A Comprehensive Energy Model Development For Off Highway Vehicles

Utilizing machine and thermal system simulations (vehicle energy models) can be very helpful for vehicle manufacturing companies to develop a machine with acceptable component temperatures, less heat loads to the vehicle cooling systems, and reduced emissions that will also reduce the overall product development cycle. Energy models of vehicles were developed mostly in the automotive industry, and most of these studies in the past were based on partial energy models. The objective of this study is to create a comprehensive energy model for agricultural machinery by using EASY5, which will be a basis for future work on similar products and a subject of advanced modeling and simulation classes in engineering technology institutions. A tractor model from a Midwest off-road machinery manufacturing company was selected as a starting point for modeling. The work in creating the model has been presented in detail. Verification of the simulation model was carried out using the results from three different wind tunnel tests that were conducted by the Midwest Company; namely the PTO test, the AXLE test, and the highspeed wind tunnel transport test. The critical parameters were selected to be analyzed for each test were the top tank temperature, the intake manifold temperature, the oil cooler inlet temperature, the oil cooler outlet temperature, the fuel cooler inlet temperature, the fuel cooler outlet temperature, the fan speed, the engine speed, the PTO torque and the axle torque. Most of the electrical and mechanical engineering and technology curricula include instrumentation, advanced CAD, and control courses using AutoCAD and LabViewTM combined with a variety of instrumentation inputs from proximity sensors and other transducers provided a good learning tools for undergraduate and graduate students. This comprehensive energy model promises to be included in an elective undergraduate senior and graduate level advanced simulation and data acquisition classes.