OEM Off-Highway July/August 2014

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

www.oemoffhighway.com

2 4 EMISSIONS: Growing demand for biofuels?

We Modeled Our New Water-Cooled Engine After The Sleekest Machine In The World.

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HATZ DIESEL OF AMERICA PO Box 258 Waukesha, WI 53187-0258

262.544.0254

sales@hatzusa.com www.hatzusa.com

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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

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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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www.oemoffhighway.com/11564554

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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Ele c t r onics

www.oemoffhighway.com/11564554

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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A LT ER N AT I V E ENERG Y: S OL A R

Ener g y

www.oemoffhighway.com/11537977

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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A LT ER N AT I V E ENERG Y: S OL A R

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www.oemoffhighway.com/11537977

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

OEM Off-Highway

JULY/AUGUST 2014

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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

25

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

JULY/AUGUST 2014

27

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

OEM Off-Highway

JULY/AUGUST 2014

29

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

JULY/AUGUST 2014

31

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

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TO POWER APPLIED Brakes

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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

Wheels

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Clutches & Brakes

eDrive and Hybrid Systems

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High Performance Structures

product engineers assess the

Sensors & Controls ..... and offer customized solutions, an expanding global footprint, trusted products, services and people.

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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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33

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

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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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­36

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

microstrain.com oemoffhighway.com/10055737

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

OEM Off-Highway

JULY/AUGUST 2014

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

www.sae.org/comvec Executive Leadership Provided By:

P140784

oemoffhighway.com/10250528

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.

足40

OEM Off-Highway

JULY/AUGUST 2014

A D V ER T ISER S’ INDE X www.oemoffhighway.com

Advertiser................................................. Pg #

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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OEM Off-Highway

JULY/AUGUST 2014

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

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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