Commercial Vehicle Technology 2024: Proceedings of the 8th International Commercial Vehicle Technology Symposium (German Edition)

Die Beiträge des Tagungsbandes Commercial Vehicle Technology 2024 sind eine Sammlung von Publikationen für das 8. Internationale CVT-Symposium der Commercial Vehicle Alliance Kaiserslautern. Es wurden zahlreiche Beiträge zu aktuellen Entwicklungen im Nutzfahrzeugbereich zu einer interessanten und informativen Sammlung zusammengestellt. Die Beiträge sind für Maschinenbauer, Elektrotechniker und Informatiker aus Industrie und Wissenschaft von Interesse und zeigen den aktuellen Stand der Technik auf diesem Gebiet. Die Inhalte der Publikationen umfassen die Themen alternative Antriebstechnologien, innovative Entwicklungs- und Produktionsmethoden, assistiertes und automatisiertes Fahren und Arbeiten, Simulationsmethoden, vernetzte und integrierte Systeme und Services sowie Sicherheit, Zuverlässigkeit und Lebensdauer. The proceedings of Commercial Vehicle Technology 2024 are a collection of publications for the 8th International CVT-Symposium of the Commercial Vehicle Alliance Kaiserslautern. Numerous submissions focusing on current developments in the field of commercial vehicles have been composed into an interesting and informative collection. The contributions are of interest for mechanical engineers, electrical engineers and computer scientists working in industry and academia and show the current state-of-the-art in this field. The contents of the publications span the topics alternative propulsion technologies, innovative development and production methods, assisted and automated driving and working, simulation methods, connected and integrated systems and services as well as safety, reliability and durability. Preface CVT 2024 Organization of the Symposium Organizing Committee Organizers Program Committee Contents Alternative Propulsion Technologies The potential and challenges of hydrogen powered construction machinery Potenziale und Herausforderungen wasserstoffbetriebener Baumaschinen 1 Einleitung und Motivation 2 Stand der Technik und Wissenschaft 2.1 Entwicklung der Emissionswerte 2.2 Hybridisierung durch Brennstoffzellen 3 Systemauslegung 4 Prototyp 5 Herausforderungen 6 Zusammenfassung Referenzen Comparison of Mixture Aspirating and Air Aspirating Biopropane-Diesel Dual-Fuel Combustion Vergleich gemischansaugender und luftansaugender Biopropan-Diesel Dual-Fuel Brennverfahren 1 Einleitung 2 Stand der Technik und Einordnung 3 Experimenteller Aufbau 4 Methodik 5 Ergebnisse der Untersuchungen 6 Zusammenfassung und Ausblick Literaturverzeichnis Danksagung Energy-efficient and Wear-optimized Operating Strategies for special and commercial vehicles with Fuel Cell Drives 1 Introduction 1.1 Generality 1.2 Framework Overview 2 System Modelling 2.1 Fuel Cell System 2.2 Battery System 2.3 Generic EMS 3 Results 3.1 Sample power profile 3.2 Dresden Line 61 Test Case 4 Conclusion References Practical and customer-oriented electrification of agricultural tractors 1 Introduction 2 Challenges in electrifying agricultural tractors 2.1 Understanding agricultural tractors 2.2 Energy consumption challenges related to different customer profiles 3 Addressing the Energy Consumption challenges 3.1 Battery Electric Tractors 3.2 Operating strategies for Battery Electric Tractors 3.3 Hybrid Electric Tractor 4 Outlook 5 Conclusion References Innovative Development and Production Methods Load-bearing lightweight hydrogen tanks for optimal use of design space in commercial vehicles. Lasttragende Leichtbau-Wasserstofftanks zur optimalen Bauraumausnutzung im Nutzfahrzeug 1 Einleitung 1.1 Stand der Technik für Typ 4 Wasserstoff-Drucktanks 1.2 Neuartiges Wasserstoff-Druckbehälterdesign 2 Materialien und Methoden 2.1 IVW-Lasteinleitung 2.2 Neuartiges IVW-Druckbehälterdesign 3 Experimentelle Prüfungen 3.1 IVW-Lasteinleitung – Zugprüfung 3.2 Erste Generation IVW-Druckbehälter – Berstdruckversuch 3.3 Zweite Generation IVW-Druckbehälter – Berstdruckversuch 4 Zusammenfassung und Ausblick 5 Danksagung 6 Referenzen Design methodology for synthesis of additive manufacturing and tailored fiber placement for load introduction in FRP components Konstruktionsmethodische Synthese der additiven Fertigung und des Tailored-Fiber-Placements zur Lasteinleitung in FKV-Bauteile 1 Einleitung 2 Technologien 2.1 Additive Fertigung 2.2 Tailored Fiber Placement 2.3 Hybride Strukturen 3 Methodik 4 Erkenntnisse 4.1 Additiv gefertigter metallischer Insert 4.2 TFP-Struktur 4.3 Hybride Struktur 5 Zusammenfassung und Ausblick References Optimizing Metal-Composite Joints: 3D-Printed Inserts and Tailored Fiber Placement 1 Introduction 1.1 Motivation 1.2 Research objectives and scope 1.3 Contributions and Novelty 2 General Concept 2.1 Tailored Fiber Placement (TFP) 2.2 Resin Transfer Molding 2.3 Topology Optimization 3 Methodology 3.1 Finite Element Modelling and Optimization 4 Results and discussion 5 Conclusion and Outlook Acknowledgements References Truck Seat – Strategy for a Green Product LKW-Sitz – Strategie für ein grünes Produkt 1 Einleitung 2 Lebenszyklusanalyse basierend auf DIN ISO 14040/44 2.1 Systemgrenzen und funktionelle Einheit 2.2 Datensammlung für die Sachbilanz 2.3 Primärdaten 2.4 Sekundärdaten 2.5 Datenlücken 2.6 Wirkungsabschätzung und Auswertung 2.7 Treibhausgasemissionen GWP100 3 Reduktion der CO2e-Emissionen 3.1 Wissenstransfer 3.2 Verbesserungsmöglichkeiten Produktion und Material 3.3 Darstellung aller Treibhausgasemissionen (THG) -Verbesserungen 4 Kreislaufwirtschaft 4.1 Langlebige Produkte 4.2 Kreislauffähige Rohstoffe und Design 5 Zusammenfassung und Ausblick References Functional Safety in the Development Process of Mobile Cranes 1 Introduction 2 Tadano Product Development Process 2.1 Interdisciplinary development teams 2.2 Advanced quality process 3 Case Studies 3.1 Case Study 1 - Rear axle steering system 3.2 Case Study 2 - Sideways Super Lift (SSL) 3.3 Conclusion of the case studies 4 Measures for process improvement 4.1 Functional safety department 4.2 Integration of functional safety in advanced quality process 4.3 New alignment of development teams 4.4 Defining clear reporting structure 4.5 Further measures for improvement 5 Conclusion and outlook References Assisted and Automated Driving and Working Advanced Driver Assistance Systems and Teleoperation: Technical Solutions for Market Requirements Fahrerassistenzsysteme und Teleoperation: Technische Lösungen als Antwort auf Marktanforderungen 1 Einleitung 1.1 Motivation 1.2 Liebherr-Hydraulikbagger GmbH 1.3 Automatisierungsstufen bei Hydraulikbaggern 2 Assistierter Betrieb 2.1 Wiege- und Prozessdatenerfassung 2.2 Werkzeugdatenverwaltung – Attachment Assist 3 Funkfernsteuerungen 3.1 Aufbau von Teleoperationssystemen 3.2 Einsatzbereiche von Teleoperationssystemen 4 Zusammenfassung References Full Virtual Workflow to support Automation & Autonomy Applications for Commercial Vehicles including AI Introduction Related Work Simulation in Product Development Game Engines for Product Development Crop Row Detection Simulation Software in Machine Learning Workflow for Asset Creation Within John Deere Gathering, Optimization and Verification of CAD Data for Machinery High-Fidelity Asset Modelling and Retopology UV Mapping and Texture Baking Rigging Python and Matlab API for Usability Assets and Physics Evaluation of Usefulness on Downstream Machine Learning Conclusion References Simulation Methods AI-Based Surrogate Modeling for Highly Efficient Soil-Tool Simulation 1 Introduction 2 Workflow for the Generation of a Surrogate Model 2.1 Generation of Tool Trajectory Data 2.2 Generation of Training Data – MBD-DEM Co-Simulation 2.3 Training of Surrogate Model 3 Test and Validation of the Surrogate Model 3.1 Testing of the Surrogate Model 3.2 Validation of the Surrogate Model 3.3 Computing Time Study 4 Exemplary Application Scenarios 4.1 Offline Parameter Variation Study 4.2 Operator Study 5 Conclusion References Efficient HiL-Testing for Electric Heavy-Duty Drivetrains using Model-Based Systems Engineering 1 Introduction 2 State of the Art 2.1 Product Development with MBSE 2.2 motego-Method 2.3 Hardware-in-the-Loop Testing 2.4 HiL – Models 3 Problem formulation 4 System of Interest: Electromechanical Drivetrain 5 HiL-Model Creation Process 6 Model transformation using MBSE 7 Validation 8 Summary and Outlook References Efficient development processes for optimal commercial vehicle drive solutions through the consistent use of scalable simulation models Effiziente Entwicklungsprozesse für optimale Nutzfahrzeug-Antriebslösungen durch den durchgängigen Einsatz skalierbarer Simulationsmodelle 1 Einleitung – Virtuelle Produktentwicklung 2 Anforderung an die Modelle und die Simulationsumgebung 3 Modellarchitektur und Numerik 4 Entwicklungsprozess während der Innovations-Phase 5 Entwicklungsprozess während der Core-Entwicklung 6 Entwicklungsprozess während der Applikations-Phase 7 Zusammenfassung und Ausblick References Abkürzungsverzeichnis Cloud-Based Identification of Dynamic Trailer States 1 Introduction 2 Offline process and cloud infrastructure 3 Digital twin and simulation environment 4 Road profile identification 5 Demonstration scenarios and results 5.1 Straight-line maneuver 5.2 Rough road maneuver 5.3 Bump maneuver 6 Summary and conclusion Acknowledgements References Workflows for the Virtual Validation of Autonomous Heavy-Duty Vehicles in the Cloud Workflows für die virtuelle Absicherung von autonomen Nutzfahrzeugen in der Cloud 1 Einführung 1.1 Motivation 2 Zentrales Simulationsdatenmanagement 3 Simulationsmodellvalidierung 4 Automatisierung von Simulationsprozessen 5 Workflow für die automatisierte Absicherung 6 Fazit und Ausblick References Connected and Integrated Systems and Services Prediction of energy consumption in road transport by simulation of the vehicle’s field of application and its performance 1 Introduction and Overview 2 The LIFE Ecotravid project in short 3 Saving potential of real transport missions 4 Extrapolation to additional fields of application – creation of routes 4.1 Modeling of scenarios and data pre-processing 4.2 Creation of trips 5 Processing and analysis of simulated routes 6 Extension of the technique to E-mobility solutions 7 Summary References Vehicle activity recognition using machine data 1 Introduction 2 Data from a wheel-based excavator 2.1 Categories of excavator activities 2.2 Relevant recorded channels 2.3 Data preprocessing 3 Derivation of activity relevant features 3.1 Using temporal windows 3.2 Applying a discrete wavelet transform 3.3 Using summary statistics 4 Machine Learning techniques for activity recognition 4.1 XGBoost algorithm 4.2 Training and testing process 5 Results and discussion 6 Conclusion References The (important) Role of Digital Twins and AI Methods within Predictive Maintenance Strategies 1 Motivation 2 Current approaches 3 New Approach 4 Study setup 5 Results of approach 6 Advantages of the approach 7 Outlook References Safety, Reliability and Durability Tree-SLAM: Localization and Mapping in Dense Forest Environments for Autonomous Vehicles 1 INTRODUCTION 2 RELATED WORK 3 TREESLAM 3.1 Tree Trunk Detection 3.2 Local Tree Trunk Mapping 3.3 Global Mapping and Optimization 3.4 Data Association 4 PERFORMANCE ANALYSIS 4.1 Experimentation Platform 4.2 Local Tree Trunk Mapping 4.3 Global Mapping and Optimization 4.4 Data Association 4.5 Integration Test 5 CONCLUSIONS References Utilizing sensory uncertainty detection for robot health monitoring and performing active perception adaptation 1 INTRODUCTION 2 RELATED WORK 3 INTEGRATED BEHAVIOR-BASED CONTROL 4 OFF-ROAD ROBOT UNIMOG U5023 5 DATA QUALITY ASSESSMENT 6 DATA QUALITY GUARDING 7 ACTIVE EXPOSURE CONTROL 8 EXPERIMENTAL RESULTS 9 CONCLUSION References Dynamic Risk Assessment for Automated Driving System using Artificial Neural Network 1 Introduction 2 Related Work 3 Methodology 3.1 Data Preparation and Processing 3.2 Classification of Severity and Controllability Levels 3.3 Training and Testing 3.4 Model Evaluation 4 Experimental Results 4.1 Unintended Acceleration Scenarios 4.2 Unintended Braking Scenarios 4.3 Limitation 5 Conclusion Acknowledgment References Extended Language Server Support for Robotics Frameworks 1 Introduction 2 Related Work 3 Concept 3.1 LSP 3.2 clangd 3.3 finroc 4 Implementation 4.1 clang-tidy 4.2 Features 4.3 Tweaks 4.4 List of Checks and Tweaks 5 Lab study and Survey 5.1 Methodology and Evaluation 5.2 Results 6 Conclusion References Author Index