Assessment of Fuel Saving Potential in a Hybridized Off-Road Vehicle: A Study Combining Virtual Simulation and Experimental Validation

Authors

  • Weijin Qiu Ray W. Herrick Laboratories, Purdue University, West Lafayette, Indiana, USA
  • Shubham Ashta Ray W. Herrick Laboratories, Purdue University, West Lafayette, Indiana, USA
  • Gregory M. Shaver Ray W. Herrick Laboratories, Purdue University, West Lafayette, Indiana, USA
  • Scott C. Johnson John Deere Intelligent Solutions Group, John Deere, Fargo, North Dakota, USA
  • Bryan C. Frushour John Deere Electric Powertrain, John Deere, Waterloo, Iowa, USA

DOI:

https://doi.org/10.13052/ijfp1439-9776.2621

Keywords:

Off-road vehicle, hybrid electric vehicle, energy management, hardware-in-the-loop simulation

Abstract

Stricter emissions regulations have imposed significant pressure on off-road OEM companies to decrease fuel consumption in their products. This situation has led to the adoption of powertrain hybridization as a viable solution, making the timely assessment of fuel-saving potential for hybridized vehicles essential. In this study, a real-time hardware-in-the-loop (HIL) simulation platform was developed to incorporate a vehicle power management strategy for efficient power distribution, component-level controllers for overseeing actuator functions, and physics-based models of powertrain components to accurately replicate vehicle performance. Results from simulations conducted on the HIL platform indicate that the hybridized off-road heavy-duty wheel loader under investigation can achieve fuel savings of over 10%. Furthermore, additional field testing confirmed these findings by comparing the fuel consumption of a prototype vehicle equipped with the hybridized powertrain to that of its baseline counterpart.

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Author Biographies

Weijin Qiu, Ray W. Herrick Laboratories, Purdue University, West Lafayette, Indiana, USA

Weijin Qiu received the B.S. degree in Agricultural Engineering from China Agricultural University, in 2018, and the Ph.D. degree in Mechanical Engineering from Purdue University, in 2023. He is currently a senior power electronics control engineer with John Deere. His research interests include systems, measurements, and controls, primarily focusing on hybrid vehicles, internal combustion engine, and power electronics.

Shubham Ashta, Ray W. Herrick Laboratories, Purdue University, West Lafayette, Indiana, USA

Shubham Ashta received the B.S. degree in Mechanical Engineering from Indian Institute of Technology, Madras, in 2018, and the Ph.D. degree in Mechanical Engineering from Purdue University, in 2024. He is currently a high-voltage product design engineer with Daimler Truck North America.

Gregory M. Shaver, Ray W. Herrick Laboratories, Purdue University, West Lafayette, Indiana, USA

Gregory M. Shaver is an American mechanical engineer and an academic. He is the director of Ray W. Herrick Laboratories and a professor at Purdue University. He earned his B.S. in Mechanical Engineering from Purdue University in 2000, followed by an M.S. in Mechanical Engineering from Stanford University in 2004. He later obtained a PhD in Mechanical Engineering from Stanford in 2005. His research interests include thermodynamics, systems, measurements and controls, primarily focusing on combustion, transportation, sustainable energy and human-machine interaction.

Scott C. Johnson, John Deere Intelligent Solutions Group, John Deere, Fargo, North Dakota, USA

Scott C. Johnson received the M.S. and Ph.D. degrees in Electrical Engineering with Purdue University studying observer design for switched systems. He is currently an engineering manager in power electronics with John Deere. He develops new algorithms for precision agriculture, hybrid vehicles, and vehicle power management. He is also a Leader with John Deere in power electronics hardware in the loop simulations. He is passionate about the latest control methods, including reinforcement learning, model predictive control, adaptive control, and more.

Bryan C. Frushour, John Deere Electric Powertrain, John Deere, Waterloo, Iowa, USA

Bryan C. Frushour received the B.S. in Electrical Engineering with Indiana University Indianapolis in 2006. He is currently a staff engineer with John Deere focusing on the design of electric powertrains.

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Published

2025-07-13

How to Cite

Qiu, W. ., Ashta, S. ., Shaver, G. M. ., Johnson, S. C. ., & Frushour, B. C. . (2025). Assessment of Fuel Saving Potential in a Hybridized Off-Road Vehicle: A Study Combining Virtual Simulation and Experimental Validation. International Journal of Fluid Power, 26(02), 99–128. https://doi.org/10.13052/ijfp1439-9776.2621

Issue

2025: Vol 26 Iss 2

Section

Maha Fluid Power 2024