ENGINEERING: Operational excellence drives growth for OEMs
26
| Design for excellence
30
JULY/AUGUST 2014 TM
Stretching beyond
TELEMATICS
GPS, the growth in smart systems and
INFORMATION and
gathering
TECHNOLOGIES
through
SENSORS has allowed equipment manufacturers and owners to truly
OPTIMIZE vehicle performance beyond
what was ever though possible. In each OFF-ROAD industry, the
ANALYZED and applied for VEHICLE design and operational EFFICIENCY
inundation of data that can now be gathered, can be a
COMPLEX and overwhelming idea, but OEMs are working to
simplify the concept of BIG DATA by breaking it upw into smaller, easier pieces. 1 6 ENERGY: Charged by the power of the sun
The
2 0 ELECTRIFICATION: A hybrid of intention and collaboration
Issue
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2 4 EMISSIONS: Growing demand for biofuels?
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Syst e m A r ch i t e ct uSryest e m A r ch i t e ct u rRe a p i d C o n t r oRlaPpri o d tCootnytpr oi nl g Pr o t o t yp i n g
E C U A uEtCoUcoAduitnog co d i n g
HH I LI LTeTesting sting
Syst e m A r ch i t e ct uSryest e m A r ch i t e ct u rRe a p i d C o n t r oRlaPpri o d tCootnytpr oi nl g Pr o t o t yp i n g
E C U A uEtCoUcoAduitnog co d i n g
HH I LI LTeTesting sting
Syst e m A r ch i t e ct uSryest e m A r ch i t e ct u rRe a p i d C o n t r oRlaPpri o d tCootnytpr oi nl g Pr o t o t yp i n g
E C U A uEtCoUcoAduitnog co d i n g
HH I LI LTeTesting sting
Syst e m A r ch i t e ct uSryest e m A r ch i t e ct u rRe a p i d C o n t r oRlaPpri o d tCootnytpr oi nl g Pr o t o t yp i n g
E C U A uEtCoUcoAduitnog co d i n g
HH I LI LTeTesting sting
e mA rAcrhciht ei tcetcutruer e SySsyt estm
t rloPl rPortoottoytpyipnign g R aRpaipdi dC oCnotnr o
E CEUC UA uAtuotcoocdoidnign g
Syst e m A r ch i t e ct uSryest e m A r ch i t e ct u rRe a p i d C o n t r oRlaPpri o d tCootnytpr oi nl g Pr o t o t yp i n g
E C U A uEtCoUcoAduitnog co d i n g
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TA B L E OF CON T EN T S: VOLUME 32, NO.5 | JULY/AUGUST 2014
The
www.oemoffhighway.com
Stretching beyond
TELEMATICS
GPS, the growth in smart systems and
gathering
TECHNOLOGIES
through
SENSORS has allowed equipment manufacturers and owners to truly
OPTIMIZE vehicle performance beyond what
was ever though possible. In each OFF-ROAD industry, the inundation of data that can now be gathered,
COVER STORY Electronics
INFORMATION and
Issue
TM
ANALYZED and applied for
VEHICLE design and operational EFFICIENCY can be a COMPLEX and overwhelming idea, but OEMs are working to simplify the
Big Data: What is it, really?
The term ‘Big Data’ has been dropping with increasing frequency in the off-road vehicle industry, but understanding the phrase, its capabilities and its potential is still a work in progress. Search: 11564554
12
concept of BIG DATA by breaking it up into smaller, easier pieces.
FEATURES
16
se of solar-based battery U charging systems in heavy-duty mobile equipment helps reduce fuel consumption and emissions.
Search: 11537977
Electrification | 20
D rivetrains: Hybrid Electric 20 Drive System
20 A destined hybrid of intention and collaboration
20
he mounting acceptance and T rapid advancement of hybrid drive system technology is paving the way for energy and fuel savings that have gone unrealized until late. Search: 11553468
Emissions | 24
Alternative Fuel 24
24 Growing demand for biofuels?
24
4
OEM Off-Highway
dvancing technology could A lead to the increased use of biofuels within the off-highway equipment industry.
Search: 11533774
JULY/AUGUST 2014
Engineering | 26
26 Operational Excellence drives growth for OEMs
hen a manufacturer has W a product that is highly customized with long production cycles measured in days, weeks and months rather than minutes, traditional lean practices must be modified to be leveraged for benefit.
Search: 11317767
Engineering & Manufacturing 30
Engineering | 30
16 Charged by the power of the sun
26 Engineering & Manufacturing
30 Design for excellence
ow manufacturers can reduce H costly design mistakes early on.
Search: 11354344
Technology Breakdown 34
Electrification | 34
Energy | 16
16 Alternative Energy: Solar
oresight into the eventual F need for an emissions-free underground mining utility vehicle caused a seven year waiting game while technology caught up with the idea.
Search: 11553507
34 Patiently waiting
EDITORIAL ADVISORY BOARD
IN EVERY ISSUE Editor’s Notebook:
6 When data ends and Data begins
Craig Callewaert, PE
Chief Project Manager, Compaction
Search: 11564410
Volvo Construction Equipment, Road and Utilities
Economic Outlook:
Jules Carter
8 Firm gains for second quarter
Chief Engineer - Innovation & Hybrids
GKN Land Systems
oemoffhighway.com/economics
Steve Crow
Product Application Engineer Team Leader - Propel
40 Calendar
Sauer-Danfoss Inc.
41 Ad Index
James Grayson
Off-Highway Heroes:
Nissan Industrial Engine Manufacturing, USA, Inc.
42 Swing booms and end booms for tractors
Search: 11490303
Manager, QA, Engineering & Customer Support
Andrew Halonen Sales Engineer
Eck Industries, Inc. H. Len Walton
42
Director of Sales and Marketing
MICO, Inc.
Mike Mackool
VP Sales & Tri-Owner
Torsion Control Products Steven G. Mattson
HEAD TO THE WEB...
www.oemoffhighway.com Online Exclusives
Accumulate power to reduce fuel costs
A hydraulic hybrid system composed of composite accumulators provides greater energy storage and use capabilities for increased fuel savings. Search: 11537648
Market Forecast: Fluid Power
The NFPA’s most recent analysis of the fluid power industry’s shipments and orders for hydraulic and pneumatic components. Search: 11553838
Chief Engineer
GLSV Inc.
Matt Rushing
Director, Product Management, Global Electronics and Global Engines
AGCO Corp.
David N. Slutz President & CEO
Precix
Simone Stier
Promotion and Communication
Liebherr-Components AG Keith Thompson
Program Leader, Off-Highway
Nelson Global Products Charlie Throckmorton Technical Advisor
Sauer-Danfoss Inc. John Treharn
WHAT DOES SEARCH: 12345678 MEAN?
34
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!
Vice President Business Development - Hydraulics Group
Parker Hannifin Corp. Joe Woods
Fluid Power Segment Manager, the Americas
Trelleborg Sealing Solutions Americas
EDI T OR’S NO T EB O OK
by Michelle EauClaire-Kopier
www.oemoffhighway.com/11564410
TM
When data ends and Data begins The title is intentional-
you were not at fault for the accident
difference between data
the red light.
ly confusing. What is the and Big Data? Why are
that occurred when that other guy ran But, how far is too far to be con-
people concerned with
sidered an invasion of privacy? Does
cessibility to some data,
impersonal data trump people’s right
ownership and public acbut not other, and where is that line drawn?
What if your insurance
company could get all
equal treatment of all drivers based on to privacy for how they choose to drive their own vehicle that they purchased with their hard-earned money?
The conversation of data privacy
of your driving stats directly from your
and ownership is a hot topic right now,
going in specific speed zones; how
influx of information readily accessible
car? They know how fast you were
often you have to slam on your brakes; whether a street light was red when
as people start getting used to the to them—and to others.
Here is a scenario in the off-road
you passed through it; and whether
industry: Farmer A and Farmer B are
tune-ups and oil changes. And now,
Should the land owner be able to look
you are taking your car in for regular your insurance rate is based on true, hard data.
Or, what if law enforcement had ac-
cess to that same data and could issue
vying for the same plot of land to rent. at each farmer’s production data to see who would likely get the greatest crop
output and provide the most product? Most say no. If you make that data
speeding tickets based on your speed
public, you take away the farmer’s
you over? There is a fairness benefit to
when you make data public, you
and location without having to pull
that type of system. You are no longer
considered “unlucky” to be the one car out of hundreds caught speeding on
IN THE NEXT ISSUE
your drive home. You can prove that
»» NEW Extreme Machines! »» NEW The Big Picture »» Camera systems »» Joystick and control trends »» Hydraulic filtration »» Technology Breakdown of an advanced hybrid vehicle
+ The NEW Pump &
6
Motor Spec Guide!
OEM Off-Highway
JULY/AUGUST 2014
competitive edge. Others say that
ensure the most utility is being gained from the land for the common good. But it really isn’t that simple; and
neither is the idea of Big Data. The
concept is still being defined and its benefits still being evaluated in the
off-road industry. In the cover story on page 12, we look at how it’s currently being implemented in the construc-
tion, mining and agricultural industries. What does Big Data mean to you,
and the industry you work in? What challenges do you foresee with Big
Data? Email your thoughts to editor@ oemoffhighway.com.
PUBLISHED BY
1233 Janesville Ave., P.O. Box 803 Fort Atkinson, WI 53538-0803 (920) 563-6388 • Fax (920) 563-1700
Reprints and licensing: Please contact Nick Iademarco at Wright’s Media 877-652-5295 ext. 102 or niademarco@ wrightsmedia.com. EDITORIAL Publisher Associate Publisher/ Editor Associate Editor Field Editor Contributing Writers
Sean Dunphy sean.dunphy@cygnus.com Michelle EauClaire-Kopier Editor@OEMOffHighway.com Sara Jensen sara.jensen@cygnus.com Curt Bennink curt.bennink@cygnus.com Frank Manfredi, Thomas Berry
SALES Integrated Media Consultant Sales Associate Inside Sales Representative List Rental
Stacy Roberts (920) 563-1661 stacy.roberts@cygnus.com Jill Draeger (920) 563-1617 jill.draeger@cygnus.com Barb Levin (800) 547-7377 Ext. 1507 barb.levin@cygnus.com Elizabeth Jackson Merit Direct LLC (847) 492-1350, ext. 18
PRODUCTION Art Director Media Production Representative
Yuly Osorio Cindy Rusch (920) 563-1664 cindy.rusch@cygnus.com
CIRCULATION Audience Development Manager
Wendy Chady
CYGNUS BUSINESS MEDIA CEO CFO VP, Human Resources VP, Technology VP, Audience Development
John French Paul Bonaiuto Ed Wood Eric Kammerzelt Julie Nachtigal
CYGNUS PUBLISHING EVP VP, Production Operations VP, Marketing VP, Content Director, Expos
Kris Flitcroft Curt Pordes Debbie George Greg Udelhofen Lisa Nagle
Published and copyrighted 2014 by Cygnus 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 $55 One Year, $100 Two Years; all other countries, payable in U.S. funds, drawn on U.S. bank, $80 One Year, $150 Two Years. Canadian GST #131910168 For change of address or subscription information contact Circulation & Subscriptions, OEM Off-Highway, P.O. Box 3257, Northbrook, IL 60065-3257; Phone: Toll Free 877-382-9187, Local 847-559-7598; Circ.OEMOff-Highway@omeda.com 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 Cygnus Business Media, 1233 Janesville Avenue, Fort Atkinson, WI 53538. Periodicals Postage paid at Fort Atkinson, WI and additional entry offices. POSTMASTER: Send address changes to: OEM Off-Highway, P.O. Box 3257, Northbrook, IL 60065-3257. Printed in the U.S.A. Canada Post PM40612608. Return undeliverable Canadian addresses to: OEM Off-Highway, P.O. Box 25542, London, ON N6C 6B2. Volume 32, NO. 5, JULY/AUGUST 2014
O
L IK
ON FAIR
FI
E
LD
ER
Anniversary
oemoffhighway.com/10056505
ECONOMIC OU T L O OK
Firm gains for second quarter We knew that first quarter
was bad, but the revised GDP
growth estimate of -1.0% firmly reinforced that notion. Fortunately, there are many signs
pointing to better conditions from quarter two onward.
So the plodding expansion remains firmly in place.
The ECB has had enough.
After waiting and waiting for
U.S. Leading Indicator: 䀜䀜 The latest leading indicator report
was quite positive.
䀜䀜 The index rose 0.4 points in April
and the already very strong March estimate was revised upward.
䀜䀜 The strong performance in recent
months is consistent with the economy bouncing back from the weak first quarter.
U.S. Total Industrial Production:
100
98.3%
99.2%
99.2%
99.6%
Sep ’13
Oct
Nov
Dec
Jan ’14
Feb
4.5%
4.5%
Sep
Dec
75
50
25
0
5.00
Annual % change in quarterly averages
Mar
Apr
4.6%
4.5%
Mar ’15
Jun
3.8%
3.75
䀜䀜 Production took a somewhat sur-
prising dip during April; it fell -0.6%.
100.0% 101.0% 101.4%
98.2%
Actual index (2004=100)
www.oemoffhighway.com/economics
3.3%
3.4%
Dec
Mar ’14
2.7%
2.50
䀜䀜 This seems likely to be just a
temporary blip.
䀜䀜 The survey based Purchasing Man-
agers Index reported a relatively healthy manufacturing sector in both April and May.
1.25
0.00
Sep ’13
Jun
conditions to improve in Eu-
rope it has made several strong policy moves designed to fend off deflation and stimulate growth.
Housing Starts: 䀜䀜 Housing continued to gain
ground during April.
䀜䀜 There was a 0.8% gain in
single-family starts that confirmed the strong advance during March.
䀜䀜 While single-family activity has
Go to y.com highwa oemoff ign up for to s thly our monMIC O ECON TER! ET E N WSL
lagged multi-family activity of late, the positive trajectory remains encouraging.
Private Nonresidential New Construction: 䀜䀜 Nonresidential construction
slipped a minimal 0.1% in April.
QUESTIONS? Contact Steven Crane, Senior Economist at C3 Statistical Solutions, at
scrane@c3stats.com.
8
OEM Off-Highway
JULY/AUGUST 2014
䀜䀜 But downward revisions to the
previous months’ estimates occurred once again.
䀜䀜 Construction has now declined
during each of the first four months of 2014.
10
Annual % change in quarterly averages
8.9%
8 6.5%
6 4
3.2%
3.1%
2
2.4%
2.6%
Mar ’15
Jun
1.3%
0 -0.4%
-2
Sep ’13
Dec
Mar ’14
Jun
Sep
Dec
Total Public New Construction:
Construction Machinery, New Orders: 䀜䀜 Real orders dropped 7.2% in April,
䀜䀜 Some retrenchment is due, given
the sustained substantial advance since last October.
25 Annual % change in, 12-Month moving total (1982 Dollars)
17.9%
Mining, Oil & Gas Field Machinery New Orders: 䀜䀜 Orders remained relatively stable
for the second consecutive month.
15
䀜䀜 April real orders were up a
10.7%
modest 1.4%.
10 5.9%
5
䀜䀜 Somewhat softer pricing during
4.8%
April helped sustain order volume.
2.0%
0
-1.0
activity remained only modestly above its post-2008 low.
have been at very high levels by any reasonable historical standard.
20
䀜䀜 In addition, the previously
䀜䀜 Nevertheless, public construction
䀜䀜 Recent monthly order volumes
21.8%
0.5
reported decline in March was revised away.
1.2%
-0.2%
Dec
Mar ’14
Jun
Sep
Dec
Mar ’15
-1.4%
Defense Industry, New Orders: 䀜䀜 Orders surged 32.6% during April. 䀜䀜 This pushed the string of consec-
utive double-digit monthly gains to four.
to be a temporary blip.
䀜䀜 Shipments tumbled again in April,
-2.9%
-4.0
10
Sep ’13
the low points during the late summers of 2012 and 2013.
3.9%
4
3.1%
2.8%
2 0
Heavy-Duty Truck Shipments: 䀜䀜 After a good first quarter, truck
-2 -3.3%
-4 -6
Sep ’13
month’s best since mid-2012 level.
-8.1%
-9.7%
Dec
Mar ’14
Jun
Sep
Dec
Mar ’15
shipments dipped in April; they fell 2.1%.
䀜䀜 Volume was still not far from last
-5.8%
-8
Jun
Jun
䀜䀜 Steady production suggests
steady-to-improving near-term market conditions.
Sep
Dec
Mar ’15
Jun
Annual % change, in 12-Month moving total (2003 Dollars)
8 6 3.9%
4
2.8%
2
2.2%
0 -0.5%
-2
Sep ’13
Dec
Mar ’14
Jun
Sep
-1.1% -2.1%
-2.2%
Dec
5 2.6%
Mar ’15
Jun
2.9%
4.9%
0 -1.0%
-5
-10 -12.2%
-12.3%
-13.5% Annual % change, in 12-Month moving total (1982 Dollars)
-19.9%
-20
Annual % change, in 12-Month moving total (1982 Dollars)
6.4%
Mar ’14
8.8%
spike at the very end of 2012.
䀜䀜 This put real shipments back near
6
Dec
䀜䀜 April orders were the best since the -15
declining 16.2%.
-1.5%
-2.5
Jun
䀜䀜 The modest gain in March proved
8
-0.7%
-0.8%
-4 Sep ’13
2.3%
2.1%
1.7%
Farm Machinery & Equipment Shipments:
-10
Annual % change, in 12-Month moving total (1982 Dollars)
2.0
䀜䀜 April saw a 0.8% gain in public
construction.
essentially reversing the nice gain in March.
3.5
Sep ’13
Dec
Mar ’14
Jun
Sep
Dec
3.4%
3.4%
Mar ’15
Jun
1.3%
1.7%
6 3
2.1%
0 -1.5%
-3 -6 -8.2%
-9 -12 -15
Annual % change, in 12-Month moving total (2003 Dollars)
-12.4%
Sep ’13
Dec
Mar ’14
OEM Off-Highway
Jun
Sep
Dec
Mar ’15
JULY/AUGUST 2014
Jun
9
ECONOMIC OU T L O OK
www.oemoffhighway.com/economics
2.5
䀜䀜 Yet another positive report for the
2.3%
Euro Area Leading Indicator.
to slow, the extended string of consecutive positive moves remains intact.
䀜䀜 This is encouraging for the broader
100
2.2%
2.1%
1.9%
䀜䀜 Rising factory orders in April point to
0.5
5
better industrial performance in the months ahead.
Annual % change in quarterly averages
100.50
100.67
100.81
100.93
101.02
101.08
101.12
-0.5
4.2%
4
-0.4%
Dec
Mar ’14
Jun
Sep
Dec
Mar ’15
䀜䀜 Both overall production and
60
manufacturing production rose 0.4% in April.
40
䀜䀜 This adds to a string of consecutive
positive reports for both measures.
20
䀜䀜 It seems the industrial sector has Oct
Nov
Dec
Jan '14
Feb
Mar
Apr
become a full participant in the British economic recovery.
oemoffhighway.com/10207910
10
䀜䀜 The rebound was less than expected,
and was driven by stronger energy production.
Sep ’13
Sep ’13
lowing a revised 0.6% decline in March.
1.8%
1.5
80
0
䀜䀜 Production rose 0.2% during April, fol-
Annual % change in quarterly averages
0.0
Monthly index
100.31
2.4%
1.0
Euro area; it needs some drive to come from someplace other than Germany.
120
2.5%
2.0
䀜䀜 While the rate of increase has begun
Industrial Production, Germany:
Industrial Production, United Kingdom:
Euro Area Leading Indicator:
OEM Off-Highway
JULY/AUGUST 2014
Jun
3.6%
3.5%
3.3% 3.0%
3
2.5%
2.7%
2 1 0 -0.2%
-1
Sep ’13
Dec
Mar ’14
Jun
Sep
Dec
Mar ’15
Jun
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BIG DATA: What is it, really?
The term ‘Big Data’ has been dropping with increasing frequency in the offroad vehicle industry, but understanding the phrase, its capabilities and its potential is still a work in progress. by Michelle EauClaire-Kopier
You don’t know why you are collect-
ing all of this data yet, but there is a tidal wave of information being compiled
world of understanding and information that is yet to be harnessed.
and collected for when a question is
What it means to agriculture
of that data for finding the answer.
from the Agricultural Research Service
asked that necessitates using some You collect engine data to monitor
temperature and pressure to watch for unfavorable performance indicators.
You know why you are taking the infor-
mation off of the machine and how you will apply that information to monitor,
analyze and diagnose the performance of the engine system.
When you grab every data point
a machine can feed you—like how
often an operator pushes a specific button, something so seemingly
benign—you have not yet formulated
the question to which the information will lend an answer.
Big Data appears to be a sort of
proactive approach to future decisions and deeper analysis of specific trends. It is counter intuitive, in a sense. Big
In February of 2013, scientific leaders (ARS) held a workshop to identify its
But, then again, this may just be a
scratch on the surface of a whole new
12
OEM Off-Highway
JULY/AUGUST 2014
define exactly what Big Data is yet, but we can define what it’s not,” says Lenz. The concept of Big Data was started
azon to show users additional informa-
cally and was being collected at a faster rate. In its workshop summary, Big Data
and Computing, ARS stated,
“Scientists are now generating vast
amounts of high-quality data rapidly and relatively inexpensively. This
fundamental change in the nature of
science is presenting new challenges and demanding new approaches to maximize the value extracted from
these large and complex datasets. This
internet giants such as Google and Amtion of value, such as suggesting related products using behavioral data. Once
other non-internet companies started to see the possibilities with grabbing additional data, the idea of Big Data
spread, but the hopeful potential of all
of this information has yet to be understood. The why is still yet to be figured
out as companies open the flood gates on billions of pieces of information.
“Big Data can grab every piece of
dramatic growth in data volume, vari-
information it can through the CANbus,
as Big Data.”
if you need yet, or how you will use
ety and velocity has come to be known John Deere (company information,
off of machines and store them for Big
of unique environments.
modifications. We may not be able to
high quality data had increased drasti-
tion management as the amount of
better to highlighting the minute
ditions to optimize the circumstances
purposes or product development
in universities and initially applied by
10634462) helps machine owners
differences between very specific con-
are used to working with for diagnostic
changing needs of scientific informa-
Data does not support Big Picture
ideas, but rather seems to correlate
engineering and marketing data we
collect millions of records per month
Data purposes, according to Jim Lenz,
Manager, Enterprise Sensors at the John Deere Technology Innovation Center. “I define Big Data by realizing it is
something different from the typical
information you don’t even know
it. Machines alone have over 1,000
messages per second coming off the
CANbus,” says Lenz. John Deere pulls data off of every machine equipped
with a telematics system roughly every
30 minutes and creates a data record for each 30 minute block.
Lenz has found that the Big Data
chunks of information John Deere is
collecting and storing are not easy to
helped them to see possible correla-
agronomic information like soil moisture
like diagnostics. “We still need engi-
provider or a recent design modification
a plant to adjust the specific amount
use for engineering support of needs neering data from the machine for
that purpose. We are hoping that this Big Data idea will be able to answer
all of our questions, but in reality I’m
searching for a question that Big Data can easily answer for us.
“The big difference between en-
gineering data, for example, and Big
Data, as we see it, is that Big Data has a
difficult time capturing the information’s context,” Lenz says. “Was the machine
attached to the same implement as yesterday? Was dust blowing and clogging the air intake more than usual causing
the machine to run hotter than normal? All of these contextual factors are diffi-
cult to isolate in the sea of data, and it is really important when analyzing data to make sure you are correlating data
tions. For example, a change in a part
to a component that is having repeated issues can now be seen and evaluated more closely, faster.”
The issue of complexity
The ARS conducts research on natural resources and sustainable agricultural
systems at multiple locations characterized by variable agro-climatic condi-
performance and manufacturing. “The
information is coming back to the manufacturer almost right away, no more
waiting for a customer to raise a feature fault to the dealer, and waiting for the dealer to bring any recurring faults to the manufacturer’s attention. We can
track and see when certain messages
are showing up that are related to system faults,” says Lenz.
“To be clear, Big Data still can’t isolate
data in real time to change a machine’s
behavior or output, you aren’t collecting it, you just use it and lose it after the
change is implemented. Now, people want to collect all of it,” says Lenz.
“There are a lot of people in our in-
that have been attempting to create a
can be conducted across several locations and years to better understand and unify the complex interactions
between crop types, soil types, water,
weather, climate and management that produce differing results.
If methods are created that enable
breeding programs with genetic condi-
view into quality issues of a vehicle’s
“At that point, when you are using
opportunities. With Big Data, analysis
implementing the foundation for data
ics system is a faster and more accurate
particular section of field.
dustry, because the process of growing
systems presents both challenges and
the precise and valuable analysis of Big
collection through a machine’s telemat-
of fertilizer or pesticide to spray on a
tions. The high variability of agricultural
gathered within the same context.”
One benefit that has been realized by
or IR sensors to measure the health of
Data, it could also be used to improve
plants has so many variables to consider, model of the process of growing plants.
For example, oil refining has a model for how to make gasoline, lubricating oils, greases, fuel oils, diesel, etc.,” explains
Lenz. “Growing a plant still has a lot of
interactions that are difficult to model, and many people are hoping that Big
Data will provide enough information to build an effective model.
“My farm alone has 350 different
tion variability which produce different
soil types, and between that variability
identify genes in an agronomic context
of individual crops and the unpredict-
agronomic traits. Traditional attempts to have had to limit analysis to loci that produce large effects across several
environments; but, many important
traits are driven by multiple genes with
small effects. The complexity of the analysis required to extrapolate the useful information out of the ‘small effects’
data pool, along with a smaller subset of environments to which the results would apply create an unappealing
and the differences in temperament
ability of weather patterns, it is difficult for the crop to be perfectly uniform. A
vision would be that our combine could self-adjust for this variability. But a
combine is designed to harvest over 30
different types of crops and then would
need a crop model for every single crop and soil type combination the machine may encounter. That’s a lot of models.” Companies like IBM Research are
amount of work for smaller return.
working with OEMs to create precision
typical engineering data can. The mil-
plexity of the data collected that makes
ers make proactive decisions. These de-
amount of information, so the three or
Machine performance metrics and
and diagnose an individual fault like
lions of records of data is an enormous four specific messages normally used to understand a particular fault code can be buried in thousands of other data
points averaged over 30 minutes. But,
Big Data has allowed our engineers to see trends in machine faults and has
It is the significant volume and com-
Big Data so difficult to use effectively. GPS location is already being layered
together to create automated steering
systems for navigating a field. A machine can have over 100 sensors on it to gather information that can be used to modify the machine’s performance, such as
ag models and simulations to help farmcisions are based on predictive information extrapolated from situational data
collected through sensors in the fields to measure temperature, humidity and soil
conditions, as well as field pictures taken from satellites and drones. Coupled with 48 hour weather, a farmer can comfort-
ably make predictions on future actions.
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What it means in construction and mining
But one of the most forward thinking ways Caterpillar is utiliz-
For a corporation as large as Caterpillar Inc. (company infor-
ing the idea of Big Data is with its demand planning team which
you would probably get a lot of different definitions,” says John
built, which models specifically and for what regions of the
mation, 10055175), “if you asked us to define what Big Data is, Thomas, Marketing & Strategy Manager for the Construction
Technology & Solutions group at Caterpillar. “If you talked to our group focused on sales, Big Data would have a lot to do with
analyzes information such as: how many machines are being
world, and what does it mean for parts support and allocation for that specific part of the world?
“Being able to look at a combination of things including
customer relationship management and answering questions
commodities and housing starts on top of our internal
machines do they have?
that are indicators for us to increase or slow down produc-
like, who is your customer; what are they doing; and, what
“It would certainly touch on some information we get from
telematics as far as how the customer is using each machine
and for how many hours.” For the people trying to drive parts and service sales at Caterpillar, information on the number of
hours a machine is being operated, for example, is important in order to see when the next preventative maintenance appoint-
ment should be scheduled and if the machine is producing any
production numbers, we can start to see and identify trends tion rates or shipping rates to specific parts of the world,”
explains Thomas. “Some of that information we are just now working on integrating into our standard processes. It is
certainly not something we are using to its fullest today. We
are working on improving all of this information application with the use of Big Data.”
Some of the early analyses done by Caterpillar’s demand
fault codes that may lead to part repair or replacement needs.
planning team show that for certain parts and machines, there
as a tool to better understand how the machines are being
machine utilization, there can be a several-month lag between
The product development group would describe Big Data
applied and used in the field for consideration in the next
generation of vehicle design. “Which of the dozens of features we can build into our machines are being utilized the most by
our customers? In some cases, it answers questions such as, ‘Are
is a definitive lag indicator. “If we see a decrease or a drop off in that machine usage drop-off and a decrease in sales numbers. So, the challenge for us is determining what that lag is so we can be as responsive as possible,” he says.
“When we think about using Big Data, typically we are fo-
we overbuilding a particular machine?’ ‘Is the way that these
cused on the data that is specifically coming from the machines
our differing vehicle structures don’t have to be as significant
data coupled with Caterpillar’s SOS (scheduled oil sampling)
different machines are being used similar enough that perhaps to reduce manufacturing complexity?’ That doesn’t happen
very often, but that is a question that is asked and evaluated by looking at that data,” Thomas says.
What Caterpillar and other manufacturers are working
towards is building capabilities into their equipment that base
a system’s performance parameters on the current application
combined with related information. For example, machine
provides information from samples of the various fluids collected by the dealer to help determine the health of the machine. Higher than normal levels of certain metals in a fluid can
indicate a particular pump is failing or that a certain component is wearing abnormally.
“There are a lot of pre- and post-shift inspections and weath-
being performed by a machine. And, while it is not an exact
er information, all of which can be combined with general
example, if a dozer is moving forward in first or second gear and
is performing. Caterpillar offers condition monitoring that
science, things can be determined with some certainty; for the ripper is down, it is highly likely the machine is ripping.
“In some cases, this information will be very generalized and
perhaps not as specific as some customers may like. A customer may say, ‘Part of the work we do is fine grading, and we want to make sure we can track that.’ If our definition of the application
machine data to give us a better idea of how the equipment includes five key inputs – SOS; data off of our machines via
Product Link; site information (weather, temperature, altitude); service history; and inspection reports. You can tie customer information on top of that for even more unique analysis.”
Big Data doesn’t necessarily mean only big picture extrapola-
or task is broad and it covers all of grading from rough to fine,
tions or overarching trends, but also helps to take a closer look
it still gives us, from a product development standpoint, an un-
Data to create specific models for each crop and soil combina-
it may be hard for us to separate that out for the customer. But,
derstanding of how the machine is being used in the field,” says Thomas. This information can also give the customer an idea of machine usage for future job estimations based on more
accurate task data like how much time was spent fine grading versus bulk earth moving.
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OEM Off-Highway
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at specific instances. Just as the agricultural industry can use Big tion on the planet to integrate into its equipment for optimized
crop care, a construction equipment manufacturer can evaluate the globe with a microscope, finding regional differences and similarities that can help it to fine tune how it delivers to each market effectively.
“It helps us get a better understanding of the differences
Caterpillar’s user interface, VisionLink, is an easy-to-use dash-
between different regions of the world, beyond demand
board a customer can use with Caterpillar and non-Caterpillar
customers different? Is the utilization different? Is the approach
collected from the Product Link hardware that Caterpillar
planning. Are the machines being used differently? Are the
to how they do their work different? It helps us understand the world better,” confirms Thomas.
“We are cautious, however. A lot of customization and
configurations bring forth a lot of manufacturing and logistics
challenges. We’re not expecting that this data analysis practice will uncover a lot of significant differences that would drastically impact our manufacturing capabilities. We are actually
hoping that it uncovers more commonalities to reduce the high number of existing customizations already out there.”
Benefits beyond the OEM
equipment. VisionLink takes a small subset of the information believes will add the most value to its customers.
The start of something Big
The mining industry is extremely data driven already, according to Fabio Mielli, Mining, Offer Manager at Schneider Electric.
“Mining vehicles are already delivering data continuously on
things like the engine system, fuel usage, load, emissions and
location. At Schneider Electric, we consider Big Data to be the
collection of large data sets that require analytics and processing to manage and deliver actionable insights.”
Some companies are already finding valuable ways to use
From a customer standpoint, the value that can be generated
the data to modify their decision making processes. “The main
of engagement and utilization of the data that the customer is
from this data–like predictive maintenance, performance
is a broad spectrum, and ultimately depends on the amount prepared to do.
The return on investment of using Big Data depends a lot
on the willingness of the customer to invest time in frequent
analysis and also to change processes based on that information. “The amount of value a customer gets who only looks
opportunity resides in what other insights can be extracted and efficiency—and enhanced with contextual data like
shifts, cost and weather. The proper use of Big Data can drive decisions, foresee scenarios or support strategic movements in the industry.”
When an OEM begins to think about Big Data and what
at operation hours to determine maintenance needs is going
it can provide to its customers, the starting point should be
data actively to determine operation and idle times to try and
Mielli. The goal of Big Data is not to inundate the user with lots
to get significantly less ROI than someone who is looking at maximize their fleet utilization,” Thomas says.
“The key thing that we’ve noticed with customers is they
have to be ready to change their processes in order to capture a lot of this value. The more they react to Big Data, the more value it can deliver to them.”
But even Caterpillar is not ready to fully capitalize on Big Data.
First and foremost, it wants to get more of its machines in the
field connected to collect even more data. Right now Caterpillar has over 250,000 connected units across the globe, and while
that may be a good population, more is better, especially if there are certain regions with particularly low connectivity.
Start small with Big Data
For many customers, Big Data is a scary term. It encompasses a
lot, much of which isn’t clearly defined or understood yet, even
understanding the data that is already available, according to
of useless information, but deliver insights that drive decisions. The final objective is to drive productivity decisions.
All Big Data management systems have three major parts:
1. Smart sensors or devices to collect the data from the vehicles; 2. A wireless or wired network to transmit the data; and
3. An IT infrastructure (namely data centers) and analytic soft-
ware able to gather the data, understand it and display it in a
way that makes sense contextually and is of value to the user. Particular attention should be paid to the security and
integrity of the data as it is being transmitted and shared
among different systems. Most importantly, so as not to over-
whelm or overload a user, Big Data should maintain high data
quality to provide information that is of value and can be used to drive decisions.
Mielli believes that the future opportunity for Big Data lies
by data experts in the off-road industry.
with data quality, not quantity. “Data quality will play a huge
great ways to start simply with smaller, more digestible pieces
even inaccurate data. The next step is to cross-reference differ-
Thomas says that though it may be called Big Data, there are
of valuable information that an OEM and its dealers can help
identify for the user. “You don’t have to dive into the deep end
of the data pool to get results. We rarely encourage customers
to try and do it all at once because they often get overwhelmed and lose faith that it can provide ROI,” he says.
role in avoiding an overflow of information from too much or
ent sources of data to deliver insights and decision making that wouldn’t be immediately achieved without co-relating such
information. Basically, put the data in context. When the results of cross-referencing are combined, the users are able to make better business decisions.”
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CHARGED by the power of the sun
Use of solar-based battery charging systems in heavy-duty mobile equipment helps reduce fuel consumption and emissions. by Sara Jensen
Just 30 years ago, the thought of
to the battery system, while a solar
energy was not considered to be a
net get overcharged, which can cause
using solar power to provide vehicle viable option for the transportation industry. At the time it was mainly
used on satellites out in space, and
was so expensive only NASA and the military could afford to use it. “Back
controller ensures the batteries do
damage. The stored energy can be used to power various systems on
the vehicle such as safety lighting, lift gates and telematics systems.
eNow Inc. has developed a so-
then a solar panel cost about 10 times
lar-powered cab climate system (learn
costs, and would be 33% larger in size,”
ship with Bergstrom Inc. (company
more per watt than what [our product] says Sean O’Connor, Sales Channel Manager for Go Power! (company
information, 11336753).
However, various technology
advancements over the years—
including the development of lighter weight solar panels—have enabled solar power to become a reality
more, 10980428) through a partnerinformation, 10056440). An eNow
solar-based auxiliary power unit (APU) powers the Bergstrom NITE no-idle
climate system (product information, 10057834), eliminating the need to idle the engine for cab heating and cooling during rest periods.
for mobile applications through
Panel adjustments
charging systems.
Carmanah, has been providing solar
the creation of solar-based battery Solar panels affixed to the top of
the vehicle collect the sun’s energy. The Go Power! system uses a cable
harness to direct the captured energy
eNow’s solar-based system not only charges batteries via solar panels at the top of the vehicle, but also generates power through sources such as the engine alternator and regnerative braking. ENOW INC.
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OEM Off-Highway
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Go Power!, and its parent company technologies for harsh environments, such as military and
The lightweight, semi-flexible eNow solar panels are less than 1/16th inches thick to provide low overhead clearance and wind drag. ENOW INC.
marine applications, since 1996. The
company knew its technology could
be used in almost any market, but its
solar panels needed to be lighter, thinner, more durable and flexible in order to be used in applications such as the heavy-duty or work truck markets. To
achieve this, Go Power! redesigned its
rigid solar panel—typically composed of tempered glass and an aluminum
Go Power! Solar Flex panels are composed of a flexible polymer that can bend up to 30 degrees for easier mounting. GO POWER!
frame—by combining all of its com-
The flexibility makes them easier to
polymer free of the yellowing and de-
curved ones. According to O’Connor,
ponents into a flexible, UV-resistant
terioration concerns of other plastics. Introduced in early 2014, the Go
Power! Solar Flex solar panels pair the
plastic layer with high-efficiency solar
install on various surfaces, including removing the frame and tempered
glass made the panel 82% lighter than standard tempered glass solar panels. Jeffrey Flath, President and CEO
cells that can bend without break-
of eNow Inc. (company information,
flexibility is added by removing the
lightweight, semi-flexible solar panels
ing (learn more, 11336763). Further aluminum frame to allow the Solar Flex panels (product information,
11336795) to bend up to 30 degrees.
Head to the Web... Learn more about the industry partnerships which are bringing solar power into the mobile equipment industry. Search: 11360206 Cummins Crosspoint chooses Go Power! Solar Flex panels for Climacab Search: 11230978 eNow forms partnership to provide Anthony Liftgates with solar power battery charging system for liftgates Search: 10982609 eNow partnering with Mitsubishi Truck to provide solar powered battery charging systems Search: 11172538 eNow partnership with Hercules Manufacturing providing two new no-idle solar solutions to fleets
11230975), says the company’s
(learn more, 10895574), in combination with the mounting system, weigh less than 0.6 pounds per square foot and
are able to conform to roof contours,
including roof fairings. In addition, the panels are less than 1/16th of an inch thick to provide low overhead clearance and wind drag. “The complete
on-roof subsystem, including electrical junction box, is aerodynamically designed,” he adds.
Due to the reduced weight and
durability of the solar panels now
available, solar-based technology
can be used in just about any mobile equipment application—everything from heavy-duty trucking to agricul-
ture and military. “Basically any application where power is being drawn from a battery, our solution is designed to
replenish that power,” says O’Connor.
Flath adds that eNow’s systems are
adaptable to various transportation applications, and that the main limitation
is the amount of flat space available on a vehicle for mounting the solar panel. He says that while eNow’s focus is
currently on medium- and heavy-duty trucks, buses and military vehicles, it
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can create solutions for custom transportation applications, as well.
Both eNow and Go Power! will work
closely with customers—both OEMs and aftermarket—to integrate their
solar systems into a vehicle. O’Connor
says many customers don’t know how large a load they are pulling from a
battery, which is a significant deter-
mining factor for choosing the right solar system for an application. He
to make sure we can power vehicle systems wherever they are,” he explains.
says it’s also important to know where
Why go solar?
the varying amounts of sun exposure
mobile applications can offer many
the vehicle will be used because of
across North America and the world.
“We size our solar system accordingly
The use of solar-based systems for
benefits. First and foremost are the fuel and emissions savings realized
by taking the power draw of vehicle systems off of the engine. And be-
cause solar systems are often used for power when the engine is off, engine idling is eliminated, allowing fleets
to be compliant with anti-idle laws.
O’Connor adds that these systems are also very quiet, reducing noise levels in the vehicle or at a work site, and
require little maintenance other than
having to occasionally wipe clean the solar panels.
Utilizing solar energy to charge a
vehicle’s batteries ensures that any time the sun is out, the vehicle will
have a constant power supply. The Go
Power! system can also work with other charging systems, such as alternators. Working in tandem with another
charging system means the batteries
can be charged even faster. It can also reduce the amount of work the other
To help reduce fuel use and emissions, Cummins Crosspoint has chosen to use Go Power’s Solar Flex panels (pictured at top of vehicle) to power its cab comfort system, Climacab. GO POWER! oemoffhighway.com/10056097
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Head to the Web...
charging system has to do to charge the batteries, extending its lifespan.
Search: 11538035 White Paper Reducing Fleet Operating Costs Using Solar Powered Idle Reduction Technology
In addition, even when the battery
system is sitting idle, it can be charged
by the solar panels. “Our Solar Flex system is designed to keep the batteries
charged to 100% whether the vehicle’s
running or not,” says O’Connor. He goes on to explain that many people do not
battery. This discharging can deplete
even as it sits idle due to the battery
unable to start even if it has only been
realize there’s a discharge on a battery
the battery and cause the vehicle to be
releasing energy and other electron-
sitting idle for a couple of days. Using a
ic systems pulling power from the
solar-based charging system, however, will help extend the battery’s life by keeping it topped off with energy during day-time operation.
The Go Power! solar-based battery charging system collects and stores energy in the vehicle batteries whenever the sun is out, ensuring the batteries are always fully charged.
Besides absorbing energy from the
sun, the eNow system can also receive power from other sources including
the engine’s alternator, regenerative
braking and shore power. “In certain sit-
GO POWER!
uations such as night time or low light
conditions, alternate power sources can
FLEXIBLE SOLAR MODULES Solar Flex modules can bend up to 30 degrees, are 1/8” thick and made from a durable (marine-grade) material.
augment our solar-based system to ensure the batteries are always charged,” explains Flath.
Despite the many benefits, Flath says
the transportation industry’s hesita-
tion to adopt new technology is one
of the biggest challenges to bringing solar power to mobile applications.
“People want to see proof that
our technology works but are hesitant to be the ones to
adopt the technology and
prove it.” eNow tries to com-
bat this challenge by bringing a
demonstration truck to tradeshows
SOLAR CONTROLLER Prevents batteries from overcharging.
and one-on-one meetings to show
firsthand how the technology works.
Creating partnerships with OEMs and
system providers has also been key (see
sidebar, pg. 17), and will continue to be, in order to help grow the presence of solar power for mobile applications.
Solar ensures a constant charge to the battery bank. During long periods of trailer inactivity, batteries remain topped-up and ready.
To find more news, products and related content for this article, search the 8-digit codes found within the text at www.oemoffhighway.com oemoffhighway.com/10056373
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DR I V E T R A INS: H Y B R ID EL EC T R IC DR I V E S Y S T EM www.oemoffhighway.com/11553468
Ele c t r if ica t ion
A destined hybrid of intention and collaboration The mounting acceptance and rapid advancement of hybrid drive system technology is paving the way for energy and fuel savings that have gone unrealized until late. by Michelle EauClaire-Kopier
Some companies must reeval-
a multi-speed transmission tailored
order to stay the course with the
Moreland, Global Manager of Market
uate their business strategies in
changing tides of technology and
the direction of the industry. Others
are fortunate to have an established foundation which allows them to
capitalize on emergent trends with ease. Such is the case for Oerlikon’s Drive Systems segment (company
information, 11531711), consisting of two distinct brands—Fairfield
and Graziano—that gave way to the development of its hybridpower
for electrified vehicles,” says Greg
ment with electric drive technolo-
& Product Research for Oerlikon
industry’s growing interest in hybrid
Drive Systems. “Graziano’s subsidi-
ary, Vocis Driveline Controls, has the capability to develop the control
logic for these new vehicle designs. What is new for us is that we now
have leveraged our capability across our organization to put together a complete driveline system for off-highway equipment.”
So, two years ago, Oerlikon Drive
electric drivetrain system
Systems began work with collabora-
Oerlikon Fairfield (company informa-
pany information, 10055252) and
announced at CONEXPO 2014.
tion, 10056505) focuses globally on gear and drive products for OEMs.
Oerlikon Graziano (company infor-
mation, 10259533) is a recognized
developer for electric passenger cars and an early manufacturer for twospeed electric drivelines.
“[Graziano] was an early manufac-
turer for two-speed electric drive-
lines, and currently has developed
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OEM Off-Highway
JULY/AUGUST 2014
tive partners Cummins Inc. (com-
gy. While Oerlikon recognized the
and electric drive systems and their expected increase in applications,
the organization had already been developing products that support
these systems. “Research in hybrids and power management systems
is ongoing and is no longer only of interest for passenger vehicles. We believe the application for these
systems in off-highway vehicles will definitely increase during the next few years,” says Moreland.
Versus a standard mechanical
Nidec Corp. (company information,
drivetrain, hybrid electric drivetrain
its hybridpower electric drivetrain
store energy that would otherwise
11531704) on what would become (product information, 11317459).
Intention
The hybridpower program was the outgrowth of a pure research and
development program, along with the company’s historical involve-
technology is able to capture and
go unused, which is the benefit that
has garnered the greatest interest in the off-road community. Once the
energy is harvested, it can be used to lower engine speeds thereby
improving fuel performance, as well as channeled back into the system
The hybrid electric concept technology is designed for a wheel loader, but consists of modular components that can be configured for a broad range of applications.
to address temporary energy
demands in the duty cycle helping the machine to be more energy efficient and responsive.
“Our intention was to develop and
OERLIKON FAIRFIELD
offer a complete hybrid driveline
system incorporating a generator, inverters, motors, final drives, ca-
pacitor, and the control module and software,” says Moreland. However, each of the elements could be tailored for specific applications. “Furthermore, OEMs may only be interested
in certain items,” he ex-
plains. While the complete
system may appeal to smaller OEMs who lack the internal resources to develop a complete hybrid system, larger OEMs may only
be interested in the step-up
generator or inverters, for exam-
ple, and wish to bundle these with
existing intellectual properties they
have developed internally. “We plan to address both needs and provide configurable systems which match
the technology requirements of the individual client,” Moreland says.
The drivetrain technology utilizes a Tier 3 or Tier 4 engine driving a 227 kW switchreluctance generator with step up gearing to produce electrical energy. Alternators and starter motors are eliminated to improve system reliability. OERLIKON FAIRFIELD oemoffhighway.com/10056373
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DR I V E T R A INS: H Y B R ID EL EC T R IC DR I V E S Y S T EM www.oemoffhighway.com/11553468
Ele c t r if ica t ion
Watch and Learn Oerlikon Fairfield brings new technology to IFPE 2014
Dan Phebus, Head of Oerlikon Fairfield’s Business Unit–Americas, talks about the company’s new technology developments at CONEXPO-CON/AGG & IFPE 2014 in Las Vegas, NV. Watch it now at www.oemoffhighway.com/11329858 The concept system that debuted at CONEXPO (event
information, 10207294) was designed specifically for a
wheel loader, though as Moreland previously commented,
the system is designed with modularity in mind in order to
The hybrid system also features a custom software con-
fit each application optimally. A Tier 3 or 4 engine-driven
trol unit provided by UK-based Vocis Driveline Controls;
produces electrical power, allowing alternators and starter
at each wheel end allow for higher motor speeds and
227 kW switch-reluctance generator with step-up gearing motors to be eliminated from the system design to im-
prove overall reliability. Cooled, dual power inverters are
integrated into the front and rear axles, allowing them to function unconstrained by the mechanical driveline and provide simple, clean wiring.
As the application machine gets larger and/or heavier,
and finally, four high power density traction motor drives good performance over a wide ground speed range. The
system eliminates the connection between engine speed and vehicle speed, permitting operation of the engine at
a constant speed that can be selected to achieve best fuel economy.
“There are several manufacturers who have been
there is more opportunity for fuel savings, with severe-
developing technology using different approaches to
for energy reclamation through the system’s regenerative
“These approaches have sometimes included the use of
duty start-and-stop applications holding the most chance braking system. The hybrid electric system uses a 1.2
mega-joule ultra-capacitor bank (with operating temperature range of -40 to 65 C) to store energy developed by the generator or recovered through braking.
“The use of ultra-capacitors in heavy equipment has
been understood and employed in a few select appli-
cations for many years; but, the focus on energy man-
agement has been renewing interest as of late. Creating
opportunities to consider [ultra-capacitor] inclusion into a
the drivetrain and energy management,” says Moreland. batteries, dual generators and electric motors connected to mechanical transmissions in a parallel drive architec-
ture, whereas Oerlikon’s hybridpower system is in a series configuration.” (Read more on the differences between
parallel and series hybrid architecture in Joining Forces, 10166528.)
Throughout the electric drive system’s development
process, Oerlikon’s experienced vehicle electrification
much wider base of equipment can be addressed through our system,” says Moreland.
22
The system uses an ultra-capacitor bank to store energy developed by the generator or recovered through braking.
The system control unit and logic is provided by UKbased Vocis Ltd, a subsidiary of Oerlikon Graziano, Oerlikon Drive Systems Segment.
OERLIKON FAIRFIELD
OERLIKON FAIRFIELD
OEM Off-Highway
JULY/AUGUST 2014
Collaborative engineering is not
The hybrid electric drivetrain features 65 kW reluctance motors to provide constant power over a wide speed range. OERLIKON FAIRFIELD
a new idea (see coverage of col-
laborative engineering from OEM
Off-Highway ’s article, Collaboration and open innovation, 10226643),
but its acceptance with companies is spreading quickly, creating an open
engineers have been overseeing the
dialogue about unique and previ-
ously guarded system properties in order to deliver the fully integrated
systems OEMs continue to demand, rather than individual components. To find more news, products and related content for this article, search the 8-digit codes found within the text at www.oemoffhighway.com
program and are responsible for the
system’s architecture. “They certainly have been driving the program. But, with a complex system, you
need to be aligned with very capa-
ble partners who are willing to col-
laborate and make modifications to
their existing products, if necessary. In that regard, the cross-communication between the firms involved has been extensive and ongoing,” says Moreland.
Side Comments Electric vs. Hydraulic Hybrid Systems?
“There is much activity underway within the off-highway equipment industry experimenting with systems which incorporate many options—hydraulic accumulators, battery technology, capacitors and kinetic energy recovery systems. [Oerlikon] does not believe that any one technology will ‘win out’ over the others as best for all applications. Future vehicle designs will have a choice between competing technologies, and those selected will be the most appropriate for particular vehicle applications and duty cycles.” - Greg Moreland, Global Manager of Market & Product Research for Oerlikon Drive Systems oemoffhighway.com/10056097
OEM Off-Highway
JULY/AUGUST 2014
23
A LT ER N AT I V E F UEL S: BIOF UEL S
Emissions
www.oemoffhighway.com/11533774
Growing demand for BIOFUELS?
Advancing technology could lead to the increased use of biofuels within the off-highway equipment industry. by Joshua David, Associate with Ricardo Strategic Consulting
The use of biofuels dates
the gasoline sold in the U.S. contains
imately 10% of the fuel consumed
the diesel engine itself, which
stations represent approximately 2%
proposed a similar overall quantity of
back to the very beginning of
was built by Rudolph Diesel in
the 1890s using peanut oil as the
fuel. Fast forward 120-some years and biofuels are still used, albeit in a relatively small quantity.
A biofuel is any fuel produced from
living organisms that provides an alternative to non-renewable fossil fuels. The most common biofuels in use
today are ethanol or biodiesels. There
up to 10% ethanol (E10), whereas E85 of the public fueling stations. B20 bio-
diesel blend is rarer with less than 0.5% of public U.S. stations carrying the
fuel. Some states are trying to change
and then B5 in the winter months. In 2013, the annual production
ethanol and 1.8 billion gallons of
els are made from non-food crops or
Gasoline
eration biofuels use algae and quickly growing biomass; and fourth genera-
or second generation types.
Petroleum Fuels
99% of biofuels sold are either first
Replacers
Different to
higher energy yields. Currently
Demand for biofuels in the U.S. has
to help accelerate the development
of biofuel, with the goal of having 36
billion gallons of biofuel blended into transportation fuels by 2022. Most of
24
OEM Off-Highway
JULY/AUGUST 2014
Petroleum Fuels
policy was originally enacted in 2005
Resemble
been stimulated through the “Renewable Fuel Standard” (RFS). The RFS
approximately 90% diesel fueled. emphasis will be placed on biodiesel rather than ethanol for
off-highway applications. Switching costs, maintenance, productivity and fuel prices are all key factors when choosing to use biofuel.
BIOFUEL OPTIONS
agricultural waste (biomass); third gen-
land or bodies of water and produce
From a cumulative power stand-
Therefore, it is likely that greater
sold to be B10 from April to October
biodiesel, which represents approx-
plants which grow on non-agricultural
and newer production processes.
is requiring all transportation diesel
requirements. For example, Minnesota
duced from sugars, starches, oils and
tion biofuels are genetically modified
more in favor of second generation
point, the off-highway market is
of biofuels was 13 billion gallons of
animal fats; second generation biofu-
biofuel, but the distribution has shifted
this by setting their own biodiesel
are currently four generations of bio-
fuels. First generation biofuels are pro-
in the United States. In 2014, the EPA
Ethanol
Fermentation of sugar/starch crops
Diesel Replacers
FAME
Biodiesel made from transesterification of vegetable oils
Alternatives Biogas
Methane created from biomass
Biogas
Created from bio-materials, can be used in fuel cells or ICEs
DME
Produced from the dehydration of methanol. Can be used in diesel and petrol engines.
Methanol
Fermentation of sugar/starch crops
Butanol
Fermentation of sugar/starch crops
HVO
Biodiesel made from hydrogenation of vegetable oils and animal fats
Biodiesel
Biodiesel from pyrolysis of Lignocellulosic material
BTL
Biodiesel created from biomass to liquid process
Algae Fuel
SVO or transesterification into Biodiesel. Carbonhydrate content fermented into ethanol and butanol
Switching costs between running
Fuel cost is a large portion of
biodiesel and diesel are small or
a machine's total operating cost
fundamental engine architecture
ing which fuel is used. Using U.S.
negligible to the end customer. The between the two fuels are identi-
and is very important when selectEnergy Information Administration’s
Studies have shown that B20 and lower blends typically do not show a noticeable power loss to the operator in real world operation. cal, which allows them to be used
(EIA) January 2014 data, diesel was
biodiesel’s chemical properties, some
pared to $3.97 for B20, and $4.28 for
interchangeably. Depending on the components made of nitrile rubber compounds, such as hoses and
gaskets, are susceptible to degrada-
tion. Engines compatible with B100 use
approximately $3.89/gallon com-
B100. While the EIA only publishes
on-highway diesel prices, they should compare favorably on a percentage
basis with off-road diesel, which is
on average 55 cents less expensive. Advances in technology are
working to increase production
output and decrease costs. Until that occurs, biofuel demand will
follow the mandated level stated in the RFS, and will likely see low
adoption rates until a more attractive cost/benefit scenario prevails.
About the author: Joshua David is
an Associate with Ricardo Strategic Consulting (RSC). RSC is active in
the off-highway market and offers a
comprehensive portfolio of management consulting services, addressing high-impact strategic issues and
solving operational problems at every stage of the value chain. For more in-
formation, visit www.ricardo.com/rsc.
compatible materials like Teflon, Nylon and fluorinated plastics. Currently
all major diesel engine manufacturers support the use of B5, and 78%
support the use of B20. A few manufacturers support the use of B100. Compared to diesel, biodiesel
provides improved lubricity, poten-
tially extending engine component life. However, biodiesel is also more
prone to sticking on the cylinder walls
and blowing past the piston rings into the crankcase. Also, in winter months, some fleets located in colder regions had to switch to petroleum-based diesel. This is because biodiesel
has a higher cloud and pour point,
causing it to gel at a higher temperature than conventional diesel fuel. Biodiesel has roughly 8% less
energy content than diesel, which correlates into 5 to 7% less power,
and therefore fuel economy. Studies have shown that B20 and lower blends typically do not show a
noticeable power loss to the operator in real world operation.
oemoffhighway.com/10835480
OEM Off-Highway
JULY/AUGUST 2014
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ENGINEER ING & M A NUFAC T UR ING: P ROJEC T M A N AGEMEN T www.oemoffhighway.com/11317767
Eng ine er ing
Operational Excellence drives growth for OEMs
When a manufacturer has a product that is highly customized with long production cycles measured in days, weeks and months rather than minutes, traditional lean practices must be modified to be leveraged for benefit. Heavy equipment manufacturers typically deal with large, complex, highly engineered products with high work content that is
measured in hours, days, weeks or
even months. These companies are not like automotive manufacturers
that produce a repeatable product in minutes or seconds. Consequently,
Level of Improvement
by Kevin Duggan, Founder of the Institute for Operational Excellence THE STAIRCASE OF
ment industry. The idea is that lean
CONTINUOUS IMPROVEMENT
is not an endless journey without a
destination (as originally taught), but has a destination. And that destination is Operational Excellence.
1
5 Time in Years
10
ward. However, options for applying
Graph 1. Source Citation: Duggan, Kevin J., Design for Operational Excellence: A Breakthrough Strategy for Business Growth (New York, New York: McGrawHill, 2011), 13.
build exist that will not only improve
attacks it, improves it, then sustains the
business growth.
finds the next area to improve, and
applying continuous improvement techniques from the automotive
industry like lean is not straightfor-
lean techniques to heavy equipment efficiency, but also add to top-line
The destination of Operational Excellence
Lean taught practitioners seek out
and eliminate waste through the use
of tools such as 5S, Kaizen, Poka-Yoke (mistake proofing), Total Production
improvement. The organization then
repeats this process endlessly, resulting in a journey that yields incremental
improvements in efficiency year after
year if all goes well. (See Graph 1 for a
visualization of continuous improvement through incremental changes and implementation.)
To arrive at the destination of Op-
erational Excellence, manufacturers follow a process. (See Graph 2 for a
comparative visualization of Opera-
tional Excellence versus Continuous Improvement seen in Graph 1.) The first step is to define clearly where
the improvement is going and what
the organization is trying to achieve so employees at every level know
what their respective work environments would look like when they
arrive. And a practical, hands-on definition is the definition of Operational Excellence, which is when “Each and every employee can see the flow of value to the customer, and fix that flow before it breaks down.”
setup reduction, quality in process,
lean is providing significant gains in
The importance of self-healing flow
tools, an organization finds an area of
performance, as well—in months,
builds highly complex products over
Maintenance (TPM), visual systems,
standard work and more. Using these
the operation that needs improvement,
26
OEM Off-Highway
JULY/AUGUST 2014
However, a new understanding of
productivity and top-line business
not years, even in the heavy equip-
To be successful in an industry that
very long cycle times, it is critical to
understand the application of lean
The eight principles of OpEx
Excellence, the foremost of which is:
or strong leadership or management
concepts that drive Operational
Operational Excellence is not about
eliminating waste. Instead, it is about creating a lean value stream flow
from raw material to the customer. But it is not just any flow; it is a
“self-healing” flow, or flow that can
be fixed without the intervention of
management. This means that the employees in the flow are able to
visually distinguish normal flow from abnormal flow and correct abnormal flow on their own before it becomes catastrophic and disrupts the flow of product to the customer. While traditional lean thinking teaches
that creating flow is a method to eliminate waste, in Operational
Excellence, organizations strive to
create flow simply so they can see
While lean relies on a “change agent”
»»Make abnormal flow visual »»Create standard work for abnormal flow
to drive it, Operational Excellence
»»Have employees in the flow
the design and implementation
»»Perform offense activities
follows a process that provides
methods. Operational Excellence
improve the flow
The first principle – design lean
can be achieved by following eight
value streams – is where heavy equip-
quence, and each principle may have
tional lean techniques to be success-
principles that should be done in semany guidelines within it. In short,
it is a recipe that can be adapted to many different production envi-
ronments, including those faced by heavy equipment manufacturers. The eight basic principles of
Operational Excellence are1:
»»Design lean value streams
»»Make lean value streams flow »»Make flow visual
»»Create standard work for flow
ment manufacturers can modify tradiful in their complex environments. In this step, rather than having a team map out the current state and then
brainstorm or kaizen out waste, which is the typical approach, value stream flow is designed using guidelines.
The eight guidelines for designing
value stream flow are as follows2:
»»Takt: The rate of customer demand »»Finished goods strategy: How the factory will know what to build
when flow stops.
And there is an “acid test” to see
if Operational Excellence has been achieved. It’s simple: just bring a
visitor in to the operation, have them walk through it, and then ask, “Can
you tell if we are on time to our cus-
tomer needs right now?” If the visitor cannot, then the operation has not yet arrived at its destination. THE “JUMP” TO
OPERATIONAL EXCELLENCE Level of Improvement
Operational Excellence
1
5
Time in Years
10
Graph 2. Source Citation: Duggan, Kevin J., Design for Operational Excellence: A Breakthrough Strategy for Business Growth (New York, New York: McGrawHill, 2011), 20. oemoffhighway.com/10856476
OEM Off-Highway
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ENGINEER ING & M A NUFAC T UR ING: P ROJEC T M A N AGEMEN T www.oemoffhighway.com/11317767
next for a given value stream
»»Continuous flow: A method of
production that produces parts in a make-one, move-one fashion
»»FIFO: A method of production
»»Pitch: The management time-
frame, or how often completed parts are taken away from the pacemaker process
that makes parts first in, first out
Adapting design for heavy equipment
between disconnected processes
adapted to address the unique envi-
between disconnected processes
»»Pull: A method of production
where a fixed amount of inven-
tory is held and consumed on an as-needed basis
»»Single point scheduling: The one process in the value stream to
which the production schedule
is issued, identified as where flow stops and pull begins
»»Interval: How long it takes the pacemaker process to cycle
through each part in a given product family
Many of these guidelines can be
ronments of heavy equipment build.
Eng ine er ing
The key is to create the ability to innovate with the customer.
For example, consider the concept of
the operation should produce a case
to create a timeframe so everyone
customer demand. Once established,
“Pitch.” Pitch teaches organizations (not just management) will know if
the flow of the product is on time to customer demand. It is usually done by multiplying takt time by a physi-
cal quantity such as a case pack. For example, the result of multiplying
takt time (say two minutes) by the
pack quantity (say 10 per case) is that
every 20 minutes in order to meet
the material handler would be told
to pick up a case every 20 minutes. If the material handler cannot pick up a case every 20 minutes, there is a problem, and everyone knows it. However, in heavy equipment
build, the application of Pitch in the traditional method simply will not
work. With such long takt times, and
no “case quantity,” it could be days or weeks before the operation knows if
it is on time. Therefore, this guideline would be adapted by modifying it
to inverse pitch, which is used when products have long takt times. With
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28
OEM Off-Highway
JULY/AUGUST 2014
inverse pitch (meaning pitch time
is shorter than takt times) the long
takt time build would be broken up
into four-hour increments. Each four hours, parts would be presented in a kit, each kit taking four hours to
assemble. If a kit is not consumed in
four hours and parts still remain, the operation knows it is not on time, which is the purpose of Pitch.
Another technique for heavy
equipment is creating a “Master
Pitch” by sequencing crane moves.
Similar to a flight leaving an airport
at a preset time, preset times would
be established when the crane would
move heavy parts through the shop –
creating a normal flow for the product
build. By creating and defining normal flow, the operation can also see ab-
normal flow. Once it can see abnormal
flow, the employees working in the
About the author: Kevin J. Dug-
ates, an international training and
advanced lean techniques to achieve
educated and assisted many major
flow can be taught methods to correct
gan is a renowned expert in applying
achieving the destination of Opera-
Operational Excellence and the
it without management intervention – tional Excellence.
The result? Business growth Enabling employees to fix the flow
before it breaks down means management is free to spend its time
working on something very valuable
to future growth, which is to work on
offense, or the activities that grow
author of three books on the subject: Design for Operational Excellence: A Breakthrough Strategy for Business
Growth; Creating Mixed Model Value Streams; and The Office That Grows Your Business – Achieving Operational Excellence in Your Business Processes.
As the Founder of the Institute for
the top line of the business. Offense
Operational Excellence, the leading
new product development, spending
Excellence, and Duggan Associ-
activities might entail working on
more time with Operations upfront in the innovation funnel to better
design products for manufacturability, working more closely with
existing customers and meeting with potential ones, becoming a solution
educational center on Operational
advisory firm, Duggan has formally corporations worldwide over the
past 12 years, including United Technologies Corporation, Caterpillar,
Pratt & Whitney, Singapore Airlines, IDEX Corporation, GKN and Parker Hannifin.
A recognized authority on Op-
erational Excellence, Duggan has
contributed to many publications,
is a frequent speaker at both public and private conferences, and lec-
tures graduate students in business at colleges throughout the U.S.
Footnotes: 1. D uggan, Kevin J., Design for Operational Excellence: A Breakthrough Strategy for Business Growth (New York, New York: McGraw-Hill, 2011), 123. 2. Rother, Mike and John Shook. Learning to See. The Lean Enterprise Institute. Cambridge, MA. 2003.
or service provider rather than a part supplier, or anything else that might
grow the business in either the shortor long-term.
The key is to create the ability to
innovate with the customer. To do this, organizations must first earn that right by delivering product seamlessly to
the customer, with no interruptions. That means the customer places an
order, the operation produces the or-
der, and the order is shipped, without any stress or worries. Factories – even ones producing large products with
high work content and long takt times – run like this for one simple reason:
they were designed to do so using the principles and guidelines of Operational Excellence.
Once this state is achieved, the
organization can then begin to talk
to the customer about how they use
its product and create solutions they want now and in the future. The re-
sult? An operation that is designed to
support the top-line business growth of the company.
oemoffhighway.com/10056076
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ENGINEERING & MANUFACTURING: PRODUCTIVITY AND EFFICIENCY www.oemoffhighway.com/11354344
Engineering
Design for EXCELLENCE by Joe Barkai, Industry Consultant and Analyst
In the course of designing and
manufacturing new products, en-
gineers often make costly mistakes.
change notices (ECN) or engineering change requests (ECR).
ECOs are an excellent gauge of
They do not design functionality as
the product development process
materials that meet reliability re-
defines and implements require-
intended or select components and quirements. They often create prod-
ucts that are difficult to manufacture and service, and, all too often in an
effort to correct these mistakes, they miss schedule and budget targets.
A method to gain an insight into
the frequency, causes and severity of these mistakes is to examine
the changes engineers make to
the design and the manufacturing
maturity: how well the organization ments, follows design guidelines,
sustainability standards. ECOs can be extremely disruptive and resource
intensive, and essentially represent waste that mature organizations strive to eliminate.
The chart (pg. 30) highlights find-
ECOs generated by an industrial
tion, tools and processes.
The analysis suggests that prevent-
of all ECOs. A similar analysis of data turer estimated that a little over 80% of the ECOs were caused by pre-
ventable errors. To put this point in
perspective, an industrial equipment manufacturer estimates its annual
labor cost of researching and imple-
menting ECOs at $40M. (See Figure 1
for a breakdown of ECO.)
There are several reasons why
over the course of three months. The
designers make such patently
preventable errors and those that are
and manufacturing organizations are
chart groups ECOs that resulted from
obvious mistakes. Most engineering
under constant pressure to accelerate the time to market of new inno-
80%
Assembly Issues
vative products, improve product
quality and reduce manufacturing
costs, while R&D budgets continue to shrink and resources are scarce.
60%
Costing Issue Error Discovered During Simulation/Prototyping
40%
Error: Geometry, Drawing, BOM Manufacturability
20%
Mistake Proofing Production Line Problems
0
Supplier Capabilities
OTHER ISSUES
30
reasonable use of existing informa-
from a heavy equipment manufac-
equipment manufacturing company
sometimes also called engineering
could have been eliminated through
and complies with quality and
production commences. These
engineering change orders (ECOs),
“Preventable” ECOs are those that
able ECOs account for nearly 70%
manufacturability best practices,
ings from the analysis of over 2,000
changes are typically recorded as
be avoided easily and completely.
understands and implements
process during the early phases of
the product lifecycle, before volume
inherent to the process and cannot
OEM Off-Highway
PREVENTABLE Figure 1: ECO breakdown
JULY/AUGUST 2014
Under these conditions, it is easy
to see how “obvious” mistakes are
being made repeatedly and very little is invested to stem them by eliminating their root causes. Furthermore,
research shows that many ECOs are the result of poor adherence to es-
tablished best practices, nonconformance with downstream guidelines and resources, and just overzealous
engineering, all issues that should be reasonably easy to thwart.
These pressures on industry will
not ease any time soon; quite the
Continental Smart NOx Sensor: Figure 2: Design Validation Workbench GEOMETRIC GLOBAL
opposite. Increasing competitive
in the design. However, because
design complexity and the applica-
are typically implemented as a lin-
pressures will continue to drive up
product development processes
tion of new material and processes,
ear forward-feeding process, they
and mandates to accelerate innova-
tion and time to market. At the same time, the aging of the experienced workforce is resulting in gradual
manufacturing knowledge that is not
easily replaceable by the tepid supply of well-educated yet inexperienced engineers.
design met the thermal dissipation
ufacturing and in the field. Good
manufacturing errors. Studies show
product lifecycle management
five key areas in which successful
Advanced, stand-alone, multifunctional sensor helps manufacturers meet regulations for vehicle emissions and reduced fuel consumption. Measures exhaust gas NOx and the air/fuel-ratio in diesel and gas engines. Features SAE J1939 CAN-Bus interface to transmit NOx, binary and linearλ output to ECU. Operates independently of catalyst, ECU and engine management – no adaptation necessary. Fully integrated electronics.
practices bring all requirements
companies excel:
and constraints, which can often
»»Frontload Decisions. This is old
be in conflict with one another,
has ever been, yet many do not fol-
be evaluated and optimized early
Simulation showed that the new
from high rate of breakage in man-
occurrences of costly design and
and product end-of-life should
was redesigned to improve airflow.
However, the new design suffered
taking proactive steps to reduce the
facturability, supply chain, service
enclosure of an electronic module
was released to manufacturing.
some manufacturing companies are
considerations, including manu-
manufacturability and maintain-
requirements and the new design
Recognizing these challenges,
low it. All product lifecycle related
downstream activities, such as
ability. In one study, the plastic
attrition in practical design and
advice that is still as relevant as it
delay critical decisions concerning
The intelligent solution for a friendlier environment.
and address them holistically to reach an optimal solution.
»»Standardize Designs and
Processes; Maximize Reuse.
One of the bigger challenges
encountered in many companies
For more information: 800-564-5066
is the insatiable urge to innovate, oemoffhighway.com/10281230
OEM Off-Highway
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ENGINEERING & MANUFACTURING: PRODUCTIVITY AND EFFICIENCY www.oemoffhighway.com/11354344
Engineering
to come up with new designs,
standardize design elements and
ence, although many do not make
are all important traits in today’s
they can accelerate the learning
apply. Mature organizations recog-
to do things differently. These
manufacturing processes so that
competitive economy. At the
curve and reduce potential risks.
»»Implement Best Practices. This
same time, smart companies
are careful not to innovate for
is easy advice to follow, yet not
innovation's sake. When practical,
many do. Organizations amass vast
these companies make sure to
amounts of knowledge and experi-
this knowledge easy to find and
nize that a culture to generate and use best practices has a significant impact on reducing unnecessary
design and manufacturing errors
and avoid repeating the mistakes of the past. And when errors do
occur, they can be identified and corrected swiftly, and the new
knowledge is incorporated into the corporate knowledgebase.
Integrated PowerTrain Solutions
FROM POWER SOURCE Couplings
Clutches
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TO POWER APPLIED Brakes
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Wheels
GKN Land Systems is a global leading supplier of technology differentiated power management solutions and services. We design, manufacture and supply products and services for agricultural, construction, mining and utility machinery offering integrated PowerTrain solutions.
WHAT WE DO:
[O]rganizations are under $ constant pressure to accelerate the time to market... while R&D budgets continue to shrink...
As a leading partner in the off highway industry GKN Land Systems works closely with Global Original Equipment Manufacturers to meet the needs of the ever changing and demanding operating environment. Extensive R & D in increasingly intelligent and integrated engineering solutions ensures that we supply products that are efficient, enable increased productivity of machinery and take into consideration requirements for lighter weight and increased payloads. At GKN Land Systems we engineer an extensive range of products and systems:
complexity and multidisciplinary nature of product design today
demands the use of a number of design and analysis tools to help
Coupling & Driveshafts
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Clutches & Brakes
eDrive and Hybrid Systems
Integrated Drive Systems
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product engineers assess the
Sensors & Controls ..... and offer customized solutions, an expanding global footprint, trusted products, services and people.
design from multiple perspectives simultaneously: functionality,
cost, reliability, manufacturability, serviceability and others. These
should be synthesized into a single
Further information can be found at www.gkn.com/landsystems
ENGINEERING
»»Unify Methods and Tools. The
decision-making framework to
THAT MOVES ENGINEERING THE WORLD
create a complete, accurate and
up-to-date context for better de-
sign trade-off decisions, identifying oemoffhighway.com/10110734
32
OEM Off-Highway
JULY/AUGUST 2014
opportunities for design reuse, applying best practices, and improving engineering productivity.
»» Maximize Communication and
Collaboration. The use of multiple engineering and manufacturing disciplines, and the increasingly
elongated and often fragmented design and supply chains strain
About the author: Joe Barkai is
an industry consultant and analyst, specializing in product lifecycle
management and the application
of advanced information technol-
ogy tools and methods to improve
product development practices. He
advises manufacturers, engineering
companies and software vendors on engineering and manufacturing
innovation, and comments regularly on industry events in his blog www.JoeBarkai.com.
Contact him at 781-864-9011 or
jbarkai@outlook.com.
product companies. Effective
collaboration in product design,
manufacturing and quality man-
agement are critical. Here, again,
a unified framework for encapsulating best practices, both formal and informal, can help to create
an effective and agile design and manufacturing environment.
Studies of manufacturing compa-
nies that implement a formal work-
bench to maximize the application of best practices in design and manufacturing through design rules and automatic design validation show significant process improvement.
Figure 2 shows a typical workbench view of a sheet metal design with
potential manufacturability prob-
lems highlighted, including relative
placement of cutouts and holes and incorrect bend radii. Typical savings
these companies experience include: »»10 to 20% overall
productivity improvement
»»7 to 15% reduction in rework »»3 to 9% savings in tooling
»»1 to 3% reduction in waste »»1 to 2% reduction in warranty expenses
Manufacturers should pursue a
deliberate and consistent Design for Excellence strategy to reduce the
impact of disruptive and resource
consuming design mistakes by implementing formal methods and tools to validate design and manufacturing procedures early in the lifecycle.
oemoffhighway.com/10056320
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T ECHNOL O G Y B R E A K D O W N www.oemoffhighway.com/11553507
Ele c t r if ica t ion
Patiently waiting
Foresight into the eventual need for an emissions-free underground mining utility vehicle caused a seven year waiting game while technology caught up with the idea. by Michelle EauClaire-Kopier
There can be a downside to being a forward thinker,
industry. Its existing UT99C utility truck was the logical
with your vision. Back in 2004, Industrial Fabrication Inc. of
tering into development of a new vehicle, restrictions and
namely waiting around for the rest of the world to catch up Sudbury, Canada (company information, 11553841), saw the eventual need for an emissions-free mining utility vehicle,
and by 2011 the necessary technology had matured enough for its engineering team to finally pursue the endeavor.
“In 2011, we decided to create the first battery-electric
vehicle purpose-built for the environment in a hard rock
mine,” says Dave Schmidt, Engineering Manager for Industri-
al Fabrication. “The result is the [UT150-eMV] we have today.” The development of the electric vehicle was based on
Industrial Fabrication’s experience and knowledge of the
requirements of underground utility vehicles in the mining
34
OEM Off-Highway
JULY/AUGUST 2014
platform to base its emissions-free vehicle on. When en-
limitations of the industry must still be taken into consideration, such as cost and performance. “The cost pres-
sures on mining utility vehicles are chiefly purchase price,
operating cost (maintenance and fuel), and ventilation re-
quirements,” says Schmidt. “We believe the time has come
when the electric drive system provides enough benefits
designed for the UT150. The electric drive system (EDS) is
outweigh the increase in purchase price. In addition, every
and uses high voltage for efficiency.
by reducing maintenance, fuel and ventilation costs to
passing year brings more focus to reducing emissions and
fully-electric with on-board charging, regenerative braking The motor’s liquid cooling system ensures the motor will
increasing operator health and safety.�
not overheat or be subjected to dust and debris compromis-
The vehicle breakdown
motors force air over copper windings which expose them
It was learned early on that existing off-the-shelf compo-
nents would not meet the performance requirements of the modern mining world, so custom-built components were
necessary to make the vehicle a reality. The technologies developed are scalable, allowing drive systems to be tailored for different applications.
The rugged frame from the UT99C needed minor design
modifications to accommodate the changes made to the powertrain which included removing the diesel engine, as well as the four-speed transmis-
sion and torque converter. The diesel engine was replaced by a 150 kW
ing its performance when clogged in an air vent. Air-cooled
to the harsh environments in which mining vehicles operate. The liquid-cooled motor design also allowed it to be more compact and lighter while delivering higher power than a comparable air-cooled system. The motor can also be
submerged or splashed with water without issue. The motor is directly coupled to an industrial two-speed transfer case
to deliver power efficiently to the axles. The Minecat UT150eMV has been ramp test certified and has a fully enclosed SAHR wet braking system at each axle.
The electric motor is powered by a system of batteries
that fits entirely under the hood, so no cargo space is lost.
brushless, permanent magnet AC electric drive motor that was specifically
The UT150-eMV was built to suit the rugged needs of an underground mine. INDUSTRIAL FABRICATION INC. oemoffhighway.com/11576344
OEM Off-Highway
JULY/AUGUST 2014
35
T ECHNOL O G Y B R E A K D O W N www.oemoffhighway.com/11553507
Ele c t r if ica t ion
The system is scalable to suit the particular needs of a
is important,” says Schmidt. “We have a large library of
pack capacity is changed by simply adding or removing
part of our eMV electric line. These configurations have
mine and has a projected life span of 10 years. The battery modules, and the cells are 100% recyclable.
The final key component to complete the electric drive
system is the on-board battery charger, which can operate in a variety of configurations, including 220V single phase; 208V three phase; and 600V three phase for the quickest
charging option. Since the charger is always with the vehicle, multiple charge points can be distributed throughout the mine.
proven machine configurations which are all available as been developed for our underground customers over the years by responding to their specific needs. We wanted the weight to be as close to the weight of the diesel as
possible, and we surpassed that goal, ending up with the UT150-eMV 40 kg lighter than the diesel counterpart.”
The electric drivetrain was developed in conjunction
with a North American partner with specific expertise in
electric drivetrain systems. “Our baseline surface testing,
combined with the data collected at underground mining
Testing the first prototype
During the development of the Minecat UT150-eMV
design, several additional benefits were achieved beyond the zero-emissions goal. For example, the EDS has over
1,000 fewer parts than the diesel system it replaced; and
fewer parts equals fewer opportunities for failed systems and service needs.
The vehicle design also placed the battery system under
the hood so as not to impact the rear cargo area. “This
Specify CROSS Fluid Power…
operations in Sudbury, provided the benchmark data to
design the EDS,” Schmidt says. The data was collected on a diesel UT99, the same mine-proven platform the 150-eMV utilizes. “The data we collected is unique in the industry
and may be the only data of its kind in the world. We fur-
ther mitigated our risk by partnering with energy simula-
tion specialists at the top of their field to analyze the data. These partners have high profile clients such as General Motors, and the U.S. Department of Energy.
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OEM Off-Highway
JULY/AUGUST 2014
Introducing LORD MicroStrain’s new IEPE-Link™-LXRS® Wireless Vibration Monitoring Node ∙ Burst sampling up to 104kHz ∙ Accurate node-to-node synchronization ∙ Interoperable with other LORD MicroStrain nodes ∙ Programmable low-pass filter ∙ Universal 2.4GHz radio using 14 channels ∙ 24-bit analog to digital converter Ideal for long-term machine health monitoring, modal and structural analysis, flight testing, and crash/impact testing
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A side-by-side comparison between the UT150-eMV (on left) and the UT99C (on right) demonstrates just how similar the vehicles are on the outside and how different they are under the hood, all within the same footprint. INDUSTRIAL FABRICATION INC.
“The prototype ran for thousands of kilometers of surface
and underground mine testing. We have tested in very cold
conditions, hot temperatures, high humidity, wet conditions and dusty environments. The prototype has exceeded our
in mine power. The production models now incorporate
all the changes made to the first UT150-eMV, as well as a 40% improvement in the maximum available torque.”
On the outside, the UT150-eMV looks very much like its
expectations with regards to reliability and performance.
UT99C predecessor. But on the inside, this emissions-free
that the duty cycles of utility type vehicles vary widely
ground mining operations. In the end, Industrial Fabrica-
“During our underground testing phase, we determined
according to their intended function. We are able to tailor
our scaleable drive system for the maximum benefit of the end-user. During testing we tuned the EDS programming
for maximum range and performance, and made improvements to the charging system to accept greater variations
oemoffhighway.com/10055148
vehicle provides a quieter, safer environment in under-
tion’s team of inspired engineers was patient to ensure the vehicle they envisioned was created to the best of their
ability and with the capabilities demanded by a demanding industry.
oemoffhighway.com/10056179
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37
oemoffhighway.com/ 10457260
October 7-9, 2014
Engineering Leadership – Changing, Guiding, Influencing
SAE 2014 COMMERCIAL VEHICLE ENGINEERING CONGRESS ON-HIGHWAY OFF-HIGHWAY DEFENSE
Donald E. Stephens Convention Center Rosemont, Illinois USA
2014 EXECUTIVE PANEL DISCUSSIONS: • Blue Ribbon Panel: Engineers as Leaders • Math to Lab to Road • Efficiently Engineering for Global Markets
NEW for 2014: • Enjoy MORE technical sessions on a variety of hot topics • Young Professional Activities and Programs engage all levels of engineers • Chat with the Experts enhances technical understanding and facilitates interactive problem solving in an informal environment
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C A L END A R OF E V EN T S www.oemoffhighway.com/events
2014 PROFESSIONAL EDUCATION SEMINAR-SERVICE AND OPERATION FOR IMPROVED HYDRAULIC SYSTEMS RELIABILITY Milwaukee School of Engineering
August 8-15, 2014 | Milwaukee, WI www.msoe.edu
NFPA INDUSTRY ECONOMIC AND OUTLOOK CONFERENCE Westin Chicago North Shore
August 11-13, 2014 | Wheeling, IL nfpaevents.com/ieoc/
APAC OFF HIGHWAY VEHICLES INNOVATION & AFTERMARKET SUMMIT
THE BATTERY SHOW
Suburban Collection Showplace
September 16-18, 2014 | Novi, MI www.thebatteryshow.com/
ELECTRIC & HYBRID VEHICLE TECHNOLOGY EXPO Suburban Collection Showplace
September 16-18, 2014 | Novi, MI www.evtechexpo.com/
NTEA NEW MODEL TRUCK PRODUCT CONFERENCE Adoba Hotel Dearborn/Detroit
Sept. 16-18, 2014 | Dearborn, MI www.ntea.com
August 21-22, 2014 | Beijing, China
NORTH AMERICAN INTERNATIONAL POWERTRAIN CONFERENCE
ohv2014/
September 17-19, 2014 | Chicago, IL
BOYUE Beijing Hotel
ohv05.greenlinkgrouphk.com/
www.sae.org/events/naipc/
THE GREAT AMERICAN TRUCKING SHOW
HTUF NATIONAL MEETING
Dallas Convention Center
August 21-23, 2014 | Dallas, TX www.gatsonline.com/
LAKE STATES LOGGING CONGRESS AND EQUIPMENT EXPO EAA Grounds
September 5-6, 2014 | Oshkosh, WI timberpa.com
Tampa Convention Center
September 8-12, 2014 | Tampa, FL www.ion.org/gnss/
Sept. 22-24, 2014 | Argonne, IL www.htuf2014.org/
ALGAE BIOMASS SUMMIT
San Diego Marriott Marquis & Marina
Sept. 29-Oct. 2, 2014 | San Diego, CA www.algaebiomasssummit.org/
HIGH HORSEPOWER (HHP) SUMMIT
Oct. 7-9, 2014 | New Orleans, LA www.hhpsummit.com/
SAE COMMERCIAL VEHICLE ENGINEERING CONGRESS
FTR TRANSPORTATION CONFERENCE
Crowne Plaza Hotel Downtown at Sept. 9-11, 2014 | Indianapolis, IN www.ftrconference.com
Argonne National Laboratory
Earnest N. Morial Convention Center
ION GNSS+
Union Station
Westin Chicago River North Hotel
Donald E. Stephens Convention Center
October 7-9, 2014 | Rosemont, IL www.sae.org/events/cve/
oemoffhighway.com/10055853.
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OEM Off-Highway
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A D V ER T ISER S’ INDE X www.oemoffhighway.com
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Almo Manifold & Tool Company............................................. 41 The Battery Show.......................................................................... 43 C.E. Niehoff & Co............................................................................ 37 CLEANFIX North America Ltd................................................... 41 Continental Corp........................................................................... 31 Cross Mfg., Inc.................................................................................36 dSPACE................................................................................................. 3 EZ Oil Drain...................................................................................... 41 GKN Land Systems........................................................................ 32 Hatz Diesel of America, Inc.......................................................... 2 HHP Summit....................................................................................38 John Deere Power Systems.......................................... 17, 19, 21 Litens Automotive Group........................................................... 27 LORD MicroStrain Sensing Systems.......................................36 Master Bond Inc............................................................................. 41 Murphy by Enovation Controls................................................ 11 North American Hydraulics Inc................................................40 Oerlikon Fairfield............................................................................. 7 SAE 2014 Commercial Vehicle Engineering Congress................................................................. 39 Scania USA........................................................................................ 10 Separ Filter....................................................................................... 29 Shaw Development...................................................................... 28 SKF USA, Inc.............................................................................. 18, 23 SuperBrightLEDs.com..................................................................25 Thermal Control Products.......................................................... 35 Thermal Transfer Products Ltd................................................. 37 WPT Power Corp............................................................................ 33 Yanmar America Corp..................................................................44
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41
OF F - HIGH WAY HEROE S www.oemoffhighway.com/11490303
Swing booms and end booms for tractors
Swing booms saw much use by the Armed Forces in World War II, but were not designed for picking, carrying and placing long sections of pipe for civilian use. by Thomas Berry, Archivist, Historical Construction Equipment Assn.
Along with sidebooms (read the
eral utility work. Swing booms saw
tractor-mounted cranes were de-
World War II, and one such crane—
article Sidebooms, 11429429), other
veloped starting in the 1920s to add
the capability to lift and carry a load to a tractor’s mobility, be it crawlers on rough terrain, or the industrial
wheel tractor over pavement and in
much use by the Armed Forces in
the so-called “Anteater” built by Austin-Western as a munitions handler
for the U. S. Navy—was the ancestor of today’s hydraulic cranes.
Many military surplus swing
industrial settings.
booms were resold into the civilian
a full 360 degrees from a pivot atop
handy machines for general lifting
Swing booms that rotated nearly
the tractor were marketed for gen-
market after the war; while they were needs such as placing short sections
of pipe, their designs rendered them unsuitable for picking, carrying and placing long strands of pipe.
End-mounted booms were also
available. Unlike the side or swing
boom, some end booms, such as the Hyster Hystaway, were fully convertible and could be used as shovels,
backhoes, draglines or cranes. They
were also available for larger tractors for which swing booms are not
One of the most recent machines to be offered with a swing boom was the Long 5N1 loader/backhoe. The model nomenclature was a reference to five functions in one machine. LONG MANUFACTURING NC INC. BROCHURE, 1976, HCEA ARCHIVES
known to have been available. While those with excavator
capabilities could help in a limited
capacity with the trench work, they
The problems involved in placing pipe with an end boom are illustrated by this rather crude rig, designed by R. G. LeTourneau for a Cat Sixty and used by his construction company on the grading contract for Southern Pacific Railroad’s Carquinez Bridge approach in Benicia, CA, in 1929. Ballasted by sandbags, it provided ample capacity for a single section of pipe, but was unable to carry long strands along the trench. R.G. LETOURNEAU IMAGE, COURTESY OF ERIC C. ORLEMANN
for crawler tractors evolved into
purpose-built pipelayers, no such
evolution apparently took place with the end boom or swing boom.
End booms and, for the most part,
faced the same problem as the
swing booms have been obsolete for
Where the sideboom attachment
continue to be manufactured.
swing booms in pipeline placement.
years, but sidebooms and pipelayers
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 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.
42
OEM Off-Highway JULY/AUGUST 2014
Detroit | Michigan | USA
Co-located with
September 16-18, 2014
*
OVER
ATTENDEES THE BATTERY SHOW ATTENDEES BY JOB FUNCTION (%)
350 OVER
*
EXHIBITORS
TECHNICAL/ENGINEERING BUSINESS DEVELOPMENT/SALES
Information based on 2013 event *Projected 2014 statistics
CEO/PRESIDENT/MD RESEARCH & DEVELOPMENT MARKETING OTHER
This is our third year and so far it’s been excellent. Already in this show we’ve surpassed our number from all three days of last year and we’re not through Day 2!” CHADWICK R. TAYLOR, TE CONNECTIVITY
CONSULTANT PURCHASING FINANCE ACADEMIC GOVERNMENT
What I found most useful is the structure of the conferences; they’re very engaging and very diverse. In addition to the trade show floor which is getting much better participation than I had hoped for and it’s drawing in a lot of my colleagues”. OLIVER GROSS, ENERGY STORAGE SYSTEMS SPECIALIST, ENERGY STORAGE AND HV SYSTEMS, CHRYSLER GROUP LLC
32
I E SD R T N TE
U CO PRESEN RE
REGISTER NOW FOR YOUR FREE PASS www.thebatteryshow.com
www.evtechexpo.com
THIS IS
THE FUTURE. YANMAR FINAL TIER IV ENGINES ARE EPA CERTIFIED
AND ARE DESIGNED WITH THE FUTURE IN MIND. In an era of changing emission regulations, YANMAR’s EPA certified Final Tier IV solution offers customers, quite possibly, the cleanest engine on the market. If you don’t power with
YANMAR, what do you tell your customers?
EASTERN REGION:
McDonald Equipment Company Willoughby, OH / 440.951.8222 www.mcdonaldequipment.com
Industrial Irrigation Services Hastings, NE / 800.289.6478 www.industrial-irrigation.com
Wolter Power Systems Brookfield, WI / 262.790.6230 www.wolterps.com
Northstar Power LLC Ankeny, IA / 515.964.6100 www.northstarpowerllc.com
CENTRAL REGION:
WESTERN REGION:
Martin Diesel, Inc. Defiance, OH / 866.868.9911 www.martindiesel.com
C&B Equipment Wichita, KS / 800.362.3222 www.candbwichita.com
Cascade Engine Center Seattle, WA / 800.238.3850 www.cascadeengine.com
Mastry Engine Center St. Petersburg, FL / 800.545.4574 www.mastry.com
engines, inc. Jonesboro, AR / 870.268.3911 www.enginespower.com
Western Power Products Bakersfield, CA / 661.397.9155 www.westernpowerproducts.net
Bell Power Systems LLC Essex, CT / 800.225.8669 www.bellpower.com Crosspoint Power & Refrigeration Indianapolis, IN / 800.426.7693 www.crosspointpowerandrefrigeration.com
CANADA: Diesel-Bec Inc. Quebec, Canada / 866.441.3401 www.diesel-bec.com New Way Diesel New Brunswick, Canada / 877.663.9929 www.newwaydiesel.com LATIN AMERICA: PIASA Guadalajara, Mexico / 52.33.1815.4051 www.piasa.mx
CONTACT YOUR LOCAL YANMAR DISTRIBUTOR TODAY. oemoffhighway.com/10056323