Browse Topic: Heavy trucks

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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
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
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
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
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
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
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
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
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
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
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 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
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
Integral–Derivative-Tilted Controller for Semi-Active Magnetorheological Truck Suspension System Using Combined Multi-Objective Ant Colony Optimization Algorithm02-19-02-000910/29/2025
This study proposes a novel control strategy for a semi-active truck suspension system using an integral–derivative-tilted (ID-T) controller, developed as a modification of the TID controller. The ant colony optimization (ACO) algorithm is employed to tune the controller parameters. Performance is evaluated on an eight-degrees-of-freedom semi-active suspension system equipped with MR dampers. The objective is to minimize essential dynamic responses (displacement, velocity, and acceleration) of the sprung mass, cabin, and seat. The controller also considers the nonlinear effects including suspension travel, pitch dynamics, dynamic tire loads, and seat-level vibration dose value (VDV). System performance is assessed under both single bump and random road excitations. The ACO-tuned ID-T controller is compared against passive suspension, MR passive (OFF/ON), and ACO-tuned PID and TID controllers. Simulation results demonstrate that the proposed controller achieves superior performance in
Gad, S., Metered, H., Bassiuny, A. M.
Balancing Safety, Stability, and Comfort in Semi-Truck Platooning: A Study on Safe and Optimal Headways under Real-World Traffic Conditions2025-99-001710/17/2025
On highways, platoons of semi-trucks are a common phenomenon. By maintaining a small headway, these platoons can effectively reduce air resistance, thereby improving fuel efficiency and reducing carbon emissions. However, this driving mode is also accompanied by many safety and operational risks, such as increased risk of rear-end collisions, reduced driving comfort, and susceptibility to interference from other vehicles outside the platoon. Therefore, behavioral analysis and evaluation of semi-truck platoons naturally formed in real traffic environments are of great significance for improving their driving safety, comfort and stability. This study focuses on the headway characteristics of semi-truck platoons, analyzes their headway distribution, headway gap and braking response behavior, and then proposes a safe headway threshold for emergency braking to effectively reduce the probability of rear-end collisions. In addition, the study also defines an optimal headway range to reduce
Hu, Xiaoqiang, Cao, Qiang
Rethinking VEHICLE CONTROLS25TOFHP10_0310/1/2025
Smarter control architectures including CAN- and LIN-based multiplexing can elevate operational efficiency, customization and end-user experience. From long-haul Class 8 trucks navigating cross-country routes to articulated dump trucks operating deep in a mining pit, the need for smarter, more reliable and more efficient control systems has never been more critical. Across both on- and off-highway commercial vehicle segments, OEMs are re-evaluating how operators interact with machines - and how those systems can be made more robust, flexible and digitally connected. Suppliers have responded to this industry-wide shift with new solutions that reduce complexity, improve durability and help customers future-proof their vehicle architectures. For example, Eaton's latest advancement is the E33 Sealed Multiplexed (MUX) Rocker Switch Module (eSM) - a sealed, modular switch solution that replaces traditional electromechanical designs with a multiplexed digital interface. Combined with Eaton's
Ortega, Carlos
Analysis of Front Axle Wheel End Temperature Measurements in Heavy-Duty Trucks2025-01-03649/15/2025
The Front Axle wheel end assembly is a critical component of Vehicle functionality, comprising a wheel hub positioned to rotate smoothly on an Axle spindle. This rotational movement is enabled by bearings positioned between the hub and the spindle, allowing for frictionless rotation. The Front Axle wheel ends’ temperature typically depends on several factors such as type of Vehicle, Load & driving conditions and health of the components involved. In general, the wheel ends can become warm during normal operation owing to friction generated by the rotation of the wheels and the interaction of various mechanical components such as Bearings and Brakes. However, if the temperature of the wheel ends becomes excessively hot, it could indicate potential issues such as Overheating brakes, Wheel bearing problems, improperly inflated tyres, and faulty components. As temperature rise, materials tend to expand. This expansion can affect the dimensions of critical components in the Front Axle wheel
Pandiyan, Mahendran, Jayaraman, Karthik, R, Sabari, B, Ellavarasan, Bhanja, Subrat Kumar
Impacts of Hydrotreated Vegetable Oil as Renewable Diesel Fuel on Engine Performance and Emissions in a Heavy-Duty Diesel Engine03-18-06-00359/8/2025
As the pressure increases to move to renewable carbon-neutral fuel sources, especially in heavy-duty diesel engine applications, hydrotreated vegetable oil (HVO) has shown to be an attractive alternative fuel to fossil diesel. Therefore, this study investigated the impacts of HVO used as a drop-in fuel on performance and emissions of a nonroad heavy-duty diesel engine by running back-to-back D2 ISO 8178 cycles with ultra-low sulfur diesel (ULSD) and HVO. The measurement results showed that brake specific fuel consumption with respect to mass reduced by 1.1%–3.6% switching from ULSD to HVO due to greater heating values of HVO, which is supported by 0.7%–3.5% lower CO2 emissions recorded with HVO. Conversely, brake specific fuel consumption with respect to volume increased by 0.3%–2.9% with HVO because of its smaller density. Combustion analysis revealed that combustion of both fuels is comparable at high loads while HVO ignites earlier at low power. Thus, lesser reductions in NOx
Duva, Berk Can, Abat, Bryan, Engelhardt, Jens
Flexible an Low Cost Fuel Consumption Prediction in Heavy-Duty Vehicles Using Machine Learning2025-24-01219/7/2025
This study presents a novel approach for predicting fuel consumption in heavy-duty vehicles using a Machine Learning-based model, which is based on feedforward neural network (FFNN). The model is designed to enhance real-time vehicle monitoring, optimize route planning, and reduce both operational costs and environmental impact, making it particularly suitable for fleet management applications. Unlike traditional physics-based approaches, the FFNN relies solely on a refined selection of input variables, including vehicle speed, acceleration, altitude, road slope, ambient temperature, and engine power. Additionally, vehicle mass is estimated using a methodology presented elsewhere and is included as an input for a better generalization of the consumption model. This parameter significantly impacts fuel consumption and is particularly challenging to obtain for heavy-duty vehicles. Engine power is derived from both engine torque and speed (RPM), ensuring a direct relationship with fuel
Vicinanza, Matteo, Pandolfi, Alfonso, Arsie, Ivan, Giannetti, Flavio, Polverino, Pierpaolo, Esposito, Alfonso, Paolino, Antonio, Adinolfi, Ennio Andrea, Pianese, Cesare, Frasci, Valentino
Reducing Range Prediction Uncertainty in Heavy-Duty Electric Vehicles Using a Route-Informed Transformer-Based Model2025-24-01229/7/2025
Electrification of heavy-duty on-road trucks used for regional freight transportation is a viable option for fleets to reduce operation and maintenance costs and lower their carbon footprint. However, there is considerable uncertainty in projecting their daily range because highly variable payload mass, among other factors, confounds battery state of charge (SOC) prediction algorithms. Previous work by the authors proposed an electric vehicle range prediction model based on two parallel recurrent neural networks (RNNs). The first RNN used mean-variance estimation to output a predicted mean and variance, and the second used bounded interval estimation to provide bounds on the SOC required to complete a trip. The dual RNN approach resulted in estimating the remaining range and error bands of the SOC over the route. The previous work was limited because it did not incorporate driving conditions, like road type and ambient temperature, that affect driver behavior and energy consumption
Jayaprakash, Bharat, Eagon, Matthew, Northrop, William F.
Effect of PEM Fuel Cell Technology Advancement on the Energy Efficiency of a Heavy-Duty Vehicle2025-24-01119/7/2025
Fuel cell hybrid electric vehicles (FCHEVs) are a promising solution for decarbonizing heavy-duty transport by combining hydrogen fuel cells with battery storage to deliver long range, fast refuelling, and high payload capacity. However, many existing simulation models rely on outdated fuel cell parameters, limiting their ability to reflect recent technological improvements and accurately predict system-level performance. This study addresses this gap by integrating a state-of-the-art, physics-based model of a polymer electrolyte membrane fuel cell (PEMFC) into an open-source heavy-duty vehicle simulation framework. The updated model incorporates recent advancements in catalyst design and membrane conductivity, enabling improved representation of electrochemical behavior and real-time compressor control. Model performance was evaluated over a realistic 120 km long-haul drive cycle. Compared to the traditional fuel cell model, the updated system demonstrated up to 20% lower hydrogen
Dursun, Beyza, Johansson, Max, Tunestal, Per, aronsson, Ulf, Eriksson, Lars, Andersson, Oivind
Energy Prediction for Hotel Loads in Mild-Hybrid Heavy-Duty Vehicle02-18-03-00208/29/2025
Long-haul truck drivers are mandated to take off-duty time of 10 h (a.k.a. hoteling) before driving. During the hotel phase, drivers spend time inside their trucks (sleeper cabs) and idle the internal combustion engine for comfort by utilizing the heating, ventilation, air-conditioning (HVAC), and other onboard appliances. For one 10-h period, the average cost is about $40, which can be a lot when considering a million truck drivers idling overnight. SuperTruck II is a 48 V mild-hybrid heavy-duty truck with auxiliary loads powered by an onboard battery pack. An optimal control algorithm is developed to charge the battery pack during the drive phase up to a certain state-of-charge (SOC) level, sufficient to meet the power demands of the auxiliary load during the hotel phase. This article captures the research done to predict energy consumption in a mild-hybrid heavy-duty sleeper truck during hoteling. Physics-based gray box models are developed to estimate the power consumption of an
Khuntia, Satvik, Hanif, Athar, Ahmed, Qadeer, Lahti, John, Jorgensen, Iner
Validation of Wind Noise for Class-8 Truck Using Lattice Boltzmann Method02-18-03-00218/29/2025
The transportation and mobility industry trend toward electrification is rapidly evolving and in this specific scenario, wind noise aeroacoustics becomes one of the major concerns for OEMs, as new propulsion systems are notably quieter than traditional ones. There is, however, very limited references available in the literature regarding validation of computational fluid dynamics (CFD) simulations applied to the prediction of aeroacoustics contribution to the noise generated by large commercial trucks. Thus, in this work, high-fidelity CFD simulations are performed using lattice Boltzmann method (LBM), which uses very large eddy simulation (VLES) turbulence model and compared to on-road physical tests of a heavy-duty truck to validate the approach. Furthermore, the effect of realistic wind conditions is also analyzed. Two different truck configurations are considered: one with side mirror (Case A) and the other without (Case B) side mirrors. The main focus of this work is to assess the
Guleria, Abhishek, Novacek, Justin, Ihi, Rafael, Fougere, Nicolas, Dasarathan, Devaraj
SAE TOMORROW TODAY - Powering A Cleaner Commercial Vehicle Industry135328/29/2025
From battery-electric trucks to hydrogen fuel cell vehicles, the company behind Kenworth, Peterbilt, and DAF is leading the charge toward zero-emissions. PACCAR is a global technology leader in the design, manufacture, and customer support of premium light-, medium- and heavy-duty trucks. The company is also actively investing in zero-emission technologies, positioning itself as a leader in the transition to cleaner commercial vehicles. To learn more, we sat down with Dr. Philip Stephenson, General Manager, PACCAR Technical Center and Executive Chair of this year's COMVEC, the annual commercial vehicle engineering conference hosted by SAE International. Listen in for an engaging discussion on PACCAR's approach to battery-electric trucks, hydrogen fuel cell vehicles, and charging infrastructure partnerships. And if you enjoyed this conversation, register now for COMVEC and join us as we bring together industry leaders, engineers, and innovators to discuss the latest advancements in on
Patterson, Lori
Methods for Estimating Coasting Resistance of Heavy-Duty Commercial Vehicles under Various Loads02-19-01-00058/19/2025
This research primarily addresses the issue of resistance model setting for chassis dynamometers or EIL (engine-hardware-in-the-loop) systems under various loads. Based on the data available from the heavy-duty commercial vehicle coast-down test reports, this article proposes three methods for estimating coasting resistance. For heavy-duty commercial vehicles that have not undergone the coast-down test, this article proposes the GA-GRNN (AC) model to predict coasting resistance. Compared to the GA-BPNN model proposed by previous studies, the new model, which achieves 93% prediction accuracy, demonstrates higher estimation accuracy. For heavy-duty commercial vehicles that have undergone the coast-down test, the coasting equal power method proposed in this article can estimate the coasting resistance under various loads. The accuracy and stability of the new method are verified by several coast-down tests. Compared to the existing method proposed by existing scholars, the new method has
Liang, Xingyu, Sun, Shangfeng, Li, Tengteng, Zhao, Jianfu
Multibody Analysis for Vehicle Dynamics and Durability: Application to a 6x2 Truck and 1+3 Grain Semi-Trailer Combination2025-36-03188/1/2025
The development of modern road implements demands rigorous and comprehensive analyses of various design aspects, including the dynamic behavior of vehicles and the structural durability of their components. Multi-Body System Simulation (MBS) has become an essential tool in developing efficient products, allowing engineers to virtually assess how a truck + semi-trailer combination responds to different operational and loading conditions. By employing models that account for detailed interactions among various vehicle systems -such as suspension, chassis, axles, and fifth wheel-vehicle dynamics can be investigated in complex scenarios. These scenarios replicate real road usage, abrupt maneuvers, and special testing tracks, providing insights into performance under demanding conditions. This approach also facilitates the cascading of loads between systems to conduct durability calculations and estimate the operational lifespan of the implement. This study introduces a development cycle
Justo, Gabriel, Crocoli, Micael, Vigânico, Carlos, Pio, Frederico Nodari
Refurbishing high-voltage batteries FOR ELECTRIC TRUCKS25TOFHP08_038/1/2025
Mercedes-Benz Trucks employs “like-new” reworked batteries to expand its spare parts portfolio and to inform future battery designs that are more sustainable. Remanufacturing engines for medium- and heavy-duty trucks is nothing new to the industry. Reworking high-voltage batteries for reuse in electric trucks is a newer practice. Used batteries are often recycled or find a second life in stationary energy storage systems. Mercedes-Benz Trucks is all in on the approach, launching the new reworked CB400 battery for first-generation eActros 300/400 and eEconic trucks. The so-called “Genuine Reworked Batteries” offer a resource-efficient and economically attractive alternative to brand-new replacement batteries, the manufacturer says, providing customers with like-new quality, tested safety and full functionality.
Gehm, Ryan
Self-Controlled Electrically Powered Semitrailer02-19-01-00027/28/2025
In this article, the hybrid drive is discussed of the combination of conventional tractors with electrified trailers, usually referred to as E-trailer. We demonstrate that this approach offers the possibility of achieving fuel savings exceeding 20%. For regional trips, about half of this reduction is achieved without offline charging, i.e., without applying electric energy from the E-trailer battery. For motorway dominant trips, more use is required of the battery energy. A new control strategy is proposed, validated through simulations, in which only three control parameters are required, which can be tuned effectively to achieve maximum fuel reduction under certain trip and loading conditions. This control strategy adjusts the E-trailer torque request, based on the requested power for the tractor diesel engine, being estimated through a smart kingpin sensor. It ensures that the E-trailer supports the tractor propulsion when significant power is required, and recovers energy when the
Pauwelussen, Joop, Kural, Karel, Hetjes, Bas
Cab Roof Strength Evaluation - Quasi-Static Loading Heavy TrucksJ2422_202507 (Current)7/22/2025
This SAE Recommended Practice describes the test procedures for conducting quasi-static cab roof strength tests for heavy-truck applications. Its purpose is to establish recommended test procedures that will standardize the procedure for heavy trucks. Descriptions of the test setup, test instrumentation, photographic/video coverage, and test fixtures are included.
Truck Crashworthiness Committee
Data-Driven Vehicle Specification of Conventional and Electric Heavy-Duty Commercial Trucks for Improved Energy Consumption02-18-03-00187/9/2025
In the heavy-duty commercial trucks sector, selecting the most energy-efficient vehicle can enable great reductions of the fleet operating costs associated with energy consumption and emissions. Customization and selection of the vehicle design among all possible options, also known as “vehicle specification,” can be formulated as a design space exploration problem where the objective is to find the optimal vehicle configuration in terms of minimum energy consumption for an intended application. A vehicle configuration includes both vehicle characteristics and powertrain components. The design space is the set of all possible vehicle configurations that can be obtained by combining the different powertrain components and vehicle characteristics. This work considers Class 8 heavy-duty trucks (gross combined weight up to 36,000 kg). The driving characteristics, such as the desired speed profile and the road elevation along the route, define the intended application. The objective of the
Villani, Manfredi, Pandolfi, Alfonso, Ahmed, Qadeer, Pianese, Cesare
Investigation on Thermal Management of Heavy-Duty Commercial FCEV with Focus on Vehicle System Efficiency2025-01-02657/2/2025
The primary approach to meet the objectives of the EU Heavy Duty CO2 Regulation involves decarbonizing the road transport sector by battery electric vehicles (BEV) or hydrogen-fueled vehicles. Even though the well-to-wheel efficiency of hydrogen-fueled powertrains like fuel cell electric vehicles (FCEV) and H2-internal combustion engines (H2-ICE) is much lower in comparison to BEV, they are better suited for on-road heavy-duty trucks, long haul transport missions and regions with scarce charging infrastructure. Hence, this paper focuses on heavy-duty FCEVs and their overall energetic efficiency enhancement by intelligently managing energy transfer across coolant circuit boundaries through waste heat recovery, while ensuring that all relevant components remain within required temperature boundaries under both cold and hot ambient conditions. Results were obtained using a 1D-model that comprises all thermal fluid circuits (refrigerant, coolant, air) created through GT-Suite software
Uhde, Sophia, Langhorst, Thorsten, Wuest, Marcel, Naber, Dirk
Systematic Derivation of Requirements for the Perception Task of Free Space Driving Assistance Function Applied to Trucks2025-01-02797/2/2025
The larger size and expanded blind spots of heavy-duty trucks in comparison to passenger cars, create unique challenges for truck drivers navigating narrow roads, such as in urban scenarios. For this reason, the detection of free space around the vehicle is of critical importance, as it has the potential to save lives and reduce operating costs due to less maintenance and downtime. Despite the existence of numerous approaches to free space detection in the literature, few of these have been applied to the trucking sector, disregarding important aspects for these kinds of vehicles such as the altitude at which obstacles are located. This paper aims to present the initial results of our research, a “Not Free Space Warner”, a driving assistance function intended for implementation in series trucks. A methodology is followed to define the characteristics that the perception component of this function shall fulfill. To this end, an analysis of the most critical accidents and common driving
Martinez, Cristian, Peters, Steven
Design of a New Overhead Two-Stroke Engine Braking Device and Braking Performance Evaluation2025-01-50487/1/2025
The braking safety of heavy-duty vehicles is widely concerned. This paper proposed a new purely mechanical transmitted OHC two-stroke braking device. The rigid–flexible coupled dynamics model of the device and the engine working process simulation model were used for joint simulation. The effects of CR lift, environmental conditions, compression ratio, and braking type on the engine braking performance were comprehensively evaluated. The result shows: good consistency of valve operation is obtained by using pure mechanical transmission. During the braking process, the in-cylinder pressure acts directly on the valves and significantly affects the maximum valve lift of the CR phase, therefore excessive in-cylinder pressure will reduce the reliability of the braking device. When the CR lift increases from 1.9 to 2.8 mm, the braking power per liter increases at low altitude, but first increases and then decreases at high altitude. The decrease in engine speed and compression ratio as well
Cui, Jingchen, Wang, Bing, Tian, Hua, Tian, Jiangping, Long, Wuqiang
Heavy-Duty Vehicle Lubricating GreasesJ2695_202506 (Current)6/30/2025
This SAE Recommended Practice was developed by SAE and the section “Standard Classification and Specification for Service Greases” cooperatively with ASTM and NLGI. It is intended to assist those concerned with the design of heavy-duty vehicle components and with the selection and marketing of greases for the lubrication of certain components on heavy-duty vehicles like trucks and buses. The information contained herein will be helpful in understanding the terms related to properties, designations, and service applications of heavy-duty vehicle greases.
Fuels and Lubricants TC 3 Driveline and Chassis Lubrication
Optimal Onboard Battery Charging Strategy for Hotel Load Management in Mild-Hybrid Heavy-Duty Truck02-18-03-00176/12/2025
Heavy-duty trucks idling during the hotel period consume millions of gallons of diesel/fuel a year, negatively impacting the economy and environment. To avoid engine idling during the hotel period, the heating, ventilation, and air-conditioning (HVAC) and auxiliary loads are supplied by a 48 V onboard battery pack. The onboard battery pack is charged during the drive phase of a composite drive cycle, which comprises both drive and hotel phases, using the transmission-mounted electric machine (EM) and battery system. This is accomplished by recapturing energy from the wheels and supplementing it with energy from the engine when wheel energy alone is insufficient to achieve the desired battery state of charge (SOC). This onboard battery pack is charged using the transmission-mounted EM and battery system during the drive phase of a composite drive cycle (i.e., drive phase and hotel phase). This is achieved by recapturing wheel energy and energy from the engine when the wheel energy is
Huang, Ying, Hanif, Athar, Ahmed, Qadeer
Clarios brings AI to idle management for heavy trucks25TOFHP06_086/1/2025
The predominant low-voltage battery maker Clarios announced that IdleLess, a sensor-and-AI-driven system for heavy-duty trucks that it says can save up to $3,300 per year per truck and reduce CO2 emissions by up to 8.6 metric tons per year, is commercially available in the United States and Canada. Long-haul Class 8 trucks spend an enormous amount of time idling. Much of this time occurs when a driver is on rest at a truck stop or during loading/unloading at warehouses. Operators keep the truck running to power the air-conditioning and other systems without draining the four or more 12V batteries too much, which would prevent them from being able to start their diesel engines. IdleLess addresses that and is not the type of automatic start-stop system that has drawn the ire of truck operators and passenger-vehicle drivers, who routinely disable such systems.
Clonts, Chris
Enabling Neat Alcohol Combustion in a Heavy-Duty Diesel Engine with Exhaust Rebreathing13-06-03-00225/23/2025
In this study, a strategy for MCCI combustion of a novel alcohol fuel is demonstrated. The novel fuel, “GrenOl”, is the result of the catalytic upgrade of sustainable ethanol into alcohols of higher molecular weight. The composition of GrenOl includes approximately 70% 1-butanol, 15% 1-hexanol, and 5% 1-octanol by mass, resulting in a cetane number around 18. In order to achieve mixing-controlled compression ignition with GrenOl, an exhaust rebreathing strategy is employed. In this strategy, the exhaust valve reopens for a part of the intake stroke, inducting hot exhaust into the cylinder and preheating the fresh air. This study investigates the feasibility of operating with such a valve strategy from idle to peak torque. At idle, the primary challenge is ensuring stable combustion by inducting adequate exhaust to achieve ignition. Under load, when cylinder temperatures are higher, the primary challenge is ensuring sufficient air is inducted to achieve the target torque. It was found
Trzaska, Joseph, Xu, Zhihao, Boehman, André L.
Comprehensive Analysis and Optimization of Door Closing Sound Quality of a Heavy Truck2025-01-00665/5/2025
Based on the objective and subjective experiment and finite element analysis, the influencing factors on the door closing sound quality of a heavy truck is analyzed and optimized. Results show that the loudness and sharpness can be reduced by increasing stiffness and damping of the door. The sound quality can be enhanced by increasing the pressure release area, which can decrease the air pressure resistance of dooring closing. By adding holes on the inner liner and changing the pressure release location, the dooring closing air pressure resistance is reduced from 289 Pa to 181 Pa. In terms of the rebound sound, the sound level is positively related to the door closing force. Increasing the protrusion height and decreasing the stiffness of the vibration absorber of the handle can improve the rebound sound quality. Optimizing the absorbers on both ends of the handle and adding damping material can decrease the loudness by 47.8%, reduce the cavity sound, reduce the rattle and improve the
Wang, Jian, Zhang, Yongshen, Feng, Lei, Xie, Chenhao, Lin, Jiewei, Sun, Changchun
Active Control of Engine Order Noise for Heavy-Duty Trucks: Using the Genetic Algorithm for the Optimization of Error Microphone Arrangement2025-01-00135/5/2025
The arrangement of error microphones for a vehicle active noise control (ANC) system is no trivial work, especially for heavy-duty trucks, due to the dilemma resulted from the large volume of the cab and the limited number of microphones accepted by most manufacturers in the auto industry. Although some pioneering work has laid the foundation for the application of numerical methods exemplified by the genetic-algorithm (GA) to optimize the error sensor arrangement in an ANC system, most ANC developers still resort to trial and error in practice, which is not only a heavy workload given the amount of interested working conditions to be tested, but also does not guarantee to yield the optimum noise cancellation performance. In this paper, the authors designed and implemented an error microphone selection process using a genetic-algorithm (GA) -based mechanism. The target vehicle was a heavy-duty truck with a six-piston diesel engine, and two application scenarios were particularly
Wang, Jian, Ling, Zihong, Zhang, Zhe, Cai, DeHua, lv, Xiao, Zhang, Ming, Gao, GuoRan
Prediction and Optimization of Noise radiation from a Heavy-Duty Commercial Vehicle Transmission using Statistical Energy Analysis2025-01-00515/5/2025
Heavy Duty (HD) linehaul vehicles are majorly used in transportation of goods and heavy loads between different cities or long distances. Considering the current trend, payload capacity of these heavy-duty trucks are increasing due to constant increase in the load demand. Due to which engine torques of these HD vehicles are increasing which in turn increases the transmission input torque. At higher torque levels, gear excitation also increases and transmission becomes more susceptible towards higher noise radiation. The transmission is an integral part of the driveline in a heavy duty commercial vehicle. Along with speed and torque conversion, the transmission design is crucial to achieve better fuel economy. Important factors to consider in the transmission design are duty cycle, torque capacity, fuel economy and overall weight. Global vehicle pass-by noise regulations for HD commercial vehicles are becoming more stringent and transmissions are expected to be very quiet. Historically
Rastogi, Sarthak, Milind, T. R.
Single Conductor Cable for Heavy-Duty Applications - Truck and BusJ2549_202504 (Current)4/16/2025
This SAE Standard establishes the minimum construction and performance requirements for single conductor cable for use on trucks, trailers, and converter dollies.
Truck and Bus Electrical Systems Committee
Network ManagementJ1939/81_202504 (Current)4/14/2025
SAE J1939-81 (“Network Management”) defines the processes and messages associated with managing the addresses of applications communicating on an SAE J1939 network. Network management is concerned with the management of addresses and the association of those addresses with an actual function and with the detection and reporting of network related errors. Due to the nature of management of addresses, network management also specifies address selection and address claiming processes, requirements for reaction to brief power outages, and minimum requirements for ECUs on the network.
Truck and Bus Control and Communications Network Committee
Adapting Basic On-Road Data to the Heavy Heavy-Duty Diesel Truck Schedule for Guiding the Electrification of Long-Haul Truck Transport14-14-02-00114/10/2025
Heavy heavy-duty diesel truck (HHDDT) drive cycles for long-haul transport trucks were developed over 20 years ago and have a renewed relevance for performance assessment and technical forecasting for transport electrification. In this study, a model was constructed from sparse data recorded from the real-life on-road activity of a small fleet of class 8 trucks by fitting them into separate driving-type segments constituting the complete HHDDT drive cycle. Detailed 1-s resolution truck fleet raw data were also available for assessing the drive cycle model. Numerical simulations were conducted to assess the model for trucks powered by both 1.0 MW charging and 300 kW-level e-Highway, accounting for elevation and seasonally varying climate conditions along the Windsor–Quebec City corridor in Canada. The modeling approach was able to estimate highway cruising speeds, energy efficiencies, and battery pack lifetimes normally within 2% of values determined using the detailed high-resolution
Darcovich, Ken, Ribberink, Hajo, Soufflet, Emilie, Lauras, Gaspard
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