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As a rule, the design process of any vehicle is divided into phases of conceptualization, development and industrialization. The most important is the conceptualization phase, on the good elaboration of which the final appearance and quality of the final product will depend. In terms of design, the fundamental engineering issue is the correct choice, interpretation and modelling of load conditions for cascading loads across all components of the power structure of the vehicle chassis. The most correct and classic vehicle chassis design process is based on the study of vehicle benchmarking. This article describes the process of developing the original geometry of the load-bearing arms of the mechatronic transmission of an energy efficient truck based on the study of a design vehicle benchmarking of a foreign manufacturer. The result of this article is a general demonstration of the advantages of using the «reverse engineering» method on the example of designing the load-bearing arms of a mechatronic transmission of an energy efficient truck, as well as confirmation of the adequacy and validity of the applied calculation modelling methods. The aim of the work is to develop design methods and gain experience in the field of computational research through the use of the «reverse engineering» method.

The article presents a research of the lubricity of the elements of the mechatronic transmission of an energy efficient truck. Particular attention is paid to the processes associated with ensuring reliable operation of the transmission and reducing friction between the components. Analysis of the distribution of fluids, performed using the SPH method, allows us to determine the lubricity conditions to improve performance characteristics, as well as reduce the temperature of the mechanisms to increase the service life and improve the overall efficiency of the system. The results of the research demonstrate the importance of choosing lubricants and their application modes, which directly affects the durability of transmission elements and the energy efficiency of the entire vehicle. These findings can serve as a basis for developing recommendations for optimizing the operation of mechatronic transmissions of cars.

In electric modern energy efficient trucks and buses, transmissions with an electric motor and inverter located directly in the drive axle are increasingly used to increase the useful volume of the passenger compartment or cargo space and improve performance. This highly integrated electromechanical unit is called a mechatronic transmission. The procedure for forming technical requirements for the parameters and operating modes of traction electric motors is relevant and different from that of energy efficient trucks with traditional transmission in this case [1, 2]. Thus, the purpose of this study is to determine the requirements for different values of traction electric motor power as components of mechatronic transmission based on the analysis of the driving modes of vehicles with internal combustion engines and mechanical transmission. In the course of the work, a number of representative recorded cycles of movement of mainline modern energy efficient trucks of PJSC KAMAZ on the roads of the Russian Federation were studied and a synthesis of a generalized cycle with identical statistical characteristics was carried out. In addition, the article provides a comparative analysis of the formulated requirements with the parameters of similar samples of mechatronic transmissions from global manufacturers.

See the retraction notice BIO Web of Conferences 138, 00001 (2024), https://doi.org/10.1051/bioconf/202413800001

The article assesses the capabilities of regenerative braking in terms of braking efficiency when studying the motion of a model of an energy-efficient electric vehicle with a mechatronic transmission using motion cycles recorded on real vehicles. Based on statistical data, a study of driving conditions was conducted, the required braking power and the required braking deceleration were calculated, and the obtained requirements were compared with the capabilities of the traction motors installed on the vehicle, taking into account the peak short-term characteristic. Based on the results of the work, a conclusion was made that the use of energy-efficient traction electric motors allows in 86% of cases to do without using the service braking system, providing the required level of deceleration according to the studied motion cycles, which fully corresponds to serial models of electric trucks.

The article provides an overview and analysis of modern energy efficient trucks with traction electric drive wheels. A description is presented indicating the main technical characteristics of the model range of energy efficient trucks with electric drive wheels, such companies as DAF Trucks, Mercedes-Benz, Daimler Trucks North America, Kenworth, Mack Trucks, Quantron, Renault Trucks, Scania, Xos, Volvo. The results of the review and analysis of promising technology made it possible to identify the dependence of the mass of the car on the power of the electric motor. A comparison is made between the developed prototypes of energy efficient trucks and foreign energy efficient analogues. Based on the analysis and review, conclusions are formulated about the selected power and weight indicators for newly developed energy efficient trucks.

The article examines the heating of a truck’s energy efficient mechatronic transmission during operation of an electric motor in maximum power mode. Particular attention is paid to the process of modeling conjugate heat transfer and its impact on the energy efficiency of mechatronic transmission. To solve this problem, computational fluid dynamics (CFD) methods are used, in particular the finite volume method (FVM), which allows for an accurate assessment of heat flows between different environments inside the transmission. Analysis of thermodynamic processes occurring in mechatronic transmission is of great importance for optimizing its operation and increasing reliability. The simulation results demonstrate the influence of various factors, such as driving speed, loads and temperature conditions, on the efficiency of heat exchange and, as a result, on the energy efficiency of the entire vehicle. These research contribute to the development of more efficient cooling systems and improved performance of trucks.

See the retraction notice E3S Web of Conferences 549, 00001 (2024), https://doi.org/10.1051/e3sconf/202454900001

The article discusses the relevance of the problem of calculating the elements of electromechanical transmissions of trucks for strength and durability. The main methods used for the formation of load conditions on electromechanical transmissions of trucks are given. The driving cycles of trucks used to obtain loads when calculating the durability of the elements of electromechanical transmissions are given. The universal driving cycles of vehicles obtained on the basis of the collection of statistical data on the movement of trucks are considered. A simulation model of the movement of a truck used to determine the loads on the electromechanical transmission while overcoming driving cycles of trucks is presented. The durability of the gears of the electromechanical transmission of a truck is analyzed on the basis of load cyclograms obtained during simulation modeling of movement. Numerical results of the safety factors of one of the gear stages are obtained. Conclusions are drawn about the optimality of the use of existing driving cycles of trucks in strength calculations. Conclusions are worded about the need to synthesize driving cycles of trucks based on the collection of statistical data on the movement of truck vehicles on the territory of the region under consideration.

The paper describes methods for generating (modeling) representative driving cycles of the vehicle used to solve engineering problems in the design of electric vehicles, such as resource calculations, determination of the required capacity of traction batteries and evaluation of power reserve, etc. The general approaches used in the processing of real traffic data and algorithms for modeling driving cycles using deterministic and probabilistic approaches are described. This paper presents driving cycles that ensure convergence with parameters corresponding to the real conditions of vehicle movement. The developed driving cycles can be used in the design of electric vehicle transmission components and allow for the analysis of operational properties.

Traction battery vehicles (TBV) are currently gaining more and more popularity and are gradually replacing vehicles with ICE and traditional transmissions. The usage of an electric traction drive as part of TBV solves a number of problems that manufacturers of this type of equipment face today: reducing harmful emissions into the atmosphere, reducing noise, used lubricants recycling, and the increase of the energy efficiency. From the point of view of the scientific research, this type of wheeled vehicles is also of high interest due to the large number of problems and tasks that have formed at the moment. It is a common knowledge, that one of the main problematic issues for the TBV is a rather limited range. In cargo electric vehicles and buses, in order to reduce the size and increase the usable volume of the passenger compartment or cargo space, as well as to unify the products of the power unit and drive, there are used the transmissions, which are the combination of mechanical and electrical components with appropriate control systems. The mechanical component includes a gearbox with one or more gear ratios, an inter-wheel differential, axle shafts, bearings and other components. The electrical component is a traction motor located directly in the drive axle (integrated) or on the outside of the crankcase, as well as a voltage converter with a control system and the necessary switching elements. Similar implementations of the driving axles of vehicles with traction batteries are called mechatronic transmissions.

The article describes the process of analyzing and processing statistical data on the movement of freight transport obtained using navigation equipment installed on the vehicles in question. A detailed analysis of the source data, as well as all stages of their processing, was carried out using specialized Python tool packages such as Pandas, Numpy and Sklearn. The effectiveness of the proposed approach to data processing is shown by comparing the driving cycles of vehicles generated on the basis of the original and modified data. The topic of data analysis and processing is not new, but the relevance of the article lies in the successful application of common and effective processing methods to statistical data on the movement of vehicles, work with which is complicated by the fact that they are obtained using widespread, but focused on other tasks equipment. Thus, the work opens up new opportunities for statistical analysis of the movement of freight transport without the need to replace navigation equipment.

At the initial stage of designing a dump truck it is necessary to determine the main units and assemblies of the vehicle, their parameters and dimensions. One of the systems of the dump truck is the hydraulic system. When creating new dump trucks, there is a necessity to define parameters and characteristics of hydraulic system components. The peculiarity of quarry dump trucks, in contrast to dump trucks, which are used on public roads, is that the modes of their operation are different. Therefore, when creating new dump trucks, it is necessary to develop an algorithm for selecting and justifying the parameters of the hydraulic system at the early stages of design. The article substantiates the necessity of developing an algorithm for determining the parameters of the hydraulic system. The main hydraulic consumers are defined and the requirements of each of the consumers are presented. The algorithm of justification of the parameters of the hydraulic system of the quarry dump truck is described. Determination of the required pump capacity of the hydraulic system is described. The use of the described algorithm for justification of the hydraulic system parameters of the dump truck contributes to the reduction of terms of development of design documentation at the early stages of design.

The article discusses the problem of determining the rational number of gears for a mechatronic transmission of a truck vehicle. A review of the designs of existing mechatronic transmissions from leading manufacturers of motor vehicles was carried out, with an emphasis on analyzing the number of gears used in them. A method has been developed for determining the rational number of gears based on simulation modeling of the movement of a truck along driving cycles, synthesized on the basis of statistical data on the movement of trucks across the territory of the Russian Federation. A synthesized driving cycle and a simulation model of truck movement, designed to determine the loads on the electromechanical transmission when moving along this cycle, are considered. Based on the results of simulation modeling of the movement of a truck with a different number of gears in a mechatronic transmission, conclusions about the influence of multi-speed transmissions on the energy efficiency of electric truck vehicle were drawn. Conclusions have been formulated about the required number of gears for mechatronic transmissions of trucks moving on the roads of the Russian Federation.

The paper considers different ways of controlling the braking systems of haul trucks. The general approaches used in the development of control systems for such braking systems are described. Methods of testing and imitational mathematical models, used for the analysis of brake system control systems operation, are presented. The developed control system and the imitational model allow us to analyze the brake system behavior under different operating modes of a haul truck.

It’s known that the use of the automobile vehicles in a quarry for transporting the rock mass is characterized by a cyclic nature and the ability to overcome the slopes of up to 8-12% along the road as well as curves with the radii of at least 20-24 m. However, the disadvantage of this way of transportation of quarry loads is relatively high costs [1]. One of the ways to reduce costs is to implement the software-based operation of the mining dump truck while ensuring energy efficiency and safety. This way implies following the route “mine face – concentrator” when driving with the rock mass and the route “concentrator – mine face” when driving without a cargo along the specified trajectory and at a given driving speed using the information management systems in a quarry and on the board of the mining dump truck controlled by the driver as well as in an unmanned version in case of autonomous driving. The article describes the method to optimize the function “way – speed” and as a result the way to optimize the control of the traction electric motors in a mining dump truck during cyclic movement along the specified trajectory with a fixed time to pass the route in order to ensure energy efficiency and safety when using the method of dynamic programming developed by Richard Bellman.

For today’s composite materials have many advantages over steel materials. The composite materials take the main part in modern automobile constructions. Suspension system is the main automobile part. Components of suspension system are made of metal. Therefor suspension system have a high weight that have a negative effect for all of vehicle especially for vehicle dynamics and stability properties. The main part of suspension system is a spring element. Coil springs are the most widely used spring type for independent wheel suspension for trucks and passengers vehicles. Using composite springs can less vehicle weight especially less unspring masses. It is one of the main features of composite materials. Another feature is viscoelastic properties and hysteresis effect. That can be give excellent noise and vibration properties for vehicles.