OEM Off-Highway January/February 2015 by OEM Off-Highway

SOFTWARE: Simulation Software ...Page 24 | Testing Software ...Page 28

www.oemoffhighway.com

JANUARY/FEBRUARY 2015

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Solving today’s challenges with tomorrow’s technologies

A direction is determined

A solid consensus emerges at APTA EXPO 2014.

Page 14

NE W S B R IEF S

The Cuban Benefit

Obama recently announced relaxed diplomatic relations with Cuba, so what does this mean for heavy-duty OEMs? PAGE 12

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TA B L E OF CON T EN T S: VOLUME 33, NO.1 | JANUARY/FEBRUARY 2015

COVER STORY TM

Cover Story: APTA EXPO 2014 Review

14 A direction is determined

For years, the transit market has been feeling out alternative fuel options for public transportation systems, and APTA EXPO 2014 saw a solid consensus emerge.

Search: 12029948

FEATURES News Brief: Cuba Policy

12 The Cuban Benefit

Reopening diplomatic relations between the U.S. and Cuba has been a welcomed development by key OEM players in the construction and ag equipment market, which stand to benefit from exports.

Search: 12030163

Technology Breakdown: SuperTruck to Military

Technologies developed during the DOE’s SuperTruck project have potential to meet the U.S. military’s future vehicle efficiency needs.

20 SuperTruck provides guidance for a more efficient military

Search: 12028636

Software: Simulation Software

Advancements in simulation software are making it easier for engineers to test and validate designs early on to ensure a more productive and cost-efficient design process.

24 More engineering up front

30 24

Search: 12028626

Software: Testing Software

28 Enhance durability through data

Software and hardware systems continue to advance and offer engineers more information to use for understanding a vehicle’s durability capabilities over the life of the vehicle.

Search: 12030116

OEM Off-Highway | JANUARY/FEBRUARY 2015

OOH0115_02-05_TOC.indd 4

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EDITORIAL ADVISORY BOARD IN EVERY ISSUE

Online Exclusives    www.oemoffhighway.com

Editor’s Notebook:

6 2015 Starts with ABC Search: 12030386

oemoffhighway.com/economics 105.2% 104.3%

104 103

102.5%

101

100.9%

101.2%

Actual index (2004=100)

100 99

Mar ’14

Apr

May

Jun

Jul

Aug

Sep

Oct

32 The first hydraulic excavators

Collaboration stretches R&D resources

Ricardo Strategic Consulting

Consultant

Andrew Halonen Sales Engineer

Eck Industries, Inc.

Terry Hershberger

Director, Sales Product Management, Mobile Hydraulics

Bosch Rexroth Corp.

A drivetrain manufacturer adds its first assembly line in the U.S. to better meet the needs of its North American customers.

Tracy Kiser

Off-Highway Marketing Communications Manager

Search: 12026151

Cummins Inc.

Market Forecast: Fluid Power

VP Sales & Marketing

Mike Mackool

The NFPA’s most recent analysis of the fluid power industry’s shipments and orders for hydraulic and pneumatic components.

Off-Highway Heroes

Torsion Control Products

Alistair McLelland

Vice President Marketing, North America

AGCO

Search: 12028920

sing four steam cylinders and U no cables or chains, the design eliminated cylinder shock and damage when working at high speed.

Search: 12022256

GKN Land Systems

Joshua David

Localized manufacturing for improved customer service

101.8%

102

Chief Engineer – Innovation & Hybrids

Search: 12031254

Search: 12031263

103.6% 103.6%

Jules Carter

Siemens Large Drives US

Danfoss’ Application Development Center addresses industry demand on OEM research and development departments.

106 105

Volvo Construction Equipment

Business Segment Head, Minerals Projects and Global Mobile Mining

Cab suspension systems have become essential for a healthy and efficient operator.

8 U.S. ends year on a positive note

Chief Project Manager

Roy Chidgey

Operate in isolation

Economic Outlook:

Craig Callewaert, PE

Doug Meyer

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Global Director of Construction Engineering

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Allen Schaeffer Executive Director

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Keith T. Simons

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President – Controls Products

OEM Controls, Inc.

Simone Stier

Promotion and Communication

Liebherr-Components AG

WHAT DOES SEARCH: 12345678 MEAN?

33 Ad Index 33 Calendar of Events

Bob Straka

Business Development Manager, Transportation

Each article, product and advertisement found in OEM Off-Highway’s pages has a unique 8-digit code that can be entered into the search bar found at the top of www.oemoffhighway.com. By searching for the unique number, you will be instantly taken to that specific piece of content online where you can find more images, online exclusive sidebars, related products and videos, and more!

Southco, Inc.

Charlie Throckmorton

Principal Applications Engineer

Danfoss

John Treharn

Vice President Business Development HYD GROUP

Parker Hannifin Corp.

Len Walton

Transportation Market Director

Minnesota Rubber & Plastics

OEM Off-Highway | JANUARY/FEBRUARY 2015

OOH0115_02-05_TOC.indd 5

1/9/15 12:50 PM

EDI T OR’S NO T EB O OK www.oemoffhighway.com/12030386

2015 Starts with ABC

The end of the year is always busy for our magazine. Travel is

frequent between September and November, making the day-to-

Published by AC Business Media Inc.

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

www.OEMOffHighway.com

day tasks a little more difficult to accomplish. On top of that, we also decided to

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

most popular content of 2014 in a fun, interactive format. Now, while the theme

Associate Publisher/Editor Michelle EauClaire-Kopier meauclaire@ACBusinessMedia.com

create and launch a new digital product, the Year in Review, to encapsulate the

of starting 2015 with the ABCs may seem rudimentary, our content and products in 2015 will be anything but basic.

Managing Editor Sara Jensen sjensen@ACBusinessMedia.com Senior Field Editor Curt Bennink cbennink@ACBusinessMedia.com

A is for App

Contributing Writers Thomas Berry

OEM Off-Highway has officially

Ad Production Manager Cindy Rusch crusch@ACBusinessMedia.com

launched its own app to better view and engage with its digital editions.

You will still get the same great content on a mobile-device optimized

platform for a more intuitive and in-

teractive reading experience. The first product you’ll find in the OEM Off-Highway app’s library is our brand new Year in Review digital wrap-up. In a quick glance

Art Director Dave Haglund Senior Audience Development Manager Wendy Chady Audience Development Manager Tammy Steller ADVERTISING SALES (800) 538-5544 Stacy Roberts....................sroberts@ACBusinessMedia.com Jill Draeger..........................jdraeger@ACBusinessMedia.com Sean Dunphy....................sdunphy@ACBusinessMedia.com Erica Finger.........................efinger@ACBusinessMedia.com

you can see the 10 most popular news, articles and products of the 2014 year.

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B is for Bus

Reprints — For reprints and licensing please contact Nick Iademarco at Wright’s Media (877) 652-5295 ext. 102 or niademarco@wrightsmedia.com.

Find it in the App Store by searching “OEM Off-Highway magazine” on your

This issue, OEM Off-Highway took a look at what is happening in the heavy-duty on-highway vehicle market. With the triennial APTA EXPO 2014 taking place in Houston, TX, the public transit industry was alive with excitement on all-electric bus options. Our cover story on page 14 takes a closer look at a few of the

all-electric buses seen on the show floor, as well as major players in the battery, fuel cell and ultracapacitor marketplace. C is for Cuba

President Obama recently announced relaxed diplomatic relations with Cuba,

which could mean new export opportunities for construction and agricultural

IN THE NEXT ISSUE

MARCH

••Global market trends ••Value equipment ••New engines ••Electrohydraulic controls for efficient operation ••Extreme Machines in sub-zero ambient temperatures

equipment manufacturers. Shortly after the announcement, statements were

made by several organizations including AEM, Caterpillar Inc. and John Deere

supporting the diplomatic shift. See what they had to say on page 12. What oppor-

tunities does Cuba hold for you and your company? |

AC BUSINESS MEDIA INC. Chairman President and CEO Executive Vice President CFO VP Content VP Marketing Digital Operations Manager

Anil Narang Carl Wistreich Kris Flitcroft JoAnn Breuchel Greg Udelhofen Debbie George Nick Raether

Published and copyrighted 2015 by AC Business Media Inc. 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 on-line) is published eight times per year: January/ February, March, April, May/June, July/August, September, October and November/December by AC Business Media Inc., 201 N. Main Street, 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. Canada Post PM40612608. Return undeliverable Canadian addresses to: OEM Off-Highway, PO Box 25542, London, ON N6C 6B2. Volume 33, No. 1, January/February 2015

OEM Off-Highway | JANUARY/FEBRUARY 2015

OOH0115_06-07_Editorial.indd 6

1/9/15 12:54 PM

Don’t Miss It! Now available online and on iPad.

http://bit.ly/14yZNef

http://bit.ly/1DfMmOn

OEM Off-Highway’s new Year in Review digital product features an annual wrap-up of the hottest news, articles and products of 2014! See what captured the attention of the heavy-duty on- and off-road industry for the year.

OOH0115_06-07_Editorial.indd 7

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ECONOMIC OU T L O OK

www.oemoffhighway.com/economics

U.S. ends year on a positive note

The primary reports on the economy have been mostly quite positive. Both second

and third quarter GDP growth

was strong. Even more encouraging, the labor market has

recently been creating jobs at

an accelerating pace. The overall economic outlook for 2015 is brighter than it has been in

105.2%

U.S. Leading Indicator: •• The leading indicator saw another

103

•• The index rose 0.9 points, slightly

101

large upward move in October.

102

outpacing the revised 0.7 point gain for September.

100

•• For both months the strength was

following the strong advance recorded in September.

•• Manufacturing output inched

upward 0.2%, matching September’s performance.

•• Notable strength was found in

business equipment production which rose 0.6%.

challenging market conditions.

Housing Starts:

ress in Europe. Stagnation and

•• Single-family starts rose 4.2% in

to dominate the discussion. The

•• This was the second consecutive

ECB is talking about quantitative easing, but has deferred any action until early 2015.

Go to .com ighway oemoffhign up for to s thly our monMIC ECONO TER! ET NEWSL

QUESTIONS? Contact Steven Crane, Senior Economist at C3 Statistical Solutions, at

scrane@c3stats.com. 8

100.9%

Mar ’14

5.00

101.2%

Apr

May

Jun

Jul

Aug

Sep

Oct

Annual % change in quarterly averages

4.2%

4.4%

4.2%

4.0%

4.2% 3.7%

3.75

3.9%

4.0%

2.50

1.25

0.00

1.0

sectors will still be facing

the threat of deflation continue

102.5% 101.8%

•• Output slipped 0.1% in October,

years. Unfortunately, some

There has been little prog-

103.6% 103.6%

widespread, as the vast majority of components signaled positive.

U.S. Total Industrial Production:

104.3%

104

Actual index (2004=100)

Editor’s Note: Please note that both the U.S. and Euro Leading Indicator charts have been modified on the Y-axis to show the trend more easily.

106 105

0.4

0.0

0.86

Dec

Mar '16

0.88

0.89

Dec

Mar '16

0.76 0.65

Jun ’14

Sep

Dec

Mar ’15

Jun

Sep

Annual % change in quarterly averages

12 10.2%

lodging and transportation, but declines in power, commercial and communication.

Sep

13.4%

•• The reported slippage was

•• October saw gains in manufacturing,

0.82

accompanied by substantial upward revisions to the August and September estimates.

Jun

0.2

•• Activity was down slightly in October, but this was misleading.

Mar ’15

Millions of single-family units, seasonally adjusted annualized rates

0.63

advance, and the third over the past four months.

Private Nonresidential New Construction:

Dec

0.70

October; permits were up 1.4%.

post-recession high recorded in November of 2013.

Sep

0.8

0.6

•• Starts were only 2.0% below the

Jun ’14

2.6%

3.3% 1.6%

Jun ’14

Sep

Dec

Mar ’15

Jun

1.2%

Sep

1.5%

Dec

1.9%

Mar '16

OEM Off-Highway | JANUARY/FEBRUARY 2015

OOH0115_08-11_Econo.indd 8

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Total Public New Construction:

Construction Machinery, New Orders:

•• Public construction rebounded

•• Real orders dropped 2.0% during

2.3% in October.

October.

•• This came on top of a notable

•• In addition, September’s substantial

upward revision to the estimates for the two previous months.

decline was revised to be an even larger negative number.

•• The strength was widespread;

•• It’s been a difficult past seven

months; orders are down 21.4% since March.

7.7%

6.9%

of the 13 subcategories only residential and sewerage lost ground.

Annual % change in, 12-Month moving total (1982 Dollars)

Mining, Oil & Gas Field Machinery New Orders:

5 4 2.8%

2.5%

0 -1

-3

Jun ’14

Sep

Dec

Mar ’15

-2.5%

-3.0%

Jun

Sep

Dec

Mar '16

bang.

•• Orders jumped 21.2%, which was

volume was not sustained into October.

an impressive move even for this notoriously volatile series.

•• Shipments dropped 5.5% on the

month; they were only two-thirds of the October 2013 volume level.

•• The last time the market was this 15

•• Looking past the volatility, 2014 as a whole will have been a pretty good year for defense orders.

12.7% 9.4%

Heavy-Duty Truck Shipments:

5 0.3%

-5

continued to push truck shipments upward.

-8.4%

-15

•• The gain for October was 2.8%, just

-17.7%

-20 -25 Jun ’14

Sep

-25.1%

-24.4%

Dec

Mar ’15

Annual % change, in 12-Month moving total (1982 Dollars)

Jun

Sep

Dec

Mar '16

over half that of September.

1.8% 1.3% 0.5%

Jun ’14

Sep

Dec

Mar ’15

Jun

Sep

Dec

2.8%

2.8 0.6% -0.1%

-0.5% Annual % change, in 12-Month moving total (2003 Dollars)

-3.8

-6.0

-3.9%

-3.7%

-5.4%

Jun ’14

Sep

Dec

Mar ’15

Jun

Sep

Mar '16

Annual % change, in 12-Month moving total (1982 Dollars)

9.1% 7.9%

Dec

6 4 2 0

-0.1%

-2 -2.9%

-4

-4.8%

-6

-5.8% -6.7%

-8

Jun ’14

-7.3%

Sep

Dec

Mar ’15

Jun

Sep

Dec

Mar '16

Annual % change, in 12-Month moving total (2003 Dollars)

15.0%

15.2% 13.5%

10.6%

10 6.3%

4.1% 2.6% 1.3%

Jun ’14

Sep

Dec

Mar ’15

Jun

Sep

Dec

OEM Off-Highway | JANUARY/FEBRUARY 2015

OOH0115_08-11_Econo.indd 9

Mar '16 5.2%

5.0

•• Volume was up 34.2% year-to-date and 28.4% from October 2013.

1.1%

0.9%

•• Booming market conditions

-5.1%

-10

-30

1.9%

weak was back in early 1996.

of the range of values recorded over the past two years.

•• The fourth quarter began with a

•• September’s uptick in shipment

3.1%

•• All of the gains from this summer

Defense Industry, New Orders:

Farm Machinery & Equipment Shipments:

-1.6

•• October volume fell at the bottom

-2

0.6

have been wiped out over the past two months.

-0.8%

Annual % change, in 12-Month moving total (1982 Dollars)

•• Real orders tumbled in October, falling 16.8%.

1.2%

6.0%

Mar '16

1/12/15 12:51 PM

ECONOMIC OU T L O OK

www.oemoffhighway.com/economics

Euro Area Leading Indicator: •• The leading indicator fell in October

3.0

for the sixth consecutive time.

•• The only encouraging element was that the decline was more modest than in previous months.

2.4%

2.4% 2.2% 1.9%

100.87

•• It will probably be 2015 before the German industrial sector regains momentum.

1.0

3.5

100.84

100.7

100.67 100.62

100.6

100.60

Jun ’14

Sep

Dec

Mar ’15

Jun

Sep

Dec

•• Production declined 0.1% during

October; a gain was expected by most analysts.

100.5 100.4

•• Virtually all the weakness came from

100.3

manufacturing, which fell 0.7%.

•• A softer export market, especially Apr

May

Jun

Jul

Aug

Sep

Oct

to Europe, has been hurting the manufacturing sector.

Mar '16

3.5%

2.8%

0.0

100.73

Mar '14

3.4%

Annual % change in quarterly averages

3.0

100.79

100.8

smaller and October’s production was up only 0.2%. disappointments.

1.5%

0.5

100.86

•• September’s rebound was revised •• Both results were mild

1.8%

Monthly index

101.0

100.0

2.8%

2.6%

1.5

sluggish near-term growth in the Euro area.

100.9

2.5

Annual % change in quarterly averages

2.0

•• This pattern points toward very

Industrial Production, Germany:

Industrial Production, United Kingdom:

2.5 2.0

1.8% 1.5%

1.5 1.0%

1.0 0.5

0.2%

0.0

Jun ’14

Sep

Dec

0.1%

Mar ’15

Jun

Sep

Dec

Mar '16

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NE W S B R IEF S: C UB A P OL IC Y www.oemoffhighway.com/12030163

The Cuban Benefit by Michelle EauClaire-Kopier

On December 17, 2014, President Obama made a surprise

announcement that the U.S. will normalize its relations with

Cuba ‒ the most significant change to the U.S.’s Cuba policy in over 50 years. The changes in policy will be implemented

will open up certain kinds of products that will be mainly

Treasury and Commerce, and aim to further enhance the

has initiated and is growing. It will be residential construc-

via amendments to regulations of the Departments of the U.S.’s goal of empowering the Cuban population.

Shortly after the announcement, the Association of

Equipment Manufacturers (AEM) released a brief news

statement titled, “Relaxation of Restrictions on Cuban Ex-

ports Will Benefit AEM Members.” The immediate implica-

used by the private sector within Cuba, which only recently tion, goods used by private sector Cuban entrepreneurs

such as restaurants, barber shops, small business opera-

tors, and agricultural equipment for small farmers. So it is

designed to strengthen civil society and the private sector. “To give you some round numbers for dollar values, last

tions for AEM members referred specifically to a portion of

year, in 2013, we at Commerce issued licenses for almost

amended policy.

ucts alone and about $3 billion of agricultural exports. So

authorized construction and agricultural exports under the “Specifically, the Commerce Department will be issuing

regulations that will authorize for export certain building

materials for private residential construction, goods for use

$300 million worth of commercial sales for medical prod-

just in those two areas that have already been authorized, there are some substantial potential.”

Key OEM players in the construction and agricultural

by private sector Cuban entrepreneurs, and agricultural

equipment market, Caterpillar Inc. (company information,

tion official in an excerpt from a press briefing call, (docu-

supporting the policy change.

equipment for small farmers,” stated a senior administra-

Reopening diplomatic relations between the U.S. and Cuba has been a welcomed development by key OEM players in the construction and ag equipment market, which stand to benefit from exports. ment titled Background Conference Call on Policy Changes

in Cuba and the Release of Alan Gross). “These changes

10055175) and Deere & Company also released statements Caterpillar Global Governmental Affairs Director Bill Lane

said, “The reopening of diplomatic relations between the U.S. and Cuba is a welcome development, a move which

Caterpillar has been a long-standing proponent. Engage-

ment, rather than isolation, can provide a strong incentive

for change, benefitting American and Cuban communities alike. We are hopeful that today’s events represent a key step toward a true open relationship between both na-

tions, offering opportunities to export to a new market and Cuba the necessary goods to modernize.”

Ken Golden, Director of Global Public Relations for Deere

will make it easier for Cuban citizens to have access to

& Company, echoed Lane’s sentiment. “We consistently

greater economic independence from the state, and over-

provide opportunities for the citizens and markets of

lower-priced goods to improve their living standards, gain all develop the private sector in Cuba.”

Later on in the call, a member of the press posed the ques-

tion, “Regarding the trade portion of this plan, how would

you characterize how open trade will be with Cuba? Is there any estimate on the potential market for U.S. exporters?”

In response, a senior administration official stated, “This

support the principles of free trade that we are confident the world. There is a need in Cuba, as there is around the globe, for productive, modern machinery to help feed,

clothe and shelter the world’s rapidly growing population. “Cuba is a potential market for John Deere products and

services. We look forward to serving customers in Cuba as

we do throughout Latin American and around the world.” |

OEM Off-Highway | JANUARY/FEBRUARY 2015

OOH0115_12-13_Cuba.indd 12

1/12/15 12:51 PM

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CO V ER S T ORY: A P TA E X P O 20 1 4 R E V IE W www.oemoffhighway.com/12029948

A direction is determined At only 57 dB in motion, Proterra’s all-electric bus is quiet and operates below a normal conversation level, ensuring that communities and neighborhoods remain undisturbed. PROTERRA INC.

For years, the transit market has been feeling out alternative fuel options for public transportation systems, and APTA EXPO 2014 saw a solid consensus emerge. by Michelle EauClaire-Kopier Once every three years, APTA

per gallon in the case of compressed

Assn.) EXPO (event information,

or five miles per gallon for diesel and

(American Public Transportation

12029847) arrives in a major U.S. city

to showcase the products, technolo-

Houston, TX, and several vehicle and

school, where our hospitals are, our

ments were made in line with

cleaner air and fuel efficient transportation systems.

Transit buses, while they

“In the areas we care about the

most—the areas where we live and

advanced technology announce-

MAXWELL TECHNOLOGIES

diesel hybrid.

gies and services available in public

transit. The 2014 show was hosted in

Maxwell Technologies’ K2 series ultracapacitors work in various applications including hybrid drivetrains and utility vehicles.

natural gas (CNG), and maybe four

help to relieve traffic con-

gestion, are some of the

most polluting vehicles on

the road, and they run all the time.

Many vehicles only get three miles

where we work, where our kids go to great museums, our airports—those

are our most emission-sensitive areas and those routes are currently served by some of the dirtiest vehicle technology in the market. Our goal, and we think this is entirely possible, is

to move toward a future where fossil fuels are not consumed in cities for transit,” commented Ryan Popple,

CEO of Proterra Inc., during a video

OEM Off-Highway | JANUARY/FEBRUARY 2015

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The Nova Bus LFSe 100% electric bus is based on Nova’s existing LFS bus platform with an integrated electric propulsion system. NOVA BUS

interview at APTA EXPO 2014.

Proterra (company information,

12003190) is a designer and manufacturer of zero-emission vehicles. “We have a very simple mission at Proterra. Our goal is to help cities

move away from fossil fuel usage

entirely for their urban transit fleets,” Popple continued. “The reason we’re so excited at this show, the 2014

APTA EXPO, is that we think this is

the first year that it’s really obvious that that’s where things are going.

It’s not just Proterra. There are four

or five other electric transit vehicles

here, and for the first time I think the industry is seeing the potential of

something other than a dependency

Proterra’s bus body was specially designed to be durable and functional. Its lightweight, fiberglass balsa wood construction delivers an outstanding strength-to-weight ratio and offers a number of cost-saving advantages over conventional buses. PROTERRA

OEM Off-Highway | JANUARY/FEBRUARY 2015

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CO V ER S T ORY: A P TA E X P O 20 1 4 R E V IE W www.oemoffhighway.com/12029948

Inside the cab of BYD’s electric transit bus.

BYD

on fossil fuels.”

tion, 12011357), part of the Volvo

All-electric buses

was BYD (Build Your Dreams) Co. Ltd.

solution at APTA EXPO 2014 which

its second generation all-electric

One of those other companies

(company information, 12023179), a Chinese corporation specializing in

rechargeable battery technology for IT, automotive and new energy. Its

BYD Auto brand develops innovative electric vehicles such as the BYD 40-

and 60-foot articulated battery-electric buses which utilize the compa-

Group, displayed its electro-mobility features an en-route fast-charging

system (learn more, 12029883). “At

Nova Bus, we believe transit systems need to be efficient and reliable, but we also believe it should be sustainable,” says Jacques Bergeron, Vice President Engineering,

Product Development &

In the areas we live and work, where our kids go to school, are our most emission-sensitive areas served by unclean transit. The goal is to move toward a future where fossil fuels are not consumed in cities for transit. ny’s iron-phosphate “Fe” battery

Procurement. “Our goal

“Fe” battery technology features

solution that is adapted to North

technology. BYD’s iron-phosphate life cycles up to 10,000 cycles while

maintaining a capacity of over 70%, and the battery can be recycled when its usable life is met.

Nova Bus (company informa-

is to develop a reliable

American conditions and is based on

a modular and versatile system. Tran-

In September, Proterra Inc. launched bus in a 40-foot V2 model (vehicle

information, 12029784). It features

a fast-charge system that keeps the

bus on the road with no requirement to take it out of service for long

charging periods, one-step access

for ease-of-maintenance and industry-leading ergonomics.

“A charge system is any means or

mechanism for putting energy back

into the bus,” explained Seamus McGrath, Charge Systems Manager for Proterra, during the same

video interview. The

Proterra V2 uses an

overhead charge meth-

od that charges a bus from

empty to fully charged in about 10

minutes through a charge of 450 kW. “With respect to that, typical route charge recovery time is about four

minutes; just like a car, you don’t run it until empty and then fill it up.” Proterra’s fast charge system is

sit authorities will be able to select

enabled through its lithium titanate

suits their operational needs.”

vehicle to run with fewer batteries on

the electric configuration that best

battery chemistry, which allows the

OEM Off-Highway | JANUARY/FEBRUARY 2015

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BYD’s 40-foot electric transit bus utilizes its proprietary iron-phosphate “Fe” battery technology.

BYD

board for a lighter and more efficient

option is based on the company’s ex-

ogy experts to co-develop a battery

vehicle body features a lightweight,

electric bus system reduces energy

EXPO 2014, these battery experts

system. Besides fewer batteries, the fiberglass balsa wood construction. The drivetrain and propulsion

system has demonstrated 20.8 miles per gallon equivalent (MPGe) and

over 17 MPGe during typical fleet operation. The buses Proterra is able to provide offer zero tailpipe emissions while simultaneously reducing CO₂

isting and proven LFS platform. The

consumption by 80% compared with conventional diesel buses. The inno-

vative solution minimizes the weight and maximizes the loading capacity by removing the all-charging ele-

ment from the bus and optimizing the number of batteries.

An overhead inverted pantograph,

emissions by 180,000 pounds of CO₂

conceived by Siemens, creates an in-

per year versus a CNG-powered bus.

infrastructure power distribution

equivalent greenhouse gases (GHG)

Download a spec sheet of Proterra’s

all-electric 40-foot bus at 12029784. The BYD Electric Bus offerings

include a 40-foot model with a range of 155+ miles per charge, while the 60-foot articulated model can get upwards of 170 miles per charge.

Bi-directional AC charging allows full charging from 0 to 100% SOC

within 5 hours. Energy recovery and battery recharging is accomplished through a regenerative braking

system. High-efficiency, in-wheel

tegrated and efficient transportation system. Robert Hardt, President and

CEO, Siemens Canada, says, “As cities throughout North America continue to grow, the need for efficient and clean transportation solutions has

become critical. At Siemens we are

committed in finding new and inno-

industry’s investment and confi-

dence in this technology as the next generation of clean public transit. Ballard Power Systems, Inc.

(company information, 12029987)

is a global leader in PEM (proton ex-

change membrane) fuel cell technology. Ballard’s PEM fuel cells combine hydrogen fuel and oxygen from the

air to produce electrical energy effi-

ciently, quietly and without combustion. The only by-products are water and heat. Its clean energy fuel cell

products enable optimized power

systems for a range of applications, not just for the bus market.

Its FCvelocity–HD6 fuel cell power

module for bus applications has over

great example of this commitment.”

in the field all over the world. This

and the High Power Charger is a

Download a spec sheet of Nova Bus’ all-electric LFSe bus at 12029909.

Batteries and fuel cells

maintenance.

internal battery competency, most

Nova Bus’ LFSe all-electric bus

were prevalent, only reaffirming the

vative ways of to meet these needs,

traction motors allow for ultra-low

floor loading options and simplified

electric powered transit bus. At APTA

While OEM BYD may have its own

rely on battery and fuel cell technol-

200,000 operation hours logged

sixth-generation model can deliver

75 or 150 kW of power, and features a control unit to interface with a

system controller, allowing it to be a true plug-and-play product for any fuel cell bus platform.

Another player in the battery

OEM Off-Highway | JANUARY/FEBRUARY 2015

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CO V ER S T ORY: A P TA E X P O 20 1 4 R E V IE W www.oemoffhighway.com/12029948

and ultracapacitor manufacturing

market is Maxwell Technologies Inc. (company information, 10325608)

who showcased its latest K2 Series of ultracapacitor cells (product

information, 10325612).

Unlike batteries, Maxwell ultra-

capacitor products store energy in

an electrical field that is larger than

that of a capacitor – meaning greater energy storage capacity. This elec-

trostatic energy storage mechanism enables ultracapacitors to charge

and discharge in as little as fractions of a second, perform normally over

The FCvelocity–HD6 fuel cell power module for bus applications from Ballard has over 200,000 operation hours logged in the field all over the world.

65 C), operate reliably in hundreds of

BALLARD POWER SYSTEMS INC.

resist shock and vibration.

tion technology to the requirements

a broad temperature range (-40 to

thousands or more duty cycles, and

The 2.85-volt, 3400-farad ultraca-

pacitor cell increases the range of

of global transportation applications. APTA EXPO 2014 proved to be

available specific power and stored

an instrumental stepping stone in

mm cylindrical “K2” form factor, and

rection for the development of clean

energy in the industry-standard 60

features DuraBlue shock and vibra-

determining a solidified, unified dipublic transportation. As battery

technology continues to advance and more companies and transit

authorities get on board (figurative-

ly) with all-electric bus development, there is no telling what vehicles will be proven and on display at APTA EXPO 2017. |

In the News: Read Online    Proterra named to Global Cleantech 100 list

For more, go to www.oemoffhighway.com/12009728

Proterra named top global technology pioneer by World Economic Forum For more, go to www.oemoffhighway.com/12003192

BYD to showcase new 60-foot electric bus

For more, go to www.oemoffhighway.com/12023184

Antelope Valley Transit Authority’s two BYD electric buses are ready to “POWER ON” For more, go to www.oemoffhighway.com/12029940

Nova Bus showcases Electro Mobility solution at APTA EXPO 2014 For more, go to www.oemoffhighway.com/12029883

Ballard and Van Hool Launch Service Centre to Support European Clean Energy Fuel Cell Buses For more, go to www.oemoffhighway.com/12029989

SARTA receives federal grant for pollution-free bus For more, go to www.oemoffhighway.com/12005396

CALSTART recieves approval to develop 60-foot fuel cell/battery zero-emission bus For more, go to www.oemoffhighway.com/12009732

OEM Off-Highway | JANUARY/FEBRUARY 2015

OOH0115_14-19_APTA.indd 18

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L I N E A R AC T UATO R T E C H N O LO G Y

Dave Moorman dmoorman@linak-us.com 502 292 4215 linak-us.com/techline

WE ONLY USE

OIL FOR COOKING

GO ELECTRIC

LA36

LA25

LA14

oemoffhighway.com/10055720

OOH0115_14-19_APTA.indd 19

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T EC HNOL O G Y B R E A K D O W N: SUP ER T RUCK T O MIL I TA RY www.oemoffhighway.com/12028636

provides guidance for a more efficient military

by Sara Jensen

In February 2014, the Cummins-Peterbilt SuperTruck achieved 10.7 mpg during real-world driving conditions. CUMMINS INC.

Technologies developed during the DOE’s SuperTruck project have potential to meet the U.S. military’s future vehicle efficiency needs. As with many industries, the U.S.

truck market which are working to

8 truck designs, while also providing

improve the efficiency of its vehi-

8 truck with a 50% freight efficiency

methods they too can attempt to

military is looking to find ways to

cles while reducing emissions and fuel use. Major weight reductions,

semi-autonomy to assist but not re-

place fighters, and a reduction in fuel and water consumption are among

the key goals stated in the U.S. Army Tank Automotive Research Devel-

opment and Engineering Center’s (TARDEC) “vision for the future.”

During a recent CALSTART we-

develop a final demonstration Class improvement, 50% brake thermal

efficiency (BTE) and pathways to 55%

Engines

enhancements to the engine and

element in meeting the efficiency

improve vehicle efficiency through

aerodynamics, as well as developing or employing newer technologies

such as waste heat recovery systems (see sidebar, pg. 22).

Every system plays a part

developed for the U.S. Department

at making adjustments or enhance-

of Energy’s (DOE) SuperTruck pro-

gram could be implemented by the

military to help it meet the efficiency goals set out by TARDEC.

Started in 2010, SuperTruck is a

cost-shared program consisting of four teams from the heavy-duty

increase vehicle efficiency.

BTE. Each team has been working to

binar, the organization examined

how technologies being utilized and

industries such as the military with

For SuperTruck, the teams looked

ments to all aspects of the vehicle in order to reach their efficiency

targets, everything from the engine to the wheels to the shape of the cab and the mirrors. Many of the techniques utilized have already

started making their way into Class

Engine optimization has been a key needs of the SuperTruck program, which Ted Bloch-Rubin, Associate

Project Manager at CALSTART, said

during the webinar directly ties into TARDEC’s interest in advanced combat engines. To achieve this, many

of the teams looked into improving engine control. Bloch-Rubin said that while engine controls in the

past have been more reactive, the

SuperTruck teams found predictive

abilities—such as route adaptation and planning ahead via GPS—are

the next step for improved engine utilization and efficiency.

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Getting to a point where the

predictive engine controls use al-

gorithms to predict future response of an engine is a key interest area of the military, said Bloch-Rubin. Not

only would these capabilities help

improve the efficiency of the engine, but also provide the first steps

toward vehicle automation, another interest of the military.

Integrating the engine with other

systems, such as a transmission, has

also been found to be key for engine optimization. The Cummins/Peterbilt-led team, for example, paired

their engine with an advanced manual transmission from Eaton which

allowed the team to downspeed the engine while getting the same level of performance at higher rpms. This is already a commercially available

option from Cummins Inc. (company

information, 10055252).

Improved engine combustion is

also a top priority for the military, said Bloch-Rubin. Increased peak

combustion pressure, optimum valve

timing, higher injection pressure, turbo optimization, reduced EGR rates

bowl shape and turbo optimization for improved combustion capabili-

ties (product information, 12025599).

recovery or hybrid systems.

can have just as much impact on its

Alternative technologies

or systems within it, which is why

tigated the use of alternative power

The shape and weight of a vehicle

efficiency as any of the components improving aerodynamics and reducing weight have become integral to vehicle design. Each of the Su-

perTruck teams used readily available technologies to improve the weight and aerodynamics of their designs. Though many of the aerodynamic systems, such as trailer skirts and boat tails, are only applicable for

Class 8 trucks, employing rear-view cameras instead of large mirrors

is one technique the military may

find advantageous. The cameras are

said using the technologies together and thinking of them as a package

solution will bring about the efficiency benefits for which manufacturers

are looking. He also pointed out that some of these strategies are already being used in the market. The new Detroit DD15 engine, for example,

uses optimum valve timing, piston

efficiency, such as through electrification and hybridization. While a

full hybrid system could not be used because added weight and limited

regenerative braking opportunities

in long-haul applications would mitigate potential savings, the increased

amount of electrification in the vehicle enables partial hybridization for the use of idle reduction and start/ stop systems.

Start/stop and idle shutdown

with a clearer in-cab view of whatâ&#x20AC;&#x2122;s

to continue running even when the

ic, as well as provide the operator

happening behind the vehicle which also increases safety.

Weight reduction techniques

however, are much more applicable about reducing vehicle weight by

using lighter weight brake rotors and calipers, plastic fuel tanks, and composite front axle leaf springs. Using components made from aluminum such as axle hubs, wheels and cab

frames helped

significantly reduce weight, as well.

Strategies for improved engine combustion investigated during SuperTruck have already started making their way into the market, such as the new Detroit DD15 engine which includes optimum valve timing and piston bowl shape to increase efficiency. DETROIT DIESEL CORP.

sources as a means of increasing

systems are similar in that they both

for military vehicles. The teams went

much of a difference, Bloch-Rubin

Each of the SuperTruck teams inves-

slimmer and thus more aerodynam-

ployed by the SuperTruck teams to

dividual technology might not make

by the inclusion of unconventional

reduction

used on the SuperTruck designs,

improve combustion. While each in-

ing weight added to the vehicle

technologies such as waste heat

Aerodynamics and weight

and a thermal barrier coating are

among the many technologies em-

Techniques for lightweighting can

be especially beneficial for mitigat-

allow certain functions of the vehicle engine is off. More commonly seen

in newer passenger cars on the road

today, start/stop systems turn off the engine when the vehicle comes to

a stop, such as at a traffic light, and starts it up again once an operator presses the gas pedal. While the

engine is off the operator still has full use of the radio, windshield wipers and other auxiliary functions.

Idle shutdown sys-

tems work in much the same way in that they allow

the vehicle oper-

ator to shut off the

engine and instead

use a battery or auxiliary

power unit (APU) to provide

power for functions such as

lights, HVAC systems or com-

munication devices within the cab.

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T EC HNOL O G Y B R E A K D O W N: SUP ER T RUCK T O MIL I TA RY www.oemoffhighway.com/12028636

This is most typically used in Class 8

said that because military vehicles

from the exhaust heat to generate

during their rest periods.

a lot of heat, advanced thermal

ing uses a turbine to recover energy

trucks to keep drivers comfortable

Having the ability to shut off the

engine and use another power

source reduces emissions and fuel

consumption, as well as noise levels. This is especially important for mili-

have large engines that produce

management systems, such as those using waste heat recovery technology, have the potential to provide efficiency benefits.

Most waste heat recovery technol-

tary applications where being able to

ogies are still in the prototype stages

still utilize critical systems within the

mercial availability, said Bloch-Rubin,

eliminate the noise of the engine but operator environment can save lives.

“Both SuperTruck and the military are focused on idle fuel reduction. For

the military, they see it as a need for enabling silent watch while saving fuel; there really is a dual purpose there,” said Bloch-Rubin.

Waste heat recovery systems were

also investigated by the SuperTruck teams, and are a key technology of

interest for the military. Bloch-Rubin

and are about five years from comas there is still work to be done to

optimize their weight and integrate them with other systems. For the SuperTruck program, the teams

focused on two types of waste heat recovery—Organic Rankine Cycle

from the exhaust system to generate

electrical power. All three SuperTruck teams are using waste heat recovery systems in their final designs.

In addition to these systems, the

military is also interested in three

other forms of waste heat technology. • Thermoelectric Generators that

generate a current across a hightemp/low-temp gradient.

• Mechanical Turbo-Compounding which uses a turbine to recover

energy from the exhaust system to generate mechanical power.

and Electrical Turbo-Compounding.

• Electrically-Assisted Turbocharg-

capture a portion of the waste heat

shaft to generate power or help

Organic Rankine Cycle systems re-

from the exhaust gas recirculation

(EGR) aftertreatment system and/or

SuperTruck participants Currently there are three teams still actively participating in the SuperTruck program. »»Cummins/Peterbilt: The team being led by Cummins Inc. and Peterbilt Motors Co. (company information, 10752762) recently completed its SuperTruck design which has demonstrated 51% BTE and overall 85% freight efficiency improvements (learn more, 11313987). Technologies utilized include auxiliary power units, a downsized engine coupled with an automatic transmission and a waste heat recovery system which will mechanically recover energy to achieve up to a 6% fuel efficiency improvement. »»Daimler Trucks: Daimler Trucks North America (DTNA, company information, 10247983) reported in June its truck had demonstrated over a 50% freight efficiency improvement, as well as a greater than 50% BTE improvement (learn more, 11528482). DTNA downsized its engine from a 15 liter to 11 liter, and has chosen to go with an electrical waste heat recovery system. »»Volvo Trucks: Volvo Trucks North America (company information, 10959413) will be finishing its final SuperTruck design in June 2016. The company has already demonstrated a 48% BTE improvement and a 43% freight efficiency improvement. Using an aluminum frame has allowed Volvo to reduce the weight of the frame by 45%.

power. Electrical Turbo-Compound-

er using a small motor on a turbo spin the turbo.

Through the SuperTruck program,

manufacturers within the heavy-duty trucking industry have had the

opportunity to research various technologies and design techniques for improving vehicle efficiency; many

of these technologies have already

been brought to market or are now closer to being implemented than they might have been otherwise. And because of this, industries

such as the military can immediately use these technologies in their own vehicle designs. Though work may still be necessary to develop the

products for more rugged environments, the groundwork has been

laid to enable faster development

of safe, fuel efficient vehicles for the military.

Visit www.oemoffhighway.com

to read more about the SuperTruck

program and the technologies being investigated in the articles It’s a

bird…it’s a plane…it’s SuperTruck

(search 10602353) and SuperTruck rides towards completion (search 11269209). |

OEM Off-Highway | JANUARY/FEBRUARY 2015

OOH0115_20-23_Supertruck.indd 22

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Preparing Hardware-in-the-Loop Tests Developing and validating tests on the PC

The challenge: Downtimes of the HIL simulator HIL simulators should run around the clock for optimal use. But today they are used to prepare, design, and validate tests, which leads to undesirable downtimes. Add to this overnight tests that are terminated prematurely due to faulty test sequences â&#x20AC;&#x201C; wasting valuable time and delaying projects.

The advantages: Preparing HIL tests with VEOS n Preparing HIL test artifacts such as automated tests, layouts, and model configurations on the PC n Identifying errors in the HIL tests even before execution n Maximizing HIL simulator utilization n Support of the HIL API standard

The idea: Preparing tests on the PC The PC-based simulation platform dSPACE VEOSÂŽ has the same interfaces as a HIL simulator, so you can design and validate test scenarios and layouts for the HIL simulation in advance. In addition, you can develop, parameterize, and test plant models without actually needing a HIL system. VEOS can run automated HIL test simulations to later on avoid termination of the actual HIL tests due to faulty test sequences. Layouts that were previously developed for the HIL system can be reused and adapted to new requirements. Layouts and tests are created once and can be reused across the different development stages to save both time and effort. Frontloading HIL tests yields higher test quality and cuts the total cost of ownership (TCO) by using the HIL simulator more efficiently.

One example: Autonomous parking in a parking garage To test control functions for autonomous parking in a realistic parking garage environment, the entire parking garage including other vehicles has to be modeled and designed. Different parking scenarios with different available parking spaces and borders require individual HIL test scenarios. With VEOS, you can design models, layouts, and tests on the PC in advance and identify the right HIL test for each project. The simulation models can be parameterized early on while the HIL simulator can continue testing. Testing and validating tests before the actual HIL simulation avoids corrections and terminated overnight tests. Would you like to know how to reduce the downtimes of your HIL simulator? We are always glad to help: viva@dspace.com

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OOH0115_20-23_Supertruck.indd 23

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S OF T WA R E: SIMUL AT ION S OF T WA R E www.oemoffhighway.com/12028626

More engineering up front Advancements in simulation software are making it easier for engineers to test and validate designs early on to ensure a more productive and cost-efficient design process. by Sara Jensen

Computer-aided design tools have been in existence for sev-

eral decades. While traditionally they were used to verify single designs, their capabilities and computing

power have increased over the years to simulate and test several design iterations. “The trend in all engi-

neering now is not just to verify the design, [but] to explore the whole

design space,” says Richard LaRoche, & Software Development at DEM

EDEM is a discrete element modeling software which models various types of bulk materials to provide users with the realistic forces exerted on a machine by various materials such as clay, boulders or sand. DEM SOLUTIONS INC.

10958093). “[Engineers] want to be

process to ensure the best possible

very early in the design phase when

an equipment design [and] all the

physical prototype phase. LaRoche

he says. “That’s a trend everywhere,

Ph.D., Vice President of Engineering Solutions (company information,

able to explore all the changes in

different conditions a machine will deal with.”

The use of simulation software has

become integral to a manufactur-

er’s design process. It provides the ability to test and validate numer-

ous design options early on in the

one is chosen before reaching the

says a manufacturer can go through hundreds or thousands of design

[they] can be fixed most effectively,” to have more engineering up front.”

iterations virtually before ever build-

Modeling bulk materials

significant cost and time savings. “It

design is understanding how a piece

ing a prototype, which can provide

allows the equipment manufacturers to uncover issues with the design

An important aspect of equipment of equipment may be affected by

materials it moves or transports. To

OEM Off-Highway | JANUARY/FEBRUARY 2015

OOH0115_24-27_Simulation.indd 24

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Using the GPS simulator to test GPS-enabled devices allows engineers to test their designs in the safety of a laboratory, as well as run scenarios that might not otherwise be possible in a real-world setting. DSPACE

determine this, LaRoche says often

times engineers will create estimates of what the forces would be on the equipment, or else build a physical prototype to measure the actual

load and its effects on the machine. While both are useful methods, he

says they are not beneficial for test-

ing multiple iterations of a design or

the various motions and conditions a piece of equipment may encounter. To make this process easier, DEM

Solutions worked with its long-

time partner ANSYS Inc. (company

WINTER 2014 0˚F CRITICAL LOAD 100˚F

information, 10284948) to bring its

discrete element modeling software known as EDEM into the ANSYS

Workbench FEA tool (learn more,

12007264). EDEM models a variety of bulk materials—such as sand,

sticky soil and boulders—to evaluate how they will interact with a piece of equipment and provides users

with the realistic forces exerted on a machine.

The forces determined by EDEM

are fed directly into ANSYS Workbench which allows engineers to

conduct structural analysis and other evaluations of their designs based

on the provided information. They

can see how various movements or

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OEM Off-Highway | JANUARY/FEBRUARY 2015

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S OF T WA R E: SIMUL AT ION S OF T WA R E www.oemoffhighway.com/12028626

environmental conditions, as well as

systems did not yet exist in the mar-

the company’s GPS simulator can

affect the overall design. If an issue

solutions out there, but there isn’t a

multiple times to ensure consistency

different types of bulk materials, will is found, they can make a change to

the design and run more simulations. Incorporating EDEM into the

ANSYS software means engineers

have a highly integrated solution to

ket. “There are some closed turn-key true platform-based solution that is

open and flexible and user customiz-

able for this type of hardware-in-theloop (HIL) test,” he says.

Advancements in field program-

validate their designs. “People want

mable gate array (FPGA) technology

options; that way [they] also uncover

made it possible for NI to bring this

to explore all the different design

new, innovative designs that they wouldn’t have found otherwise,” says LaRoche.

Designing more effective electronics systems

Increasing use of electronics systems in today’s vehicles has made equipment designs more complicated, requiring more software geared

towards easing the development

of these systems. Ben Black, Ph.D., Market Development Manager at

National Instruments (NI, company

information, 11151299), says the

company introduced its new electric motor simulation toolkit because a

reliable way to test control systems

and motor drives for power

electronic

within the past few years is what

simulation technology to market.

FPGA consists of an algorithm that is compiled and runs physically in

a chip within a piece of hardware.

“It’s incredibly fast, the math is very

debug issues.

Designed in partnership with

Spectrocom Corp., the simulator is able to mimic the exact signals a

GPS-enabled device receives from GPS satellites at any user-defined

location and time, and can be combined with additional information

such as vehicle speed to dynamically produce exact GPS signals.

“Technology in the automotive

the simulation and the IO of the

assistance systems (ADAS), leading

simulation because they’re all on the same chip,” Black explains. He says

this is important because simulations need to be completed orders of

mangitude faster for power electronics and electric motors to accurately simulate the electronic system’s behavior.

The toolkit allows users to perform

real-time simulations of their designs in a virtual environment, reducing

the time and complexity of physical

tests. Black says customers often test

leapfrogging with advanced driver

to fully autonomous vehicles in the near future,” says Warra. However,

testing of these systems has often

been difficult. Though GPS is a key technology for determining the

location of a vehicle, Warra says the inability to dynamically simulate its signal has required it to be tested

using real satellite signals in vehicles on the road which can be costly and unsafe, especially during the development stages of a system.

With the GPS simulator, users can

their prototype system to failure,

test their algorithms and overall

large traction motors for heavy-duty

environment before hitting the

which can be costly. Prototypes of

engineers generally have one shot

to get the test data they need. With the toolkit, however, a

model of the system can be

tested to failure as many times

also makes it easier for engineers to

and commercial vehicle industries is

access between the processing of

half of a million dollars or more; and

NATIONAL INSTRUMENTS INC.

for better quality test results. This

deterministic, and it gives us direct

applications can cost upwards of

FPGA technology in the NI electric motor simulation toolkit enables fast, deterministic simulations of power electronics and electric motors which require faster testing speeds to accurately simulate the electronic system’s behavior.

repeat and reproduce test conditions

as an engineer wants without

having to spend time or money producing a physical prototype.

Using simulation software can also

help improve test data. Jeff Warra,

Technical Specialist at dSPACE (com-

pany information, 10055313), says

system reaction in a laboratory

test track. “This gives the customer confidence in their development

work before going to the field,” says

Warra. “It also cuts testing times and

costs significantly.” Testing in the lab

makes it possible to define other test conditions, such as loss of tracking

and degradation of signals, to ensure the quality and robustness of a

design. “Engineers can define their

test driving maneuvers once in this

environment, and all the test signals are simulated cohesively without

requiring any additional efforts for

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The GPS simulator is able to mimic the exact signals a GPS-enabled device receives from GPS satellites, and can be combined with additional information such as vehicle speed to dynamically produce exact GPS signals. DSPACE

synchronizing various signal sources,” Warra says.

The simulator also allows engi-

neers to test scenarios they would

not otherwise be able to in the real world. For example, they wouldn’t

be able to reduce the transmitting power of one or more global GPS

satellites. Additionally, Warra says

weather, drivers and driving condi-

tions vary too much in the real world

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which hinders the development

of GPS signal algorithms. “Precise repeatability of test conditions is

almost impossible in real-world con-

ditions and that makes an engineer’s job really difficult to debug and verify system behavior,” he says. With the GPS simulator, however, engi-

neers can enter the parameters they want and run numerous simulations to get the information they need.

While prototypes and real-world

testing are still a vital part of the

design process, simulation software

is making it easier for manufacturers

to reach those final stages faster and in a more cost-efficient manner. It

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S OF T WA R E: T E S T ING S OF T WA R E www.oemoffhighway.com/12030116 Kverneland Group engineers have already tried pressure, flow and temperature measurements for hydraulics applications and expect a lot from additional sensor information, such as measuring the hydraulic folding and unfolding of the machinery. KVERNELAND GROUP

Enhance durability through data by Allison Fassin, Communication Manager, Samtech S.A., Digital Factory Division

Software and hardware systems continue to advance and offer engineers more information to use for understanding a vehicleâ&#x20AC;&#x2122;s durability capabilities over the life of the vehicle. 28

Kverneland engineers use LMS SCADAS Recorder, LMS Test. Xpress and LMS Tecware jointly to collect and analyze load data during field and laboratory tests. KVERNELAND GROUP

In the off-road vehicle space, and the agricultural machinery industry in particular, durability is one of the most im-

portant metrics for manufacturers to consider. Farm equipment is used in conditions that vary greatly from market to

market, as well as the degree of roughness at which a farmer operates the machine.

Kverneland Group Kerteminde AS (Kverneland Group)â&#x20AC;&#x201D;an

international farming equipment company that develops,

OEM Off-Highway | JANUARY/FEBRUARY 2015

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produces and distributes machinery

To illustrate the local nature of this

and services for a broad range of

issue, consider the following: crops

balers, sprayers and electronic solu-

Benelux. Clover is denser compared

products including seeders, foragers, tions for tractors and other ag ma-

chines—suspected that the existing

durability testing process resulted in

over-testing designs and was leading to results that were not indicative of the true durability of its products.

To overcome this issue, Kverneland

Group adopted a testing system

consisting of LMS SCADAS Recorder hardware (downloadable product

information, 12030124), LMS Test. Xpress software (downloadable

product information, 12030130) and

are heavier in Ireland than in the

to grass. Some Asian countries harvest sorghum Sudan grass hybrids,

drive at excessive speeds on bumpy field roads, exposing the tractors to severe conditions.

New designs are also influenced

by economic trends. With rising fuel

harvest several times a year. Some

and efficient as possible to reduce

bamboo. Benelux farmers cut and American farmers cut only once a

year. Kverneland Group exports to the United States, France, United Kingdom, Germany, Spain, Italy,

prices, machines need to be as light fuel consumption. Both the weight and size of the equipment need to be optimized.

It is critical that the Kverneland

Japan and Korea, so its equipment

Group have a precise understand-

variety of conditions such as these.

equipment will undergo to succeed

needs to operate effectively under a Experience shows that the great-

est damage can be caused by driving

tion, 10839254). The newly acquired

comfort-

equipment will help engineers

vibration. As a result, farmers tend to

a very thick type of crop almost like

LMS Tecware software from Siemens PLM Software (company informa-

able and less sensitive to noise and

on a road. Modern tractors are more

ing of the lifetime loads its farming at durability engineering. As such, testing teams determine dynamic

loading through physical testing in

the field, on the road and in the lab.

validate different load scenarios and

Collecting more proof points

SCADAS Recorder and LMS Test.

Kverneland Group has received

design realistic lifetime tests. LMS

By using LMS SCADAS Recorder,

Xpress are used jointly to collect

detailed information about load pro-

dynamic load data during field and

files. It increases the company’s

laboratory tests, and LMS Tecware

knowledge of the load history,

is used to streamline the process of

enabling it to reproduce more

consolidating load data and analyz-

realistic load conditions and test

Local demands

used manual testing with five

ing durability characteristics.

according to the majority.

Previously, Kverneland Group

Agricultural machinery typically

or six points (typically strain

must withstand high loads, so

sensors) of reference on its

loads must be measured accurate-

test stand. Now strain gauge

ly. For instance, with every

sensors are placed on up to 30

cut, 50 to 60 kg (110 to 132

measuring points, pro-

pounds) of grass can flow

viding more accurate

through the mower. Two

results. Consequently,

to three metric tons can

Kverneland Group is

flow through the ma-

able to perform:

chine every minute. Many

•

local constraints exacerbate

the need for extensive testing.

Therefore, Kverneland Group is

using Siemens PLM Software testing products to collect more data to

determine a number of possible load profiles.

practical measure-

ments of how equipment

will react to field work and

The LMS SCADAS products cover a wide range of industry applications and are available for every testing job, from pocket-sized data collectors to in-lab solutions. SIEMENS PLM SOFTWARE

road transport,

• measurements of how the equip-

ment will react to standard bumps,

• an evaluation of results, determin-

ing how high the strain was on the

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S OF T WA R E: T E S T ING S OF T WA R E www.oemoffhighway.com/12030116

information about the load history.

The collected data can also be used

as input for finite element modeling (FEM) and fatigue life prediction

using Palmgren-Miner Rule (mea-

suring damage accumulation). Since it’s impractical from a cost and time management perspective to travel

around the world to collect information on every machine, Kverneland Group engineers use LMS Tecware to provide a verified test track or

procedure that matches the customer’s usage.

As software and hardware tools

Siemens PLM Software has launched its LMS SCADAS XS, a portable noise and vibration data acquisition system which combines the productivity and measurement quality of the LMS SCADAS family with the autonomy and flexibility of a pocket-sized solution. SIEMENS equipment,

sured data. The engineers get a com-

are most important, and

in the easiest way.” Engineers are

• an analysis of which sensor signals • a check on values used for accelerated lifetime testing.

Enhanced insight

The Kverneland Group has been

recording time data in the field using the LMS SCADAS Recorder embedded GPS sensor, and its engineers now acquire diverse loading data

from various strain, pressure, flow,

plete overview of the measured data

various conditions, such as mowing

with one side of the machine folded and mowing with unequally sus-

pended machines. They can perform direct measurement of loads to use

in calculations, and use strain gauges and various sensors to measure the

Kverneland Group engineers have

the map using LMS Tecware export

draulics applications and expect a lot

“Our engineers are very happy

with the insight delivered by this

information,” says Jan Vestergaard

Madsen, head of the design department at Kverneland Group. “Over

time, this improved insight will help

define standard profiles to reproduce realistic tests in the lab.”

Henrik Christensen Aarenstrup,

Project Engineer at Kverneland

Group, adds, “It is particularly easy to check values and to find back-mea-

will be able to find new ways to

continuously improve their products using new and more precise infor-

mation gathered in faster and more reliable ways. |

Downloadable Resources: Head online to download product info sheets for Siemens PLM Software products.

effect across a number of factors. already tried pressure, flow and

to the Google Earth feature.

equipment and system engineers

able to accurately measure loads in

position and acceleration sensors.

They are able to visualize events on

and resources continue to advance,

temperature measurements for hy-

from additional sensor information,

such as measuring the hydraulic folding and unfolding of the machinery,

LMS SCADAS Recorder Hardware

www.oemoffhighway. com/12030124

which will provide more insight into

the hydraulic forces on the equipment.

Ultimately, they intend to use loading data as input for fatigue life analysis using finite element analysis (FEA). Meanwhile, engineers continue

to work on improving Kverneland Group’s durability engineering

process, looking to add torque and

LMS Test. Xpress Software

www.oemoffhighway. com/12030130

power requirements and provide full

OEM Off-Highway | JANUARY/FEBRUARY 2015

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Building the future

together

INTERMAT c/o IMEX Management, Inc. Tel: 704.365.0041 - Fax: 704.365.8426 Email: rebeccaj@imexmanagement.com

www.intermatconstruction.com BLOG

#intermatparis

Design: madmac - ÂŠ Lev Kropotov

e x p e r t i s e - i n n o vat i o n - n e t w o r k i n g

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OF F - HIGH WAY HEROE S www.oemoffhighway.com/12022256

The first hydraulic excavators by Thomas Berry, Archivist, HCEA

Using four steam cylinders and no cables or chains, the design eliminated cylinder shock and damage when working at high speed. The very first excavator to use

hydraulic technology was built in

1882 by Sir W. G. Armstrong & Co. in England, where it was used in construction of the Hull docks. Unlike

today’s excavators, water was used to operate the hydraulic functions.

Also, it was not a true hydraulic ma-

The photograph in this advertisement clearly shows the steam cylinder that raised and lowered the dipper stick. The second cylinder, which powered the crowd function, is barely visible inside the boom between the hoist cylinder and the boom tip.

chine, but a hybrid that used cables

DONALD W. FRANTZ COLLECTION, HCEA ARCHIVES

hydraulic cylinder operating a set of

other shovel. Unlike most other shov-

to operate the bucket but with a

range of motion unlike that of any

working parts. The simplicity extend-

multiplying sheaves. The idea was

els, it could crowd horizontally, and

ders were controlled by two levers,

not successful.

The first all-hydraulic excavator,

using only four direct-acting steam

it could manipulate boulders and other obstructions more easily.

All of its movements had equal

cylinders and no cables or chains, was

power; the bucket could be with-

the Kilgore Machine Co. in 1897.

instead of having to pull it up to the

the Direct Acting excavator built by

Kilgore touted several advantages

to the design compared to conven-

tional cable- or chain-operated shovels. It was built almost entirely of

steel, making it sturdy. All motions,

including each end of each cylinder’s stroke, was cushioned, eliminating

ed to its operation. The four cylin-

and the engineer’s hand motion on

each lever was exactly and instantly duplicated at the bucket.

The engineer’s station swung with

drawn from the bank under load,

the dipper, rather than being on the

top to clear the cut. If the shovel de-

shovels. And rather than a trip rope

railed, the full application of power

through all bucket motions could be

deployed to lift it back onto the rails. The dipper could be shaken force-

fully with the cylinders to dislodge

rigid main frame as on other railroad or lever, a foot pedal was used to

dump the bucket. The engineer was able to operate all of the machine’s functions.

Kilgore is known to have produced

material jammed inside it.

two Direct Acting railroad shovels

full stroke at high speed.

cables, sheaves, drums, friction

2-1/2 yards. As advanced as its con-

bucket functions gave the dipper a

its design was very simple with few

shock or damage when working at The use of steam cylinders for all

With the elimination of chains,

clutches, gears and hoisting engines,

with dipper capacities of 1-1/4 and cepts were, Kilgore’s Direct Acting excavators had limited success. |

The Historical Construction Equipment Assn. (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 4,000 members in 25 countries, activities include publication of a quarterly educational magazine, Equipment Echoes; operation of National Construction Equipment Museum and archives in Bowling Green, OH; and hosting an annual working exhibition of restored construction equipment. Individual memberships are $32.00 within the USA and Canada, and $40.00 US elsewhere. HCEA seeks to develop relationships in the equipment manufacturing industry, and offers a college scholarship for engineering students. Information is available at www.hcea.net, by calling 419-352-5616 or e-mailing info@hcea.net.

OEM Off-Highway | JANUARY/FEBRUARY 2015

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C A L END A R OF E V EN T S

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AGRICULTURAL EQUIPMENT TECHNOLOGY CONFERENCE

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April 28-May 1, 2015 | Napa Valley,

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ARPA-E ENERGY INNOVATION SUMMIT Gaylord National Hotel and Convention Center

Feb. 9-11, 2015 | Washington, D.C. www.arpae-summit.com

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February 15-18, 2015 | Denver, CO www.smeannualconference.com

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February 18-21, 2015 | Tuscon, AZ

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SAE NOISE AND VIBRATION CONFERENCE AND EXHIBITION DeVos Place Convention Center

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BAUMA CONEXPO AFRICA Gallagher Convention Center

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Johannesburg, South Africa www.bcafrica.com

MID-AMERICA TRUCKING SHOW

WASTEEXPO

Las Vegas Convention Center

BICES

March 26-28, 2015 | Louisville, KY

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INTEGER EMISSIONS SUMMIT & ADBLUE FORUM EUROPE

April 13-17, 2015 | Hannover,

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Kentucky Expo Center

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INTERMAT

Paris Nord Villepinte Exhibition Center

April 20-25, 2015 | Paris, France en.intermat.fr/

Page #

June 1-4, 2015 | Las Vegas, NV

New Beijing International Sept. 22-25, 2015 | Beijing, China www.e-bices.org

Sheraton Brussels Airport Hotel

BUSWORLD EUROPE

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Oct. 16-21, 2015 | Kortrijk, Belgium

VALVE WORLD AMERICAS EXPO & CONFERENCE

CONEXPO LATIN AMERICA

Kortrijk Xpo

kortrijk.busworld.org

George R. Brown Convention Center July 15-16, 2015 | Houston, TX

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HATZ NEW WATER-COOLED ENGINE IS OVERFLOWING WITH FEATURES! Introducing The Revolutionary H50 Awesome Fuel Economy Most Compact In Class

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Vanguard delivers more Man-hours Per Gallon. By combining closed-loop EFI with the optimum displacement for zero-turn mowing, our 810cc engines can achieve a fuel reduction of up to 25%* versus a carbureted equivalent. That means your customers can do more with every tank of gas. When you consider how many man-hours they can log in a season, the savings could be in the thousands. And thatâ&#x20AC;&#x2122;s some serious coin.

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