Electronic Brakes Fire With Lightening Speed at Truck Tech Demo
IVsource.net
15 November 2000

The Truck Maintenance Council's Fall Meeting was highlighted by a day full of dramatic Electronically Controlled Braking System demonstrations at the Transportation Research Center near Columbus, Ohio.  TMC is part of the American Trucking Association.  Highlights are offered here, as well as observations as to how IV systems are playing into the thinking of truck fleet managers.

This evidences how far IV systems have come towards entering routine use --   among topics such as Alternator Terminal Standardization, Proper Tire Air Pressure Guidelines, and Coolant Hose Rating Factors were sessions on Collision Avoidance systems.  Within this diverse group, Intelligent Vehicle topics are addressed primarily in Study Group 12, "Total Vehicle Electronics."  An ITS Activities Task Force within this Group is chaired by Guy Rini of Mack Trucks, who briefed meeting attendees on the latest developments in ITS and IVI. 

TMC participants are maintenance managers from large and small fleets around the US and Canada.  In many cases, these maintenance professionals are responsible for fleet safety and can be very influential in a fleet's decision to adopt new technology, in no small part due to the fact that they have to understand how to maintain these systems.   These people are on the "front lines," with a mission to keep trucks moving with optimum safety and productivity.  And at the Columbus meeting, it was clear they had come to work -- sessions started early and lasted all day. 

Collision Avoidance Plenary

At 7 am on Tuesday, October 17, a plenary session commenced on "Fleet Application of Collision Warning and Vehicle Event Recording Devices."  Attendees heard from Dick Gunderson of Altra Technologies and Tom Mattox of Eaton Corporation, the key providers of collision warning systems to the trucking industry.  Gunderson offered tips on what to look for in collision warning systems, and challenged the group to "buy only what you need" and to define requirements carefully before approaching suppliers for safety technologies.

Robert Gosnell of Liberty Mutual Insurance proferred the "bad news" that his industry was not inclined to offer discounts for these types of systems, until they first prove themselves through statistical data showing accident reductions.  Further, he pointed out that safety is a broad landscape involving driver training, maintenance, and other aspects, of which particular technology "boxes" are only part of the picture.

Later that day, Mike Dozier, Assistant Chief Engineer with Peterbilt Motor Company, provided a keynote luncheon speech, in which he noted collision warning, electronic braking, and vehicle event recorders as only a few of many factors that play into their overall vision of the truck of the (near) future.

Safety is Attractive To Drivers

Retaining drivers within a fleet's workforce is a major challenge in the trucking industry today -- many fleets experience annual driver turnover in excess of 100%.  In a session entitled "Innovative Spec'ing for Driver Retention," representatives from Volvo Trucks, Freightliner, and fleets Shopko Stores,  Proline Carriers, and Lord Corporation offered their insights on "what works" in keeping high quality drivers happy on the job.  Retaining these professionals means avoiding having to tap profits for recruiting and training new drivers when the workforce is not stable -- experts estimate it costs almost $5,000 to replace a single driver.

Ralph DeGenova, Sales/Marketing for Volvo Trucks, noted that "driver safety" devices such as collision warning, adaptive cruise control, and drowsy driver alerts are now available if fleets want to specify them on new truck buys.  His recommendations for driver retention include driver training, fuel efficiency rewards, upgraded interiors, and safety equipment (which engenders confidence in operation  of the vehicle).   Herman Miller, Fleet Equipment Manager with  Shopko Stores, Inc., noted that fleets in general are providing Eaton VORAD and other object detection devices.  His company's approach includes providing   automatic traction control,  a highly sophisticated seat, 'premium' interiors, and infrared thermometers to keep tabs on road temperatures.

Transponder Revolt Brewing

Clearly the ITS item most prominent on the minds of these maintenance managers is the maddening diversity of transponders required for wireless communications with toll authorities and state administrative sites, as well as new applications for private terminals and truck stops.  With frustration directed at the toll industry, tag providers, and the government, the clear call from this group is to standardize on a single transponder.  Expect this issue to become increasingly prominent within the trucking industry, because the current situation is beginning to put a damper on the increased profitability possible with wireless transactions.

"EBS is ... providing the platform for the advanced safety systems of the future" --  Meritor WABCO 

The Star of the Show

The electronic stars shone brightly on the final day of the meeting, as the full TMC group assembled at the extensive test track facilities of the Transportation Research Center to view an array of advanced braking system demonstrations.

While the trucking industry has taken pains to bring Anti-lock Braking Systems into their operations in the past several years, the intent of this demo was to illustrate the "next wave" for braking systems.  Electronically Controlled Braking Systems (ECBS, or simply EBS), otherwise known as "brake-by-wire," serve to replace air lines to trigger brake applications.  This enables both faster brake control and the ability to brake individual wheels at different times and with varying intensities, to achieve the optimal braking effect.  Manufacturers are also introducing air disc brakes to replace the drum (S-cam) systems that currently predominate.  "Air disc brakes promise to provide high fade resistance resulting in superior stopping performance and remarkable stability," according to the conference program.

While the trucking industry has taken pains to bring Anti-lock Braking Systems into their operations in the past several years, the intent of this demo was to illustrate the "next wave" for braking systems.  Electronically Controlled Braking Systems (ECBS, or simply EBS), otherwise known as "brake-by-wire," serve to replace air lines to trigger brake applications.  This enables both faster brake control and the ability to brake individual wheels at different times and with varying intensities, to achieve the optimal braking effect.  Manufacturers are also introducing air disc brakes to replace the drum (S-cam) systems that currently predominate.  "Air disc brakes promise to provide high fade resistance resulting in superior stopping performance and remarkable stability," according to the conference program.Industry experts expect that, within three years, government regulators will introduce new brake performance standards that will mandate the use of ECBS and air disc technology.

Attendees at the demo had the chance to see heavy trucks operating at high speed on the TRC "skid pad," performing braking maneuvers using equipment from all vehicle and brake component manufacturers.  Manufacturers Volvo, Mack, Freightliner, International, Peterbilt, and Kenworth provided trucks, with equipment from suppliers Meritor/WABCO, Bendix, Eaton/Dana, and Haldex.  Trailers from manufacturers Wabash, Fruehauf, Great Dane, and Dorsey were equipped with ECBS as well.

Several key maneuvers illustrated these advanced braking capabilities.  For disc brakes, a Volvo tractor and a passenger car proceeded side by side at 75 mph across the skid pad and braked simultaneously -- the car stopped first, but the truck stopped only about two car lengths later; this represents a significantly better performance level than can be achieved by drum brakes in an emergency stop.

System Components from the Meritor WABCO EBS
Graphic courtesy  Meritor WABCO

Some high drama was provided by the performance of several "J-turns," with and without ECBS.  The tractor-trailer combinations were equipped with outrigger devices, so that as the trailer wheels left the ground in these high speed turns (easily four feet in the air -- a recipe for a rollover in normal circumstances), the outrigger wheels contacted the pavement to stabilize the vehicle.  That was the case without ECBS.

When the same vehicle rig turned on its electronics and performed the identical maneuver, it was much less dramatic -- the electronic equipment controlled individual wheel brakes under supervision of stability control algorithms to slow the vehicle significantly while still tracking the curve.  For intelligent vehicle systems, a successful  demonstration is not altogether exciting ... which is, of course, the point.

A third key maneuver was performed on a specially treated pavement surface, which emulated a rainy, oily roadway.  The worst-case condition for safely stopping a heavy truck in these conditions is a "split-co" situation, where the coefficient of friction for the wheels on one side of the truck is vastly different than the other side (i.e., dry on one side, wet/oily/icy on the other).

Again, ECBS rose to the occasion, as the driver drove his vehicle intentionally halfway on / halfway off the slippery surface, with the electronics controlling the brakes appropriately to reach a prompt, straight-line stop.

If the comments of fleet managers in the bleachers were any indication, the demo was immensely successful in raising their awareness of the potential of these systems:  "Wow-- that was incredible."  "I had no idea that was possible."  "Amazing."  These comments issued from the lips of those who have firsthand experience with the aftermath of truck crashes, and who have responsibility for taking steps to minimize their occurrence.

ECBS is widely seen as a key enabler in providing the platform for advanced driver assistance systems in coming years.  As to collision warning, systems are now part of the technology suite that appears to be considered routinely in new truck buys.

"Major suppliers have to offer collision warning systems to stay significant on the industry scene," as one insider put it.

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Tractor-Trailer Combination Performing Extreme Maneuvers on TRC's Skid Pad

... access  www.trcpg.com  (the Transportation Research Center) or  sample one vendor's approach to ECBS at www.arvinmeritor.com.

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