the chassis without having a rack behind the cabin is an issue as well as the ambient temperature level, at which the fuel system is to be derated. Solutions are highlighted in the article how to reach the performance of today’s standard diesel trucks. Furthermore, the
Döbereiner, Rolf, Schörghuber, Christoph, Schenk, Alexander, Schubert, Thomas, Stöckl, Bernhard
Optimizing Heavy-Duty Mining Operations with LNG Powertrains: Boosting Efficiency and Minimizing Environmental Impact2025-28-023611/6/2025
Heavy-duty mining is a highly demanding sector within the trucking industry. Mining companies are allocated coal mine sites, and fleet operators are responsible for efficiently extracting ore within the given timeframe. To achieve this, companies deploy dumper trucks that operate in three shifts daily to transport payloads out of the site. Consequently, uptime is crucial, necessitating trucks with exceptionally robust powertrains. The profitability of mining operations hinges on the efficient utilization of these dumper trucks. Fuel consumption in these mines constitutes a significant portion of total expenses. Utilizing LNG as a fuel can help reduce operational fuel costs, thereby enhancing customer profitability. Additionally, employing LNG offers the potential to lower the CO2 footprint of mining operations. This paper outlines the creation of a data-driven duty cycle for mining vehicles and the simulation methodology used to accurately size LNG powertrain components, with a focus
John, Ann Veena, Pendharkar, Koustubh
Multi-Objective Design Optimization and Pugh Matrix Analysis to Develop Exhaust Tail Pipe Mounting for EU6 Heavy Trucks2025-28-029311/6/2025
The key performance evaluation criteria for any automotive exhaust system are pass-by noise (PBN), exhaust backpressure, durability and reliability, exhaust brake performance, aesthetics (if visible from outside the chassis), cost, weight and safety. Also, with changes in emission norms, emission from Exhaust Aftertreatment Systems (EATS) is one of the crucial parameters while designing the exhaust system. This paper covers a critical problem faced during the Beta Proto Build and Testing phase of exhaust tail pipe assembly. The exhaust tail pipe assembly had loose fitting issues, which can cause problems during the functioning of the truck. Parameters like material of the pipe, length of strap, tightening torque and tolerance of the pipe diameter were considered to resolve the fitment issue. The resolution is done with the help of Design of Experiments (DoE) and Pugh Matrix Analysis based on QDCFSS (Quality, Design, Cost, Feature, Safety and Sustainability). Design for Assembly (DFA
P, Balu Mukesh, Rokade, Aditya, Biswas, Sanjoy
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