OEM Off-Highway July/August 2022 by OEM Off-Highway

JULY/AUGUST 2022 oemoffhighway.com THE JOURNEY TO HYBRID & TECHNOLOGYELECTRIC Charging infrastructure, lack of battery management systems, and the perception of electric power have been the main barriers to adoption. PAGE 14 Photo courtesy of Allison Transmission READ BONUS ISSUE OF THE ENGINE SPEC GUIDE HERE

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4 EDITOR’S NOTE EQUIPMENT MARKET OUTLOOK 5 Europe’s Markets Continue to Be Down 32 WHAT’S NEW ON THE WEBSITE 33 NEW OFF-HIGHWAYPRODUCTSHEROES 34 Hydraulic Graders and Scrapers  WEB EXCLUSIVES Video Network www.oemoffhighway.com/videos OEM Industry Update www.oemoffhighway.com/podcasts Premium Content www.oemoffhighway.com/premium-content CONTENTS VOLUME 40, NO. 4 | JULY/AUGUST 2022 Published and copyrighted 2022 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. OEMOff-Highway (USPS 752-770, ISSN 1048-3039 (print); ISSN 2158-7094 (online) is published 6 times a year: January/February, March/April, May/June, July/August, September/October and 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 OffHighway, PO Box 3605 Northbrook, IL 60065-3605. Printed in the U.S.A. ELECTRONICS 8 Employing Vehicles with Aftermarket Automation Keeps Existing Fleets on the Road How COM Express software for small footprints fuels the extended deployment, long lifecycle, and value of today’s heavy mobile equipment 10 Improving Linear Actuator Design Flexibility with Noncontact Position Sensing Potentiometers determining where the actuator is in its stroke to track changes in electrical resistance or related voltage drops. ENGINES & EMISSIONS 22 The Fastest Path to Emissions Reduction for Heavy-Duty Diesel Engines Make the most of current technology and alternative fuels. 26 Overcoming Electric Vehicle Adoption Barriers How OEMs can help fleets be safer, cleaner, and more efficient by encouraging the move to EVs MINING 28 Rear Eject Bodies and Other Features Decrease Mining Costs Considerations for selecting a truck body selection must include the equipment’s total cost of ownership. OEM Off-Highway | JULY/AUGUST 2022 3 10 22 28 COVER STORY 14 The Journey to Zero Emissions with Hybrid & Electric Power How is the industry moving away from diesel and toward other sources? 14

Steven Nendick, Marketing Communications Director, Cummins Inc.

Roy Chidgey, Business Segment Head, Minerals Projects and Global Mobile Mining, Siemens Large Drives US Andrew Halonen , President, Mayflower Consulting, LLC

John Madsen, Director Engineering & Product Management, GKN Wheels & Structures

Bob Straka, General Manager, Transportation SBU, Southco, Inc.

Chris Williamson, PhD, Senior Systems Engineer Global Research & Development, Danfoss Power Solutions Company n the editor’s note in sue,May/JunetheisIdiscussed my excitement to be industry,insignersthecriticaltionaltechnology,learningtoagain.in-personattendingeventsInadditionseeingandaboutneweducasessionsaretohelpyou,engineers,deandotherstheoff-highwaystayuptodate on their techni cal and industry knowledge. However, because of the demands of your jobs, many of you do not have the time to attend live, in-person events. This is one reason that our team will launch the inaugural OEM Off-Highway Industry Sum mit. This is an online, educational event that we plan to hold every year. This year, the dates are November 8 through November 10. See Image 1 for the tentative schedule of presentations. In the future, if not this year, we are plan ning to offer professional development hour credits for some of our presentations during this event. We hope that this summit becomes part of the content that you enjoy along with the print

Terry Hershberger, Director, Sales Product Management, Mobile Hydraulics, Bosch Rexroth Corp.

Luka Korzeniowski, Global Market Segment Leader, Mobile Hydraulics, MTS Sensors

EDITOR’S NOTE OEM Off-Highway | JULY/AUGUST 20224 LDITORO@ACBUSINESSMEDIA.COM E HTTPS://OEMOH.CO/Q8W6J6 D HTTPS://OEMOH.CO/ZR5QQ4 C HTTPS://OEMOH.CO/8A5ZHP M HTTPS://OEMOH.CO/95TAYS EDITORIAL ADVISORY BOARD

Craig Callewaert, PE, Chief Project Manager, Volvo Construction Equipment

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

Allen Schaeffer, Executive Director, Diesel Technology Forum

publication, webinars, podcasts, videos, premium content and newsletters. Let us know what you think about this summit by emailing me at lditoro@acbusi nessmedia.com. An added section to this issue is “What’s New on OEM.com?” on page 32. This section will spotlight some of our online content, including upcoming webinars, podcasts, digital industry news updates and more online features. As always, tell us what you like from this issue. We love hearing from you! | Image 1. The tentative schedule of presentations for the OEM Off-Highway Industry Summit Published by AC Business Media 201 N. Main Street, 5th Fl., Fort Atkinson, WI 53538 (800) 538-5544 • www.OEMOffHighway.comwww.ACBusinessMedia.comPRINTANDDIGITALSTAFF Publisher Sean Dunphy Editorsdunphy@ACBusinessMedia.com Lori Ditoro Managinglditoro@ACBusinessmedia.comEditor Gigi Wood Senior Production Manager Cindy Rusch Artcrusch@ACBusinessMedia.comDirector Dave Haglund Audience Development Manager Angela Franks ADVERTISING SALES (800) 538-5544 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 AxlePhone: 402-836-2768 | bart.piccirillo@dataReprintsaxle.com— For reprints and licensing please contact Greg Schulz at 920-542-1239 | gschulz@ACBusinessMedia.com AC BUSINESS MEDIA Chief Executive Officer Ron Spink Chief Financial Officer JoAnn Breuchel Chief Digital Officer Kris Heineman Chief Revenue Officer Amy Schwandt Brand Director Construction Sean Dunphy VP, Operations & IT Nick Raether VP, Audience Development Ronda Hughes Director, Demand Generation & Education Jim Bagan General Manager – Online & Marketing Services Bethany Chambers Content Director Marina Mayer

Daniel Reibscheid, Business Development Manager, MNP Corporation Matt Rushing, Vice President, Product Line, Global Crop Care, AGCO Corp.

Doug Meyer, Global Director of Construction Engineering, John Deere Andy Noble, Head of Heavy Duty Engines, Ricardo

Alexandra Nolde , Senior Communication & Media Specialist, Liebherr-Components AG

• High tax receipts at the federal, state and local levels bode well for construction rise into next year.

• Trends within private nonresidential con struction vary, with sectors such as office and education trending below year-ago levels, and sectors such as warehousing and manufactur ing offering areas of relative opportunity.

• Leading Indicators signal business-cycle decline is likely to be the predominant trend for pro duction for at least the remainder of 2022.

• Annual U.S. public new construction is rising but was 2.1% below the year-ago level in April.

@EVP82 – STOCK.ADOBE.COM OEM Off-Highway | JULY/AUGUST 2022 5 EQUIPMENT MARKET OUTLOOK 0 1 2 3 4 5 6 JanFebMarAprMay ’22 OctNovDec ’21 Annual % change in 3 month moving totals 4.8%4.7% 4.1% 4.5% 4.9% 5.5% 6.0% 5.4% 0 2 4 6 8 10 12 AprMarFebJan’22DecNovOctSep’21 Annual % change in 12 month moving totals 10.3% 9.9% 0.6% 3.0% 5.7% 8.2% 10.1% 9.6% -5 -4 -3 -2 -1 0 AprMarFebJan’22DecNovOctSep’21 Annual % change in 12 month moving totals -4.1%-4.0%-3.9%-3.9% -3.8% -2.1% -2.6% -3.2% US Leading Indicator ITR Economics is an independent economic research and consulting firm with 60+ years of experience. QUESTIONS? economics@oemoffhighway.com Go to oemoffhighway.com to sign up for our monthly ECONOMIC NEWSLETTER! US ProductionIndustrial US Private Non-Residential New Construction US Total Public New Construction 0 99.7 99.8 99.9 100.0 100.1 MayAprMarFebJan’22DecNovOct’21 Actual index (2010=100) 100.2% 100.2% 99.9% 100.0% 100.1% 99.9% 99.8%99.8% oemoffhighway.com/economics Editor’s Note: Please note that this chart has been modified on the Y-axis to show the trend more easily. Indicators in several markets show that while growth is still slow, several areas are seeing improvement. Annual U.S. construction machinery new orders and U.S. heavy-duty truck production are higher than a year ago. With inflation threatening and oil and gas prices well above nor mal, growth in the U.S. will be slow for most of 2022. Europe’s markets continue to be down because of many factors, including the ongoing War in Ukraine. | US INDICATORS GROW; EUROPE’S DECREASE FURTHER

• Quarterly average U.S. industrial production in May was up 5.5% from the year-ago level; growth is generally slowing.

• General decline in the monthly rate-of-change sig nals that the U.S. industrial sector annual growth rate will move lower into at least early 2023.

• In the three months through April, U.S. private nonresidential construction came in 10.3% above the year-ago level.

• The U.S. OECD leading indicator raw data and monthly rate-of-change were both virtually flat in May.

• ITR Checking Points™ signal production will continue to soften in the coming quarters.

• Europe agricultural and forestry machinery production came in 5% above the year-ago level in April.

• China large diesel bus production in the 12 months through April moved sharply lower but came in 4.3% above the year-ago level.

US ProductionDutyHeavy-Truck DieselChina ProductionBus Germany ProductionIndustrial

• Quarterly Germany industrial production in April came in 2.5% below the year-ago level.

• U.S. farm machinery and equipment ship ments in the 12 months through April came in 0.3% below the year-ago level.

EQUIPMENT MARKET OUTLOOK OEM Off-Highway | JULY/AUGUST 20226 oemoffhighway.com/economics -2 0 2 4 6 8 10 AprMarFebJan’22DecNovOctSep’21 Annual % change in 12 month moving totals9.2% 5.2% 5.1% 4.5% 3.1% -0.3% 1.9% 6.3% 0 5 10 15 20 AprMarFebJan’22DecNovOctSep’21 Annual % change5.0%16.5% 16.3% 15.4%15.6% 14.1% 13.2% 9.3% 0 5 10 15 20 25 MayAprMarFebJan’22DecNovOct’21 Annual % change in 12 month moving totals 20.6% 21.9% 20.7% 22.2% 17.6% 10.9% 4.7% 20.3% -2 0 2 4 6 8 10 AprMarFebJan’22DecNovOctSep’21 Annual % change 4.3% 5.1% 4.6% 9.0% 8.6% 3.0% 2.6% -0.3% -2.5 -2.0 -1.5 -1.0 -0.5 0.0 0.5 1.0 1.5 2.0 2.5 AprMarFebJan’22DecNovOctSep’21 Annual % change in 3 month moving totals 2.4% -2.3% -1.7% 0.2% 2.0% 0.9% -2.5% -0.3% 0 99.3 99.5 99.7 99.9 100.1 100.3 100.5 100.7 100.9 101.1 MayAprMarFebJan’22DecNovOct’21 Monthly index 100.2 100.4 99.7 99.9 100.6 101.1 101.0 100.8 Editor’s Note: Please note that this chart has been modified on the Y-axis to show the trend more easily. Europe IndicatorLeadingUS Farm ProductionMachinery Europe Ag & Forestry Machinery Production

• Persistent business cycle decline in the leading indicator rate-of-change signals decline for the Europe industrial production annual growth rate into at least early 2023.

• Annual U.S. heavy-duty truck production in May came in 4.7% above the year-ago level.

• COVID-19 restrictions—though easing—and weak economic growth in China are warning signs for the future direction of production.

• German leading indicators signal production will continue to trend on the back side of the business cycle (slowing growth or recession) during at least the next few quarters.

• War in the breadbasket of Europe has placed upward pressure on food prices, potentially incentivizing more agricultural production in the U.S. However, supply chain disruptions are hindering growth in the agricultural machin ery space.

• The Europe leading indicator raw data and monthly rate-of-change moved lower in May.

• Expect growth but at a generally slower pace as improvement in the supply chain allows more trucks to be produced while waning macroeconomic momentum reduces the pressure to upgrade trucking fleets.

OEM Off-Highway | JULY/AUGUST 2022 7 • “Pluggable” shield contact solution • Maximum process reliability in pre-assembly and final installation • Exceptionally quick and easy installation on the vehicle • Full reliability in the most demanding operating conditions • System solution for cable cross-sections from 16 to 120 mm2 Detailed information about this world-first development can be found on our website www.agro.ch under Solutions / E-Mobility. , AGRO has developed a completely new type of EMC cable gland, precisely tailored to the Maximum EMC reliability on high-voltage cables STRONGER FASTER SMARTER InformationMore AGRO www.agro.chAG Tel. +41 (0)62 889 47 47 Member of KAISER GROUP 0 5 10 15 20 25 AprMarFebJan’22DecNovOctSep’21 Annual % change in 12 month moving totals 20.7% 24.2% 24.3% 23.7% 24.0% 22.0% 16.1% 19.9% -10 0 10 20 30 40 50 60 70 80 MayAprMarFebJan’22DecNovOct’21 Annual % change in 12 month moving totals -9.8% 1.9% 14.3% 28.5% 62.3% 44.7% 71.9% 73.0% -4.0 -3.5 -3.0 -2.5 -2.0 -1.5 -1.0 -0.5 0.0 0.5 1.0 1.5 2.0 AprMarFebJan’22DecNovOctSep’21 Annual % change in 12 month moving totals 1.2% 1.6% -2.7% -0.5% -3.7% -1.9% -2.6% -3.1% US NewMachinery,ConstructionOrders North RotaryAmericanRigCount US NewIndustry,DefenseOrders • Annual U.S. construction machinery new orders in April totaled $38.9 billion, up 16.1% from the year-ago level; growth is slowing. • A cooling housing market, slowing macroeco nomic growth and anticipated easing inflation beginning late this year will contribute to ongoing slowing growth in new orders in at least the coming quarters. • The annual North American rotary rig count in May averaged 745 rigs, 73% above the yearago level. • High oil and gas prices signal robust demand for drilling, but supply chain disruptions—es pecially shortages of materials and equip ment—are posing challenges for oil and gas firms. • U.S. defense capital goods new orders in the 12 months through April came in 3.1% below the year-ago level. • Trends in U.S. federal government current tax receipts suggest that the nascent annual new orders rise is likely to persist, though the U.S. withdrawal from Afghanistan still suggests a downside risk.

NORDRODEN, ADOBESTOCK The trucks and heavy machin ery used to build our infra structure and withstand the rigors of farming, construc tion excavation and earthmoving, and mining, embody rugged technology. While heavy mobile equipment (HME) has advanced during the last centu ry—continuous improvements to ca pabilities, hydraulics and fuel efficien cy—more progress is required. Data is in the driver’s seat, sometimes literally, and is the key to smarter, better-con nected systems. Today’s telematics and advanced driver assistance systems must capitalize on artificial intelligence (AI), deep learning, GPS, 5G and a range of computer vision applications. To transform these machines, OEMs must use fleet-specific software and hardware. It should be applicable to a spectrum of automation applications and compatible with existing systems. Small footprint COM Express modules are an option and demonstrate how aftermarket automation aligns with the extended deployment and long life cycle associated with HME assets. With COM-Express-based systems, develop ers have an open architecture platform deployable across a vehicle portfo lio—a holistic fleet strategy using a single, high-performance system to manageAutomatingapplications.heavy machinery doesn’t have to mean soaring startup costs or replacing fleet assets. Com Express systems provide customizable, reusable and scalable solutions. Driving Flexibility and Longevity

The COM Express standard defines a range of form factors that allow developers to balance flexibility, cost and performance as they consider the needs of their embedded devices. As a result, COM Express is well-suited for small footprint, rugged applications that rely on customization. In system development, modules are paired with a carrier board containing all customi zation (instead of the COM itself). This powers system performance across technology generations—for instance, a CPU core can be replaced with a more advanced version when the application requires enhancements or greater performance. It’s an inherent design attribute that adds longevity and flexibility. Instant Platform or Building Block COM Express platforms provide two disparate development tracks for data-intensive construction, trucking,

Employing Vehicles with AFTERMARKET AUTOMATION Keeps Existing Fleets on the Road

How COM Express software for small footprints fuels the extended deployment, long life cycle and value of today’s heavy mobile equipment by Jack London, Kontron | Andrea Thomas, Intel Software HME design needs onboard edge computing platforms based on industry-standard COM Express technologies. COM Express platforms provide two disparate development tracks for data-intensive construction, trucking, mining and agricultural applications.

ELECTRONICS OEM Off-Highway | JULY/AUGUST 20228

Predictable costs, such as fuel and insur ance, give greater control over expenses and can improve total cost of ownership (TCO). Operating costs are reduced with more precise actions and responses, such as just-in-time analysis of engine parts, low-voltage motors and other mechanical devices. Costs also improve when maintenance crew resources are not wasted on unnecessary rounds. In addition, accidental breakdowns become fewer, and unplanned downtime is mini mized or eliminated. Overall productivity increases as payloads are maximized, and bottlenecks are identified. Aligned with the goal of improved productivity and safety, workers can be removed from hazardous envi ronments. Mining, for example, is inherently dangerous. The industry is moving toward a zero-entry mine landscape in which no humans are physically inside the mine. Absent humans onboard, heavy mining equipment can go deeper and into more dangerous environments, such as areas with gas buildup. Profit ability and mine life can be extended. The mine can be excavated more deeply, and with steeply sloped walls that allow operators to remove more materials, including the lower quality ores often left behind. With greater efficiency in place, organizations can also free operators to focus on high-value tasks. This is strategic in the face of labor shortages and allows valued personnel to put their insights and judgment to use beyond basic equipment op erations. It is also a competi tive advantage for emerging economies—their mines can quickly become more viable with automated heavy machinery. Fewer human re sources are required to get systems up and operational in the field. Progress can be made with fewer costly assets, reducing economic and environmental impact. Automation designs with low development and deployment costs, will eventually lower the barrier to market entry for less-developed countries.

The Impact of Automated HME

• Use machinery safely

• Minimize waste

Andrea Thomas is senior product mar keting engineer for Intel. With a COM Express platform, versatility is key along with small form factor attributes. This single, sealed IP67 enclosure includes a broad range of high-speed input/output options such as 10GbE USB 3.0, SMA or FAKRA connectors for RF and rich camera interfaces. Read More https://oemoh.co/fjtrkz

Jack London is vice president, business development, for Kontron North America.

Decreased Design Complexity With retrofit for greater automation, heavy mobile equipment OEMs can equip their components with the technology to secure, observe and use data from other technology-equipped machines for better insight into equip ment procedures. Synchronized work flows empower teams and equipment for better, safer productivity. Effectively and efficiently retrofitting systems is critical. Smart, autonomous solutions are new necessities in HME markets, empowering operators to:

OEM Off-Highway | JULY/AUGUST 2022 9 KONTRON mining, and real-timedevice,spacenonstopthisforandonlycenter.recordsgenerated.areimmediateandthesetheirvalueingcantheirdardizationInternationaltosafetyprocesses.relevantfleetapplications.mancetheplatform’smachinemachineatorgraphics,adapterprocessortyisdedanddeeptegratedplatformofapplications.agricultureOneexampleanapplication-readyfeaturespre-incapabilitiesforlearning,in-vehicleAIhigh-performanceembedcomputingHPEC.Theplatformoptimizedforuseonboardheavy-dumobilemachineryandfeaturesapairedwithadualnetworkcardandarangeofoptionsforprocessingunitsoraccelercardsdesignedtohandleAIandlearningworkloads.Coupledwithbuilt-inAIandlearningcapabilities,thetoolkithelpsacceleratedevelopmentofhigh-perforinferenceandcomputervisionThisallowsOEMstohelpoperatorsgatherandanalyzedataandquicklydevelopnewOEMsmustalsoconsiderregulationsandofferanoptionprovidefunctionalsafetythatmeetsOrganizationforStanspecifications.Alternatively,developersbuildingownautonomousapplicationsusethesameplatformasabuildblock.TheycanaccesstheinherentofCOMExpressandcustomizecarrierboardsandsolutions.Acrucialadvantageprovidedbysystemsistheabilitytointerpretanalyzedatainthevehicle.AlmostdecisionsandactionsenablednearwherethedataisOutcomesanddecisionaretransmittedtothecontrolCloudtransmissionisreservedfordatathatisnottime-sensitiveislaterdeliveredtodatacentersarchiveoradditionalanalysis.Inapproach,vehiclesnolongerneedcloudconnection.Storageisalsofreedinthevehicle-basedprovidingreal-timeorneardataasrequired.

The benefits of connected and in telligent heavy machinery include predictive analysis, for example alerting operators to danger ous situations and equipment failures. Predictive maintenance increases uptime and diminishes potential outages. Mechanical data analysis also enables operators to reduce fuel consumption.

• Improve overall production and Retrofittingoperationsdrivesnew competitive advantages and efficiencies provided by data gathered and processed close to where it is generated. This rapidly evolving environment brings oppor tunities and hurdles for developers—decreasingembeddedcomplexity is vital, but so is taking intelligent steps to automate for broad competitive value and jobsite safety.

Improving Linear Actuator

PositionNoncontactFlexibilityDesignwithSensing

THOMSON

©DMITRY S. GORDIENKO – STOCK.ADOBE.COM

One of the most common methods for determining where the actuator is in its stroke potentiometers,uses also called pots, to track changes inresistanceelectricalorrelatedvoltagedrops.

M10any linear applicationsmotionthatuse rodstyle electric actuators require information on the position of the load at every point of travel. However, because stroke lengths and applications vary, finding the ideal position feedback solution can be challenging. One of the most common methods for determining where the actuator is in its stroke uses potentiometers, also called pots. They track changes in electrical resistance or related voltage drops as the actuator extends and retracts. To function as position-recording devices, potentiometers must maintain an electrical connection to the actuator power circuit. Designers can accom plish this using contact or noncontact potentiometer architectures. Con tact-based position measurement has been the simplest and most econom ical approach but is limited in resolu tion, design flexibility and durability. Noncontact architectures overcome many of those drawbacks but have tra ditionally been too expensive to justify for many mainstream applications. Today, however, the market for non contact potentiometers has matured, and prices have dropped. Understand ing the advantages of noncontact po tentiometers will help motion system designers determine the most effective way to meet customer requirements.

by Travis Gilmer, Thomson Industries Inc.

The Basics Feedback voltage from a potentiom eter typically changes from 0.5 VDC to 4.5 VDC as the actuator extends. Potentiometers are generally rated in ohms of resistance across their range and on the shaft’s number of turns (revolutions) from zero to full cover age. The most common units are 10k (ohms) 10 turns. As the actuator screw extends or re Due to eliminating gearing and wipers, noncontact potentiometers better absorb shock and vibration from heavy-duty applications. These potentiometers, along with many other control and performance features, can be found in select electric linear actuators.

ELECTRONICS OEM Off-Highway | JULY/AUGUST 2022

Cummins is always looking for ways to help our customers succeed – pushing harder to deliver a range of power solutions, that help get the job done whilst reducing environmental impact. We’re breaking new ground with advanced diesel, renewable fuels, hybrid, battery electric and hydrogen, increasing productivity and lowering maintenance costs. We’ve been powering agriculture for over 100 years and we’ll be doing so for 100 more. Delivering power, efficiency and reliability as well as peace of mind. So, no matter what powers your farm, Cummins has the technology to meet your needs.

Power to Break New GrouNd

Durability

A contact-based potentiometer reads these voltage changes by gliding its wiper across wire-round resistance coils, counting each move from one wrap to the next. Noncontact potenti ometers read the voltage changes as well but do so with electromagnetic sensors instead of contacting wipers.

Designing for High Resolution

tion, if the customer required position information for only 40% of travel, they would sacrifice resolution because there would be less resistance change given the shorter travel time. Because the number of wraps in the coil of a contact-based architecture is physically limited, there are only so many step changes to count, limiting the resolution of the position informa tion it can deliver. And once a manu facturer has configured it for a specific number of turns needed to achieve the desired resolution, the design is set. Noncontact potentiometers, on the other hand, enable higher resolution because they do not rely on physical wipers or gearing. Like contact-based potentiometers, noncontact sensors determine position by recording resistance changes across the stroke length. Instead of getting this infor mation from a physical wiper touching a coil, they use an electromagnetic sensor that detects pulse changes in the surrounding magnetic field. The sensor outputs this digital signal to a noncontact potentiometer’s integrated circuit, which converts it to analog for reading by the actuator’s onboard electronics. This signal rep resents the analog values as position. Because these signals do not need to correlate with physical constraints, the noncontact potentiometer gives vir tually infinite granularity in measuring the stroke position.

for res

The ability to infinitesimallyrecordsmallvoltagechanges without physical contact and manage them through a software interface makes resolution programmable. If the end user needs tighter resolution, the designer can change it through the in terface. For instance, if the application requires a high resolution between 0.5 volts (V) and 4.5 V, they can program the system to accomplish that. If the end user didn’t need as much resolu tion, the designers might program it to go to 2.5 V at the end of the travel. The designer can do it all with software rather than physical gear reductions. Such programmability can be valu able in applications needing to change the stroke to compensate for different geometries. Actuators with contact potentiometers might return different feedback from different strokes. Cor recting this would require dedicated gearing for each stroke length. With a programmable noncontact device, the designer can maintain the same feedback over the stroke regardless of changes in geometry. A user can keep that consistency without having to modify the physical architecture.

Design Flexibility

With contact potentiometers, the de signer’s primary option for increasing resolution is modifying the gearing to correlate potentiometer turns with mo tor or actuator screw turns. Designers who need position feedback across a full, long-stroke application might gear the potentiometer to turn less as it moves. For example, in a short-stroke applica

OEM Off-Highway | JULY/AUGUST 202212

Noncontact potentiometers would also make it easier for the designer to program more complex movement profiles. For example, they may move forward a few millimeters or make a small set of movements back and forth to zero on the desired position. Noncontact potentiometers can be valuable when the actuator must move repeatedly and consistently to a location, such as managing the flow gate in a seeding application. In these applications, the actuator operation may be controlled by a programmable logic controller (PLC) and hidden from an operator’s view, so there is no visual feedback to help determine whether the actuator traveled far enough. The programmability of noncontact poten tiometers also makes them excellent for custom applications. One part num ber, for example, can be programmed to manage multiple stroke lengths.

tracts, discrete step-change in resistance occurs, which can be converted into linear position measures. The more turns the potentiometer takes before it reaches its full resistance range at the end of the stroke, the more precise the position measurement capability it can deliver.

Noncontact potentiometers have Noncontact potentiometers are ideal for applications such as mobile off-highway/agricultural (left) and factory automation/automated guided, vehicles (right). In these applications, the actuators might be hidden from view and under the control of a PLC. The potentiometer can be programmed to drive the same distance and travel the same length every time. THOMSON

The designer’s degree of flexibility in installing contact- or noncon tact-based potentiometer position sensing depends largely on the users requirements.Customerrequirements

olution and durability will impact a designer’s options to use contact or noncontact position measurement.

ELECTRONICS

THOMSON

When you have a job to get done, you can count on Gorman-Rupp. Our product line includes self-priming centrifugal, standard centrifugal, priming-assisted, submersible and diaphragm pumps used extensively for dewatering applications in quarries, streams, foundations, mining, coffer dams and sewage bypass operations. Simple pump designs with few moving parts minimize the need for repair or service. On most models, routine field maintenance can be completed with common hand tools. And, Gorman-Rupp pumps are proudly manufactured right here in the U.S.A. Read More https://oemoh.co/7s69gr durability advantages. Eliminating the gearing improved durability. Gearing is subject to routine wear, contamina tion and misalignment resulting from vibration and shock. As such, they are excellent candidates for replacing hydraulic cylinders that may be spec ified for environmentally challenged applications needing position control. Eliminating the need for wiper contact and gearing gives noncontact potentiometers another durability advantage when compared to contact devices. In an application in which the actuator does not change position for an extended period, the wiper may vibrate and wear a dead spot on the coil. This would drop the signal and cause the potentiometer to fail. When this happens in a system that runs process logic, a contact device loses track of the position and can also interfere with some controlled moves. A movement profile that depends on a specific value will not find it, which could replace the potentiometer or the actuator.

OEM Off-Highway | JULY/AUGUST 2022 13 476 © 2022 The Gorman-Rupp Company Gorman-Rupp Pumps USA is an ISO 9001:2015 and an ISO 14001:2015 Registered Company GORMAN-RUPP PUMPS P.O. BOX 1217 I MANSFIELD, OH 44901-1217 I USA I GRPUMPS.COM PH: 419-755-1011 I FX: 419-755-1251 I GRSALES@GORMANRUPP.COM

Breaking Contact Designers who have believed that non contact potentiometers were only for high-precision applications may want to revisit them for all applications. Even if high resolution is not critical, remov ing gearing from the bill of materials, programmable position feedback and a more rugged solution could offer significant advantages. As the design and specification pro cess becomes more iterative between engineering and customer teams, programmable capabilities such as the noncontact position sensing will deliv er more tailored solutions in less time, without creating additional tooling.  Travis Gilmer is a product line specialist for linear actuators at Thomson Indus tries, Inc. Requirements for accuracy, flexibility and durability will determine whether contact (left) or noncontact potentiometers (right) are a better fit for a given application.

By Lori Ditoro Original equipment manufac turers (OEMs) have options for powering heavy-duty, off-highway equipment: diesel, gasoline, electrification, alter native fuels and hybrid configurations. What are the drivers for electric or hybrid mobile equipment? What goes into the power selection decision?

Sustainability

OEM Off-Highway | JULY/AUGUST 2022COVER14 STORY

The Journey to Zero Emissions

How is the industry moving away from diesel and toward other sources?

Goals

Climate change and the global goal to decrease emissions are well-known reasons to move away from the use of fossil fuels. Other reasons that some OEMs have abandoned diesel specif ically include end-user or customer needs and meeting Environmental Social and Governance (ESG) sus tainability goals, which go beyond environmental stewardship. With en vironmental concerns understandably a major driver, OEMs aim to give their end users what they want. “Many utilities have set a goal of 100% electric fleets by 2030. Helping our customers reach their sustainabili ty goals has been and continues to be a priority for Terex Utilities,” said Joe Caywood, director of marketing and product management, Terex Utilities. As Terex’s customers’ requirements change, the company will shift and research to meet them. “Customer demand, which is the product of several factors, is the driving force behind the trend toward hybrid and electric equipment,” said Zach Gilmor, product manager, Genie. “Regulatory requirements are, obviously, one of the factors driving electrification. As regulations are adopted that place limits on noise and emissions, demand is increasing for efficient, clean, quiet jobsite equipment. Beyond that, hybrid and electric equipment also can help companies meet their ESG sustainabil ityThegoals.”innovations in technology and equipment required to meet emission regulations and customer needs requires research and investment. This is a priori ty for the Allison Transmission team. “In the coming years, OEMs in the off-highway industry will look to pro pulsion solution manufacturers as they begin to evaluate electric vehicle capa bilities,” said Kartik Ramanan, executive director, global off-highway, customer support and service engineering, Alli son Transmission. “Allison is committed to taking a leadership role in power ing advancements to sustainability and environmental initiatives across global markets. Allison has made approximately $350 million in direct investments to advance electrified propulsion technology.” Terex has also been making that investment, according to Cay wood. “We have been investing in green solutions for more than electric bucket truck

According to Dr. Wilfried Aulbur, a senior partner with industry consultant Roland Berger, “The off-highway segment will require different technologies for different use cases. Most compact equip ment, like mini excavators, are good use cases for battery electric equipment because they require less power density variations in their duty cycle. On the other hand, hybrid technology is more suitable for larger, heavy-duty appli cations because hybrid configurations can provide significant operating cost benefits as well as performance stability, with some OEMs claiming to reduce fuel consumption by more than 25%.”

for utilities TEREX

Emission Reduction and Meeting

As electric vehicle use expands, the perception is changing. The technol ogy has become part of daily life with multiple major automakers either producing electric vehicles or plan to soon in the future. Some manufac turers have made promises to move

15 years. With each introduction, it was the right solution with the technology that was available at theWhiletime.”fully-electric equipment is a goal for many end users and OEMs, challenges exist that prevent the tran sition for some mobile equipment.

TECHNOLOGY LIMITATIONS

Initially, Terex’s plan to produce a fully-electric utility truck was limited by the“Overall,technology.[wewere] waiting for reliable technology to be available. We had the vision early but at that time things like battery management systems were not reliable and batteries weighed too much,” said Caywood. Technology remains a challenge for some OEMs. While battery system innovations have occurred, not all types and sizes of mobile equipment can be fully electric. Electric power is often insufficient for many actions required of these ve hicles, including startup, acceleration and transient operations.

OEM Off-Highway | JULY/AUGUST 2022 15

Electrification Barriers

The transformation of passenger vehi cles with internal combustion engines (ICEs) to electric is well in process. However, OEMs producing heavy-duty, mobile vehicles face challenges when attempting to move to 100% electric. Among them are:

• Power demands and the perception of electric • Charging infrastructure

PERCEPTION Even if the power capability matches the equipment’s functioning, the per ception for some end users is that an electric vehicle will not function as well or be as efficient as an ICE. “We’re starting to get beyond the perception challenge,” said Gilmor. “And as more people have exposure to hybrid and electric equipment on the jobsite, and as we’re seeing it more in personal lives, the perception is shifting, and people are realizing the benefits of electrification.”

• Technology limitations

with Hybrid & Electric Power

• Higher costs “The most limiting factors for battery electric equipment, such as excavators, are battery costs and charging availabil ity at the construction site,” said Giovan ni Schelfi, Principal, Roland Berger. “Additionally, significant improve ments in battery technology and charging technology are re quired to make use feasible, for example via overnight charging,” saidAccordingSchelfi. to Gilmor, taking a holistic approach to electrification can help OEMs avoid some challenges. “We didn’t just think about the power source, but the entire design of the machine, to take advantage of the benefits of electrification and improve efficiency, enhance jobsite performance and lower the total cost of ownership,” Gilmor said.

Terex

• AC electric-drive equipment, including slab scissor lifts and multiple boom lifts.

Allison Transmission

Charging infrastructure, a major challenge that OEMs do not control, presents a substantial challenge. For the construction industry, most sites do not have access to electricity when a project begins. Even when electricity becomes available, problems exist. “Even when there is electricity on site, there’s the question of the physical space necessary to make full electri fication realistic, said Gilmor. “Many construction sites are already space constrained, and having room to stage all the equipment for charging over night is not practical.”

• H 40/50 EP, electric hybrid propulsion system has operating in transit buses for almost 20 years.

INFRASTRUCTURE

Genie

• DC electric boom lifts.

An articulated boom lift, which is available in fully electric and hybrid configurations GENIE

• 4000 Series transmission, the TerraTran, is designed for off-highway applications such as mobile crane, articulated dump truck, wide-body mining dump trucks and defense vehicles.

• An Optima 55 aerial device powered by the HyPower SmartPTO by Viatec is now available on an International Navistar eMV 33,000 GVW chassis.

• The eGen Power 130D is specifically designed for the European and Asia Pacific markets, where many commercial vehicles require a heavier, 13-tonne gross axle weight rating.

In off-highway, heavy-duty mobile vehicles, a hybrid approach often trumps a 100% electric solution. The main reason, as mentioned earlier, is power limitations of electricity for larger equipment and specific functions. While alternative fuels are options that engine OEMs are investi gating, hybrid diesel-electric equip ment is prevalent. One example from Bosch Rexroth is an electric hydraulic system for implements on equipment, but the primary driver on is still typically a diesel ICE. While Bosch Rexroth focuses on fluid power, the need to reduce emissions and expectations for components to be integrated, au tomated and electrified have inspired the move to electric. Another example is from Allison Transmission. The drive of a passenger bus is hybrid but allows for fully-elec tric propulsion for up to 10 miles de pending upon duty-cycle. This can be used when entering areas that require low noise or lower emissions.

COVER STORY OEM Off-Highway | JULY/AUGUST 202216

“As interest in electrification contin ues to gain momentum, many fleets remain reluctant to go all in on fully electric vehicles at this early stage,” said Ramanan. “Critical feedback from our customers is what inspired Allison to develop the eGen Flex with enhanced capabilities for coach and transit buses, effectively serving as a bridge solution between conventional fuel and full electric solutions.”

In addition to hybrid transmis Technologies Available from Allison, Genie, & Terex

• HyPower SmartPTO by Viatec is a simple and reliable product that reduces idling, increases fuel savings and minimizes noise and air pollution (Earlier this year, Terex announced its investment in Viatec, Inc.).

• Fully electric boom lifts.

• The eGen Power 100S e-axle was developed to address the needs of heavy-duty 6x4 tractors and heavy-duty straight trucks, as well as medium-duty trucks and school bus applications.

• eGen Power 100D electric axel (e-axel).

on page 20

The participants interviewed for this article have multiple electric and hybrid options available that can help OEMs with electric and hybrid options for mobile, off-highway equipment.

Hybrid Solutions Electric is not the sole low-emission technology, and because some vehicles cannot be 100% electric, hybrid may be the solution. The research and equip ment around alternative fuels (hydro gen, natural gas and biofuels) continues to grow. In addition, many OEMs are producing components and systems to function in hybrid configurations.

Continued to all-electric vehicles in the future, including GM. Ford recently produced an all-electric F150 truck, Lightning, and had more than 200,000 orders for“Asit. more people have exposure to hybrid and electric equipment on the jobsite, and as we’re seeing it more in our personal lives, the perception is shifting and people are realizing the benefits of electrification,” Gilmor said.

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Curtis Instruments Electrification Solutions for Construction Equipment and Mobile Machinery

For the electrification of construction equipment or mobile machinery, think Curtis, the electrification division of Kohler Co. With over 60 years of electric vehicle expertise and a global record of innovation and product excellence, we are ready to partner with you in every stage of electrification with hybrid diesel-electric and fully electric solutions. Curtis will support your engineering team at every step in the product development, from initial prototype design through to production release. Our inverters/motor speed controllers and electric control systems set the standard for electric power at 48V and beyond. Highly reliable Curtis components are available in a range of models suitable for every type of application. Our sophisticated electric drive systems are packed with cutting edge features and functions that make vehicle design simple. We will work with you as needed, whether it is to assist with the design and development of electric traction systems, On-Engine Generator Control or to assist with the design of the complete control system for all mobile application types, including complex electro-hydraulic control systems. Curtis has partnered with leading manufacturers of batteries and electric motors to help OEMs design new electric powered dumpers, mini excavators and wheeled loaders. All benefit from proven Curtis 48V technology and the robust, reliable and sustained performance that was previously assumed to be confined to diesel engines. See for yourself. We are ready to help you.

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Looking to the Future Powering medium- and heavy-duty off-highway equipment continues to

COVER STORY OEM Off-Highway | JULY/AUGUST 202220

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Isuzu Motors America, LLC :: 46401 Commerce Center Drive, Plymouth MI 48170 :: 734.582.9470 :: www.IsuzuEngines.com sions, Allison Transmission also manufactures electric axles. The eGen Power 100D, the first e-Axle that Allison brought to market in 2020, is powerful and fully integrated. It was developed for heavy-duty trucks such as 6 x 2 Genietractors.produces fully-electric and hybrid approaches in its vehicles and has for a while. “More than 70% of the equipment Genie manufactures is already elec trified,” Gillmore said. “Our FE hybrid technology, which is available on a range of Genie boom lifts, has been [on] the market since it was introduced on our boom lifts six years ago.” Terex has fully electric bucket truck, but it also worked with hybrid solu tions. “For many years, we have offered a hybrid solution to reduce idling, fuel usage, and exhaust emissions,” Cay wood said. “At various stages, we have had several hybrid models working in the field and continue to see this solution helping to reduce emission and meet sustainability goals.”

A HYBRID CHALLENGE: PARALLEL OR SERIES ARCHITECTURE? With electric hybrid solutions, a choice must be made—should be made, ac cording to Ramanan. Should a parallel or series architecture be used? Each architecture is faced with tradeoffs. “Allison initially launched with a series architecture,” Ramanan said. “Allison later made the investment to convert to a parallel architecture. This change enabled Allison’s electric hybrid systems to realize the benefits of electric hybrid propulsion, while still offering a direct mechanical con nection to the driveline to maximize performance and torque delivery.” This was critical decision because it allowed the system to operate large commercial vehicles on significant grades while meeting the perfor mance requirements. This can be challenging, perhaps impossible, for series“Allisonarchitectures.thenfurther optimized our architecture by adding a disconnect clutch to the transmission in our parallel electric hybrid system,” said Ramanan. This enabled the efficiency benefits of a series hybrid system by creating a mechanism that allows the system to disconnect from the mechanical connection when it is not needed to meet the demand for power. This disconnection is determined by the operator of the vehicle through throttle input.

OEM Off-Highway | JULY/AUGUST 2022 21 For Your Harsh Conditions Wesgarde, a provider of interconnect solutions for the ConAg, industrial, and transportation industries, carries Molex products. Designed to withstand high temperatures and wet, dusty, or dirty environments, Molex rugged connectors and cordsets provide reliable connections for trucks, farm equipment or RVs. TM ISO 9001 Delivers applicationswideperformancehigh-currentforarangeof Micro DistributionPower Box Sealed Modules Busbar ConnectorsPowerMX150L Industrial Sealed SystemConnector Seals guarantee full submersion in wet environments Supports upapplicationspowerto40.0A SealSupportspower Talk to us today! Wesgarde has many locations across the country. Call 1-800.554.8866 or emails us at info@wegarde.com to connect with our sales representatives. Sealed Solutions NEMA rated Brad M8 & M12 Cordsets protectsinsulationWraparoundcrimpagainst seal punctures TerminalsSolderless Splices, SolutionsWire-ManagementDisconnectsQuickandand rangewideperformancehigh-torsionovertemperature IP68-rated Squba Sealed SystemConnector be fluid. Traditional diesel-driv en ICEs remain the dominant power mode in the current land scape. This will continue for the near“Futureterm.proofing their business to the upcoming ESG challenges is essential for all corporations to remain sustain ably competitive,” said Aulbur. “Most off-highway players are therefore committing to sustainability as a key strategic topic, with some OEMs giving themselves challenging targets. This includes achieving net-zero operational emissions by 2050. Hybrid-diesel engine technolo gies, which consume significant ly less fuel than traditional ICEs, use less fluids, and have fewer components, provide a tangible bridge toward those goals” | ALLISON TRANSMISSION A mining dump truck with a hybrid propulsion system

ENGINES & EMISSIONS OEM Off-Highway | JULY/AUGUST 202222

olutions are needed that can mitigate the 4.8 gigatons of annual carbon dioxide (CO2) emissions generated globally from heavy-duty sectors that use diesel fuel. These include on-road transpor tation and off-highway equipment. While electrification helps curb tailpipe emissions of light-duty, medium-duty and short-range transportation, largescale deployment for heavy-duty and off-highway sectors is still decades away. These industries need solutions for decarbonization today to help meet global climate goals. The Challenge Diesel engines are critical to world economies. However, they contribute to local air pollution, and the burning of fossil fuels is currently the largest contributor to greenhouse gas emis sions from human activities. Projec tions suggest that even with a growing number of alternatives, only 25% of new, heavy-duty trucks in 2035 will be rated for zero tailpipe emissions. This leaves the remaining 75% to rely on fossil fuel unless other alternatives are developed. Additionally, the number of heavy-duty vehicles on the market continues to increase, with nearly 359,000 Class-8 vehicles expected in production in 2022. The size of the diesel emission prob lem and the wide range of applications in which these engines are used have created a search for decarboniza tion solutions across the heavy-duty industry. One question often asked is: How fast can we get to zero emissions?

The Fastest Path to Emissions Reduction for Heavy-Duty Diesel Engines

Key Considerations Four key factors should be considered when assessing emissions reduction for on- and off-highway applications: • Life-cycle emissions as the pri mary metric—Reducing life-cycle greenhouse gas (GHG) emissions is essential for lowering atmospheric

Figure 1. Emission reduction trajectories associated with limiting warming below 1.5°C based on the starting year. Solid black lines show historical emissions while dotted lines show emissions constant at 2018 levels.

Make the most of current technology and alternative fuels. by Julie Blumreiter, ClearFlame Engine Technologies

Framing the question in this way creates a single, acceptable outcome— only the solutions with perfect, zero emissions are the ones worth imple menting.However, if all the diesel emissions were cut in half today, the industry would have twice as long to find the quickest path to zero emissions. Per haps a better question is: How quickly can we reduce emissions? This way, the industry can prioritize progress toward that perfect future without discounting provisional solutions that can help get the industry there sooner. In stronger words, focusing exclusively on zero tailpipe emission solutions impedes the progress the industry can make and needs to be making by deploying midterm solutions that offer significant emissions reductions today

TECHNOLOGIESENGINECLEARFLAMES

ReliabilityPerformancePrecisionQuality

Figure 2. Current production levels of alternative fuels on a DGE basis

Axial Piston Motor • 85, 112, and 160cc displacements 420 bar pressurecontinuousrating • Electric, hydraulic, two-position displacement and pressure related displacement controls 85 & 112cc ﬁxed displacement versions available • Optional Speed Sensor X GHG levels, the driver of climate change. Different actions generate the addition or removal of GHGs into the atmosphere. However, like a bank account, the net effect of those activities impacts the balance. To illustrate, while a vehicle powered by net-carbon-negative fuel might not deliver zero CO2 emissions at the tailpipe, the aggregate effect of that fuel reduces GHG levels in the atmosphere. Similarly, battery-pow ered equipment charged by a carbon-intensive source contributes to climate change, despite emit ting zero tailpipe emissions. This life-cycle framework has been used for decades by leading institutions studying climate. It is essential when assessing the true emissions reduc tions of alternative technologies.

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•

• Time sensitivity of emissions reduction—The financial analogy of atmospheric carbon also applies to the time-sensitivity of reducing GHGs. Like a loan deferral, getting a later start on emissions reduction requires moving more quickly to arrive at the same climate impact by 2100 (see Figure 1). Global emis sions have already arrived at a point where the rate of reduction required is basically impossible. If the indus try starts in 2022, emissions need to reduce by 14% in 2024. That is the same size as the total emissions from transportation (road, rail, air and marine). That rate only increases the longer action is deferred.

• Air quality considerations—Air quality continues to impact human health, particularly in heavily congested, urban areas. Criteria emissions such as soot and NOx have long been linked to higher

TECHNOLOGIESENGINECLEARFLAME TECHNOLOGIESENGINECLEARFLAME

ENGINES & EMISSIONS OEM Off-Highway | JULY/AUGUST 202224 rates of asthma, heart disease, and other respiratory and cardiovascular illnesses. For the children living in areas with significant diesel pollu tion, every step forward in emissions reduction matters. Waiting 10 to 15 years for solutions is unacceptable.

• Lee et al. Argonne National Lab oratory, DOI: 10.1002/bbb.2225; Biofuels. Bioprod. Bioref (2021).

• Clean burning capabilities Small-molecule liquid fuels, such as ethanol or methanol, burn so clean ly, even in a diesel engine cycle, that they produce soot-free emissions. Another benefit is eliminating the diesel particulate filter or at least en suring it never needs to regenerate. Engine data collected by a solution provider’s engineers demonstrat ed engine-out soot emissions at lower levels than the Environmental Protection Agency’s regulation for on-road tailpipe levels (see Figure 3).

• Scalability—Using ethanol takes advantage of an existing fuel distri bution infrastructure. More than 15 billion gallons are produced in the U.S. each year (see Figure 2).

Resources

• Total cost of ownership—The total cost of ownership (TCO) is a key driver for equipment owners. The cost of equipment, operation and maintenance all factor into a TCO calculation. While lowering emissions, the solutions must have compelling TCO so end users to remain productive and profitable.

Figure 4. A comparison among transportation energy sources: Historical and projected average carbon intensity of U.S. fuel energy efficiency ratio

• Lower emissions—Fuels like eth anol can significantly help reduce emissions. Research from Harvard and Argonne National Laboratory show that the life-cycle carbon intensity of U.S. ethanol is approx imately 45% lower than diesel or gasoline. It is also lower than that of electricity using the national grid average.

Benefits of Decarbonized Liquid Fuels With life-cycle emissions, time sensitivity, and air quality framing the emissions challenge, alternative solutions are necessary and timely. De carbonized liquid fuels can provide a rapid pathway to reducing engine-out emissions. These include biofuels and synthetic fuels, which can be scaled more quickly than electrification and enable faster emissions reduction. Using 100 percent renewable, plant-based fuels like ethanol is the basis for some engine modifications. One solution enables these fuels to be easily integrated into existing diesel engines, replacing diesel fuel and offering a quickly scalable, lower emission, lower-cost solution. Ethanol offers these key advantages:

• “Bloomberg NEF’s global EV out look 2021: Commercial vehicles,” https://bloom.bg/3BlMGiF/Bloomberg.

• Carbon intensity of corn ethanol in the United States: state of the science, https://bit.ly/3cA6zZ2IOPscience.

The Future No silver-bullet solution exists today to help the industry meet its emission and climate targets. However, a policy and market environment that incentiv izes outcomes rather than one solution benefits on- and off-highway equip ment end users. By embracing a range of technologies, the industry can move closer to a clean and equitable future.

Figure 4 compares fuel and ener gy types used in transportation and equipment, demonstrating their car bon intensity and how it has decreased over time. Alternative fuels have and continue to improve, contributing to the low life-cycle GHG of any equip ment or vehicles that use those fuels.

• Hausfather, Zeke, Carbon Brief. UNEP: 1.5C climate target ‘slipping out of reach.’ https://bit.ly/3vl9NGj Dr. Julie Blumreiter is the chief technolo gy officer and cofounder of ClearFlame Engine Technologies. Read More https://oemoh.co/hq4ftc LEE ET AL., ARGONNE NATIONAL LABORATORY

• Cost—A fuel like ethanol can lower the TCO for end users when com pared to existing diesel equipment. On a diesel gallon equivalent basis (DGE), ethanol was lower cost than diesel fuel in 2021. In the current, 2022 environment, it is $2 per DGE lower. This fuel price advantage impacts the TCO of equipment. While many solutions ask customers to pay more to “go green,” low-cost liquid fuels can simultaneously lower costs and emissions. For agricultural applications, the po tential exists to create a virtuous cycle by operating the equipment on the same fuel that many farms help pro duce. The life-cycle carbon intensity of ethanol accounts for the emissions of the equipment used to plant, harvest and transport the crops.

• “All Signs Point up: Analysts See Robust and Growing Demand for Future Diesel Products in on and Off-Road Applications in 2022,” Diesel Technology https://bit.ly/3cEZvKJForum.

dSPACE is assisting the University of Alabama at Birmingham (UAB) with the development of vehicle perception technol ogy for ADAS/AD applications using physics-based sensors. The university is using dSPACE’s AURELION solution to create complex, simulated driving scenarios, including the model ing of sensor behavior.

Solution: The level of detail that had to be simulated in various nature scenes presented interesting challenges, but dSPACE was able to help UAB identify bottlenecks and resolve processing issues. With AURELION, they were able to simulate lidar and radar simulations from maps in real time with outstanding realism. Further research is ongoing to increase the size of the simulated scenes, so that multiple kilometers can be simulated. See a live demo of AURELION at COMVEC –dSPACE booth # 113.

Challenge: UAB was seeking help to integrate a traditional map into its 3-D sensor simulation environment. Their goal was to produce a realistic sensor response for different sensor simulations (i.e., camera, radar, lidar) in complex, off-road environments, which far exceed the challenges associated with traditional road and city settings.

OEM Off-Highway | JULY/AUGUST 2022 1 Advertisement

Success Story: dSPACE’s AURELION Helps the University of Alabama Implement Complex 3-D Sensor Simulation Environments

ince its invention more than a century ago, the internal combustion engine (ICE) has been responsible for power ing the majority of the world’s 1.466 billion (and counting) vehicles. It also has fundamentally remained the same.

ENGINES & EMISSIONS OEM Off-Highway | JULY/AUGUST 2022

While automakers and manufacturers have learned to refine the ICE, their innovations have been applied else where—improving safety; streamlining operations and efficiency; and, more recently, reducing fuel consumption and limiting climate impact. A renewed global focus on the environment, several commendable but failed attempts (such as the rotary engine), and modern technologies have brought about the next true auto motive evolution nearly one-hundred years later: the electric vehicle (EV). According to the Alternative Fuels Data Center from the Department of Energy, the average EV emits 3,774 pounds of carbon dioxide (CO2) equiv alent per year—a 67% reduction from the 11,435 pounds of CO2-equivalent from a gasoline-powered vehicle emits. And it is a more drastic reduction from the 223 tons (491,631 pounds) of CO2 produced by diesel vehicles. Reducing fuel consumption and emissions is critical for smart fleet management.

Additionally, studies prove that EVs are safer than traditional gasoline or diesel engines because lithium-ion batteries pose less of a risk of fire or explosion. The Insurance Institute for Highway Safety also showed that crashes involving EVs resulted in less chance of Presidentinjury.Biden set an ambitious goal for half of new car sales to be electric, fuel-cell or hybrid EVs by efficienciesoperationalsafetyandcialpadoptareoverall,emissionslowermandatesgovernmentever,track.EVstransitionConsumer2030.toisonafastHowdespitetovehiclefleetsstillslowtowithoutroofoffinanbenefitsimprovedand

A major barrier to EV adoption is over head costs. From an infrastructure per spective, EV charging stations can cost about $1 million to install. On the fleet side, on average, early model EV school buses are two to three times more than the cost of a diesel bus. However, gov ernment funding is available through the annual Bus and Bus Facilities Grant and Discretionary Grant Program for Charging and Fueling Infrastructure. This money supports states and transit organizations that want to invest in new or rehabilitated transit equipment and infrastructure, includ ing EV charging. The Biden Adminis tration also announced private U.S. investments that will help develop the nation’s EV charging network. With low-cost overnight charging, reduced cost and downtime for main tenance, and overall savings on energy costs, EVs will have lower total cost of ownership (TCO) than a typical diesel vehicle. McKinsey estimates that by 2030, electric fleets will have a 15% to 25% lower TCO than ICE vehicles. Infrastructure Needs Another concern is the relative lack of EV charging infrastructure. In some cities, charging stations are available at grocery store lots, but in others, options are more limited. While government is focused on investment in charging infrastruc ture with the previously mentioned funds, diesel trucks already struggle to find truck parking spots en route let alone EV charging stations. In fact, 2021 marked the tenth year in a row

Overcoming Electric Vehicle ADOPTION BARRIERS

How OEMs can help fleets be safer, cleaner and more efficient by encouraging the move to EVs by Greg Colvin, Zonar Software can connect GPS, electronic logging devices and predictive maintenance technology with transportation management systems to provide insights for drivers and dispatchers.

The Reality of EV Costs

S26

American Transportation Research Institute’s annual survey: https://bit.ly/3PSDre5

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Planning for EV Adoption

The decision to add EVs to a fleet requires planning and investment. OEMs can help contractors understand the long-term benefits, which in clude saving money, keeping vehicles and drivers safe, and reducing the overall carbon footprint. Greg Colvin, senior director, OEM solutions, for Zonar Read More https://oemoh.co/6jqee8

Technology and Data For EV route planning, OEMs should include smart fleet management software. This software can connect GPS, electronic logging devices and predictive maintenance technology with transporta tion management systems to provide insight. Data overload may be another obstacle. Left un touched, data only accumu lates. Organizations must be able to use data to manage electric and hybrid fleets. OEMs can help fleet managers understand how to use the data that software provides to make decisions. Smart mobility solutions provide data critical to iden tifying charging inefficiencies and compliance needs. This gives predictive maintenance guidance and a look at diag nostic information they may not have had. A solution like this provides a health score with actionable data, which can be used to improve asset uptime. Preventive tools help identify inefficient charging or ill-timed

POSITIONED PRODUCTIVITY.FOR

OEM Off-Highway | JULY/AUGUST 2022 27

Resources Alternative Fuels Data Center: https://bit.ly/3OuToFY The Insurance Institute for Highway Safety: https://bit.ly/3PRkclc Bus and Bus Facilities Grant: https://bit.ly/3cCLwVW National Electric Vehicle Infrastructure Formula Program: https://bit.ly/3opojsU Discretionary Grant Program for Charging and Fueling Infra structure: https://bit.ly/3Bbm0RS “Charging electric-vehicle fleets: How to seize the emerging opportunity,” from McKinsey: https://mck.co/3OojWbX

isviewingonThepowermanagerssystems,applicationsThroughmaintenance.in-cabtablets,andmanagementdriversandremotereceivedataonEVusageandanalytics.necessarydataiscapturedaunifieddashboard,soreandactingasneededsimplified.

CONTACT US FOR YOUR CUSTOM SOLUTION ALMMH.COM that truck parking was listed among the top 10 industry concerns in the American Transportation Research Insti tute’s annual survey. Fleet drivers of ICE vehicles must preplan routes for fuel stops based on the hours-ofservice rules and estimated parking spots. EV and hybrid trucks will have to do the same. Fleets must plan for EV charging options at work facil ities, employee’s homes and/ or public access points. Utili ties also recommend charging during off hours or overnight for cheaper prices and less strain on the power grid.

and Other Features Decrease

Thisfloor.feature nearly eliminates the chance that the loading equipment will damage the truck’s sides. It also simultaneously reduces the wholebody vibration associated with mass dumping. A wide-body option offers well-balanced weight distribution across all the tires, which minimizes Rear eject bodies use an ejector blade to discharge material. This simplifies the dumping process and enhances efficiency. for selecting a truck body must include the total cost of ownership.

Considerations

T28o reduce expenses, every mine plays its own game of give and take. Equipment selection, especially with the beating that mine equipment takes, is a large part of cost considerations. When selecting a truck body, finding ways to balance longevity and produc tivity creates a challenge. For addressing cost, selecting a heavier, durable truck body provides years of low-maintenance operation. These heavy-duty units also tend to be ... heavy. Extra weight reduces the amount of material that can be hauled by the vehicle. Heavy-duty units also have an initial high price. In contrast, an emphasis on in creased hauling capacity and higher productivity from a lighter weight body provides another option. These units are lower priced but often wear out quickly. Vehicle failures lead to downtime with lost production and a need for repairs or replacements. Even mines seeking a middle ground are challenged with an off-the-shelf truck body that may not maximize the mine’s potential. An option that provides a sustainable solution to the productivity dilemma is a custom-de signed truck body, manufactured to meet the specific challenges of the individual mine. Focus on the Mine Before mine managers research truck body features, they must examine their mine. Each mine is different and needs specified equipment. Does a humid environment cause issues with carryback? Do trucks haul corrosive materials? When dumped, do materi als need to exit slowly? These questions lay the groundwork for. Working with a custom equipment manufacturer adds benefit. These man ufacturers work in tandem with mine managers to analyze specific require ments while offering an objective and experienced eye to suggest consider ing of often overlooked details. Important options that can maxi mize effectiveness in a mine go be yond add-ons like sideboards and floor liners. The truck body’s design, material make-up and other factors should be discussed with a custom manufac turer to select the ideal body for the mine and ensure that strong bones make it up. With the groundwork in place, mine managers can look for the features that will ensure that they get a functional, efficient and durable truck body for their mine. Body Basics No matter the skill level, operators may not be able to avoid damaging many standard or off-the-shelf truck bodies. Damage often occurs when the loading tool contacts or bumps the truck body while filling. What causes this contact? The truck body may be too small. It may be mismatched with the loading tools, or the body may not have the proper height. Regardless of the cause, repeated damage during loading can quickly destroy a body, causing expensive maintenance and repair issues on the truck.

Customizing truck bodies to the mine’s specifications increases loading safety and reduces the potential for loading damage by ensuring that the width is correctly paired with the loading tool. This provides the lowest possible loading height and allows the shovel bucket to get closer to the truck body

equipment’s

MINING OEM Off-Highway | JULY/AUGUST 2022

by Josh Swank, Philippi-Hagenbuch Inc. INC. Mining Costs REAR EJECT BODIES

PHILIPPI-HAGENBUCH,

PHILIPPI-HAGENBUCH, INC.

OEM Off-Highway | JULY/AUGUST 2022 29

the potential for uneven tire wear and extends the truck components’ and body’sWithlives.heavy use and high reliability required in mining applications, main tenance is inevitable. Simple design considerations in the body improves reliability. They can either speed the maintenance process or decrease is sues and/or the need for maintenance. Adding four free-floating lifting eyes into the floor of the body rather than the sides is one example. This enables fast and easy removal or installation of a body for maintenance without the risk of bowing the body, a common issue with lifting points incorporated on the sides. As body sides age, traditional lifting points in tegrated into the them, such as pivots and holes, can become fatigued. This weakening risks a potential safety situation when removing or installing a body down the road. Bolsters and frame rails provide maximum reinforcement to the sides and floors of bodies. Traditional bodies simply have butt-welded bolsters to frame rails, making them vulnerable to wear and tear. Bodies with intersecting bolsters and frame rails offer superior High sides and a poor baffling design can cause round water tanks to be unstable. Square tanks like these help address these issues.

Rear eject bodies offer an efficient, low-maintenance alternative to enddump trucks for smaller, niche areas within a mine. As the name implies, rear eject bodies use an ejector blade to discharge material. Without moving or raising the truck bed, the blade pushes material toward the rear of the truck. This simplifies the dumping process and enhances efficiency since operators don’t have to wait for the bed to lower before driving away. When selecting a rear eject body, less is more. Rear eject bodies with a single hydraulic cylinder that operates the ejector blade and the rear tailgate mechanism at the same time minimize maintenance costs and maximize uptime. Selecting a body with ejector guides inside the truck bed delivers smooth operation and decreases over all maintenance requirements. They eliminate rollers that often break or bind. With the guides and track within the bed, no external rails can be hit by loader operators, which can disable a unit until costly repairs are made. Some rear eject bodies feature designs tailored to reduce carryback. The natural, sweeping action of the ejector blade reduces the chance for carryback, even with materials prone to sticking to the sides or floor of the truck bed. However, certain conditions, such as a humid, sticky environment, present even greater challenges. In these instances, a manufacturer can work with mine managers to add exotic steel liners to the ejector blade to deter sticking and further ensure no carryback.Integrating a rear eject body into a truck has obvious benefits for dump ing. However, these bodies can also be fitted with add-on attachments that further increase the flexibility and utility value of the specialty body in the mine. SPREADING In some applications, materials must be evenly and precisely distributed. By safely controlling the dumping rate and pairing it with a material spreading at tachment, rear eject trucks can increase efficiency in these tasks. They are ideal for applications such as haul road main tenance or certain drying applications, such as spreading salt, diatomaceous earth or lime onto leach beds. Material spreading attachments are available from custom equipment manufacturers and are designed to integrate seamlessly with the rear eject bodies. Spreading attachments can handle a wide range of material— from very fine to 2-inch-minus-sized material. Also, the spread width can be adjusted from approximately 5 feet to 60 feet or more (1.2 meters to 18.2 me ters). In addition to hauling and road maintenance, it can also help spread grit for traction on icy roads.

MINING OEM Off-Highway | JULY/AUGUST 202230 support that won’t buckle under the immense stress of materials, keeping the payload at maximum capacity. A truck body with these design features has good bones. A well-de signed body can be customized and refurbished to find the sweet spot for handling the daily abuse of the mine while maintaining productivity. With supply chain issues and a volatile steel market, the custom manufacturer must also use the best steel throughout the body. It must also ensure that parts and materials are available and made in-house. Checking all these boxes pro vides mine managers with a solid base to expand on with other truck body options that can further streamline operations, like rear eject bodies.

STEMMING

PHILIPPI-HAGENBUCH, INC.

Many mining operations rely on sidedump buckets or loaders to fill blast holes with stemming material after the explosives are packed in the bottom. Stemming can be time-consuming, but an attachment can transform produc tivity and increase rear eject versatility. Opting for a rear eject body with a stemming attachment, however, can greatly improve efficiency. For example, using a single 3-ton loader, operators might only be able to fill two holes per load before travel ing back to aggregate piles for more material. Depending on how close the stockpile is, this can result in cycle times of 15 minutes or more. With each blast averaging 100 or more holes, filling the blastholes with stemming material often takes two Customized truck bodies designed for the mine’s specifications increase loading safety and reduce the potential for loading damage by ensuring that the width is correctly paired with the loading tool.

Rear Eject Bodies

Instability is worsened by a baffling system that incorporates open mainte nance access cutouts. This system may lead to poor water compartmentaliza tion and excessive water churn. Because of safety concerns and in stability in water trucks, operators may not completely fill the tank, leading to less efficiency and more trips for refills.

To combat this, mine managers should specify a square tank that addresses these issues from the ground up. The squared corners and a more sophis ticated baffling system can prevent water surges between compartments. The baffling system also has doors instead of cutouts, which allows easier access for maintenance. Not rounding the sides also allows for a higher stor age capacity, so drivers can be more efficient with their trips.

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OEM Off-Highway | JULY/AUGUST 2022 31 to four crew members several days. This can create a significant drain on productivity.Alternatively, similar work with a rear eject body with a stemming attach ment on a 40-ton articulated truck would be streamlined. An increase in efficiency of 200% or more would be realized with a rear eject body and stemming attachment when compared to traditional methods. The stemming attachments incorpo rate into the rear eject body, offering an adjustable arm that can easily be positioned over the stemming hole to precisely deposit material in less time and with minimal labor. The ejector blade pushes material to a cross auger, which loads the articulating stemming arm and conveyor. The ejector blade speed, in-cab controls, stemming conveyor and operator controls at the stemming arm all precisely control the flow of material for even distribution. Water Tanks In addition to truck bodies, water tank selection provides an excellent oppor tunity for improvement. Though they may seem basic, water tanks are crucial for many tasks including dust suppres sion and firefighting. Traditional round water tanks limit productivity and increase costs. Round tanks often have high sides, which result in a poor cen ter of gravity that can lead to tipping.

Lasting Solutions Mine managers want their mines to operate at their full potential, and that usually rides on the back of a haul truck. By laying the groundwork and incorporating the assistance of a custom manufacturer, mine managers can include their wants and needs into their unique operation instead of work ing with off-the-shelf options.  Josh Swank is vice president of sales and marketing for Philippi-Hagenbuch, Inc.

NewAnnouncedCumminsCEO Rumsey is the first woman to hold this title since the company’s inception in 1919. by Lori Ditoro Cummins Inc. announced that, effective August 1, 2022, Jenni fer Rumsey, president and chief operating officer, will assume the role of seventhwillRumseytermwillLinebargerandandpresidentCEO,TomendhisasCEO.betheCEO and first woman to lead the company since it was founded in 1919. Rumsey is an advocate for diversity, equity and inclusion, and women in STEM fields.

Tanks and reservoirs in off-highway vehicles require special design considerations to deal with more adverse conditions. Mobile hydraulic reservoirs are expected to perform as well as their industrial counterparts. However, tanks and reservoirs in off-highway vehicles require special design considerations to deal with more extreme and often adverse conditions, such as machine motion, extreme ambient temperatures, as well size limitations. Sponsored by The IFH Group Read More https://oemoh.co/cwzs7d When Selecting Fasteners A dependable supplier helps decrease lead times, improve operations and increase environmental and sustainability progress. by Paul Przyby, Optimas Solutions

OEM Off-Highway July/August 2022

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