OEM Off-Highway April/May 2021 by OEM Off-Highway

APRIL/MAY 2021

TELEMATICS GO BEYOND FLEET MANAGEMENT Advancements in telematics technology is bringing about more capabilities for OEMs and their customers. PAGE 16

MINING EQUIPMENT MARKET OUTLOOK

Mining equipment production is forecast to rebound in 2021, and grow 3.8% through 2026.

oemoffhighway.com

PAGE 30

Your link to the world of modern automation - X90 www.br-automation.com/mobile-automation/

Scalable hardware platform Preprogrammed software components < 3-times faster development < <

VOLUME 39, NO. 3 | APRIL/MAY 2021 © NAYPONG STUDIO | CHINHENG | SERGRAY | SDECORETMOCKUP – STOCK.ADOBE.COM

CONTENTS

FEATURES

mart Center: CANbus S Systems

14 C ANbus Will Play Critical Role in Electric and Autonomous Vehicles

The advanced communication capabilities of CANbus

systems will help to increase the intelligence of electric and autonomous vehicles. Search: 21366214

Engine System

ON THE COVER

24 E ngine Technology to Meet Emissions Regulations and Beyond

Advancements in engine systems will continue to focus

Cover Story: Telematics Systems

16 Telematics go Beyond Fleet Management

Continued advancement in telematics technology is bringing about more data collection and predictive maintenance capabilities for OEMs and end-use customers.

Search: 21354479

on improving efficiency and reducing emissions. Search: 21342647

Market Forecast: Mining Equipment

Mining equipment production is forecast to rebound in

30 B etter Times Ahead for North American Mining Equipment Market 2021, and grow 3.8% through 2026. Search: 21366090

Electrical & Electronics: Sensors

Embedding position sensors into hydraulic cylinders

34 I n-Cylinder Sensors Solve Old Problems with New Thinking

can provide new performance features previously not thought possible in heavy-duty equipment. Search: 21271252

38 New Products

oemoffhighway.com/directory

OEM Off-Highway | APRIL/MAY 2021

exceptional support, Enhanced productivity. You’re only as productive as your equipment. With a world-class support network and available 1,000-hour service intervals, you’ll experience optimal uptime. Our aim is to keep you running at full capacity. Learn More: volvopenta.us

IN EVERY ISSUE Editor’s Note

8 Engines Remain a Vital

Power Source

Equipment Market Outlook

10 F arm Machinery Production on the Rise oemoffhighway.com/economics

40 Events Calendar

oemoffhighway.com/events

41 Advertisers’ Index

Off-Highway Heroes

42 T he Great Innovator R. G. LeTourneau

Robert Gilmore LeTourneau had an

unequalled impact on the earthmoving equipment industry. Search: 21366254

Online Exclusives www.oemoffhighway.com Hardware Design Considerations for Last Mile Delivery Vehicles

Selecting the right hardware ensures last mile delivery vehicles are as secure and efficient as possible.

Published by AC Business Media

EDITORIAL ADVISORY BOARD Craig Callewaert, PE Chief Project Manager Volvo Construction Equipment Roy Chidgey Business Segment Head, Minerals Projects and Global Mobile Mining Siemens Large Drives US Andrew Halonen President Mayflower Consulting, LLC Terry Hershberger Director, Sales Product Management, Mobile Hydraulics Bosch Rexroth Corp. Steven Nendick Marketing Communications Director Cummins Inc. John Madsen Director Engineering & Product Management GKN Wheels & Structures Doug Meyer Global Director of Construction Engineering John Deere Andy Noble Head of Heavy Duty Engines Ricardo Daniel Reibscheid Business Development Manager MNP Corporation Matt Rushing Vice President, Product Line, Global Crop Care AGCO Corp. Allen Schaeffer Executive Director Diesel Technology Forum

Search: 21354262

Keith T. Simons President – Controls Products OEM Controls, Inc.

PODCAST: CLAAS Sees Positive Outlook for Agricultural Equipment Market in 2021

Alexandra Nolde Senior Communication & Media Specialist Liebherr-Components AG

Favorable commodity prices and new technology introductions will be key drivers for the agricultural equipment market.

Bob Straka General Manager, Transportation SBU Southco, Inc.

Search: 21354651

Luka Korzeniowski Global Market Segment Leader, Mobile Hydraulics MTS Sensors

Blog: Top 10 Articles of the Past Decade

The top articles from the past 10 years show how the heavy equipment engineering and manufacturing industry continues to evolve. Search: 21342880

Market Forecast: Fluid Power Search: 20846516

OEM Off-Highway | APRIL/MAY 2021

Chris Williamson, PhD Senior Systems Engineer Global Research & Development Danfoss Power Solutions Company

201 N. Main Street, 5th Fl., Fort Atkinson, WI 53538 (800) 538-5544 • www.ACBusinessMedia.com

www.OEMOffHighway.com PRINT AND DIGITAL STAFF Publisher Sean Dunphy sdunphy@ACBusinessMedia.com Editor Sara Jensen sjensen@ACBusinessMedia.com Senior Field Editor Curt Bennink cbennink@ACBusinessMedia.com Contributing Writer Thomas Berry Senior Production Manager Cindy Rusch crusch@ACBusinessMedia.com Art Director Dave Haglund Audience Development Manager Angela Franks ADVERTISING SALES (800) 538-5544 Al Bower............................abower@ACBusinessMedia.com Greg Schulz.....................gschulz@ACBusinessMedia.com Nikki Lawson.................nlawson@ACBusinessMedia.com Sean Dunphy.................sdunphy@ACBusinessMedia.com Kris Flitcroft....................kflitcroft@ACBusinessMedia.com Change of Address & Subscriptions — PO Box 3605 Northbrook, IL 60065-3605, Phone: (877) 201-3915 Fax: (847)-291-4816 • circ.OEMOff-Highway@omeda.com List Rental — Bart Piccirillo, Sr. Account Manager, Data Axle Phone: 402-836-2768 | bart.piccirillo@data-axle.com Reprints — For reprints and licensing please contact Greg Schulz at 920-542-1239.............. gschulz@ACBusinessMedia.com AC BUSINESS MEDIA Chief Executive Officer.........................................Barry Lovette Chief Financial Officer..........................................JoAnn Breuchel Chief Digital Officer...............................................Kris Heineman Chief Revenue Officer...........................................Amy Schwandt VP Audience Development............................... Ronda Hughes Director of Digital Operations & IT................Nick Raether Director of Digital Strategy................................Joel Franke Group Content Director......................................Jon Minnick Published and copyrighted 2021 by AC Business Media. All rights reserved. No part of this publication shall be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording or any information storage or retrieval system, without written permission from the publisher. SUBSCRIPTION POLICY: Individual print subscriptions are available without charge in the United States to original equipment manufacturers. Digital subscriptions are available without charge to all geographic locations. Publisher reserves the right to reject nonqualified subscribers. Subscription Prices: U.S. $35 One Year, $70 Two Years; Canada and Mexico $60 One Year, $105 Two Years; all other countries, payable in U.S. funds, drawn on U.S. bank, $85 One Year, $160 Two Years. OEM Off-Highway (USPS 752-770, ISSN 1048-3039 (print); ISSN 2158-7094 (online) is published eight times a year: January/February, March, April/ May, June/July, August, September, October, November/December by AC Business Media, 201 N. Main Street, 5th Fl., Fort Atkinson, WI 53538. Periodicals Postage paid at Fort Atkinson, WI and additional entry offices. POSTMASTER: Send address changes to: OEM Off-Highway, PO Box 3605 Northbrook, IL 60065-3605. Printed in the U.S.A. Volume 39, No. 3, April/May 2021

No matter what path you choose, we have a telematics program built for you.

ZTR is a leader in the provision of industrial telematics solutions, access management and professional support for the compact construction equipment market. Contact us today to see how we can help elevate your equipment’s digital standards. ztr.com

519.452.1233

telematicsinfo@ztr.com

EDITOR’S NOTE

ENGINES Remain a Vital Power Source

IN THE NEXT ISSUE

espite the amount of news coverage electrification receives these days, including here at OEM Off-Highway, traditional power sources like the internal combustion engine are still relevant and an area in which manufacturers continue to focus R&D efforts. The power they provide is currently unmatched in many applications, particularly in very heavy-duty equipment. And while engine emissions have been greatly reduced in the last several years, there is still a lot of interesting work going on in this space as well as others which aim to further improve engine performance and efficiency. Enabling the use of alternative fuels is a major area of focus for many engine manufacturers. The right fuel can help reduce emissions while providing performance similar to diesel or other currently used fuels. And in some instances, this can mean fewer changes are needed to engine designs which would make it easier ©JUSTCONTRIBUTOR – STOCK.ADOBE.COM to begin using the fuel immediately. This was one of the reasons FPT says it began researching the use of DME (dimethyl ether) in heavy-duty engines. The fuel’s similarity to liquified petroleum gas (LPG) make it suitable as a replacement for diesel fuel, and testing has so far shown a reduction in NOx and other emissions which are expected to be the target of future emissions regulations. Listen to our full podcast episode with FPT to learn more about its DME research at www.oemoffhighway.com/21331176. New engine technology is also looking to make it easier to use alternative fuel options. Achates Power and Libertine FPE, for instance, are developing opposed piston engine technology to provide performance enhancements in heavy-duty equipment while also enabling use of fossil-free fuels available today like ethanol. You can read more about their technologies, as well as other emissions reduction technology efforts being undertaken by engine manufacturers in our article on pg. 24. As with the many topics we cover at OEM, it will be interesting to see how engine technology will continue to advance in the coming years. We want to hear from you! What new engine advancements do you see in the future? What will be the next thing in emissions regulations? How big a role do you see alternative fuels playing in the coming JUNE/JULY SHOWCASE years? Let us know!

• Engines & Components • Drivetrains & Components • Fluid Power Systems • Electrical & Electronics • Operator Environment • Engineering & Manufacturing

NOTHING BUT PRODUCTS!

OEM Off-Highway | APRIL/MAY 2021

editor@oemoffhighway.com

@OEMEditor

SMART SMART SOLUTIONS SOLUTIONS SUSPENSION SUSPENSION COOLING COOLING DRIVETRAIN DRIVETRAIN BRAKES BRAKES CONTROLS CONTROLS STEERING STEERING IMPLEMENTS IMPLEMENTS FILTRATION FILTRATION

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EQUIPMENT MARKET OUTLOOK

Sponsored by Eberspächer

oemoffhighway.com/economics

Europe Ag & Forestry Machinery Production:

U.S. Farm Machinery Production: • Annual U.S. Farm Machinery and Equipment Shipments totaled $23.1 billion in January, down 2.0% from 1 year ago. Annual Shipments are rising from a mid-2020 business cycle low. • Business cycle rise in monthly U.S. Pesticides, Fertilizers, and Other Chemicals Shipments, as well as rising quarterly U.S. Soybeans Futures Prices, portends further business cycle rise for Shipments during the coming quarters. Annual % change in 12 month moving totals

• Annual Europe Agricultural and Forestry Machinery Production in January was down 3.0% from last year. Though trending below year-ago levels, annual Production is rising. • General recovery in Europe and abroad will likely boost Production this year.

-2

-2.0%

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Jun ’20

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-5.9%

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• The Europe Leading Indicator rose further in February, marking the 10th month of rise. • Ongoing rise in the Leading Indicator suggests that activity in the European industrial sector will rise throughout 2021.

Annual % change

-2

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Europe Leading Indicator:

Jun ’20

Jul

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Jan ’21

100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 0

Monthly index

98.2

Jul ’20

98.9

99.0

99.1

99.3

99.4

99.3

Aug Sep Oct Nov Dec Jan ’21

Feb

Editor’s Note: Please note that this chart has been modified on the Y-axis to show the trend more easily.

U.S. HeavyDuty Truck Production: • Production was down 34.9% in February from 1 year ago. However, quarterly Production, down just 2.3% from 1 year ago, is indicating a strong recovery trend. • Macroeconomic recovery and recovering quarterly U.S. Surface Trade With Canada and Mexico bode well for future demand for heavy trucks. However, the semiconductor shortage could hinder producers’ ability to meet demand in the near term.

China Diesel Bus Production: • Annual China Large Diesel Bus Production totaled 20.6 thousand units in February, down 33.1% from 1 year ago. While still below yearago levels, this was the second consecutive month of rise in annual Production. • The ITR Checking Points™ system suggests that the tentative transition to business cycle rise will hold and that business cycle rise will persist in at least the near term.

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-34.8%

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Annual % change

-34.9%

Annual % change in 12 month moving totals

-15.9% -28.8%

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-35 -37.1%

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OEM Off-Highway | APRIL/MAY 2021

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• Germany Industrial Production during the 3 months through January was down 2.7% compared to the same 3 months 1 year ago. • This marks a tick-down in the quarterly rate-of-change, consistent with 3 consecutive months of decline in the quarterly Eurozone Composite Purchasing Managers Index monthly rate-of-change. These trends are likely representative of the impact of Germany’s recent shutdowns. -0.9%

-10

-35

Germany Industrial Production:

Sep

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Dec

Jan ’21

Annual % change in 3 month moving totals

-21.7%

-35.5%

-25

Jun ’20

Jul

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Jan ’21

U.S. Construction Machinery, New Orders: • New Orders are rising but still below the yearago level. The quarterly trend shows robust recovery, coming in 14.3% above the same period 1 year ago. • Quarterly U.S. Domestic Corporate Cash Holdings were up 52.0% in the second quarter of 2020 (latest available data) compared to a year prior. This suggests firms will have the ability to spend on new construction and equipment, which may boost New Orders this year. Annual % change in 12 month moving totals

0 -2

U.S. Defense Industry, New Orders:

North American Rotary Rig Count: • The annual North American Rotary Rig Count averaged 461 in February, down 56.5% compared to 1 year ago. • A deep freeze in the U.S. South did damage to a number of rigs and took others offline. Rising U.S. Crude Oil Spot Prices will likely incentivize investment in bringing rigs back online in the coming quarters.

Annual % change in 12 month moving totals

0 -10

-4

-3.8%

-3.4%

• Annual U.S. Defense Capital Goods New Orders totaled $157.8 billion in January, up 3.4% from 1 year ago. • Defense spending often rises during times of uncertainty and declines during times of stability. Decline in the World Uncertainty Index suggests that that New Orders spending may be muted in the near term.

6.8%

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-8

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Jun ’20

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Aug

Sep

Oct

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Dec

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-53.7% -56.6%

Jul ’20

Aug

Sep

Oct

Nov

2.1%

2 -50.8%

-10.8%

-12

3.4%

-41.8%

-8.5% -9.2%

6.0%

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-40 -9.4%

8.3% 7.8%

-30

-6.0%

-10

8.0%

6 -6

Annual % change in 12 month moving totals

Dec

Jan ’21

Feb

0.1%

Jun ’20

Jul

Aug

Sep

Oct

Nov

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SMART CENTER: CANBUS SYSTEMS oemoffhighway.com/21366214

CANbus Will Play Critical Role in Electric and Autonomous Vehicles The advanced communication capabilities of CANbus systems will help to increase the intelligence of electric and autonomous vehicles. by Sara Jensen

ommunication between components and systems is common in today’s heavy-duty vehicles and equipment with CANbus (Controller Area Network). As technology continues to evolve, so have CANbus systems and the components which are connected to them. Because of its communication capabilities, CANbus will play a critical role in electric and autonomous vehicles. With the latter, it will be especially important for components and systems to communicate with one another to ensure safe and efficient operation. We recently spoke with Rod Dayrit, Director of Business Development, North America, Delta-Q Technologies, about CANbus technology and how it can help create more intelligence in vehicle systems.

What are some of the key benefits of including CANbus and how does it help with efficiency? CAN communication gives you the ability to communicate with other devices and intelligently control them based off feedback from a component. CANbus allows for a form of communication that provides intelligence between the components and the actual application itself.

How is CANbus being utilized with battery powered systems and battery chargers? The battery and the charger are very dependent on each other. Typically, the battery is the first or second largest spend in electric vehicles. So when OEs look for a battery solution, they want to make sure they’re getting the most return on investment when they purchase that battery system. What that means is getting the best performance out of it, the most life out of it, and the most cost-effective solution from that battery. Where Delta-Q comes in is doing reviews and tests of the battery to learn where we could optimize it with relation to performance, lifecycle, and the requirements of the actual customer. Lithium-ion batteries have battery management systems which act as the brains to the battery system itself. The charger has a microcontroller that is able to talk with the battery and it’s a two-way street—the battery can tell the charger it wants to charge slower to increase the life of the battery or increase the speed, and the charger could log that information. If you think back to lead-acid

OEM Off-Highway | APRIL/MAY 2021

CANbus systems can communicate with battery chargers to improve charging efficiency and battery life.

-Q T E LTA

ECH

NOL

O G IE

batteries, because there were no electronics involved you really had to characterize the battery and be as efficient as possible on that characterization. Whereas now that you have the flexibility to scale how you want to use that battery and the performance of the battery due to the communication path which most often is CAN communication, you are able to scale how and when the battery is doing what it’s doing. This is essential and important to the total cost of the battery because you could either enhance performance, or you could manipulate the battery through the communications to optimize the life at the expense of some performance. It gives you flexibility.

Head to the Web

What are some trends related to CANbus systems Delta-Q is seeing in the industry and how does it see this technology progressing in the coming years? What we are seeing is the emergence of the remote-control function on CAN. This relates more to charging architecture; prior to the implementation of CAN remote control most chargers were set up with algorithms built into them. Using this implementation, the algorithm would be optimized to include set parameters the charger would follow in order to charge the battery. It would not deviate away from these set parameters. As battery solutions become more intelligent, the charging intelligence moves from the charger to the battery. Some lithium batteries can monitor their own characteristics through their BMS (battery management system). It can provide specific charge parameters to the charger, using CAN remote control, to address a variety of purposes. It has opened a lot of new forms of communication between the charger and the battery, and the battery and the application itself. At the end of the day, it is all about cost and how efficiently you can manage your operating expenditures. Even though equipment is becoming electrified, the majority of equipment is still operated by humans. Wireless communication is going to become even more relevant as equipment becomes autonomous. Systems will have artificial intelligence and rely on communication networks they have established whether it is internal or with an ecosystem of products. It is going to get more integrated and advanced as technology moves to autonomy. CANbus will be a part of this because it is a method of communication and bridges communication to all components. It allows for communication and intelligence between components to optimize them effectively and efficiently. Visit www.oemoffhighway. com/21366214 to read an extended version of this article. |

Watch our video interview with Rod Dayrit, Director of Business Development, North America, and Mourad Chergui, Product Manager, Delta-Q Technologies, to learn more about battery charging trends in the off-highway equipment industries at www.oemoffhighway.com/21158948.

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OEM Off-Highway | APRIL/MAY 2021

COVER STORY: TELEMATICS SYSTEMS oemoffhighway.com/21354479

Telematics go Beyond Fleet Management Continued advancement in telematics technology is bringing about more data collection and predictive maintenance capabilities for OEMs and end-use customers. by Sara Jensen

elematics systems continue to play a pivotal role in heavy-duty equipment. As use of these systems has increased over the years, so too have their capabilities. “Telematics as a technology has evolved significantly over the last 10 years,” says Pankaj Sharma, Vice President, Marketing and Product at NexTraq, a Michelin group company. “It’s no [longer] just a location-based service like it used to be perceived in the past. It has evolved to be all about insights that make an impact on a fleet’s operations, whether it’s productivity, safety, cost efficiency, compliance and a lot more.” Retrieving data from a piece of equipment and making the most of that data continues to be an area in which telematics technology is evolving. Incorporation of more data analytics as well as artificial intelligence and vision technology, such as

ABOVE: Retrieving data from a piece of equipment and making the most of that data continues to be an area in which telematics technology is evolving. LEFT: For OEMs wanting software updates, remote diagnostics or monitoring of complex electronics, high level telematics systems with more connectivity are necessary. DANFOSS POWER SOLUTIONS

OEM Off-Highway | APRIL/MAY 2021

©LEONID – STOCK.ADOBE.COM

NEXTRAQ

Incorporation of vision technology such as dash cams into telematics systems are helping provide more information for vehicle and equipment owners.

dash cams, are some of the ways Sharma says telematics systems are advancing to provide more information for vehicle and equipment owners. Integration is becoming an important part of the equation, as well. “Understanding that no individual entity can provide all services, it’s very evident we need to be part of a big ecosystem to provide a higher impact for customers,” says Sharma. Because of this, forming industry partnerships—whether with service providers or OEMs—will be vital to ensuring end-use customers get the features and information they need. Sharma notes that while NexTraq currently offers an aftermarket solution, it plans to work with OEMs as they play a critical role in ensuring the right equipment and vehicle insights are provided to end users. “In addition to having a flexible portal and the ability to configure whatever data you want to collect, it’s also important to realize the level of telematics that every machine needs because not all machines are as

complex; not all of them have complex electronics that need to be monitored and updated,” says Ivan Teplyakov, Business Development Manager for Connected Solutions at Danfoss Power Solutions. For those wanting software updates, remote diagnostics or monitoring of complex electronics he says high level telematics systems with more connectivity are necessary. However, not every machine or customer needs this which is why Danfoss has made both the software and hardware used for its telematics systems flexible. “We offer a portfolio of three different devices. The customer can select the appropriate level of need for their particular machine as well as the appropriate level of cost.”

New technology improves data collection Sharma says NexTraq provides fleet management services across multiple industries, including the heavy equipment industry. Those services are focused in four main areas—productivity and cost efficiency, safety, compliance

and workforce management. “At the end of the day, all of our solutions and services are targeted toward these elements.” The heavy equipment industry has a broad range of requirements including tracking assets, projects and workforce. As such, Sharma says the NexTraq solution brings together various elements into a single solution to help meet the industry’s range of needs. This provides a complete picture of how a business is operating and what changes need to possibly be made to work safer and more efficiently. With the NexTraq solution, users can more easily track where and how their equipment is used. This can benefit rental companies which need to monitor equipment use and plan maintenance; it can also benefit equipment owners who want to ensure their employees are using the equipment in a safe and efficient manner. Telematics provider Geotab recently introduced its GO9+ solution featuring Wi-Fi connectivity to help make it easier for fleets to track and monitor their equipment. Bluetooth beacons can be placed on tools and equipment which communicate with a Wi-Fi hub which then communicates with the Geotab technology. Colin Sutherland, Executive Vice President, Sales & Marketing at Geotab, says when the company launched the new telematics solution customers said the biggest value was the amount of data generated to help with business operations. Because the device includes both cellular and Wi-Fi components, customers can potentially reduce their cellular data costs. Many equipment fleets have multiple

OEM Off-Highway | APRIL/MAY 2021

COVER STORY: TELEMATICS SYSTEMS oemoffhighway.com/21354479 DANFOSS POWER SOLUTIONS

Danfoss’ PLUS+1 connect provides an end-to-end data collection and transmission solution.

portable devices and cellular plans which can become costly. Having a single solution capable of providing all of their data needs can help to reduce these costs. Sutherland notes customers can set their rate plan to best meet their business needs. “We’re initially launching with a 2-gigabyte rate plan because we expect a lot of users to be dropping their expensive cellular plans and bringing it all through the GO9+ device,” he says. Customers have told Geotab they will be better able to track data consumption with this new device and operate more cost effectively. “It’s all about operating costs in the field,” says Sutherland. “And in 2021 it’s about staying lean, giving people productive tools, and eliminating wasted time. So you can find a tagged asset and you know where it’s used. Combining connected assets and devices enables an employee to work effectively in a really seamless way. And that’s what excited us when we launched GO9+.”

While tracking a large piece of equipment will be beneficial, so too will the ability to track and monitor non-powered assets such as attachments and tools, even cargo in some cases. Alex Romero, Product Manager for Software and Connected Solutions at Danfoss Power Solutions, says the telematics portfolio the company is launching keeps in mind the fact heavy equipment also continues evolving. “Not all machines have been equipped with enough intelligence to capture how the machine is performing in the field, and some of them are more evolved than others,” he explains. “[Some customers] may need more help from the intelligence that resides within the telematics gateway.” Reliability and security of the information is integral, as well. Ensuring that is why Danfoss has chosen to engineer its own telematics system from the ground up. Romero says doing so provides more control over the type of protocols used for communicating information. The entire communica-

OEM Off-Highway | APRIL/MAY 2021

tion chain—other than the cellular network and infrastructure—is owned by Danfoss which enables it to provide customers with the data they need in a safe and secure manner. The company is able to do this by ensuring its telematics gateways are compliant with the latest cybersecurity protocols and the right encryption to make sure the data is not exposed. “A part of this evolving digital environment is data itself,” says Teplyakov. “It’s about data ownership, and then data privacy. And by having full control over our system, we can deliver these services to our customers without including, any more than necessary, third parties which could bring an element of risk to the whole environment.”

Telematics and the growth of connectivity Over the past 20 years, Sutherland says diagnostic trouble codes (DTC) have moved beyond those which were engine or sometimes drivetrain focused to other components such as PTOs.

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More sensors are also being incorporated into components and systems to make them, and the overall piece of equipment, smarter. All of this is providing more information to help fleets maintain equipment and maximize uptime, he says. However, it can be challenging to bring all of this information together, which is where telematics plays a role. Bringing all information and connected devices together to a common upload point—such as a telematics system— makes everything easier to manage. The never-ending quest for productivity, which all of this information and maintenance planning looks to improve, has been a key driver for the increased use of digital technology in the heavy equipment industry says Romero. “We’ve seen a large wave of adoption and willingness to adopt digital technology and specifically connectivity,” adds Teplyakov. More OEMs are doing so because the cost of entry is lower due to the rate at which technology has evolved. Many see the additional features which can be provided through digitalization as a requirement to compete in the market, as well. Implementing connectivity and digitalization must be purposeful. Teplyakov says it should either solve a problem or increase reliability and productivity while reducing downtime. What that means for the off-highway equipment market can be very different. “The large OEMs understand what data needs to be collected and how they can show users the valuable information collected in order to drive these productivity improvements,” he says. “For the majority of the market, what that means could be very different.” As such, he says every OEM customer needs to look at its own machine designs and what constitutes productivity benefits and reduced downtime. Based on that, it can then implement the right technology. “Because we cater to this market of small and medium

OEMs, we need to have a very flexible platform that can be configured to these different needs,” says Teplyakov. The user interface of Danfoss’ system is customizable with various levels of dashboards. Teplyakov says customers can configure which signals they want to monitor and at what frequency. There are also customizable reporting tools through which historical data can be viewed in a way the customer needs. He says Danfoss consults with customers to determine what problems they’re looking to solve or where

GEO

TA B

they want to make improvements. “It’s a learning process that together with the customer we go through every time.” It is a growth process as well, he says. Telematics systems can provide some basic features such as machine monitoring. Adding connectivity can then further expand up these features while also making them faster and more automated. “We always say that changing what you’re already doing to implement connectivity usually will not lead to the kind of success you want. But rather, you should augment the processes that are already in place by adding these data insights into your machine,” says Teplyakov. “And then you can grow from there. As you’re learning more about what the possibilities of connectivity are, then you start looking at more and more advanced features.”

OEM Off-Highway | APRIL/MAY 2021

When adding connectivity, he again notes the importance of an OEM understanding its machine and what signals would possibly provide deeper insights to aid end-use customers. Telematics play an important role in connectivity and the digital transformation of the heavy equipment industry, and is a key enabler component, says Romero. “To create an efficient machine network and deliver the promise of internet of machines, you need to connect them,” he says. “Connectivity technologies [like telematics] and pervasive expansion of wireless infrastructure has been key Geotab’s new GO9+ to this includes cellular and Wi-Fi connectivity. proliferation of connected machines.” As machines continue to become more connected, it will be critical to also connect all of the different cloud platforms on which they run. Teplyakov says it will be necessary to have the cloud platforms communicate with one another to create machine networks which reach beyond a single IoT (Internet of Things) environment. “That then will lead to connecting not just machines themselves but the actual worksites,” he says. Doing so would enable not just machines to be monitored but also the flow of various materials and resources. This would benefit a variety of industries including construction, agriculture, mining and others.

Proving the potential of EVs and alternative fuels As alternative fuel and power sources become more prevalent in the heavy-duty vehicle and equipment markets, telematics technology will be able to provide insights into how they perform, as well. Sutherland says there are several

alternative fuel vehicles currently in the market which Geotab’s telematics technology supports. It is able to provide not only the day-to-day operational health information but also the potential re-market value of a vehicle. “We’re proving to some companies that previously thought buying an alternative fuel vehicle was going to be really expensive to maintain in the fifth, sixth or seventh year, that actually the vehicle has about double the life of their combustion vehicle,” he says. With electric and alternative fuel vehicles, customers will likely want to hang on to them for 1 million miles, not half a million miles as currently typical with combustion engine powered vehicles. “It’s pretty impressive to see the distance the alternative fuel vehicles get, and how low per running cost per mile they actually will run,” says Sutherland. As more alternatively powered vehicles and equipment enter the market, he says Geotab’s technology can help educate the industry about what is feasible with these new models. It can help a fleet see what assets could be electrified or operated on an alternative fuel, which Sutherland says is key to these new technologies’ uptake in the market. “It’s giving people some benchmarks and trust that when they have to go to an alternative fuel…they will have the confidence to make that decision.” The Geotab technology can also be used to provide insights to the OEMs of these alternatively powered vehicles to help them ensure their designs are meeting the needs of the market. Sharma says electrification and automation will provide a big opportunity for telematics and fleet management solutions providers. Vehicles will be more connected and capable of providing more insights into how they are being used. “It enables us to provide a lot more insights to our customers in a very intuitive way,” he says. There will also be a shift in safety and operations as these vehicles enter a fleet; more of the operations, such as maintenance, will become automated.

“There’s a big change which is going to happen and I think fleet management services like ours will play a huge role, intermediating the gap between what they [fleets] currently have and how they’re shifting,” says Sharma. Going forward, every component and system is going to be natively connected from the beginning, he says. “As we move forward with the technology, every piece of equipment, every piece of a vehicle will have its own insights. And the more we learn, the more it will be required for someone to gather those insights and explain or give actionable next steps to take. That’s the way this evolution is going to take place and it’s more about how you digest the information and present it to the customer so they can take the next steps,” concludes Sharma. |

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ENGINE SYSTEM A concept for Libertine’s end product which brings together the electric components as well as control hardware and software into a platform engine developers can use to command compression ratios cycle by cycle.

oemoffhighway.com/21342647

ENGINE TECHNOLOGY to Meet Emissions Regulations and Beyond

LIBERTINE FPE

Advancements in engine systems will continue to focus on improving efficiency and reducing emissions. by Sara Jensen

L IB E

R T IN

Replacing crankshafts with software control allows every combustion event to run optimally using realtime compression ratio control.

E E FP

lthough there is a lot of focus these days on alternative power systems such as batteries and fuel cells, internal combustion engines will continue to play an important role in heavy-duty applications. As such, it will be necessary for manufacturers to keep evolving their designs to optimize performance and reduce emissions. “Almost every region of the world has air pollution regulations in place or is developing them,” says Gregory Pelton, Senior Manager – Sales and Application Engineering Construction, Industrial and Agriculture at MTU America Inc. “These ever more

stringent emissions regulations require the deployment of new or optimized technology.” MTU, like most engine manufacturers, has developed a platform of dual certified engines which meet EU Stage V and U.S. Tier 4 Final emissions regulations while also offering a solution for lesser regulated areas. Stage V is the most stringent regulation to date for the off-highway equipment industry; developing engines which meet it as well as other regional regulations eases installation and design costs for OEM customers by giving them the flexibility of using the same engine for various emissions regulations. Developing these dual certified

OEM Off-Highway | APRIL/MAY 2021

engines required optimization of the entire engine package, says Pelton. Continued optimization of the engine and aftertreatment system enabled reductions in fuel consumption as well as longer service intervals, providing customers with further benefits. These types of optimization efforts will also be necessary when new regulations are introduced to the industry, he says. Nick Block, Director, Worldwide Marketing & Sales, John Deere Power Systems (JDPS), says leveraging the company’s experience to refine the technologies it has developed over the years aids engine optimization. Areas he says JDPS is focusing its efforts include improvements in package

LIB ERT INE FPE

Enabling greater control over compression ratios provides more flexibility in the types of fuels engine manufacturers can use.

size, reducing overall engine weight, and integrating new generations of electronic control systems, which offer greater capabilities. “In the future, we anticipate there will be a completely new generation of engine electronic control systems that will be more capable,” he says. “One trend we know will continue to evolve in the coming years is less reliance on physical sensors as engine control units continue to become more advanced and enable greater engine control and diagnostics performance.” Block says JDPS used a next-generation engine control unit (ECU) in its 13.6L engine; the new ECU utilizes advanced model-based controls which enhance reliability and transient control.

Technology improves performance Efficiency is a key area in which many manufacturers focus their design efforts. Block says for JDPS this includes looking at ways to improve fuel efficiency. To do so, it is addressing combustion and air handling efficiency, as well as managing friction losses by leveraging advanced modeling techniques. For its 13.6L engine, JDPS used a

clean-sheet approach; designing the engine from the ground up better enabled the company to address many of the areas it wanted to improve. “One of the objectives of that project was to manage in-cylinder efficiencies,” he says. “We designed this engine for increased firing pressures to accommodate fast fuel burn while minimizing heat losses, leading to increased performance.” “We recognize that if we’re going to make our transportation more sustainable, we need to make engines more efficient,” says Laurence Fromm, Executive Vice President of Business Development, Achates Power. Achates Power is currently evaluating the use of opposed-piston engines. Though not a new concept, Fromm says it was previously thought that while opposed-piston technology was more efficient than conventional engines it would be a challenge to meet modern emissions standards. However, the company has found it to be the opposite; the technology he says is actually cleaner in addition to being more efficient. He explains that in a conventional engine, there is a piston which goes back and forth in a cylinder. But in an opposed-piston engine, every cylinder has two pistons which come together. The piston crowns are what forms the combustion chamber. “There’s a lot of benefits to that architecture,” he says. As there is no longer a cylinder head, efficiency can be improved because heat losses typically associated with cylinder heads are eliminated. Fromm says in conventional engines cylinder heads get very hot and aggressive cooling is needed, and all the heat is wasted energy. “We can take more of the energy in the fuel and turn it into useful work,” he says. Studies have shown an opposed-piston engine can be 13-15% more efficient due to the reduced heat loss and other benefits, he notes.

Achates currently has several major projects it is working on, one of which is developing an advanced combat engine for the U.S. Army. Fromm says power pack density—how much power can be put into a unit—is the main criteria for the Army. The entire engine system including the engine itself, fuel system and cooling system are part of this power pack because it all needs to be under armor. Fromm says the engine it is developing with Cummins Inc. doubles the power pack density of other engines. “We have a smaller engine, a smaller cooling system, and because we’re more efficient we have a smaller fuel system,” he explains. “That allows us to deliver twice as much power per unit volume.” This is important for a combat vehicle because it can move and accelerate faster and more easily climb hills, all of which makes it easier to engage and evade enemies. By not having a cylinder head, heat losses are minimal; heat rejection is about 30% less than a conventional engine, says Fromm. This means the cooling system size can be reduced about 30% as well, which helps reduce space claim for the engine system. The engine itself is also smaller while providing more power density due to it being a two-stroke engine. “We get a power stroke in every cylinder on

ACHATES POWER INC.

An illustration of Achates Power’s opposed-piston engine design.

OEM Off-Highway | APRIL/MAY 2021

oemoffhighway.com/21342647

MTU AMERICA INC.

ENGINE SYSTEM

every revolution of the engine which is inherently more power dense than a conventional engine.”

MTU’s Series 1000, 1100, 1300 and 1500 engines are available with dual-certification for use in multiple global markets.

Expanding fuel options Libertine FPE is currently developing opposed free-piston engine technology which replaces the crankshafts with software control. Doing so would allow every combustion event to run optimally using real-time compression ratio control. This will enable engines to be even cleaner and more efficient, says Sam Cockerill, CEO of Libertine FPE. It will also enable a fossil free future. In particular, it will allow the use of renewable fuels like ethanol and methanol. Making fuels which act like petrol and diesel is expensive and energy inefficient. “Making simple molecules like ethanol and methanol, it’s easy to do, it’s cost effective, it’s more energy efficient, and it has lower greenhouse gas impact,” says Cockerill. However, to use these renewable fuels he says there is a greater need for more nuanced compression ratios

which today’s engines are not able to do. Libertine is looking to address this issue by using software instead of a crankshaft which is essentially a thumping piece of metal that can not be controlled as well. “We’re putting the freedom to choose your compression ratio every cycle into the hands of combustion engineers, so they can make better engines for renewable

Achates Power’s 10.6L heavy-duty diesel engine in a Peterbilt 579 truck which will be driven in fleet service in California later in 2021.

ACHATES POWER INC.

OEM Off-Highway | APRIL/MAY 2021

fuels,” says Cockerill. He notes this is a challenge engineers have been trying to overcome for several years with various designs but generating electrical power whilst maintaining piston motion control has proved troublesome. Advances in power electronics, embedded controls and magnetic materials in recent years, though, has provided new opportunities. Libertine is bringing together the electric components as well as control hardware and software into a platform which engine developers can then use to command compression ratio cycle by cycle, just as they do with fueling and ignition today. “By making that platform part of the technology environment that a combustion developer can use, it shortcuts the development of free piston engine products by years, possibly as much as a decade,” says Cockerill. This means it could be possible to bring alternatively fueled engines to market faster, helping manufacturers and end use customers meet emissions reduction targets sooner. “If you replace the crankshaft with linear electrical machines, it’s a fuel flexible engine,” he says. While there are a few aspects that still need to be considered such as material compatibility in the fuel lines and injector choice, in general having control over the compression ratio enables fuel flexibility.

A LONG WAY

TOGETHER

This in turn means that an engine can be designed to run on future fossil-free fuels such as ethanol and methanol whilst being backward compatible with fuels that are in use today. Cockerill says this flexibility solves the ‘chicken and egg’ problem that faces new engines designed exclusively for new fuels. He says there is a lot of interest in Libertine’s technology for heavy-duty on- and off-highway engine applications. This is because battery-electric solutions alone will not be sufficient to meet emissions reduction goals due to the size, weight and power density needed, as well as lack of charging infrastructure in many cases. As such, internal combustion engines and the ability to use alternative fuels will be necessary in these applications. “Renewable fuels and internal combustion engines, those work today,” he says. “I think they will be a big part of the future.” Many acknowledge that electrifying heavy-duty applications will be difficult, necessitating a mix of options to decarbonize the industry.

Meeting current and future emissions regulations Reducing emissions will continue to be an area of focus for manufacturers as they and their customers look to minimize their environmental impact in the coming years. Governments around the world are also implementing stringent carbon reduction goals which will necessitate OEMs and engine manufacturers finding ways to reduce emissions further. The latest emissions regulations have mainly been focused on the heavy-duty on-highway market, such as the Phase 2 Greenhouse Gas (GHG) standard for medium- and heavy-duty vehicles through model year 2027 in the U.S. However, many in the industry anticipate similar regulations from the on-road side will make it into the off-highway market at some point in the future as well. “The on-highway emissions regulations have typically paved the way for subsequent off-road standards,” says Pelton. “The Phase 2 GHG standards are a great example of what most in the industry expect to see in off-road equipment as well. It will become whole vehicle optimization with the diesel engine itself

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OEM Off-Highway | APRIL/MAY 2021

ENGINE SYSTEM oemoffhighway.com/21342647

playing only a part in the total solution. This will require even stronger partnerships with our OEM customers as we will have to work together even more closely to produce products demanded by both the users and whatever regulations are in place.”

ports on one side of the engine and exhaust ports on the other side. It’s the piston motion that opens and closes the ports. And that port timing allows us to scavenge the cylinder in one direction. So the exhaust ports open first, the exhaust goes out, the intake

Advances in power electronics and embedded controls have provided new design opportunities. Fromm says one of the big advanports open, we put new fresh air in, tages of Achates’ opposed-piston enthe ports close and we compress and gine design is its ability to reduce NOx ignite,” explains Fromm. (oxides of nitrogen) emissions which “We’re able to dynamically change will be beneficial for both on- and how much exhaust gas we leave in off-highway equipment manufacturers. the cylinder,” he continues. “When we “California just passed NOx emissions want to generate a lot of enthalpy, we for on-road vehicles requiring another go into what we call a catalyst light 90% reduction in NOx starting in 2027,” off mode where we reduce the flow he notes. “They said they’re going to through the engine.” now focus on off-road as their next Maximizing the area to take a look at to lower NOx.” amount of exTo reduce NOx, he says it is necessary to quickly get the selective catalyst reduction (SCR) system as hot as possible to ensure only harmless nitrogen and oxygen come out of the vehicle’s tailpipe. An opposed-piston engine is able to achieve this as it has very high enthalpy to heat up the catalyst while achieving low engine out NOx. “The reason we can do this is because in the opposed-piston JO H N DEER E PO WER SYST engine, we have intake EMS

OEM Off-Highway | APRIL/MAY 2021

haust gas that stays in the cylinder enables it to get hotter as it sits in the cylinder; the hotter it is, the better able it is to quickly light the catalyst. Fromm says because this exhaust gas has already been combusted, it has the effect of internal exhaust gas recirculation (EGR) which is commonly used for reducing NOx. Whereas a conventional engine will have to pump exhaust gas in and out, the opposed-piston engine is able to reduce this extra work through its dynamic control of the gas and leave it in the cylinder. “We have engines on our dynamometer now that we’ve measured the ability to meet the 2027 California requirement for a 90% reduction using conventional aftertreatment systems available today,” he says. “Conventional engines have been improved a lot over the last 30 or 40 years,” says Fromm. “But every time we try to make them less harmful in terms of CO2 or criteria emissions, it’s getting harder because we’ve already wrung so much out of it. We’ve reached the point of diminishing returns; it’s getting more expensive to make it better.” With the opposed-piston engine though, he says there is still room to continue making improvements. “The opposed-piston engine has built-in advantages that allow us to go beyond what’s going to be required John Deere’s 13.6L engine features a next-generation ECU utilizing advanced modelbased controls which enhance reliability and transient control.

The Integrated Emissions Control System (IECS) incorporates the components right into the system rather than utilizing a separate mixing pipe, enabling it to be more streamlined and compact.

ST EM S E PO WE R SY JO HN DE ER

in 2027 to reduce both CO2 and NOx even more.” Block also agrees that additional NOx reduction standards being considered for on-highway vehicles will eventually make their way into off-highway emissions regulations. “This will impact the industry as manufacturers continue to keep track of nuanced regulations from country to country while helping their customers manage necessary transitions,” he says. To meet these and any other new

emissions regulations, Block says it will be important to focus engineering efforts on combustion technology. “We need to continue to consider engine design elements such as power cylinder, cylinder heads, air systems, and fuel injection parameters. It’s not one single thing, but rather a variety of refinements for system optimization.” Managing air flow through the engine will be important, as well, especially if the on-highway NOx reduction standards go into effect for off-highway applications, he says. Improving the efficiency of aftertreatment systems will also be important. The company’s Integrated Emissions Control System (IECS) is an example of the improvements that can be made to an aftertreatment system.

Block says it incorporates the components right into the system rather than utilizing a separate mixing pipe. Improvements in the catalyst and substrate technologies allow for smaller sizes while also reducing the amount of metal previously used. “These combined improvements allow for an improved, streamlined aftertreatment design that is more compact, flexible and lower in cost.” Virtual analysis will play a key role in continued development efforts. Block says it allows the company to define and optimize engine subsystems to achieve performance enhancements before creating any hardware or building the combustion system. “We’re continuing to explore new technologies that enable advanced combustion concepts for continued improvement of the diesel engine,” he concludes. |

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MARKET FORECAST: MINING EQUIPMENT OE LINK™ PRODUC TION – FORECAST DATABASE

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Power Systems Research forecasts a 13% rebound for the North American mining equipment market in 2021. ©ALEX – STOCK.ADOBE.COM

BETTER TIMES AHEAD for North American Mining Equipment Market Mining equipment production is forecast to rebound in 2021, and grow 3.8% through 2026. contributed by Jim Downey, Vice President-Global Data Products, Power Systems Research

he mining equipment market in North America is showing signs of recovery based on the number of shipments being up in the fourth quarter of 2020 compared to previous quarters in 2020. COVID-19 dramatically affected the mining equipment market, driving down commodity prices, requiring labor force restrictions and disrupting supply chains. Although 2020 was a setback in terms of production of mining equipment, the short-term outlook is quite favorable based upon Power Systems Research’s (PSR) global economic forecasts and vaccine rollouts. Better times for mining appear to be ahead in 2021 and beyond.

Looking at mining equipment production, PSR sees a rebound for the overall industry from 2020 of about 13% for 2021 and compound annual growth rate (CAGR) of 3.8% for the years 2021-2026. Production information for mining equipment comes from OE Link™, the PSR proprietary database of OEM production and forecast data. OE Link™ covers internal combusion engines and electric- and hybrid-drive systems for vehicles, as well as stationary and mobile applications. PSR has been tracking these production trends since 1976.

The Caterpillar example Caterpillar is a good example of what is happening in the mining equipment

OEM Off-Highway | APRIL/MAY 2021

segment and the resulting reduced volumes from 2019 to 2020. The company’s Resource Industries business is focused on machinery used in heavy construction and mining, for both surface and underground operations. Caterpillar’s equipment is used to extract and haul copper, iron ore, coal, oil sands, aggregates, gold and other minerals and ores. The COVID-19 pandemic caused a global recession and it is uncertain when a sustained economic recovery may occur. The COVID-19 pandemic has also significantly increased economic and demand uncertainty, and Caterpillar notes that COVID-19 has led to a general decrease in demand for its products and services and caused

OE LINK™ PRODUC TION – FORECAST DATABASE

supply chain disruptions. Total sales for the Resources Group within Caterpillar were $7.906 billion in 2020, a decrease of $2.370 billion, or 23%, compared with $10.276 billion in 2019, the company reported. The decrease was due to lower sales volume, driven by lower demand for equipment and aftermarket parts and the impact from changes in dealer inventories. Cat dealers decreased inventories during 2020, compared with an increase during 2019. Mining equipment end-user demand and aftermarket parts demand were down in 2020, though to a lesser extent than in construction. Mining equipment sales were affected by mining company delays in capital expenditures due to pricing in some commodities and overall economic uncertainty. Resource Industries’ profit was $896 million in 2020, a decrease of $733 million, or 45%, compared with $1.629 billion in 2019. The decrease was mainly due to lower sales volume, partially offset by favorable manufacturing costs. The larger magnitude decrease in profitability (-45%) versus the decrease in revenue (-23%) for the Resource Industries segment within Caterpillar illustrates that in a lower volume, higher

cost industry like mining equipment production, the potential profits are likely to fall off more quickly than revenues in this rather capital intensive segment with substantial overhead costs.

Surface mining versus underground mining The mining segment has two sectors: surface mining and underground mining. Surface mining equipment includes crawlers, excavators, off-highway trucks and wheel loaders/dozers. For purposes of splitting out the market, PSR has assumed that equipment rated greater than 400 hp (298.3 kW) is used for surface mining and those equipment types less than 400 hp for crawlers, excavators, off-highway trucks and wheel loaders/dozer are used more exclusively in construction and earthmoving applications. Surface mining outlook Looking at surface mining equipment production in North America, production levels dropped from over 4,900 units in 2019 to just over 4,200 units in 2020 or a decrease of 15%. PSR sees a rebound of 13% in 2021 as unit

production increases from 4,200 units in 2020 to just shy of 4,800 units in 2021 and close to pre COVID-19 levels. The outlook includes a CAGR of 3.7% for the production of surface mining equipment in North America over the years 2021-2026. The need for new equipment for mining operations is increasing. It is speculated that there will be growth in the excavation of iron ore, nickel and bauxite then followed by gold and copper. Battery-electric mine trucks are on the way. Although in early stages, development of a battery-electric powertrain and a fast charging solution are being worked on for use in surfacing mining equipment. Underground mining outlook The underground mining segment is much smaller than surface mining and totaled only about 400 units in 2019. The products included in underground mining include a variety of purpose-built equipment including mining loaders, mining locomotives, mining personnel carriers, mining utility vehicles, ore transporters and some smaller volume niche type products that are either self-propelled The COVID-19 pandemic was a factor for many OEMs, like Caterpillar, causing a general decrease in demand for mining equipment in 2020. CATERPILLAR INC.

OEM Off-Highway | APRIL/MAY 2021

MARKET FORECAST: MINING EQUIPMENT

EPIROC

oemoffhighway.com/21366090

Equipment overview Here PSR will look at what is happening in some of the key machine applications which represent the largest share of annual volumes within mining.

Manufacturers like Epiroc are developing electric powered equipment for underground mining to help reduce emissions which improves safety for workers.

or stationary. North American production volumes of underground mining equipment dropped by 21% in 2020 to about 320 units. PSR expects production volumes for underground mining in North America to rebound by 7.5% in 2021 to a total of 344 units. Automation and electrification are also helping with market growth and

productivity. Underground mining equipment is very viable for autonomous and electrified machines. The coal segment alone accounts for approximately 40% of underground mining activity. It appears that mining for copper will be on the rise and therefore, increase the production of new mining equipment over the next couple of years.

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Wheel Loaders/Dozers PSR sees 2021 production for wheel loaders and dozers used in mining applications (greater than 400 hp) climbing about 19% to 2,374 units from a 2020 level of just over 2,000 units. This follows a decline from 2019 to 2020 of 18% driven by Tier 4 engine regulations/new machine designs that significantly increased machine cost along with COVID-19 related factors. The North American production leaders in this space, according to Carol Turner, Power Systems Research Senior Analyst, include Caterpillar and Deere with a majority share of production and other players of these heavy-duty wheel loaders and dozers including brands like Hitachi and LeTourneau. Production is expected to moderate over the next several years, driven by global economic factors, but North American production of wheel loaders and dozers for surface mining applications are expected to have a CAGR of 3.6% over the period 2021-2026. Excavators North American production of large excavators used in surface mining applications (greater than 400 hp) experienced a decrease of 7% from 2019 to 2020 falling from 993 units to 923 units in total. PSR expects a recovery within large excavators in 2021 of about 7% which will bring the excavator production back into line with 2019 levels at over 980 units. The production for excavators is typically more stable than other products within surface mining as these are generally on a more “predictable” replacement and consumption cycle. PSR forecasts a CAGR for large excavators of 1.6% over the period 2021-2026. Off-highway trucks The off-highway trucks application

OEM Off-Highway | APRIL/MAY 2021

includes both rigid haul and articulated trucks. North American production volume of off-highway trucks fell 15% from a level of 1,153 in 2019 to 975 in 2020. PSR expects a recovery of 10% in 2021 to 1,077 units and an additional 10% in 2022 to 1,187 units. The outlook to 2026 is positive with a CAGR of 5% over the years 2021-2026 which reflects the demand for off-highway trucks and the central role they play in core mining operations.

Macro outlook PSR does not expect any rapid recovery in overall global economic activity during the first half of 2021, but it does see an increase in activity in the second half of 2021. Even though COVID-19 vaccinations are underway, the pandemic continues rising in many parts of the world. This will delay economic recovery efforts, both regionally and globally.

Furthermore, potential logistical difficulties in the rollout of the vaccines, structural damage to labor markets and U.S.-China tensions also pose downside risks. With support from governments, the demand for products and services globally is slowly coming back, and PSR expects this trend to significantly increase during the second half of 2021. Government stimulus, particularly in the United States, is likely to provide a major boost to economic activities. According to a report from the Organization for Economic Development, global GDP growth is now projected to be 5.6% this year, an upward revision of more than 1 percentage point from the December OECD Economic Outlook. Overall, global output is expected to reach pre-pandemic levels in the second half of 2021. Global inflation should remain

broadly stable during 2021. While price pressures in developed economies should intensify as economic activity recovers, inflation concerns in developing markets has been declining mainly due to stabilizing currencies and reduced supply-side pressures. To briefly summarize the global industrial outlook for 2021, it is clearly visible that most market segments, including mining in North America, are set to show recovery and growth relative to 2020. Bottom line: The mining industry will continue to evolve and adjust over the next 3-5 years but nonetheless will be back on its legs from the setbacks experienced during 2020. | This article was written and contributed by Jim Downey, Vice President-Global Data Products, Power Systems Research.

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OEM Off-Highway | APRIL/MAY 2021

ELECTRICAL & ELECTRONICS: SENSORS

Embedded sensors can provide an array of data to help improve the safety and performance of heavyduty equipment.

In-Cylinder Sensors Solve Old Problems with New Thinking Embedding position sensors into hydraulic cylinders can provide new performance features previously not thought possible in heavy-duty equipment. contributed by Aaron Sabino, Product Manager at MTS Sensors

s new technology is integrated into long standing vehicle designs, the new abilities often inspire previously unanticipated uses that solve problems, improve efficiency, and lead to competitive advantages. Inspiration comes in many forms. For engineers and mechanical designers, new technology can both expose problems that were previously undetected and provide new thinking to solve problems

that were thought impossible. GPS grade control systems started a major expansion of data-driven innovation in the earthmoving and construction segment in the mid2000s. These systems combined freely available Global Positioning data with on-board machine sensors and control systems to enable automated grade checking, equipment location, and topographical surveying. These systems played a major part in shaping

OEM Off-Highway | APRIL/MAY 2021

the modern job site where each vehicle has visibility of survey points, utilities, and elevation while the site supervisors receive real-time locations of the vehicles themselves. The first GPS grade management systems employed two GPS receivers that were typically mounted on long masts that were bolted to the blade of the vehicle. Two points of position are the minimum required to calculate the angle of the machine relative

oemoffhighway.com/21271252

Sensors which can be embedded into hydraulic cylinders can provide highprecision data to enable new machine performance features. MTS SENSORS

to the site plan. This arrangement functioned well and transformed construction sites in a few short years, but there were limitations and unforeseen problems. For example, the exposed sensors became a common target of theft which often resulted in the tedious process of disassembling the masts and storing them in a secure location at the end of each workday. Not only did the assembly and disassembly of the masts take time, but the process also introduced a safety risk. Removing the masts would require the operators to handle the top-heavy poles often in slippery conditions while standing on the blade of the vehicle. In addition, the communication cables and masts themselves could be damaged from low hanging branches or other obstacles common on a construction site. Finally,

the mast assemblies could restrict the visibility of vehicle operators.

Embedded sensors provide new performance opportunities To solve these problems for the next generation of grade management vehicles, design engineers at a construction equipment manufacturer introduced their first mast-less motor grader with grade control in 2019. This new mast-free arrangement relocated the two GPS receivers to the top of the cab where their embedded construction reduced the opportunities for theft.

They then added inertial measurement units (IMU) on the body of the machine and Temposonics® linear position sensors embedded into the cylinders that control the blade. The hydraulics with the new in-cylinder sensors included the two lift cylinders, circle side-shift, blade side-shift and pitch cylinders. High-precision data from these sensors is used by the onboard control system to determine the exact position of the moldboard in real time.

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OEM Off-Highway | APRIL/MAY 2021

Use of in-cylinder positioning sensors can help maximize the cycle time of the dump process on front-loading garbage trucks.

of the machine. This would often occur with new operators during training and could result in costly downtime. However, with the new positioning information from the in-cylinder position sensors the engineers were able to use the controller to create a “keep out zone” that restricts motion when the blade approaches the sensitive parts of the vehicle, while still allowing for full maneuverability elsewhere.

Sensors deliver advanced control capabilities A similar inspiration for new features happened to a leading garbage truck manufacturer when it added in-cylinder position sensors to a family Early GPS grade control systems included masts which could be cumbersome to assemble and disassemble.

fer new innovative solutions. One such problem involved operators causing damage to the motor grader by inadvertently driving the moldboard directly into the tire, cab steps, or other parts

of front-loading vehicles. It is worth noting that the garbage collection industry was initially reluctant to integrate automated, sensor-controlled systems. However, this manufactur-

OEM Off-Highway | APRIL/MAY 2021

CATERPILLAR INC.

This resolved the issues of visibility, security, and restricted movements. The enhanced maneuverability allows an operator to cut into grades that would not be possible with the previous double mast design. The new design also enhanced efficiency. Rough cutting of a grade would often induce enough shock and vibration to potentially damage the GPS masts, so they were typically not installed until a precision fine cut was required. Removing the masts from the design means that rough and fine cuts can be completed in the same vehicle setup. Having new real-time data of the moldboard also inspired the design teams to re-think old problems and of-

er was determined to increase the productivity of its systems and found it could mitigate some real-world safety issues along the way. Construction equipment manufacturers had demonstrated that it was possible to select robust magnetostrictive linear position sensors that not only survived in harsh environments but provided a technological advantage. Could the same be done for waste collection? The waste hauling industry is very sensitive to loss incurred from vehicle downtime. Profit is driven by achieving the lowest Total Cost of Collection (TCC) where speed and efficiency of completing a collection route enables an expansion in the number of customers that can be serviced with a given fleet. Vehicles that need to stop for unexpected service issues can cause ripple effects which disrupt the entire network of carefully planned routes. In addition to speed, accuracy and noise reduction are critical to keeping customers happy. Container capture and dumping systems that miss the target can cause unpleasant or even dangerous spills, not to mention delays. Keeping noise to a minimum increases the ability of the waste hauler to run routes at early morning or late evening times when a loud banging of a garbage can getting slammed at high speed into the bed of a truck would be cause for complaint. One of the garbage truck OEM’s solutions to increase efficiency of customers’ routes was to improve the

speed of the dumping mechanism on its front loaders. To do so, the OEM reduced the number of proximity switches and employed in-cylinder positioning sensors to maximize the cycle time of the dump process. The sensors allowed real-time monitoring of the cylinder position. With advanced control algorithms, the system could maximize acceleration through the dump cycle and then ramp down the speed of the hydraulics as they approached the mechanical stops. This type of “electronic cushioning” is a common benefit of in-cylinder sensors that prolongs the life of the vehicle by reducing the impact at the end of travel faster than an unassisted operator. It also has the benefit of minimizing the noise associated with hard stops even while maximizing the speed of the cycle. In addition to reducing the complexity of the controls, integrating the sensors inside of the hydraulic cylinder made them less prone to environmental damage such as tree branches, harsh weather, or even human tampering. Once the initial benefit of the in-cylinder sensors were realized, the company’s engineering team became inspired to do more with the new data sources and capabilities that were available to them. Like the motor grader manufacturer, their first task was to identify ways to protect operators with new keep-out zones. Where it was previously possible for unskilled operators to inadvertently position the load in such a way that it could damage the cab and cause bodily harm, the data from the smart cylinders could ensure that dangerous positions were off limits and prevent costly mistakes from purely manual operation. This garbage truck manufacturer has since increased the use of in-cylinder sensors across its product line including its automated side-loader trucks which can align, reach, grasp, and dump residential waste bins with maximum efficiency. This includes the ability to retrieve waste containers that

have toppled or been knocked over. The design teams continue to be inspired by what the new sensors can do and are now investigating advanced vehicle diagnostics to drive preventative maintenance and identify hazardous conditions such as sudden loss of hydraulic pressure or the leak-

ing of hydraulic fluid. While new technology is being introduced every day, it is often the knock-on effects of utilizing these advances in real-world design which can inspire completely new advancements that were never imagined or thought possible. |

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NEW PRODUCTS

High-Speed Connector

800V Electric Motor for Commercial Vehicles

Amphenol Industrial Operations has enhanced its Max-M12 product line to include an X coding, highspeed connector with support for 10Gb/s data transmission and S coding for a safer connection with First Mate Last Break. • Endures extreme temperatures ranging from -55-125 C (-67-257 F) • Current rating of 4A • IP67 rating makes dust and waterproof • Can withstand up to 240 hours of salt spray • Ideal for high-speed data transmission • Can easily transmit high speed data in environments with high vibration, moisture, salt, dirt and debris • Can be used for off-road vehicles, ruggedized factory automation and robotics signal applications

BorgWarner’s latest High Voltage Hairpin (HVH) electric motor, the HVH 320, is ready to power a variety of hybrid and electric applications for commercial vehicle manufacturers. • 800V capabilities and available in four variants • Delivers approximately 97% peak efficiency and over 400 kW (536.4 hp) of power • Enables customers to significantly reduce charging time and achieve higher power density • Modular and flexible design platform meets customers’ varied requirements • Offers clean and quiet operation • Reaches torque output of up to 1,270 Nm (936.7 lb.-ft.) • Supports vehicle’s shifting sequence

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The Zero-Max VRT Variable Ratio Transmissions are designed to ensure accurate and consistent application rates for agricultural seeding and fertilizing equipment. • Provides critical link between control system and the mechanical seed and fertilizer distribution mechanism • Maintains seed and fertilizer placement accuracy even when the ground speed of the equipment changes • Infinitely adjustable to obtain the exact desired ratio • Ratio can be adjusted when idle or when running • Easily, quickly and precisely makes speed adjustments

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Variable Ratio Transmission

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Radial Tire for Articulated Dump Trucks, Loaders and Dozers BKT introduces its EARTHMAX SR 412 OTR radial tires. • Robust casing and all-steel belts aid transport of heavy loads while preventing tears and punctures • E-4 tread depth guarantees exceptional traction and high heat resistance • Square shoulder ensures solid grip on the ground, providing greater vehicle control and maneuverability • Available in 29.5 R 25 and 750/65 R 25 sizes • Provides better load distribution on the ground to aid comfort, safety and stability www.oemoffhighway.com/21319206

OEM Off-Highway | APRIL/MAY 2021

Stage V Engine

High Voltage Interconnection System TE Connectivity has developed the HC-STAK 25 High Voltage (HV) Interconnection System, a compact, robust and reliable high-performance connector solution. • Efficiently carries power from the battery pack to the drive motors in hybrid and electric vehicles • Handles high power surges during swift acceleration throughout the lifetime of the vehicle • Provides compact and flexible packaging geometry, weight and cost • Double-ended fork contacts • Scalable and capable of reliable high-power distribution to each aggregate throughout the lifetime of the vehicle www.oemoffhighway.com/21307376

JCB Power Systems launches the 448 range of EU Stage V-compliant engines to power OEM equipment. • Designed for off-highway applications in both static and mobile industrial equipment and generators • Available in four power nodes spanning from 81-129 kW (108-173 hp) • Peak torque outputs from 516-690 Nm (380.6-508.9 lb.-ft.) • Engineered to be as small as possible • Engine-mounted aftertreatment comprises a diesel oxidation catalyst with a selective catalytic reduction urea injection system for NOx reduction • Exhaust aftertreatment can also be supplied loose for bespoke installations where height limitations call for an alternative to the engine-mounted arrangement www.oemoffhighway.com/21295237

Compact ISOBUS Terminal Müller-Elektronik has begun series production of its ISOBUS terminal SMART570. • User-friendly with easy-to-use functions • Complies with ISOBUS standard ISO 11783 • Low weight and easy cab integration • Equipped with capacitive 5.7 in. (14.48 cm) display for optimum display of the connected implement even in sunlight • Can display work screens with up to 12 softkeys • Operated either via touchscreen, membrane keyboard or rotary encoder • Can be used in an extended temperature range from -20-65 C (-4-149 F) and even outside of cab • Suited for range of equipment applications

Compact equipment?

Meet compact HMI. Just because the equipment is smaller doesn’t mean the work is. The Murphy PowerView 700 delivers rich infotainment and powerful control to help operators get the job done. Designed for rugged, all-weather environments, the PV700 has superior sunlight-visibility, a glove-friendly touchscreen and an IP69K-protected enclosure. Learn more at EnovationControls.com/PV700

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Electric Compressors T/CCI Manufacturing introduces a range of electric compressors for the heavy-duty and mass transport markets. • High-voltage electric designs spanning 15 cc/24V to 120 cc/850V and 2-30 kW (2.7-40.2 hp) www.oemoffhighway.com/21284050

OEM Off-Highway | APRIL/MAY 2021

COME SEE US AT WORLD OF CONCRETE! BOOTH W3315

CALENDAR OF EVENTS oemoffhighway.com/events

2021 CANADIAN HEAVY EQUIPMENT SHOWCASE Virtual Event March 1-May 31, 2021 www.mpltd.ca

BUSWORLD NORTH AMERICA Virtual Event June 2-4, 2021 www.busworldnorthamerica.org

NFPA/FPIC REGIONAL CONFERENCE Virtual Event June 3, 2021 www.msoe.edu

WORLD OF CONCRETE Las Vegas Convention Center June 7-10, 2021 | Las Vegas, NV www.worldofconcrete.com

TIRE TECHNOLOGY EXPO Deutsche Messe June 8-10, 2021 | Hannover, Germany www.tiretechnology-expo.com

WASTEEXPO Las Vegas Convention Center June 28-30, 2021 | Las Vegas, NV www.wasteexpo.com

NFPA INDUSTRY & ECONOMIC OUTLOOK CONFERENCE

ACT EXPO Long Beach Convention Center Aug. 30-Sept. 2, 2021 | Long Beach, CA www.actexpo.com/

FARM PROGRESS SHOW Farm Progress Show Grounds Aug. 31-Sept. 2, 2021 | Decatur, IL www.farmprogressshow.com

NFPA/FPIC REGIONAL CONFERENCE Virtual Event Sept. 2, 2021 www.msoe.edu

SAE NOISE AND VIBRATION CONFERENCE & EXHIBITION

Suburban Collection Showplace Sept. 14-16, 2021 | Novi, MI www.evtechexpo.com

MOTION + POWER TECHNOLOGY EXPO America’s Center Convention Complex Sept. 14-16, 2021 | St. Louis, MO www.motionpowerexpo.com

BICES China New International Exhibition Center Sept. 14-17, 2021 | Beijing, China www.e-bices.org

COMVEC

DeVos Place Convention Center Sept. 7-10, 2021 | Grand Rapids, MI www.sae.org/attend/nvh

In-Person and Virtual Event Sept. 14-16, 2021 | Rosemont, IL www.sae.org

GREAT LAKES LOGGING & HEAVY EQUIPMENT EXPO

NORTH AMERICAN COMMERCIAL VEHICLE SHOW

UP State Fairgrounds Sept. 9-11, 2021 | Escanaba, MI www.gltpa.org/gltpa/Expo.asp

Georgia World Congress Center Sept. 28-30, 2021 | Atlanta, GA www.nacvshow.com

MINEXPO INTERNATIONAL

THE UTILITY EXPO

Las Vegas Convention Center Sept. 13-15, 2021 | Las Vegas, NV www.minexpo.com

Kentucky Exposition Center Sept. 28-30, 2021 | Louisville, KY www.theutilityexpo.com

THE BATTERY SHOW Suburban Collection Showplace Sept. 14-16, 2021 | Novi, MI www.thebatteryshow.com

Hilton Chicago/Oak Brook Hills Resort & Conference Center August 16-18, 2021 | Oak Brook, IL www.nfpahub.com/events/conferences/ieoc/

ELECTRIC & HYBRID VEHICLE TECHNOLOGY EXPO

OEM Off-Highway | APRIL/MAY 2021

EIMA INTERNATIONAL BolognaFiere Oct. 19-23, 2021 | Bologna, Italy www.eima.it

GIE+EXPO Kentucky Exposition Center Oct. 20-22, 2021 | Louisville, KY www.gie-expo.com

2022

BAUMA New Munich Trade Fair Center April 4-10, 2022 | Munich, Germany www.bauma.de

AGRITECHNICA Hannover Exhibition Grounds Feb. 27-Mar. 5, 2022 | Hannover, Germany www.agritechnica.com

GREEN TRUCK SUMMIT

HILLHEAD Hillhead Quarry June 21-23, 2023 | Buxton, United Kingdom www.hillhead.com

SIMA

Indiana Convention Center Mar. 3, 2022 | Indianapolis, IN www.ntea.com

Parc des Expositions Paris-Nord Villepinte November 6-10, 2022 | Paris, France www.simaonline.com

THE WORK TRUCK SHOW Indiana Convention Center Mar. 3-6, 2022 | Indianapolis, IN www.ntea.com

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Global Health Impact Editor’s note: Due to the global health crisis, many events in 2021, particularly in the early half of the year, have already been postponed, cancelled or gone virtual. Every attempt has been made to provide the most up to date information on those events listed; information is current as of the time of printing this issue. Be sure to montior our events page and individual events’ websites for updates. You can also read more about event changes at oemoffhighway. com/21354230 where we are tracking updates to industry events as they are announced.

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OEM Off-Highway | APRIL/MAY 2021

OFF-HIGHWAY HEROES oemoffhighway.com21366254

THE LETOURNEAU ARCHIVE, BY PHILIP G. GOWENLOCK

R. G. LeTourneau

s we continue looking at breakthroughs in construction equipment innovation and how they addressed problems facing contractors and other equipment users, it would be remiss if we did not also look at the individuals who developed those innovations. Robert Gilmore LeTourneau was born in Richford, VT, on November 30, 1888. After relocating to Portland, OR, he began working a series of jobs and taking correspondence courses through which he gained experience and knowledge of ironworking, foundry work, machining, vehicle mechanics, welding, applied electricity, and other manual trades. After the failure of an auto garage in Stockton, CA, he was hired to repair a Holt crawler tractor, and the course of earthmoving history changed on that day. After the repairs were completed, the owner hired him to use it and a primitive scraper to level 40 acres of land. He enjoyed the work, and in January 1920, he bought a used Holt of his own and rented a scraper, and went into business as a land leveler. He soon found that existing scrapers were inefficient, and in May 1921, he bought land in Stockton and launched an engineering shop where he began experimenting with scraper designs while continuing his contracting work. R. G. LeTourneau, Inc. was incorporated in 1929, and both the engineering and earthmoving ventures grew until he retired from contracting in 1933 to focus

The Great Innovator R. G. LeTourneau Robert Gilmore LeTourneau had an unequalled impact on the earthmoving equipment industry, holding nearly 300 patents in equipment design and manufacturing processes. by Thomas Berry, Archivist, Historical Construction Equipment Association exclusively on manufacturing. He developed an alliance with Caterpillar Tractor, and established a factory in Peoria, IL, to produce attachments, scrapers and wagons for use with Cat crawler tractors. The business boomed despite the depression as demand soared for equipment to fully mechanize earthmoving, and additional factories followed in Toccoa, GA, in 1938; Rydalmere, New South Wales, Australia, in 1941; Vicksburg, MS, in 1942; and what became LeTourneau’s world headquarters in Longview, TX, in 1945. World War II saw explosive growth as LeTourneau equipment saw widespread military use. After developing electric motors powered from a diesel generator as a power supply for his motor scrapers, wheel tractors and other equipment, he sold his entire earthmoving equipment operation to Westinghouse Air Brake Company in 1953, giving rise to the LeTourneau-Westinghouse brand. He continued developing electric power concepts for other fields, and after non-competitive clauses lapsed

OEM Off-Highway | APRIL/MAY 2021

in 1957 he re-entered the earthmoving market. The heart of his designs was the Electric Wheel, essentially an oversize tire on a hub containing a motor, and he went on to design and build a plethora of scrapers, wheel loaders and such of utterly unique design, size and power. Along with earthmoving, he also provided machinery for logging, land clearing, material handling, offshore oil drilling, arctic transport, and military applications. He received his correspondence degree in engineering in 1965, 50 years after taking the course. He stepped down as president of the company in 1966 at age 77, but continued designing new concepts for machinery until he suffered a major stroke in March1969. He passed that June 1 at age 80. “Mr. R. G.,” as he was known, had an unequalled impact on the earthmoving equipment industry. He held nearly 300 patents in equipment design and for the manufacturing processes and machine tools needed to produce the equipment. Read an extended version of this article at www.oemoffhighway. com/21366254. |

The Historical Construction Equipment Association (HCEA) is a 501(c)3 non-profit organization dedicated to preserving the history of the construction, dredging and surface mining equipment industries. With over 3,800 members in over a dozen countries, activities include publication of a quarterly educational magazine, Equipment Echoes, from which this article is adapted; operation of National Construction Equipment Museum and archives in Bowling Green, OH; and hosting an annual working exhibition of restored construction equipment. The 2021 show will be August 27-29 in Concordia, KS (learn more, 10598970). Annual individual memberships are $35.00 US within the USA and Canada, and $55.00 US elsewhere. HCEA seeks to develop relationships in the equipment manufacturing industry, and offers a college scholarship for engineering and construction management students. Information is available at www.hcea.net, by calling 419-352-5616 or e-mailing info@hcea.net. Please reference Dept. OEM.

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A LOT OF TECHNOLOGY GOES INTO IT. SO YOU’LL LIKE WHAT YOU GET OUT OF IT. You need efficient power you can count on. And that’s exactly what we offer. In fact, FPT engines are engineered with the technology to deliver dependable performance and lower operating costs. Engines with features like EGR-free combustion, common rail fuel injection, and a DPF-free After Treatment solution, all designed to improve performance and reduce fuel consumption. In other words, the kinds of engine solutions you’re looking for – and that we’ve been providing – for more than one hundred years. Learn more at fptindustrial.com

OEM Off-Highway April/May 2021

Articles inside

New Products

Market Forecast: Mining Equipment

Electrical & Electronics: Sensors

Engine System

Cover Story: Telematics Systems

CANbus Will Play Critical Role in Electric and Autonomous Vehicles