OEM Off-Highway January/February 2021 by OEM Off-Highway

JANUARY/FEBRUARY 2021

ADVANCEMENTS IN TRUCK DESIGNS Electrification and smart system development continue to lead the way in the on-road truck market.

Powerful Software Benefits Design of Heavy-Duty Vehicles oemoffhighway.com OOH0121_01_Cover_SJ_NoLabel.indd 1

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N B O

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CONTENTS

VOLUME 39, NO. 1 | JANUARY/FEBRUARY 2021

Technology Breakdown: Western Star 49X

24 Western Star Builds Next-Generation Vocational Truck

The 49X was designed from the ground up to meet the most demanding vocational applications. Search: 21196047

Engineering & Manufacturing: Software

28 Powerful Software Benefits Design of Heavy-Duty Vehicles

The latest software tools provide a full design and simulation environment to cover all aspects of vehicle systems. Search: 21159777

Electrical & Electronics: Sensors

COVER IMAGE: ď&#x2DC;łDKCOMPOSING ď&#x161;ť STOCK.ADOBE.COM

FEATURES

32 Sensors Play Critical Role in New ANSI Standard Use of various sensor technologies will be necessary to meet the safety functions described by the new ANSI 92.20 standard.

News Briefs: Engineering & Manufacturing

12 Hallite Expands In-House Testing Capabilities

Hallite is increasing its testing capabilities to improve product development for evolving market needs. Search: 21204970

Search: 21194165

Engineering & Manufacturing

34 Equipment Manufacturers Prepare for Augmented and Virtual Reality Initiatives Augmented and virtual reality technologies can bring benefits to all aspects of a business from engineering to manufacturing to end user applications.

News Briefs: Electrification

14 Commercial Availability of Electric Vehicles and Equipment Increases Several electric truck and heavy equipment models are now available for order and set to begin production in 2021.

Search: 21172020

36 New Products oemoffhighway.com/directory

Search: 21207226

Drivetrains: Electrification

16 Purpose-Built Electric Drivetrain Components Ensure Performance and Efficiency Developing components for electric vehicles assures they can handle the specific performance needs of the application.

Search: 21206852

Market Forecast: On-Highway Truck & Bus

20 2021 is Looking Better for Most Global Commercial Vehicle Markets

14 28

Orders for medium- and heavy-duty commercial vehicles improved in the second half of 2020 in many global markets, indicating improved conditions in 2021. Search: 21206827

OEM Off-Highway | JANUARY/FEBRUARY 2021

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IN EVERY ISSUE 6

Published by AC Business Media

Editor’s Note

What’s in store for industry events in 2021?

Equipment Market Outlook

Farm Equipment Markets See Positive Signs

oemoffhighway.com/economics

40 Events Calendar

oemoffhighway.com/events

41 Advertisers’ Index Off-Highway Heroes

42 The First Wheeled Scrapers The wheeled scraper became a matter of necessity for the construction industry due to the need for improved earthmoving capabilities. Search: 21207987

Online Exclusives www.oemoffhighway.com Video: New Cab Design for Volta Zero Electric Truck Improves Safety Volta Trucks created a brand new cab design for its electric truck with enhanced ergonomics and visibility to improve comfort and safety for truck drivers. Search: 21203339

Adapting Between M12 and Deutsch DT Connectors in Heavy Equipment Applications

New solutions which combine the capabilities of M12 and DT connectors will be needed as OEMs continue integrating advanced technologies into their equipment.

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

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

John Madsen Director Engineering & Product Management GKN Wheels & Structures Doug Meyer Global Director of Construction Engineering John Deere

Change of Address & Subscriptions — PO Box 3605 Northbrook, IL 60065-3605, Phone: (877) 201-3915 Fax: (847)-291-4816 • circ.OEMOff-Highway@omeda.com

Andy Noble Head of Heavy Duty Engines Ricardo

List Rental — Bart Piccirillo, Sr. Account Manager, Data Axle Phone: 402-836-2768 | bart.piccirillo@data-axle.com

Daniel Reibscheid Business Development Manager MNP Corporation

Reprints — For reprints and licensing please contact Greg Schulz at 920-542-1239 ............. gschulz@ACBusinessMedia.com

Matt Rushing Vice President, Product Line, Global Crop Care AGCO Corp.

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

Allen Schaeffer Executive Director Diesel Technology Forum Keith T. Simons President – Controls Products OEM Controls, Inc. Alexandra Nolde Senior Communication & Media Specialist Liebherr-Components AG

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. 1, January/February 2021

Bob Straka General Manager, Transportation SBU Southco, Inc.

Podcast: AVL Says Normalization of Electrification Will Bring Down Component Design Time and Costs

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

PRINT AND DIGITAL STAFF Publisher Sean Dunphy sdunphy@ACBusinessMedia.com

Senior Field Editor Curt Bennink cbennink@ACBusinessMedia.com

Steven Nendick Marketing Communications Director Cummins Inc.

Search: 21205844

www.OEMOffHighway.com

Editor Sara Jensen sjensen@ACBusinessMedia.com

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

Luka Korzeniowski Global Market Segment Leader, Mobile Hydraulics MTS Sensors

Search: 21203776

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

Market Forecast: Fluid Power Search: 20846516

OEM Off-Highway | JANUARY/FEBRUARY 2021

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EDITOR’S NOTE

What’s in store for

INDUSTRY EVENTS in 2021?

IN THE NEXT ISSUE

S. JENSEN

s we enter the new year, it is hard to get a sense of what lies ahead. There is still much uncertainty surrounding the global health crisis, and likely will be for some time yet. One of the biggest impacts for OEM Off-Highway and the industries we cover has been the inability to travel to conferences and tradeshows. This is a crucial way to see what’s going on in the industry. While travel was on hold in 2020, and is looking like it will be at least during the first quarter of 2021, many industry events and manufacturers have found virtual events to be a viable alternative. It has provided the industry a means of sharing information and connecting with one another. In some instances, event organizers we’ve spoken to have even seen an increase in attendance as the virtual offering provides an easier, and sometimes more cost-effective, alternative. While I do miss getting out into the industry, I’ve also been enjoying the virtual event options, some of which have allowed me to “attend” events I might not have otherwise had the opportunity to due to other conflicts. This has enabled me to stay on top of what’s going on in the industry and continue networking with others where possible to ensure we’re bringing our audience the most up to date information. And I look forward to seeing how events will progress this year, and even in coming years. While I don’t think in-person events are a thing of the past by any means, it does seem there could be a shift toward more digital options. Some events scheduled for 2021, such as SAE’s COMVEC and Agritechnica, have announced they will provide both in-person and virtual options. This allows the industry to still get the value of attending an event but with the option of how they will do so. To stay up to date on industry events, especially as many shift their dates or to a virtual offering in 2021, you can visit our blog at oemoffhighway.com/21123406 which is continually being updated with news about changes to events, as well as our events page on our website. What do you miss most about industry events? How do you see them changing in the coming years? What upcoming events are you most looking forward to in 2021? Let us know!

MARCH ISSUE • Operator Cab Filtration Systems • New Autonomous System Components • Hydraulic System Design Trends • Electric Construction Equipment Product Launches

editor@oemoffhighway.com @OEMEditor

OEM Off-Highway | JANUARY/FEBRUARY 2021

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Track Market Trends with OEM Oﬀ-Highway

Subscribe to the Equipment Market Outlook newsletter for monthly market updates delivered right to your inbox. OEMOﬀHighway.com/subscribe

Check online 24/7 on OEMOﬀHighway.com’s Market Analysis Channel for the latest market trends and news insights. OEMOﬀHighway.com/market-analysis

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EQUIPMENT MARKET OUTLOOK

Sponsored by Eberspächer

oemoffhighway.com/economics

Europe Ag & Forestry Machinery Production:

U.S. Farm Machinery Production: • U.S. Farm Machinery and Equipment Supplies Shipments during the 12 months through October totaled $22.6 billion, down 3.9% from 1 year ago. • Shipments tentatively transitioned to a recovery trend. Rising commodities prices, including U.S. Soybeans Futures Prices, bode well for business cycle rise in Shipments in the coming quarters.

Annual % change in 12 month moving totals

0.1% -2

-1

-4

-2 -6 -6.5%

-3

-3.2%

-6.5%

-8

-4

-8.3%

-3.9%

-8.1%

-9.0% -10

-5 -5.3%

-6

Mar ’20

Apr

May

-10.4% -5.9%

Jun

-5.7%

-5.9%

-5.5%

Jul

Aug

Sep

Oct

-12

• The Europe Leading Indicator ticked down slightly in November, likely due to new shutdown orders in several European countries. • While the tick-down in the Leading Indicator suggests that the current shutdowns may hinder recovery, our current analysis suggests that Phase A, Recovery, in Europe Industrial Production remains probable in early 2021.

-11.1%

Mar ’20

Apr

May

-10.6%

Jun

Jul

Aug

Sep

Oct

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

-3

Monthly index

98.2

98.7

98.8

-6

96.7

-9 93.0

-12

90.4

-15

Apr May ’20

Jun

Jul

Aug Sep

Oct

Nov

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: • U.S. Heavy-Duty Truck Production during the 12 months through November was down 39.0% from 1 year ago. • Rising quarterly U.S. Surface Trade with Canada and Mexico, and rise in the U.S. Business Confidence Index, suggests Production will begin recovering in the first half of 2021.

China Diesel Bus Production: • China Large Diesel Bus Production during the 12 months through October was down 29.0% compared to the year-ago level. • Expected recovery in the global macroeconomy in 2021 bodes well for recovery in Production in the new year.

-5

3.8%

Annual % change

• Germany Industrial Production during the 3 months through October was down 6.8% from the same 3 months of 2019. The quarterly rateof-change is rising from a May 2020 low point. • Germany has extended lockdown restrictions through the winter holidays, posing a downside risk to this rising trend.

-5 -5.9%

-5

-15

-7.5%

-16.3%

-6.8%

-10

-20

-10.3%

-9.4%

-11.4%

-25

-15

-25.3%

-30

-32.6% Annual % change in 12 month moving totals

Apr ’20

May

Jun

Jul

-35.6%

Aug

-37.3%

-38.1%

Sep

Oct

-30

-15.6%

-20

-25

-25.0%

-39.0%

Nov

-13.8%

-15 -17.8%

-20

-30.1%

-35 -40

Germany Industrial Production:

0.6%

-10

-28.5%

Mar ’20

Apr

May

Jun

Jul

Aug

Sep

-29.0%

Oct

-25

Mar ’20

Apr

-21.8%

-21.7%

May

Jun

Annual % change in 3 month moving totals

Jul

Aug

Sep

Oct

OEM Off-Highway | JANUARY/FEBRUARY 2021

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• U.S dur 9.1% • In t pro init am mit con cyc 0

Annual % change

1 0

• Europe Agricultural and Forestry Machinery Production during the 12 months through October was down 6.5% from 1 year ago. Annual Production is generally rising from a low point in the second quarter of 2020. • Within Europe, food and beverage consumption increased the most in the United Kingdom during the lockdowns of 2020. This may be an area of opportunity as lockdowns extend in the near term.

Europe Leading Indicator:

1/6/21 8:17 AM

-11.4

Ma ’20

U.S. Construction Machinery, New Orders:

n hutes. ator y gests ial 1.

• U.S. Construction Machinery New Orders during the 12 months through October were 9.1% below the year-ago level. • In the most recent elections, voters approved a record 94% of state and local ballot initiatives for transportation improvements, amounting to an overall countrywide commitment of $14 billion. This bodes well for construction in the coming years, and thus for cyclical rise in New Orders. Annual % change in 12 month moving totals

U.S. Defense Industry, New Orders:

North American Rotary Rig Count: • The North American Rotary Rig Count during the 12 months through November averaged 584, down 48.1% from the year-ago level. • Rise in the U.S. ISM PMI (Purchasing Managers Index) and projected recovery in U.S. Crude Oil Futures Prices signal recovery for this industry in 2021.

Annual % change in 12 month moving totals

• U.S. Defense Capital Goods New Orders during the 12 months through October totaled $156.1 billion and were up 2.1% from 1 year ago. • Decline in the World Uncertainty Index suggests a diminished sense of urgency regarding defense; this may hinder New Orders in the near term.

8.0%

8 7

-3

-10

-6

-20

-19.4% -23.7%

-9

-12

-9.4%

-9.2%

-8.5%

-9.1%

-12.3%

-12.5%

Mar ’20

Apr

May

-41.8%

Jun

Jul

Aug

Sep

Oct

-50

Apr ’20

May

Jun

Jul

Aug

2.1%

-37.8%

-40

Sep

Oct

2.1%

-45.3%

-15

3.0%

3 -33.3%

-10.8%

-11.4%

4.5%

4 -28.6%

-30

6.8% 6.0%

98.8

7.8%

Annual % change in 12 month moving totals

-48.1%

Nov

Mar ’20

Apr

May

Jun

Jul

Aug

Sep

Oct

Nov

fied on

e3 from ratepoint. ions wn-

Subscribe Now

to OEM Oﬀ-Highway’s Print & Digital products at oemoﬀhighway.com/subscribe

-6.8%

hange in ing totals

Oct

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NEWS BRIEFS: ENGINEERING & MANUFACTURING oemoffhighway.com/21204970

Hallite Expands In-House Testing Capabilities Hallite is increasing its testing capabilities to improve product development for evolving market needs. by Sara Jensen ALL IMAGES COURTESY OF HALLITE

(MSOE) partnership platform that showcases external testing capabilities. For almost a decade, Hallite has partnered with MSOE on hydraulic seal product testing and producing repeatable and comparable results that benefit end-users.

allite Seals International Ltd. announced on December 1, 2020, it will be expanding its in-house testing capabilities by constructing a new, state-of-the-art facility. The new product and material testing facility will be located at the company’s current site in Hampton, UK. Its expanded testing capabilities will help enhance product development and is in line with the company’s also newly announced refreshed branding initiative. The overall goal of this refreshed branding is to better partner and work with the industries Hallite serves to deliver sealing technologies which best meet customer needs. As part of the new branding initiative, Hallite has introduced a new website and Hallite Academy—a customer and partner portal that provides a useful toolkit of resources for collaborating with Hallite. The portal hosts a flexible, shareable fluid power training platform offering hydraulic fluid power education where trainees can gain practical knowledge about hydraulic sealing products based on demonstrations in which they are applied in industrial equipment. The Hallite Academy also hosts the Milwaukee School of Engineering

New test facility to aid product development Hallite’s new test facility will consist of consolidating all of its current inhouse testing into a single location at its site in Hampton. The company plans to break ground in January 2021 on the first phase of the three-phase facility expansion project; it expects to complete the project by the end of the third quarter of 2021. Andrew Iddeson, Global Technical Director at Hallite, says the facility will include investments in new testing analysis equipment that will provide a wider range of material and product characterization. “We’ll have hardware upgrades and improvements on those [test] rigs, and we’ll be installing an enhanced data capture and back-end system to deliver, analyze and report results with much greater efficiency, and in a platform that provides live partner feedback.” Iddeson says the new lab and test facility will allow the company to conduct research and development programs which prove a principle, design or material. It will also provide further support for quality assessments or confirmation of Hallite’s process parameters. He also noted the company will

continue its work with MSOE which is focused on endurance-based testing as well as benchmark testing against existing products in the company’s portfolio. With the new testing capabilities, Iddeson says Hallite will be better able to bring proven designs to market at a faster rate. In addition to the investments in new technology at the facility, he says the company is also looking at developing modular testing capabilities. “That will allow us to accelerate our testing programs and have rigs that are interchangeable so that we can run a wide range of variables with a relatively simple changeover,” he says. “That means testing time is reduced, and done on a much smaller footprint.” All of this Iddeson says supports Hallite’s commitment to an R&D process focused on delivering a better performing and higher quality product at the right time. He notes customers and industry partners will have the ability to witness testing at the new facility as it happens, either in a laboratory setting or remotely through live access to data collected during testing.

Adapting to industry changes As it expands its testing capabilities, Iddeson says Hallite will also be better able to take positive actions regarding changing market conditions. For instance, he notes many markets are moving toward use of water-based hydraulics as a more environmentally friendly alternative. Iddeson says

OEM Off-Highway | JANUARY/FEBRUARY 2021

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that while sealing technologies for water-based hydraulics have been in use in the mining industry for several years, other industries are starting to follow suit. This market shift presents an opportunity for Hallite, he says, to build “on our reputation and our legacy of industry-leading hydraulic cylinder sealing solutions to test and develop enhanced products and materials in what are essentially difficult markets.” Iddeson says the company is seeing movement toward electrification in the off-highway market, as well. “By taking affirmative actions now in monitoring

developments within this market [and] strengthening our technical contact that we have with our leading OEMs, Hallite will work to future proof these testing capabilities [and] continue to provide the programs necessary to meet the needs of the market.” He notes these electrification solutions could be in the form of low-friction products which reduce hydraulic demand of electric power, or sealing electrical actuators in small mobile equipment. “Innovation and the proof of it through testing are part of Hallite’s heritage, and it continues to be harnessed

to help our customers maximize their investment in the sealing solutions that they choose to buy from us. We’re thrilled to be driving our innovative spirit forward by investing in this initiative for providing valid and valuable product and material characterizations. “I’m really excited by the changes we are bringing and how testing will now be more accessible to our customers and our partners, whether this means remote access to live data or visiting the UK facility in a post-covid era. We will have a facility and program of testing that brings added value to our partners,” Iddeson concludes. |

OEM Off-Highway | JANUARY/FEBRUARY 2021

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make it all fit; I can trim text as necessary.

NEWS BRIEFS: ELECTRIFICATION

Da ch an ch

oemoffhighway.com/21207226

Commercial Availability of Electric Vehicles and Equipment Increases VOLVO TRUCKS NORTH AMERICA

Several electric truck and heavy equipment models are now available for order and set to begin production in 2021. by Sara Jensen

evelopment of electric vehicles and equipment is nothing new. However, there has been increased activity in this area in recent years as technology has matured and costs have come down. As such, many OEMs are ready to begin bringing their electric-powered solutions to market. Volvo Construction Equipment (Volvo CE), for instance, announced in mid2020 it would begin taking orders for its ECR25 and L25 electric machines. Orders are currently being taken in North America and several European countries, with the first deliveries of production machines expected in June 2021 (learn more, 21198350). Sister brand Volvo Trucks North America (VTNA) began taking orders for its VNR Electric, which has been undergoing real-world testing as part of the Volvo LIGHTS project in California, in December. It will begin producing the trucks at its facility in Dublin, VA, in early 2021. The Volvo VNR Electric is designed for customer applications and driving cycles with local and regional distribution ranges, including food and beverage and pick-up and delivery routes. The 264-kWh lithium-ion batteries, which charge up to 80% within 70 minutes, have an operating range of up to 150 mi. (241.4 km) based on the truck’s configuration. Advanced battery chemistries deliver increased power at reduced costs, while self-learning controls optimize energy usage. Regenerative braking can increase range by returning power, up to 15%, back into the battery, depending on the duty

Production for the VNR Electric is slated to begin in early 2021.

cycle. According to VTNA, cutting-edge battery monitoring technology relays the state of health for the energy source in real time, streamlining service needs and maximizing uptime (learn more, 21208147). Meanwhile, the global Volvo Trucks organization announced it plans to offer a complete range of electric heavy-duty trucks in Europe starting in 2021 (learn more, 21201831).

Component availability is key An important aspect for any vehicle or equipment design—and particularly electric vehicles—is ensuring the right components are used for the application. Introduction of new components developed specifically for electric vehicles and equipment has been a key enabler to these vehicles’ entry into the marketplace (see pg. 16 to learn more). Many OEMs have formed partnerships with component suppliers who

have also been focusing their research and development efforts on electrification solutions. Doing so helps to ensure components utilized are optimized for use in an electric-powered vehicle which has different characteristics from traditionally powered ones. PACCAR, for instance, has announced partnerships with both Meritor and Dana—companies which have introduced several electric drivetrain components in recent years. Meritor was selected as the initial launch partner and primary supplier for the integration of functional battery-electric systems on the Peterbilt 579EV and 520EV trucks, both of which are now available for order (learn more, 21204331 and 21201483). Both Peterbilt electric trucks use Meritor’s 14Xe e-axles which provide power to the wheels. Electric motors in the e-axles are capable of capturing regenerative braking energy to help re-

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The JCB Universal Charger offers customers an off-board rapid-charging solution, allowing them to extend working capability with battery-electric construction and industrial machinery.

The Mack LR Electric will be put to the test in New York City which has one of the world’s largest sanitation departments. JCB

DAIMLER TRUCKS NORTH AMERICA

Daimler’s “Electric Island” will provide charging for up to nine electric trucks, and help the company evaluate fleet charging needs.

VOLVO TRUCKS NORTH AMERICA

MACK TRUCKS

charge the trucks’ batteries and extend vehicle range. New components continue entering the market, as well, which will further aid vehicle and equipment designs. The UK-based company Equipmake recently introduced two new electric motors, one of which was designed specifically for off-highway equipment. The APM electric motor utilizes a spoke architecture to optimize cooling which helps the motor to produce more power and torque (learn more, 21197265 and 21206211). Charging infrastructure will also be a vital component to the uptake of electric vehicles. Because of this, many OEMs are doing their part to help expand charging infrastructure. Daimler Trucks North America (DTNA) recently announced it will co-develop “Electric Island”, a large public charging site for medium- and heavy-duty electric commercial vehicles. It is designed to support up to nine vehicle charging stations with charging levels of up to greater than 1 megawatt by spring 2021. According to DTNA, Electric Island will help inform the company’s work in commercial electric vehicle development as well as its partner in the project Portland General Electric’s (PGE) work in meeting customer charging needs (learn more, 21205603). Equipment manufacturer JCB recently announced it was expanding its line of electric-powered equipment. As part of of that introduction, the company has also developed a rapid Universal Charger which is designed to be compatible with its current and future E-TECH electric models. Working with machine electrical systems from 48-96V and above, the JCB Universal Charger offers customers

an off-board rapid-charging solution, allowing them to extend working capability with battery electric construction and industrial machinery. All JCB E-TECH equipment is supplied from the factory with a standard built-in charger and rapid charger preparation.

Testing remains integral part of the equation Though new electric vehicles and equipment are beginning to enter the marketplace, there is still a long way to go in the realm of electrification. Real-world testing will continue to be a necessary part of the process, especially as manufacturers look to further optimize current designs and expand the types of vehicles and applications in which their technology can be used. With production for the Mack LR Electric slated to begin in 2021, Mack Trucks announced in October pre-production models would undergo in-service trials with Republic Services. This will help the company get better insight into how the vehicle performs in demanding refuse applications. The truck is powered by four batteries and features a powertrain which delivers 4,051 lb.-ft. (5,492.4 Nm) of torque available from 0 rpm (learn more, 21197124). Southern California Edison (SCE) recently took delivery of a Freightliner eCascadia, a Class 8 battery-electric truck, which it will use for material transport for 3 months. “It’s critical that we collaborate with customers across multiple segments

to further our understanding of how commercial battery-electric trucks will be part of a long-term solution in CO2-neutral transportation,” said Richard Howard, Senior Vice President, On-Highway Sales and Marketing, Daimler Trucks North America, in a press release announcing the test project (learn more, 21204349). “Our customers provide important, continuous feedback that contributes to our ongoing design and purposeful innovation of these trucks, and together we will lead the future.” |

Head to the Web Read an extended version of this article and related content at oemoffhighway.com. Renault Trucks Delivers Electric Trucks to Swiss Brewer Carlsberg Search: 21205611 Implementing Electric Work Trucks Search: 21136298 Thomas Built Buses Delivers Battery-Electric School Buses Search: 21202055 Mercedes-Benz to Only Source Battery Cells with Cobalt and Lithium Search: 21204325 Volvo Focuses on Electrification and Emissions Reduction Strategy Search: 21203695 Visit oemoffhighway.com/trends/ electrification for even more Electrification content.

OEM Off-Highway | JANUARY/FEBRUARY 2021

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image from each company (Allison Transmission, Hyliion, ZF and Inmotive) that would be great.

DRIVETRAIN SYSTEM: ELECTRIFICATION oemoffhighway.com/21206852

PURPOSEBUILT ELECTRIC DRIVETRAIN COMPONENTS Ensure

Performance and Efficiency

Developing components for electric vehicles assures they can handle the specific performance needs of the application. by Sara Jensen

ALLISON TRANSMISSION

s the heavy vehicle and equipment industries continue their push toward further electrification, new drivetrain components enabling electric-powered propulsion are entering the market. For instance, Danfoss Editron recently introduced a full-electric wheel loader system. The company said in its announcement of the system there is growing demand for electric and hybrid machines which can help companies, cities and countries around the world achieve carbon dioxide (CO2) and emissions reduction targets (learn more, 21205162). The system features an EMPMI375-T800 motor with a speed range of up to 4,000 rpm and uses synchronous reluctance assisted permanent magnet technology. It also includes EC-C1200-AFE350 DC/ AC converters and a DC-DC converter. This configuration enables the 650V battery to supply the DC voltage, which is then inverted to AC to control the traction motor. Other subsystems can also be operated from the DC link voltage. The company says its system is designed to provide high levels of performance with greater efficiency across all system states while keeping energy consumption to a minimum. A growing global population and increased urbanization will help drive electrification, as well. The construction

industry will have a stronger focus on infrastructure and housing projects in urban centers, requiring the use of equipment—particularly compact equipment—which meets standards for reduced exhaust, particulate and noise emissions, says Alexander Eisner, Head of Product Communication Off-Highway Systems at ZF Friedrichshafen AG. In addition, he says many cities around the world have announced bans on certain internal combustion engines in the coming years which will restrict access to city centers for some types of equipment, especially those powered by a diesel engine. Because of this, ZF, like many other manufacturers, continues to develop new components for electric-powered machines such as the eTRAC driveline system introduced in early 2020 (learn more, 21126638). Eisner says the driveline system can operate on different voltage levels from 48-650V to ensure the right

The eGen Power electric axles provide packaging advantages as all components are located in a central housing.

performance for a particular application. It consists of an electric drive unit combined with front and rear axles, power electronics and a control unit. “[It] achieves the same output as conventional drivetrains, without compromising on performance factors such as traction and top speed,” he says. The first versions have been launched in compact wheel loaders in the European market. Eisner says the driveline for this compact wheel loader application uses an electric motor and transmission developed specifically for the application using actual measurement data from conventional compact wheel loaders. “This allows for greater levels of cycle efficiency and avoids the need for load reduction (derating) of the components, meaning no compromises in performance,” he says.

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HYLIION

Hyliion’s Hypertruck ERX is a fully electric truck that uses natural gas to recharge the batteries.

Designing with electrification in mind When heavy-duty electric vehicles were first under development, many of the necessary components and equipment had not yet been developed to a level comparable to conventional products. As such, there was a lot of experimentation with products that were available; while these early systems worked, they were not necessarily optimized for packaging, performance and efficiency, says Alexander Schey, Chief Commercial Officer, Electrification at Allison Transmission. Because of this, the industry has shifted toward more customized and purpose-built solutions. Doing so ensures the components being developed are better able to handle the specific performance needs of the electric vehicle. Efficiency is one of the biggest factors to take into consideration when it comes to electrification. “Efficiency has an outsized impact for electric vehicles when compared to conventional vehicles because it impacts the size, cost and weight of the battery pack, which is the largest, and certainly the most expensive cost component on the vehicle,” he explains. “So, if you’re able to increase the efficiency by 10%, you can reduce the battery pack size, cost and weight accordingly.” Schey says this is why it is important to develop drivetrain components specifically for electric vehicles. Doing

so allows manufacturers to design a component differently than they might for a conventionally powered vehicle. “Powering auxiliary systems, like braking, electrically rather than via power take off can improve the efficiency significantly,” he says. Additionally, he says that because electric motors run differently compared to an internal combustion engine, there are wider torque and speed ranges that can be optimized to maximize efficiency. It is also important to consider the higher voltage ranges utilized. Taking these factors into account when developing a system helps improve overall efficiency. Allison Transmission’s new eGen Power 100D electric axles feature two electric motors used in parallel to power the vehicle (learn more, 21196976). Schey says what makes this system different is the fact the electric motors are coaxial with the axis of the axle—essentially, the line of the axle from wheel to wheel, with the motor axes in the same orientation. “And that allows for a much more efficient transfer of energy than you would get in a typical axle where you have the prop shaft coming at a 90-degree angle,” he explains. “That alone saves 3-5% of energy.” All of the system’s components— excluding inverters which are chassis mounted—are located in a central housing, which Schey says provides packaging advantages by leaving

more space for batteries or cargo on the vehicle. Instead of replacing the diesel engine with an electric motor and continuing to use the usual driveline and transmission, Daimler chose to design a propriety e-axle for its Freightliner eCascadia. Doing so provides a number of advantages the company said during a webinar on its technology held as part of the ACT Virtual event. The e-axle consists of trusted components carried over from the company’s diesel trucks—axle housings, axle shafts and wheel ends—and the newly developed e-carrier. Daimler said this e-carrier houses the electric motor and transmission components of the e-axle, providing a compact package which fits well into the electric truck. High-performance electric motors were utilized to ensure availability of sufficient driving performance while also allowing for maximum energy recuperation during operations. It said this improves overall energy efficiency of the vehicle and enables drivers to get more range out of the truck. The modular design of the e-axle allows it to be deployed on various electric truck models from Daimler. Its modularity also enables it to be adapted to the different performance requirements of various applications to meet customers’ specific needs.

Industry needs must be achieved Thomas Healy, CEO of Hyliion, says it is a unique time in the industry because everyone knows electrification is coming, but customers are trying to figure out what solutions will fit them best. In the long-haul truck market, he says fleets have three options to choose from—full-electric plug in, hydrogen fuel cell and those like Hyliion’s Hypertruck ERX (Electric Range Extender) which is a fully electric truck that uses natural gas to recharge the batteries (learn more, 21138094). At the front of the vehicle is a compressed natural gas (CNG) powered

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DRIVETRAIN SYSTEM: ELECTRIFICATION ZF FRIEDRICHSHAFEN AG

oemoffhighway.com/21206852

The eTRAC driveline system is designed to achieve the same output as conventional drivetrains.

engine which is used to power an on-board generator that charges the truck’s batteries. The batteries are large enough to provide up to 25 mi. (40.2 km) of full-electric operation. At the back of the truck are a set of conventional axles driven by a fully electric drivetrain. With this set up, the Hypertruck ERX can provide a range in excess of 1,000 mi. (1,609.3 km) and operates 24 hours a day, says Patrick Sexton, Chief Technology Officer at Hyliion. These capabilities help to eliminate any range anxieties a fleet may have, which is a common concern with over-theroad vehicles. Sexton notes the system uses many proven technologies to provide fleets a go-forward option with low total cost of ownership, and reliable range and payload capacity without compromising performance. The company has partnered with Dana Inc. to supply the electric motor, inverter and axle technologies for the system. This collaboration provides an additional level of comfort to fleets by pairing a familiar global brand with Hyliion’s technology. It assures fleets they are getting a robust and proven system which meets the needs of their application. Healy says the Hypertruck ERX is a practical option for normal fleet operators. Electric plug-in works well for local delivery applications where a larger battery is not needed and there

are more frequent opportunities to recharge. And while hydrogen is showing potential in the long-haul space, the infrastructure for refueling is not yet available. “CNG today has the ability to actually have the lowest cost of fuel compared to all these other solutions, even diesel, with an existing network of nearly 700 refueling stations nationwide,” he says. CNG, or renewable natural gas (RNG) which can also be used with the system, can already be purchased for less than $1 per diesel gallon equivalent “so there’s a strong cost opportunity there,” says Healy. “From our standpoint, we see our Hyliion Hypertruck ERX solution as a very practical and realistic way to bring electrification forward in the present while we work toward a more sustainable tomorrow.” Paul Bottero, CEO and President of Inmotive Inc., says the company’s Ingear transmission could be used in traditionally powered vehicles, but is particularly suited for electric vehicles because of the three key benefits it provides—high efficiency, low design cost and smooth shifting. He says that if an electric vehicle transmission does not offer all three of these benefits, then there is a tendency to use a one-speed system instead. He notes that while a one-speed system works in many applications, the company sees two-speed options as the future of electric vehicle transmissions because of the high levels of efficiency they can provide. He says that most electric vehicles use single-speed transmissions, however, equipping a vehicle with an In-

gear transmission lowers cost, extends range and improves acceleration times, highway passing capability, top speed and gradeability. Typically, there are two reduction gears between the electric motor and the wheels, with the motor turning about nine times for each revolution of the wheels. The Ingear replaces the second reduction gear with a continuous chain drive and a morphing sprocket. To shift, an actuator directs sprocket segments into place during a single revolution of the wheels, effectively increasing or decreasing the gear ratio. The Ingear’s patented geometry keeps the motor and wheels in sync, enabling continuous torque flow throughout the shift process. By enabling the drivetrain to operate more efficiently with low- and high-gear ability, less energy is wasted resulting in more range from each charge. Similarly, regeneration is improved and is continuous, even while downshifting Bottero says the company’s new Ingear two-speed transmission was designed with electric motors in mind (learn more, 21195324). The transmission has a chain drive design without any clutches or power disconnect which provides smooth shifting and high efficiency. “Compared to other systems that have clutches and extra sets of meshing gears, we have lower losses. And those lower losses equate to either longer range in an [on-road] electric vehicle or better duty cycles in off-highway equipment because you have more battery life,” he explains. The continuous torque provided by the transmission is also beneficial to off-highway equipment, notes Bottero. Because there are no clutches, the transmission delivers continuous power even during shift-

IVE

The In suited its hig smoot

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ing for continuous engagement of the wheels to the motor. “What this means is if a loaded truck is going up a grade on a dirt or gravel road and trying to shift gears, disconnecting power would be a problem. With the Ingear transmission, we would allow that vehicle to continue to go up the grade without any loss of power, and be able to provide more torque as required or more speed depending on what the situation calls for,” he explains. The Ingear is not a “one size fits all” technology. Its design flexibility enables OEMs to customize the size and scale of the technology based on the specific vehicle type. While initial development has focused on the passenger car market, the technology can be adapted for a wide range of vehicles, including commercial, off-highway and fuel cell applications. Eisner says ZF uses its experience with electric lift trucks and other e-mobility applications when developing components for electric-powered off-highway equipment. He says the company has found using liquid cooling for its electric motors and power electronics ensures long-lasting performance in construction machinery applications. And to make the most of the special properties of the new eTRAC system’s electric motors, he says ZF designed a new high-speed transmission for the system. This helps to ensure optimal performance for customers. In . addition, the system INC IVE OT M N is modular in design which I makes it easy to customize The Ingear transmission is particularly suited for electric vehicles because of its high efficiency, low design cost and smooth shifting.

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it to various application and machine needs. “In the long run, the technology can also be adapted for other construction machinery applications such as excavators, site dumpers, telehandlers and larger machinery like mid-sized wheel loaders,” Eisner said. “Increased energy density, continuous price reductions and lower energy production costs thanks to renewable power sources will see batteries become the main energy source for more and more applications.” And as the number of electric vehicle and equipment applications expand, so too will the technologies which power them. |

Watch and Learn More Head to oemoffhighway.com to watch our video interviews with some of the companies featured in this article and learn more about drivetrain electrification trends and technologies. New Allison Transmission Electric Axles Bring Efficiency Benefits Search: 21206995 Hyliion Hypertruck ERX Extends Range of Electric Powered Trucks Search: 21206019

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MARKET FORECAST: ONHIGHWAY TRUCK & BUS

©DELL  STOCK.ADOBE.COM

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2021 is Looking Better for Most

Global Commercial Vehicle Markets Orders for medium- and heavy-duty commercial vehicles improved in the second half of 2020 in many global markets, indicating improved conditions in 2021. contributed by Chris Fisher, Senior Commercial Vehicle Analyst, Power Systems Research

edium and heavy commercial vehicle (MHCV) production in North America is expected to decline by 35% in 2020 compared to 2019. However, orders for Class 8 trucks improved significantly in Q4 2020 as large fleets placed their orders for a 2021 build. This appears to signal an improvement in demand for 2021 as the market aligns itself with the expected freight level moving forward. The consumer segment was strong during the last half of the year and the industrial segment is now expected to improve, as well. Within the consumer side, reefer, flat bed and dry van carriers have performed relatively well. We have also seen contract and spot rates improve primarily due to tightening truck capacity and an ongoing driver shortage. Throughout 2020, freight was also very uneven. For example, the trucking sectors that haul for the industrial and

energy industries did not see the surge in freight like the consumer side of the economy. Early in 2020 it looked like Class 8 truck production could decline to as low as 135,000 trucks compared with a current production forecast of approximately 200,000 trucks.

A shift in production and power systems During the past few years there have been some significant trends taking place in the medium and heavy truck segment in North America. In order to retain drivers, fleets have been transitioning their focus on more regional haul rather than long haul. Basically, truck drivers do not want to “live on the road.” E-commerce has helped facilitate this trend by distributing inventory to a wider range of locations. Widening the Panama Canal has been a factor, as well, since more imported goods can be delivered closer to their end destinations.

For several years, we’ve been seeing companies shifting production to China as they seek lower production costs, but now this trend has started to reverse as companies seek to decentralize production. The United States tariffs on Chinese products, new global trade deals and the introduction of the coronavirus shed significant light on the risks to the supply chain. We should note there is significant investment into technology which could move China into a different spot in the supply chain. South Asian nations and Mexico will primarily benefit from this transition. During the past decade, the commercial vehicle market has come under pressure to adopt alternative fuels such as natural gas, hybrids, electric and more recently hydrogen fuel cell technology. Hybrid vehicles have not gained traction and natural gas is currently relegated to specific applications.

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development. Power Systems Research (PSR) believes additional engine offerings will be one of the primary goals to improve profitability and long-term market share improvement within the Class 8 truck segment. To reduce costs, Ford recently ended production of the heavy Cargo series truck in Brazil. Ford has always struggled with profitability in this region and decided to focus its efforts elsewhere. Mack has a strong presence in the SOLARIS BUS & COACH

North America which have recently occurred. In November 2020, Volkswagen’s TRATON group and Navistar announced a merger agreement in which TRATON will acquire all outstanding shares of Navistar. Previously, TRATON held 16.7% of Navistar’s common shares. The deal is valued at $3.7 billion and is expected to be finalized in mid2021. Navistar has been in collaboration with TRATON’s brand MAN for a number of years primarily in engine

Electric buses, like the Slolaris Urbino 12, continue to gain market share due to the many benefits offered in this application. VOLVO GROUP

Currently, electric trucks are still in the test phase while hydrogen fuel cell trucks are just beginning the test phase. Much like the rest of the world, major OEMs have electric and hydrogen trucks in the testing stage with series production expected to commence in the 2023-2024 timeframe. However, numerous barriers still will need to be overcome before adoption can take place on a large scale. While the trend toward electrification has been slower for medium and heavy trucks, the transit bus segment is on a somewhat faster track to series production. Since transit buses typically have pre-defined routes and good access to recharging infrastructure, they are good candidates for electrification. It also helps that this segment is not-for-profit and a payback is not typically required. The significant barriers to adoption appear to have been overcome. During the past few years, numerous large municipalities have set target dates to have their entire bus fleet converted to all-electric vehicles. In California, CARB (California Air Resources Board) has established a mandate requiring all transit buses to be zero-emissions compliant by 2040. The Los Angeles Department of Transportation plans to have an all-electric bus fleet by 2028. They recently ordered 155 electric buses from BYD and Proterra to be delivered during the next 2 years. San Francisco plans to have a zero-emissions bus fleet by 2035 and plans to purchase only zero-emissions buses starting in 2025. In Seattle, King County Metro plans to transition to 100% zero-emissions buses no later than 2040. New York currently has over 5,000 buses which is the largest transit fleet in the country, and the city plans to convert the entire fleet to all-electric by 2040. The Chicago city council also approved the transition to a 100% zero-emissions bus fleet by 2040. Besides the trend toward vehicle electrification, there are some other significant OEM developments in

Starting in 2021, Volvo will offer a complete range of battery-electric trucks in Europe for distribution, refuse, regional transport and urban construction operations.

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MARKET FORECAST: ON-HIGHWAY TRUCK & BUS oemoffhighway.com/21206827 ÂŠAA+W â&#x20AC;&#x201C; STOCK.ADOBE.COM

Research and development into hydrogen fuel cell technology for medium and heavy trucks has increased in recent years.

heavy vocational market and has recently introduced its MD medium truck lineup which is produced at a new facility in Virginia. The new medium truck lineup covers Class 6 and 7 and Mack should be a strong competitor in this segment (learn more, 21113129).

International markets picking up in some regions Europe In Europe, commercial vehicle demand was down significantly in the second quarter but has since improved and this is expected to continue into 2021. During the first half of the year, medium and heavy truck registrations in the EU declined by 43% compared to the first half of 2019 while bus registrations were down by 35%. Export demand has also declined sharply this year primarily due to the impact of the coronavirus on the global markets. We believe MHCV production for Europe will decline by 25% in 2020 over 2019. South America In South America, Brazil is the largest producer of commercial vehicles.

Through the first 10 months of 2020, production declined by 31% compared to the same period in 2019. While there has been some improvement during the past few months, domestic and export demand continued to be soft through the end of 2020. Production was down sharply in April as most of the OEMs and suppliers shut down production facilities because of the COVID-19 outbreak. On a positive note, we are seeing outstanding performance in the agricultural segment in both production and commodity prices. Construction continues to recover primarily due to low interest rates for home construction. Fiscal stimulus was also enacted by the government for people who have lost their earning capacity and financial incentives for businesses to keep their employees. Looking into the future in Brazil, we expect some level of truck prebuy in 2022 as P8 (Euro 6) emissions requirements take effect in 2023. The additional cost of the emissions technology with little improvement in fuel economy typically leads to a vehicle pre-buy.

China After declining sharply in February and into March, medium and heavy truck production in China has been extremely strong in 2020. Much of this activity has been driven by the government mandate to eliminate the current Euro III and earlier emissions-compliant trucks and replace these with new Euro V compliant vehicles. The plan is to have this completed by the end of 2020. This program, along with stricter punishment for overloaded vehicles in big cities and some small cities and rural areas, has helped drive strong demand this year. As a result of this, PSR expects demand to decline significantly during the next few years. Much like the other regions, bus demand is down significantly. South Asia South Asia is a diverse region with the largest production of commercial vehicles located in India. Coupled with price hikes from the BSVI (Bharat Stage 6) emissions regulations, increasing

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fuel prices, economic recession, lower freight demand, and driver and labor shortages, the headwinds in the commercial vehicle industry continued in 2020, marking one of the worst years for the Indian commercial vehicle market. Driven by social-distancing and work-from-home policies, there is little demand for buses from the education sector. The transit bus segment is also one of the worst hit with our estimates of only 10-15% in-service transit bus fleets being operational. The improving rail freight infrastructure, the proposed vehicle extension policy, shifting focus on used-truck market and under-utilization of in-service vehicle population are likely to further dampen the commercial vehicle outlook in the mid-term. Much like the rest of the world, medium and heavy vehicle production in Japan and South Korea declined sharply in late Q1 2020 and into Q2 2020 as a direct result of the coronavirus pandemic. While demand has since stabilized in both the domestic

and export markets, it will still be a few years before vehicle replacement levels improve to more historic levels. Over half of the medium and heavy truck production is exported out of the region. Over the last number of years, we have seen the Japanese OEMs face stiff competition from the Chinese OEMs in the Asian export markets.

Early in 2020, Isuzu purchased UD trucks from Volvo (learn more, 21200716). Volvo purchased UD trucks in 2007 but never reached their profitability target. Isuzu will likely leverage UD Trucks assets and possibly work with Volvo on future initiatives including vehicle electrification and autonomous vehicles. |

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TECHNOLOGY BREAKDOWN: WESTERN STAR 49X oemoffhighway.com/21196047

Western Star Builds Next-Generation Vocational Truck The 49X was designed from the ground up to meet the most demanding vocational applications. by Curt Bennink ALL PHOTOS COURTESY OF DAIMLER TRUCKS NORTH AMERICA

t’s fairly rare to witness a completely new truck in the Class 8 market, especially one dedicated to the vocational segment. That is precisely why it took many by surprise when Western Star teased dealers with a prototype in February. “This is the culmination of nearly 6 years of work engaging thousands of people within Daimler Trucks North America on this project,” says David Carson, the company’s Senior Vice President, Vocational Segment. “We believe that we’re launching the best tool in the vocational space—the most tested, safest, most advanced vocational truck.” The Western Star 49X is designed to deliver maximum versatility in a pur-

The optional three-piece rear window is 77% larger than that of the Western Star 4900.

pose-built package. It features a stronger, lighter chassis that is equipped with the company’s new X-series cab. It enables a total weight savings of over 350 lbs. (159 kg) in like-for-like spec’ing versus the current Western Star 4900, which is currently slated to remain in production. The weight savings starts with a new vocational frame. Single-channel frame rail options are available in a variety of thicknesses and feature ratings up to 3.7 million RBMs (Resisting Bending Moments). This yields greater durability and significant weight savings for greater capability and payload. “The beauty of that single frame rail is obviously you can save a lot of weight without sacrificing the RBM, the resistance to bending,” says Samantha Parlier, Vice President of Vocational Market Development. For customers that need maximum frame strength, frame inserts are available. “One thing that is unique about Western Star inserts is we do seal them,” says Parlier. Vocational trucks can accumulate magnesium chloride, mud or even water between the rails. “Our rails are actually sealed so that doesn’t happen.”

C-channel frame reinforcements are available with RBMs up to 5.4 million. Multiple parent rail front frame extension options are available for applications requiring front-mounted equipment, such as a plow. The frame rails are kept clear to ease upfits. Clear back-of-cab packaging allows for easier upfit with features that include: forward-mounted DEF tanks; standard in-cab battery box; multiple air tank mounting locations; air dryer mounted underhood (set-back axle) or under cab (set-forward axle); optimized fuel tank sizes; a compact Detroit aftertreatment system; and functional dual vertical exhaust stacks. The 49X will also accommodate a full array of rear suspension options. “Pretty much if you have heard of it in the vocational market, we’re offering it on this new product,” says Parlier.

Purpose-built cab Western Star designed a new purpose-built cab for the 49X. “If we’re going to change the cab in terms of comfort, quietness and safety, it really requires us to transition from what we have been doing into new and more creative ways to provide that comfort

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H AMERICA

typical coil-over shock suspension on. You end up with drivers that are for the operator,” says Carson. system with spring and damper. The happier at the end of the day and “We use topology optimization, system isolates, absorbs and dissipates more energized.” which is software technology,” explains vibrations from the chassis when drivParlier. “We were able to take an aluing over uneven terrain to protect the minum cab and strategically reinforce Detroit debuts vocational series hood from damage and cracking. it with steel to make it as tough, if not automated transmission tougher, than the current cab. It was an The ISO Tech Hood Suspension is a The Detroit DT12 transmission has engineering exercise. The cab is an area first for the vocational truck industry. been redesigned for vocational where we really pulled out all of the “You’ve never seen a hood in a vocaapplications. tools in the toolbox and centered that tional market that has a suspension sys“It was about a $100 million investtopology optimization around how exment in creating a vocational transmistem,” says Parlier. “As the frame moves, actly we create an exoskeleton to keep sion,” says Carson. “It has been tested it completely isolates the hood from operators safe.” for over 35 million Western Star claims global miles. They are the X-series cab is the new transmissions largest in the segment in the same family of with 10-13% greater the DT12, but it’s not space than comsimply just a modified petitive cabs. It was transmission.” designed specifically Power is transfor vocational applimitted from either cations and provides a Detroit DD15 Gen additional vehicle 5 or DD16 engine weight savings while through the new delivering long-term DT12 Vocational durability and operaseries of automated tor comfort. Advanced manual transmissions. topology was utilized These transmissions to ensure rigidity and are available as the strength and deterDT12-V or DT12-VX mine where more and are rated up to material was needed a Gross Combined in the steel-reinforced Weight Rating (GCWR) aluminum cab. of 330,000 lbs. Development work (149,685.5 kg). Both on the cab was the transmissions include most extensive in the PTO capabilities The new hood uses a patented ISO Tech Hood Suspension system that company’s history and that allow for added behaves similarly to a typical coil-over shock suspension system with spring and damper. The system isolates, absorbs and dissipates vibrations included multiple cab flexibility. “It has the from the chassis when driving over uneven terrain to protect the hood crush tests to ensure eight-bolt left hand from damage and cracking. cab integrity in case of side PTO,” says Parlier. a rollover. Full-vehicle It also has a rear PTO. shaker tests replicated 800,000 mi. the frame in terms of force and inputs.” Unique work application modes and (1,287,475.2 km) of use to test the cab This allows a weight reduction. “We shift map strategies are available for mount system, which uses vocational didn’t need all of those reinforcements all types of terrain. A Rock-Free Mode cab isolators mounted outboard for in the mounting area and stress points allows the 49X to free itself from wheel optimal stability and reduced fatigue that you typically see because we have stuck situations. An Off-Road Mode to both the operator and the cab. the suspension protecting the hood.” enables smooth driving on extreme The hood of the 49X is constructed terrain such as logging roads and An unexpected benefit is reduced of high-strength, lightweight, moldrock quarries. Power Launch provides driver fatigue. “When driving the truck, ed composite for impact resistance powerful takeoffs while protecting the you see a lot less movement at the and durability. The new hood uses a clutch and driveline. corners of the cab, which is right by patented ISO Tech Hood Suspension The transmission also offers a the dash,” says Parlier. “So, their brains system that behaves similarly to a neutral feature for paving applications aren’t trying to figure out what’s going

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TECHNOLOGY BREAKDOWN: WESTERN STAR 49X oemoffhighway.com/21196047

that allows the truck to be pushed by the paver. “You don’t have to stop,” says Parlier. “You can just drive away.” For customers who already have a powertrain preference, there are other options. “We still provide choices,” notes Parlier.

Safety is a priority

TOP TO BOTTOM: ABA5 detects distance and speed of moving and stationary objects in the driving path of the 49X and determines if warning or automated braking is necessary. Side Guard Assist uses radar technology to detect moving objects and pedestrians on the passenger side of the truck. The Western Star 49X features a stronger, lighter chassis that is equipped with the company’s new X-series cab. It enables a total weight savings of over 350 lbs. in likefor-like spec’ing versus the current Western Star 4900.

The 49X is equipped with the Detroit Assurance suite of safety systems, which includes an advanced collision mitigation system. The Detroit Assurance system on the 49X offers Side Guard Assist (SGA), Active Brake Assist 5 (ABA5), tailgate warning, Adaptive Cruise Control (ACC) to 0 mph, lane departure warning, video capture, intelligent high-beam and automatic wipers/headlamps. With optional SGA, radar technology detects moving objects and pedestrians on the passenger side of the 49X that may otherwise fall in the operator’s blind spot and alerts them with both auditory and visual warnings for safety on the jobsite or on the way there. ABA5 detects distance and speed to moving and stationary objects in the driving path of the 49X and determines if warning or automated braking is necessary. The system works down to 5 mph (8.0 kph), making it optimal for busy jobsites and in congested urban areas. It also recognizes moving pedestrians who are crossing in the truck’s path, alerting and applying the brakes if the operator does not react. Slips, trips and falls rank second among the most common types of workplace injuries. In certain applications, such as concrete ready-mix trucks, the operator may enter and exit the cab up to 50 times during a shift. In these applications, ingress and egress are real concerns. “The real stars of every jobsite are the men and women working at it, which is why the Western Star 49X was engineered to deliver best-inclass safety with easier entry and exit to reduce workplace injury, and best-in-class visibility to benefit not

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only the operator but the entire crew,” Carson states. Door opening angles of 70 degrees, five hand holds and step treads widened by half an inch and constructed as a staircase help facilitate safer entry and exit from the cab. The steps start closer to the ground and use a volcano tread for confident footholds with high traction, added toe clearance and mud, dirt and debris pass through. Enhanced visibility comes from a sloped hood enabled by splayed frame rails; a lowered engine position and underhood engine air filtration; a 28% larger, single-piece, roped-in windshield; and a rear window that is 77% larger versus the 4900. Optional Borofloat glass in the front windshield and optional poly carbonate in the rear windows provide impact resistance from debris. The mirrors have also been improved to increase visibility in demanding applications. A C-bar mirror system features door-mounted mirrors that mitigate the effects of chassis and engine vibration to keep them stable and usable in off-road or paving applications where visibility by the operator to the crew at the back of the truck is critical. A dual-stage LED headlight system

The power behind it all.

features an internally printed heat grid and ambient air temperature sensor that can melt 3 mm (0.12 in.) of ice in less than 10 minutes at -40 F (-40 C) or burn through condensation in warm, humid environments. Combined with a 45-degree light pattern, the headlight system provides smooth, uniform illumination to improve visibility and safety.

tom lines,” says Carson. “We know the conditions our customers are working in. We know the challenges of their operations and we know that productivity at the site

Interior places technology within easy reach In all models, a wraparound dash puts the driver command center and b-panel in the operator’s line of sight. On the b-panel, a flex panel houses tablet prep or can be configured for an additional 12 switches or 10 gauges. Along with QuickFit Dash Access designed for seamless telematics or other device integration, equipment control and device access is placed within easy reach for the operator. Much attention has been spent on even the most minute details. “Our bottom-line intent was to deliver a truck that benefits our customers’ bot-

Power is transmitted from either a Detroit DD15 Gen 5 or Detroit DD16 engine through the Detroit DT12 Vocational series of automated manual transmissions which are rated up to a GCWR of 330,000 lbs.

matters most. That’s why the all-new 49X is purpose built for durability, safety and maximum uptime—and for our customers.” The 49X is available for ordering this winter and first deliveries begin in early 2021. |

Reliable for generations and proven in over 28 million engines worldwide in the most demanding environments. Contact your local Isuzu Distributor today! www.IsuzuEngines.com

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ENGINEERING & MANUFACTURING: SOFTWARE oemoffhighway.com/21159777

Ricardo’s Modelica-based Ignite provides a means to optimize hybrid and electric powertrain solutions early in a design program. RICARDO SOFT WARE | ©GORODENKOFF  STOCK.ADOBE.COM

POWERFUL SOFTWARE Benefits Design of Heavy-Duty Vehicles The latest software tools provide a full design and simulation environment to cover all aspects of vehicle systems. contributed by Spencer Chin

riven by the increasing importance of the Internet of Things (IoT) and ever-more demanding requirements from various industries including heavy vehicles, computer-aided design (CAD) modeling and simulation soft-

ware are benefiting from not only new features but also greater integration with other software tools. Powerful software tools are enabling a more multi-disciplined approach to designing vehicles and other systems. The existence of the cloud is allow-

ing data to be easily shared among designers regardless of location, and is serving as a repository to store information for future designs. There is also increasing integration between tools from different companies that is helping to streamline design workflows.

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Modeling and simulating all aspects of a vehicle’s design is enabling designers to improve product quality and time to market.

DOBE.COM

SIEMENS PLM

These developments are important as heavy-duty and off-road vehicles continue to grow in complexity, using sophisticated electronics and moving to hybrid and electric drivetrains. At the same time, designers face the pressure to shorten design and development cycles, thus requiring software that can navigate through the complexities of these cycles. “There is a continual drive to shorten the design and development of a vehicle and its powertrain, whilst also delivering ever-challenging powertrain performance targets and exploring alternative powertrain options,” says David Bell, Commercialization Manager of Ricardo Software. “There is an increasing need for system-level analysis, using products such as Ricardo’s Modelica-based Ignite, to find optimum hybrid and electric powertrain solutions early in a design program,” adds Felipe Brandao, Vice-President Product Management, Ricardo Software. “Such tools can be

used to optimize the thermal management of the vehicle, coupled to higher-fidelity CFD (computational fluid dynamics) and FEA (finite element analysis) tools, to model components such as a battery pack. “

Simulating the operating environment An increasingly important consideration in developing heavy-duty and off-road vehicles is simulating how a product or system will look and behave from physical, electrical, and other factors. Simulation software is particularly important in ensuring the comfort and safety of the operator. The ability to accurately simulate the operator’s environment is of utmost importance, says Steve Vickers, Product Manager NX Automotive, Transportation and Heavy Equipment at Siemens Digital Industries Software. “We need to work out how the operator is sitting inside the vehicle cabin. Ergonomics—the position of

the operator’s elbows, the steering wheel, the location of the head, where the mirrors will be placed—need to be carefully simulated.” Carefully modeling the vehicle operating environment is important, but so is the ability of the vehicle’s electrical and mechanical systems to work together properly. With many simulation tools part of software suites integrating design, viewing all aspects of a vehicle’s internal systems is far easier. Siemens’ NX software is an integrated toolset addressing design, simulation, and manufacturing. The tool suite addresses product modeling, cable and wiring routing, simulation, and workflow. “For instance, when the electrical engineer defines which components are used, the connection information appears so that the mechanical engineers can see where cabling is routed,” says Vickers, using the example of a vehicle’s engine. “Once the mechanical

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ENGINEERING & MANUFACTURING: SOFTWARE oemoffhighway.com/21159777

The power of IoT In an age when use of IoT is increasing, the data generated by today’s software tools can build up a rich repository of information for future design, as well as provide historical data for tasks such as predictive maintenance. Citing an example of a crane manufacturer, Paul Brown, Senior Marketing Director at Siemens PLM Software notes, “The crane manufacturer is using a lot of sensors, so we can feed this information to the design team so they can make informed decisions going forward. If you start seeing historical data that there are certain conditions that need to be looked at, the designer can then solve problems during design.” Virtual reality and artificial intelligence are also making their mark in simulation and modeling. Siemens’ NX software integrates Virtual Reality into the desktop application and is accessible with one click, extending familiar interactions into a truly immersive 3D environment. This enables users of various disciplines to more easily collaborate during product development.

“While virtual reality has been around awhile, it has been limited to big companies because of cost and complexity. Now you can buy lower cost hardware which gives designers the powerful capability of being able to virtually sit in the cockpit and define and refine features.” Siemens NX offers an expert personal assistant that uses artificial intelligence and machine learning to track and learn from user actions. It then predicts the NX commands the user will likely use next based on the context of what they are currently doing and then presents those commands on a compact adaptive UI panel.

Leveraging the cloud Software vendors are also using the power of the cloud to market tool suites promoting collaborative design and development. Dassault Systemes has enhanced its Catia V5 software (see image below) with its 3D Generative Innovator, a cloud-based generative modeling environment that combines graphical visual scripting and interactive 3D modeling, with the ability to DASSAULT SYSTEMES

engineer simulates the cable routing, the electrical designer in turn can see the effects on electrical performance.” CM Labs recently released Vortex Studio 2019b, a major version update to Vortex Studio. According to the company, the latest version makes it easier for users to install, build, test, and deploy real-time simulation. One feature of particular interest to the heavy vehicle industry is an expanded Deformable Terrain zone with features that go beyond digging and pushing soil. While still allowing the deformation of a given surface using digging tools (bucket or blade), vehicles’ wheels can now directly impact the terrain, compressing and deforming it on each pass, creating ruts and graphical marks modeled on specific textures. Another feature of Vortex Studio is parallax occlusion mapping, where materials can have a pronounced depth ‘look’ while still being a 2D element. A self-shadowing capability enables materials with a height map to render a dynamic shadow, adding depth and environmental realism.

Dassault Systemes’ Catia V5 software provides a cloud-based generative modeling environment that combines graphical visual scripting and interactive 3D modeling.

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DASSAULT SYSTEMES

use one or the other interchangeably at any time. “More customers are asking for CAD that is accessible anytime, anywhere and on any device—in other words cloud based,” says Craig Therrien, 3DEXPERIENCE WORKS Senior Portfolio Manager for Dassault Systemes. “Think of Netflix, Prime Video and other online services. You can access them on several devices—phone, PC, tablet, TV. Our customers see this as an advantage.” Cloud-based software also does away with concerns about having to download the latest updates. “And the fact that they are always accessing the latest version of CAD means no more worries about upgrading and which version of CAD their customers and/or vendors are running— everyone can run the same version,” notes Therrien. The software has a Function Driven Generative Designer which allows designers to automatically generate optimized conceptual parts and assemblies from functional specifications. The designer simply provides a set of requirements, including the 3D envelope, connections, the loading scenario, material, weight reduction targets for lightweight engineering, and the desired manufacturing process, either traditional, such as milling, casting or forging, or additive manufacturing. The push of a button runs a simulation process and generates the optimized concept assembly shapes.

Drag and drop Designing software for easier use is also a priority for software vendors. For instance, IronCAD says its INOVATE CAD software has a drag-and-drop environment to speed design and enable more users to access the tools. The tools make 3D models and engineering project data available to marketing, sales, and training teams so they can work together and communicate more effectively. Other tool vendors have modified the underlying algorithms of their software tools to make it easier for

users to model parts. For instance, RS Components (RS) has unveiled the latest version of DesignSpark Mechanical, its free 3D CAD modeling software. Developed in conjunction with Ansys Inc., the tools use direct modeling technology rather than the parametric methods used by traditional CAD software, enabling users to rapidly prototype or reverse engineer any physical object. Key features include an equations tool to sketch complex curves, con-

Where no CAD files exist Software vendors are also trying to address design scenarios with legacy parts, where CAD may not be available. Volume Graphics has released its VGSTUDIO MAX version 3.4 software which has added features to help designers and manufacturers capture and interrogate product data to improve final quality. The program’s Reverse Engineering Module can generate surfaces from a CT scan, or from any voxel model

“More customers are asking for CAD that is accessible anytime, anywhere and on any device—in other words cloud based. Think of Netflix, Prime Video and other online services. You can access them on several devices—phone, PC, tablet, TV. Our customers see this as an advantage.” –Craig Therrien, 3DEXPERIENCE WORKS Senior Portfolio Manager for Dassault Systemes

straint-based sketching and a dedicated 3D sketch mode, custom rendering, enhanced shading, and a fly-through camera mode. DesignSpark Mechanical also offers access to a 3D catalog of tens of thousands of 3D models from leading component manufacturers. 3D sculpting is also catching on as an alternative modeling technology to parametric methods. According to Therrien, “We’re hearing a lot of excitement around our subdivision modeling capabilities currently. This is relatively new for our core user base, and we see a lot of users diving into the world of 3D sculpting. And it’s not just artists and industrial designers—mechanical engineers are trying it out. It’s amazing how quickly and easily you can create incredible shapes that would take hours or even days to produce using traditional parametric modeling techniques.”

converted from a closed mesh/point cloud scan, using an auto-surface function. The feature enables manually generated design models to be available digitally—without the need for a CAD designer or reverse-engineering specialist. The software makes it possible to generate and archive 3D CAD models of legacy parts, as well as update those models in which the actual part or tool deviates from the master CAD model. This automates the creation of digital twins of individual parts and helps to validate the model-to-part relationship. The program enables the recreated or newly validated CAD model to be exported as a STEP file to any CAD system. These capabilities are particularly useful, given that more companies want to document part data and use it in future designs. |

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ELECTRICAL & ELECTRONICS: SENSORS oemoffhighway.com/21194165

SENSORS PLAY CRITICAL ROLE in New ANSI Standard Use of various sensor technologies will be necessary to meet the safety functions described by the new ANSI 92.20 standard. by Sara Jensen

ALL IMAGES COURTESY OF SIKO GMBH

The majority of safety functions described by the new ANSI standard will require the use of a sensor to deliver the necessary values.

Sensors will be required for functions such as vehicle leveling and monitoring of stabilization devices.

he American National Standards Institute (ANSI) and the Canadian Standards Association (CSA) have implemented a new safety standard for aerial work platforms in North America. ANSI 92.20 is intended to improve the safety of aerial work platforms (AWP)— now referred to as mobile elevated work platforms (MEWP) per the new standard—and have more alignment with international standards which will benefit manufacturers developing products for the global market.

According to Mathias Roth, Business Unit Manager of Mobile Automation at SIKO GmbH, ANSI 92.20 will have a big effect on the design of new machines. “The machine must be equipped with a load sensing system which actively monitors loads and interrupts normal operations if they become overloaded,” he explains. “Tilt sensing functions which were in the past an option, are now also required to disable certain boom functions if the incline surpasses the slope limit.” Because of these new requirements,

the use of various sensors will become critical for manufacturers.

Safe machine operation via technology Roth says that almost every safety function described by the new ANSI standard will require the use of a sensor to deliver the necessary values such as pressure, force, position, speed, or inclination. “I think we can say that sensors, alongside the PLC (programmable logic controller), are a big part of the heart and soul of the safety functions

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ALL IMAGES COURTESY OF SIKO GMBH

SIKO’s PURE.MOBILE sensor platform is designed exclusively for position sensing in mobile equipment which will enable compliance with the ANSI standard.

required by the new standard,” he says. “There are now safety requirements for almost every function of the machine, but definitely for all functions that pose a potential danger to people or the environment,” Roth adds. As such, sensors will be required for functions such as: • preventing travel above inclination limit, • monitoring of stabilizing devices, or • vehicle leveling system. “It is therefore necessary to integrate the safety sensor from the chassis, through the boom to the basket to meet the new requirements,” says Roth. Sensors used in these new ANSI-compliant machines will be required to meet high functional safety requirements to meet the standard, as well, says Roth. “Like all components, the sensors are divided into certain safety levels. For this purpose, they are divided into so-called ‘performance levels’ (according to the EN ISO 13849),” he explains. “These ‘levels’ provide information about the ‘safety level’ of a sensor. Since every function/component in the machine has to meet a certain safety level (PLa is the lowest, PLe is the highest), the sensor must be equipped with the corresponding safety functions, a specific hardware and software design and other systems to meet the requirements for the required safety level to fulfill.” According to Roth, SIKO is able to provide the appropriate sensors for almost every safety function in a MEWP for which a position value is necessary. For instance, the company’s wire encoder/string pots and cylinder-in-

tegrated position sensor technologies provide possible solutions for the monitoring of outrigger/stabilizer systems. SIKO’s compact and robustly designed wire encoders are able to reliably detect boom position as well as the boom tilt angle. This provides an “all-in-one” solution for OEMs, says Roth, by providing position and inclination sensing in a single device, helping save on installation time and costs. And with the SIKO rotary safety sensors, “we offer simple sensors for detecting the slewing ring position or the steering angle for self-propelled MWEPs.” The company also has a new series of safety inclination sensors, available in 1- or 2-axis versions. Roth says they can be used to detect inclination of the entire vehicle or the basket, offering design flexibility to OEMs. “All of these sensors are of course available in a safety version up to PLd which covers all requirements of ANSI 92.20 and are optionally available with an analog, CANopen, CANopen Safety or SAE J1939 interface,” says Roth. He adds SIKO’s PURE.MOBILE sensor platform is particularly beneficial for meeting the new ANSI standard as the sensors have been designed exclusively for position sensing in mobile machines. “Unlike many of the sensors on the market that were developed for

various industries and are then merely adapted for mobile machines, sensors from SIKO that use the PURE.MOBILE technology have been developed exclusively for applications of this sort,” he explains. PURE.MOBILE sensors are designed to meet the electromagnetic compatibility (EMC) requirements for MEWPs, as well as the requirements of E1 (UN ECE R10) for road vehicles. In addition, the sensors have high temperature, shock and vibration resistance “because we know that a safety sensor in MWEPs has to work under tough conditions.” Roth says SIKO will work closely with OEM customers to integrate sensor solutions which meet their machine requirements. “This includes not only delivering the right sensor to the customer, but also understanding the application and helping to implement our sensor and the whole safety concept. “Our team helps the OEM to analyze the new requirements and works together on a concept based on our sensors to meet the requirements and the necessary standard verification. Therefore, we see ourselves not only as a component manufacturer but above all as a system supplier in the field of MEWPs,” he concludes. |

“…we offer simple sensors for detecting the slewing ring position or the steering angle for self-propelled MEWPs.”

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ENGINEERING & MANUFACTURING oemoffhighway.com/21172020

Equipment Manufacturers Prepare for Augmented and Virtual Reality Initiatives Augmented and virtual reality technologies can bring benefits to all aspects of the business from engineering to manufacturing to end user applications. contributed by Dijam Panigrahi, co-founder and COO of Grid Raster Inc.

eavy equipment manufacturers have for some time now been looking for ways to cut costs out of the production cycle and increase efficiencies. While this was a priority before COVID-19, it has become even more

its sister technology virtual reality (VR). AR is a promising technology since it can improve the way equipment manufacturers operate as well as how the business customer, and even consumers, interact with products and services. For many, this is still a concept and not yet a reality. However, a recent survey shows that businesses are beginning to rapidly enter the planning and implementing stages.

important today. In response, virtually-focused production technologies are now being reviewed and planned to help with equipment production. Widely known as augmented reality (AR), this technology is partnered with

GRID RASTER INC.

A rise in manufacturers going virtual

Equipment customers can employ AR/VR technology to monitor their machines and worksite projects.

Fifty-six percent of business leaders polled1 said they have implemented some form of AR/VR technology into their organization over the last 12 months, and another 35% said they are considering doing so. More than a quarter (27%) said they have fully deployed an AR/VR solution and are looking to scale further. A business can transform how they capture, manage, and communicate information through AR technology. This transformation can be seen both within a business and its prospects and customers. Significantly, it can improve the way a business conducts collaborative engineering design reviews, sales and marketing, field service, skills transfer and manufacturing. Large tech companies like Google, Samsung, HTC, and Microsoft are predicted to dominate the AR market

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The right way to launch AR/VR technologies for your business In order to have enterprise-grade high-quality AR/VR platforms, performance and scale is required. This is

Head to the Web Watch our video interview with the founders of Grid Raster to learn more about augmented and virtual reality technology trends at oemoffhighway.com/21136064.

GRID RASTER INC.

AR is a promising technology which can improve the way equipment manufacturers and their customers interact with products and services. RENAULT TRUCKS

tough to achieve since existing systems, such as MS HoloLens, are severely limited in both aspects. Currently, most enterprises have a rich repository of existing complex 3D CAD/CAM models created over the years. These 3D models may vary in their complexity (such as poly count, hierarchy, details, etc.), making it difficult to run on standalone devices, restricted by device limitations. It is pertinent for businesses to understand that the problem of scalability will continue as richer and larger virtual environments are created. Each of the different hardware platforms will cause the cycle to repeat, creating difficulty for any enterprise to move from experiments and pilots to fullscale deployable solutions. Overall, this issue will stunt the speed of innovation and effectiveness. Device limitations continue to effect existing AR/VR systems by restricting their ability to generate and work within most cloud environments, which is essential to co-locate and precisely fuse the virtual objects on top of physical objects in the real world with complex surfaces, and varied lighting and environment. Though this is a significant challenge, manufacturers are overcoming it by partnering with AR/VR platform providers that leverage distributed cloud architecture and 3D vision-based AI. These cloud platforms provide the desired performance and scalability to drive innovation in the industry at speed and scale. The next wave of technology innovation is here and will fundamentally change the way businesses operate today. AR/VR technology will help in the new wave of technology by merging the digital and physical world to create a better, smarter, and more efficient way of operating. Organizations that take the initiative, leverage these technologies and partner with the right technology provider to help scale appropriately without having to stunt technological growth will take a leadership role. |

Renault Trucks is one of many OEMs which has incorporated the use of augmented reality into its manufacturing operations. AGCO CORP.

which is expected to have a value of $61 billion USD by 20232. So, what needs to be known about AR? To begin, a manufacturer must know the earliest advantages of AR come from virtual supplemental productivity on the manufacturing floor; virtual training modules; virtual customer visits; and virtual design and engineering. Businesses should work with a technology provider to get notable and early returns out of AR/VR through mapping of their operational needs to one of these four areas. A breakdown of where companies are leveraging AR/VR1: • 60% - Virtual Supplemental Labor on Production Lines • 53% - Virtual Customer Service Visits • 53% - Virtual Design & Engineering • 26% - Employee Training Programs A heavy equipment manufacturer that needs to keep production cycles flowing yet keeps losing plant workers who are sick from coronavirus is a perfect example of how a business can utilize AR/VR. The manufacturer could use AR/VR technology to assist the build out of trucks and loaders on the production line, as well as virtual tools to help design the new trucks from remote locations. Businesses aren’t the only ones who can make use of AR technology. Equipment customers could employ this technology to see a series of different product and vehicle looks overlaid on their smartphone device when building their ideal truck online.

AGCO has been utilizing assisted reality technology at its manufacturing facility to help improve processes. Footnotes 1: https://www.oemoff highway.com/engineering-manufacturing/ news/21129888/new-survey-shows-how-organizations-are-leveragingarvr-technology-to-increase-productivity 2: https://www.techrepublic.com/article/these-companies-will-propelthe-ar-and-vr-markets-to-95b-by-2023/

About the Author Dijam Panigrahi is co-founder and COO of Grid Raster Inc., a leading provider of cloud-based AR/VR platforms that power compelling high-quality AR/ VR experiences on mobile devices for enterprises.

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NEW PRODUCTS oemoffhighway.com/directory

Social Distancing Decals Superior Signals, Inc. (SSI) is helping fight the spread of COVID-19 with a new line of social distancing decals. • Features selection of five decals, encouraging safe social distancing and the wearing of appropriate safety gear • Durable and highly visible • Withstands the wear and tear of daily use and stands up to high-activity traffic from heavy equipment www.oemoffhighway.com/21138115

Telematically-Enabled Electronic Control Unit Appareo announces the release of its Gateway 360 telematically-enabled electronic control unit (ECU). • Rugged yet lightweight edge computing platform for mobile equipment applications • Provides wide range of communication technologies including Iridium SBD, Cellular, Wi-Fi, Bluetooth, and 433 MHz radios with GPS, BroadR-Reach, Ethernet, and controller area networking (CAN) • Built with IP67-rated rugged enclosure for use outdoors and for mounting on heavy machinery • Couples truly global wide area connectivity capabilities through both an Iridium satellite connection, LTE connectivity with local area Wi-Fi, Bluetooth, and 433 MHz radios in powerful computational platform • Receives and processes data from wide range of vehicle networks and buses www.oemoffhighway.com/21138140

Gearbox for Large Construction Machinery ZF introduces the next generation of drive gearboxes GPT4F for large construction machinery and crawler cranes. • For machines weighing from 80 to more than 200 tons • Torque range of 160-600 kNm • Provides torque increases of up to 10% • Optimized tooth flanks, modified structural components and balanced bearing provide performance advantages for machine operators

Smart HVAC System Visionaire announces the launch of a Smart System Technology Package to complement its existing HVAC units. • Allows for the integration of HVAC unit into existing cabin displays or controls, be it J1939 or another form of CAN communication • System allows for bi-directional communication • Designed to be as user friendly as smart home thermostats • Provides proactive feedback to operator regarding operating conditions of the HVAC unit • Sensor temperature, suction and discharge pressure, and a multitude of potential component failures are all communicated on demand www.oemoffhighway.com/21138228

Sensors with Modbus RTU Interface POSITAL has added a Modbus RTU interface to its rotary encoders and inclinometers. • Low-cost, easy-to-implement communications protocol commonly used in mid-sized control systems (up to 32 nodes) www.oemoffhighway.com/21159549

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Compact Electromechanical Actuator

eCrimp App

Thomson Industries Inc. announces availability of its Electrak MD, a more compact electromechanical actuator that retains all of the intelligence built into its larger counterparts. • Can be used in mobile off-highway, material handling and factory automation applications • Offers up to 2 kilonewtons (kN) of force, advanced onboard electronics and J1939 CANbus support • Comes with onboard intelligence which enhances overall performance and eliminates space consumption by keeping any external equipment like encoders and switches within the actuator housing • Provides simpler method of control and communication • Features extensive automation and maintenance enablers such as feedback on position, J1939 CANbus communication, low-current switching (PLC compatibility), and end-of-stroke indication output

Gates recently added the eCrimp app to its offering which builds on a previous North America-focused version. • Adds global capability, automatic updates and new functionality to assist fluid power customers across a wide variety of industries, applications and geographic regions • Provides access to a dynamic and unified Safe Hydraulics knowledge base, the same set of information embedded into the GC20 with Gates Cortex Intelligence crimper • Global capabilities allow users to select region to see local products • Quick access to most-used assemblies • Automatic updates when connected to WiFi provides access to live crimp specs and data on new products • Content is available regardless of connectivity • Dynamic search capability • Product image library • Copy and email specs for easy sharing and communication

www.oemoffhighway.com/21139317

Pipe-Rupture Valve Bucher Hydraulics introduces the excavator pipe-rupture valve CFS-flat. • Brings CFS (Compact Flow Control and Safety Valve) technology into a flat design • Prevents uncontrolled lowering of actuator in the event of a pipeor hose-rupture • Holds actuator in its position when main valve is centered • For use wherever so required by the standards ISO 8643, EN 474 and DIN 24093 for excavators with a lifting device • Load-independent, pilot operated design • Maximum flow rate of 350 lpm (92.5 gpm) and operating pressure of 420 bar (6,091.6 psi)

www.oemoffhighway.com/21139496

www.oemoffhighway.com/21139388

Actuator The demand for functional safety is becoming more and more important in hydraulic circuits for mobile applications, leading Sonceboz to develop the SAFE42 actuator. • Allows manufacturers to build a safe system according to machinery safety standards • Drives the spool of hydraulic valves in different sizes and with various flow rates • Meets the needs of applications required to fulfill Performance Level (PL) up to C/D • Certifies application is in accordance with ISO 25119 and ISO 13849 norms • Uses safety communication protocol CAN J1939-76 to provide safe reactions, such as actively moving valve spool into neutral position www.oemoffhighway.com/21204830

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NEW PRODUCTS oemoffhighway.com/directory

Solar LED Flasher Lights J.W. Speaker Corporation announces the launch of highpowered, low-profile solar LED flasher lights. • Helps crews, motorists and passersby identify dangerous obstructions in a wide range of settings • Offers visibility for up to 1 mi. (1.6 km) in any location • Provides optimal visibility under adverse conditions • Self-sustaining solar LEDs charge fully in as few as 6 hours and can run for up to 120 hours before a recharge is needed • Projects perpendicular to lamp for easier identification from further distances • Impact-modified acrylic housing withstands UV light degradation and is nearly indestructible, even when used on rugged job sites www.oemoffhighway.com/21139644

Tire for Forestry Applications The versatile MAXAM MS930 LOGXTRA is specifically developed for multiple forestry applications. • Deep and wide tread is reinforced with steel breaker belt package for maximum strength • Provides maximum protection from cuts, impacts and punctures • Built with signature LOGXTRA high-strength, belt-stabilized construction • Manufactured with extra-wide footprint that delivers exceptional flotation in muddy and wet ground conditions • Nylon-wrapped beads outlast alternative options and prevent common bead winding defects • Advanced compounding and enhanced features such as heavy-duty shoulder and sidewall eliminate downtime www.oemoffhighway.com/21199342

High-Speed Torque Transducer Measurement technology expert HBM has launched the T40CB torque transducer. • Features central bore hole that suits testing parts in confined spaces • Two variants available, one which measures 49 mm (1.9 in.) in length with central bore hole diameter measuring 37.5 mm (1.5 in.) • Second version measures 54 mm (2.1 in.) in length with 46.5 mm (1.8 in.) diameter central bore hole • Operates at speeds up to 30,000 rpm • Nominal torque of 500 Nm (368.8 lb.-ft.) • Provides flexible and user-friendly design for carrying out application tests on parts, such as coaxial transmissions or gearboxes

Active Turn Assist System Stoneridge-Orlaco introduces its active camera- and radar-detection system ‘SideEye’ to reduce blind spots and increase safety. • Actively alerts driver when cyclists, pedestrians or other road users are present in the blind spot of the truck • Consists of a combination of radar signals, audio signals and camera images • Short Range radar unit transmits 24-GHz radar signals at low power and receives radio signals reflected by objects • Signals received allow radar unit to detect people and objects and determine whether they are moving • Radar unit processes radar detections within 300 ms, allowing drivers to respond immediately and prevent accidents • Monitor overlay indicates on the strategically placed display that there is someone in the blind spot • Works effectively in poor visibility conditions • Rugged design is developed to operate under toughest condition www.oemoffhighway.com/21139849

More Products Online! Find even more products online at www.oemoffhighway.com/ directory where you can sort by component type or system.

www.oemoffhighway.com/21205238

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ON-ON-ON Triple Throw Rocker Switch OTTO introduces the K1S - the industry’s smallest ON-ON-ON triple throw rocker switch. • Short-behind-panel, sealed, logic level only rocker switch offering 1M cycle life in a snap-in package • Available in both single and double pole configurations with maintained action • Well suited for use as a Forward-Neutral-Reverse (FNR) switch • Double pole version offers redundancy for each switch state providing increased safety • Termination options include a Molex connector or wire leads • Sealed to IP68S and uses a flow-thru design • Shorter behind panel than OTTO’s K1 rocker series, making it an ideal choice for use in grips and panels • Consists of two rocker button style/size options for best user comfort

Development Kit for GNSS/INS Module

Novotechnik U.S. announces the Vert-X 3700 Series of angle sensors housed in a sealed stainless steel housing. • Uses Hall effect, non-contact principle • Designed for rugged applications where high humidity, dampness, dust and/or vibrations are expected • Accuracy to 0.35 degrees and repeatability to 0.05% • Measurement range up to 0-360 degrees • Up to 14-bit resolution and ±0.1% linearity • Some models are available with full redundancy • Outputs include 4-20 mA, 0.1-10V, 0.5-4.5V, ratiometric voltage, PWM and SPI

ACEINNA announces the general market availability of ACEINNA OpenRTK330LI EVK, a complete evaluation and development kit for the OpenRTK330LI GNSS/INS module. • Accelerates development and reduces time to market of custom navigation and guidance systems • OpenIMU330LI Module is a compact, low cost, state-of-theart, high performance RTK/GNSS receiver with built-in triple redundant inertial sensors • Provides essential hardware, firmware and development environment for engineers working on autonomous applications who need to quickly start developing algorithms and solutions • Includes GNSS antenna, ST-Link/ v2 debugger, 12 V Supply, USB Cable, and complimentary 30-day subscription to ACEINNA OpenARC correction service for customers in continental USA

www.oemoffhighway.com/21203297

www.oemoffhighway.com/21207329

www.oemoffhighway.com/21206884

Angle Sensors

Tires for Combine Harvesters Continental has expanded its CombineMaster tire series for combine harvesters by adding 10 more sizes, including a VF version. • Both versions feature patented N.flex technology and innovative d.fine lug technology which provides good flexibility with low vibration on the carcass and high resistance to wear and tear • Offers high core strength due to HexaBead core technology • Hexagonal core allows carcass material to wrap itself around the core better, improving power transmission • HexaCore design ensures maximum load capacity of the carcass and ensures high torque from rim to tire • Rectangular core of VF tire ensures high deflection of the sidewall www.oemoffhighway.com/21139702

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CALENDAR OF EVENTS oemoffhighway.com/events

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2021 ASABE AGRICULTURAL EQUIPMENT TECHNOLOGY CONFERENCE Virtual Event Feb. 8-10, 2021 www.asabe.org/aetc2021

WORLD AG EXPO Virtual Event Feb. 9-11, 2021 www.worldagexpo.com

NATIONAL FARM MACHINERY SHOW Kentucky Exposition Center Mar. 31-Apr. 1, 2021 | Louisville, KY www.farmmachineryshow.org

NFPA ANNUAL CONFERENCE Virtual Event Feb. 23-25, 2021 www.nfpaevents.com

COMMODITY CLASSIC, AN AEM COLLABORATION Virtual Event March 2021 www.commodityclassic.com

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

NFPA/FPIC REGIONAL CONFERENCE Virtual Event March 4, 2021 www.msoe.edu

THE WORK TRUCK SHOW Virtual Event March 8-12, 2021 www.worktruckshow.com

HANNOVER MESSE Virtual Event April 12-16, 2021 www.hannovermesse.de

WCX WORLD CONGRESS EXPERIENCE Virtual Event April 13-15, 2021 www.sae.org/attend/wcx

ACT EXPO Long Beach Convention Center May 3-6, 2021 | Long Beach, CA www.actexpo.com/

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

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

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

BUSWORLD NORTH AMERICA Baltimore Convention Center June 19-21, 2021 | Baltimore, MD www.busworldnorthamerica.org

HILLHEAD Hillhead Quarry June 22-24, 2021 | Buxton, United Kingdom www.hillhead.com

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

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

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

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SAE NOISE AND VIBRATION CONFERENCE & EXHIBITION DeVos Place Convention Center Sept. 7-10, 2021 | Grand Rapids, MI www.sae.org/attend/nvh

AGRITECHNICA Hannover Exhibition Grounds Nov. 14-20, 2021 | Hannover, Germany www.agritechnica.com

COMVEC

GREAT LAKES LOGGING & HEAVY EQUIPMENT EXPO

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

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

NORTH AMERICAN COMMERCIAL VEHICLE SHOW

MINEXPO INTERNATIONAL

DAVE HAGLUND

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

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

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

THE BATTERY SHOW

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

ELECTRIC & HYBRID VEHICLE TECHNOLOGY EXPO

EIMA INTERNATIONAL

TBD Sept. 14-16, 2021 | St. Louis, MO www.motionpowerexpo.com

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

BAUMA

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

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

SIMA

GIE+EXPO

MOTION + POWER TECHNOLOGY EXPO

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

THE WORK TRUCK SHOW

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

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

2022

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

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

AD INDEX

Advertiser........................Page #

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, canceled 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/21123406 where we are tracking updates to industry events as they are announced.

B & R Industrial Automation.......................2 Eberspacher Climate Control Systems.........9 Isuzu Motors America...............................27 Morris Coupling-Grand Bending...............23 Napoleon Engineering Services - NES........44 Nokian Tyres.............................................13 Parker Hannifin Electronic Controls Div.....19

AGATEN | PEACEFULLY7 | ISTOCK / GET T Y IMAGES PLUS

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OFF-HIGHWAY HEROES oemoffhighway.com/21207987

The wheeled scraper became a matter of necessity for the construction industry due to the need for improved earthmoving capabilities. by Thomas Berry, Archivist, Historical Construction Equipment Association

n 1951, railroad contractor James L. Allhands (1879-1978) published Tools of the Earthmover Yesterday and Today Preserved in Pictures, likely the first major book written with the intent of educating the general public about construction machinery. One section of this groundbreaking, as it were, work discusses the origins of scrapers, and that history is summarized and corroborated herein. Last issue, we looked at his study of the origins of the original scrapers (learn more, 21199478). This time, we’ll see how he traces the wheeled scraper. Allhands traces the wheeled scraper all the way back to 1805, when the oddly named book, The Abortion of the Young Steam Engineer’s Guide: Containing an Investigation of the Principles, Construction and Powers of Steam Engines by Evans Oliver, presented an Earth Leveller (sic) invented by Gershom Johnson. It operated on the same basic principle as the drag scraper, but rode on a small axle and had a larger “fore wheel” connected ahead of the scraper by iron bars. Three animals pulling it provided enough power to handle two loads a minute. Decades ahead of its time, it too seems to have faded into obscurity. After various ideas were tried in the 1860s and early 1870s, the wheeled scraper hit its stride as a matter of necessity. Allhands tells of a contract let by the Chicago, Burlington & Quincy Railroad for approximately 40 mi. (64.4 km) of grading between Leon and Mt. Ayr, IA. The job combined substantial earthmoving with a very tight deadline. Allhands reports that many thought the job impossible with the drag scrapers, wheel barrows, carts and hand

shovels available at the time. The low bid was placed by C. H. Smith & Company, whose executives knew of a tiny, 3 cu. ft. (0.08 cu. m) A Smith & Sons Royal riding wheeled scraper gave a man a capacity wooden workout, leaning forward and back on the platform to operate scraper with a steel the scraper while keeping the team under control. This is his position during dumping. bottom and an axle er. The operator stood on a platform that kept the front end off the ground. astride the rear end of the tongue; Allhands does not identify the manufacalthough there was no comfort seat or turer of this little machine, but he says CD player, it was fully air conditioned, that Smith had a blacksmith shop in although emissions could be rather fraMount Pleasant, IA, and started building grant! Called the Kansas City Platform them. Smith ultimately massed 600 of Wheeler, the scraper was painted blue, the little scrapers, supported by 100 and was eventually built in at least two plows, on the job, and finished it on time. sizes (9 and 22 cu. ft./0.3 and 0.6 cu. m). As other contractors expressed Allhands states that this line was interest in the device, Smith began acquired by “Smith Brothers,” but sales producing them for resale, and in late literature for Smith & Sons Manufac1879 the Western Wheeled Scraper turing Company of Kansas City, MO, Company was founded in Mount lists a Royal line of riding wheeled Pleasant. This firm relocated to Aurora, scrapers. According to this literature, IL, in 1891. the Royal scrapers were designed for Allhands cites one major improveone-man operation rather than two as ment to the stock-drawn wheeled on non-riding scrapers, and a modified scraper. Most were set up so that the version could be run in sets of up to teamster walked alongside his team, four behind a tractor. and a laborer loaded and unloaded the The wheeled scraper led to numerscraper. Sometime around the turn of ous other scraper innovations, and the the century (“Better than 45 years ago,” concept continues today in modern as he puts it in 1951), an inventor in tractor-drawn wheeled scrapers. | Kansas City designed a riding scrap-

SMITH & SONS MANUFAC TURING COMPANY CATALOG, N. D., HCEA ARCHIVES

The First Wheeled Scrapers

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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O in co sp de

SMITH & SONS MANUFAC TURING COMPANY CATALOG, N. D., HCEA ARCHIVES

TONS OEM Off-Highway Spec Guides are essential industry tools created by engineers, for engineers for component research. These are the only interactive specing tools in the heavy-duty market to help product development teams find exactly what they need!

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OEM Off-Highway January/February 2021

Articles inside

New Products

Technology Breakdown: Western Star 49X

Engineering & Manufacturing

Engineering & Manufacturing: Software

Electrical & Electronics: Sensors

Drivetrains: Electrifi cation

Market Forecast: On-Highway Truck & Bus

News Briefs: Electrifi cation

News Briefs: Engineering & Manufacturing