Tag: Product

TruckLabs has demonstrated its dedication to quality by participating in an OEM-level shaker test with Hexagon Agility to validate its next-generation platform. The shaker test involved subjecting the TruckWings platform to one million miles of rigorous testing, including vibration and shock testing. The goal of the test was to ensure that the platform met the highest durability and reliability standards.

About TruckLabs 

Established in 2004, TruckLabs partners with some of North America’s largest trucking fleets to make a positive impact on carbon emissions and drive operational efficiencies for their fleet customers. The company develops innovative hardware and software solutions that produce real-world results for today’s and tomorrow’s trucking fleets.

One Million Mile Shaker Test to Test Durability

TruckLabs recently conducted a shaker test in collaboration with Hexagon Agility. We shaker tested on the new Hexagon Agility ProCab® 175 CNG fuel system with TruckLabs’ TruckWings® installed. The goal of the vibration test was to assess the durability of the TruckWings over a simulated one million miles of driving.

The shaker test mounted the Hexagon Agility CNG fuel system with TruckWings onto a shaker platform that simulates vibrations in all directions. The vibrations used in the test were developed by driving a truck over various types of roads on a test track at specific speeds and distances. This process was used to develop a test regimen correlated with one million miles of real-world driving. 

Shaker tests are vital because they allow you to understand when a piece of equipment or component may encounter a problem or failure and predict a product’s life cycle. It is used across multiple industries including automotive, aerospace, defense, and aviation, and is a proven solution to shorten testing without compromising results.

Measuring Success

The test lasted for almost a week and had two criteria for success: 

1. No non-repairable component in the primary load path, including the frame and aluminum structure, could fail. 
2. Repairable component failures were allowed if identified and repaired within corresponding real-world preventative maintenance intervals.

The Results

The recent shaker vibration test of TruckWings was a resounding success, meeting all of the established goals to demonstrate the product’s reliability. We wanted to prove that our product is reliable with over 1 million simulated road miles, and we did just that. We were able to meet all our established criteria and demonstrated TruckWings’ reliability. 

Not a single non-repairable component in the primary load path through to BTC attachment failed during the test. The only issues were individual component failures that could be easily identified and fixed during regular inspections. The hinge bushing, which is designed to wear out over time, only showed signs of wear at a significant margin beyond the recommended service interval. And even when some rivets failed, the overall structure of TruckWings has stayed intact thanks to the redundant design. This test proves that TruckWings is a reliable and durable solution for the trucking industry.

The shaker test was severe, but it does not represent all contributing factors that influence the ultimate durability of TruckWings, such as aerodynamic loading, dust and other contaminants, and temperature. This test represents just one piece of TruckLabs’ overall testing puzzle, including 600,000,000 miles of on-road observations, aerodynamic analysis, and individual component tests.

TruckLabs successfully met all of our criteria and proved the reliability of TruckWings. 

Conclusion

TruckLabs is proud to have participated in and passed this shaker vibration test and is confident that the next generations of TruckWings will exceed customer expectations. “We have been able to implement many of our learnings from the field into TruckWings over the years, and it is wonderful to see that work validated by an industry-standard, repeatable test,” Burk Kladde, VP of Engineering. We are committed to providing innovative solutions that improve efficiency, reduce costs, and minimize environmental impact for fleets today and in the future.

TruckLabs’ Best Practice Approach to Continuous Improvement Helps TruckWings Raise the Bar on Over the Road Durability

As an engineering forward company, one of the best things about TruckLabs is our ability to respond fast and effectively to real-time data, results, and customer feedback. We are constantly incorporating learnings from our largest customers, our proprietary telematics data from over 500 million OTR miles, and laboratory testing into the design and operation of TruckWings. 

In this blog post, we will look at the strategies and methods that have made TruckWings one of the most reliable and cost-effective solutions for reducing fuel spend for Class 8 fleets. 

Learning From Smart Hardware

The TruckWings design has consistently evolved since its inception to improve durability and reduce maintenance. A big part of the progress we have made can be attributed to implementing lessons learned from our telematics data. The TruckLabs telematics system collects and analyzes real-time data on the performance and usage of TruckWings. Our engineering team leverages this data to prioritize product development efforts focused on product durability and reduced maintenance costs for our customers.

One recent initiative focused on increasing the precision of our Trailer Distance Sensor across multiple trailer types. Our engineering team learned from our telematics data that tuning the distance sensor would further optimize TruckWings open %, and in turn, save more fuel for our customers. We upgraded the placement of the Trailer Distance Sensor across a broader range of trailer types, allowing TruckWings to be more effective at saving fuel. Because we had real-time data, we were able to make these changes quickly in a test environment and then rollout to a larger population of trucks.

Full telemetry has enabled the TruckLabs team to identify the root cause of customer on-road events by replaying the time, location, vehicle speed, TruckWing state, and more – giving us a quicker path to continuous improvement. 

Fleet-driven Feedback Loop

TruckWings have become even more rugged by incorporating feedback from stakeholders in the trucking industry. Talking to drivers, technicians, and fleet managers, we have gained valuable insights into how our TruckWings units are being used and how we can build an even better product. 

Drivers have provided feedback on the ease of use and visibility of the TruckWings system, while technicians have pointed out opportunities for streamlining the maintenance process. By listening to our customers, we have made improvements that had a significant impact for our customers. 

For example, in the Freightliner Cascadia Day Cab, a driver noticed wind noise coming from the TruckWings. After analyzing the issue, a seal was added between the leading edge of the TruckWings and the cab side extender to block the air recirculating behind the cab.This stopped the whistling and further stabilized the panels. 

Our engineers have also been focused on ensuring TruckWings are quiet when opening and closing so that our sleeper team customers aren’t disturbed while sleeping. In order to achieve this, we use soft-close pneumatic actuators that slow down at the limit of their travel, like a kitchen cabinet drawer—allowing TruckWings to open and close quietly. Our drivers often comment on how quiet TruckWings are on the road. 

The TruckLabs team is passionate about our customers and we listen to their reactions, comments, and praise about the overall experience with TruckWings. Incorporating customer feedback has been essential in continuously upgrading the TruckWings design and deployment.

Rugged Materials for Real-world Use

One of the critical features of the TruckWings design is its use of resilient materials that can withstand the rigors of millions of miles of over-the-road trucking. As active aerodynamic devices, TruckWings are subjected to various forces and stressors as they deploy between the tractor and trailer of Class 8 trucks. To ensure that TruckWings not only stand up to these forces but overperform, we have used highly durable materials that defy the intensity of these forces and minimize any damage that may occur. 

For example, the TruckWings are mounted to the back wall of the tractor using redundant, high-strength brackets that can withstand the weight of the system and the aerodynamic forces exerted during deployment. Additionally, the TruckWings panels are made from rugged, weather-resistant, fiber-reinforced plastic that can withstand the harsh conditions encountered on the road regardless of weather conditions. We have trucks running throughout the year in the cold of northern Canada and the heat of the SouthWestern United States. Another area of focus has been introducing flexible panel end treatments that further reduce edge-case impacts on the side panels. Overall, using high-quality, rugged materials in the TruckWings design has been imperative to ensure that the system performs to the highest standards and delivers the fuel savings that trucking fleets expect with very little maintenance and repair.

Industry-standard accelerated life cycle testing helps validation 

Over-the-road trucking is full of harsh conditions, and we have accepted the challenge to ensure that the TruckWings design can stand up to the rigors on the road and in the lab. They are designed to last the life of your tractor while only requiring minimal maintenance on easily serviceable components on the back of the cab.

Beyond over-the-road testing, we have also subjected TruckWings to rigorous laboratory testing.

 

To significantly extend the service intervals on TruckWings, we designed a new serviceable bushing that introduced a bearing cartridge. We created a cyclic durability test that accelerates the wear on bushings to validate the system, gather data and make any necessary design changes. Lab testing is ongoing, with 210k deployment cycles completed (an average truck will deploy 10k a year).

This repeatable testing method has been beneficial in identifying potential issues with the design and finding solutions to address them before we deploy updates in the field. Laboratory testing gives TruckLabs the data necessary to quickly promote design changes, allowing TruckWings to perform at its highest standards. 

There are two aerodynamic devices in the trucking industry that are sometimes confused: TruckWings and TrailerTails. Yes, they’re both aftermarket accessories designed to help trucks reduce drag and improve fuel efficiency and have both been proven successful at achieving fuel savings. And it’s true each has anatomical names. But, that’s pretty much where the similarities end.

The products are significantly distinct from one another: They’re mounted on different parts of the truck. One’s fully automatic and the other isn’t. And most importantly, TruckWings is available pre-delivery via all major OEMs while TrailerTails is no longer available.

The parallels between the two products are just enough to have caused some confusion in the marketplace. The following table was developed to make distinctions clear—and hopefully dispel the notion that TruckWings and TrailerTail are one and the same.

TruckWings	TrailerTails
TruckWings is an aerodynamic device installed on the tractor.	TrailerTails is an aerodynamic device installed on the back of the trailer.
TruckWings was designed to close the gap between tractor and trailer to reduce drag.	TrailerTails was designed to streamline airflow off the back of the trailer to reduce drag.
Introduced to the market in 2015 and is available pre-delivery from all major OEMs.	Introduced to the market in 2008 and as of 2020 Stemco ceased sales of TrailerTails.
TruckWings operates in two positions: Closed (when the truck is going fast on an open highway). Open (when going slow/making turns).	TrailerTails operated in two positions: Open (when truck was moving). Closed (when it backed up/docked).
TruckWings automatically opens and closes. There’s no manual intervention required—although driver override is possible for safety purposes.	TrailerTails automatically opened but did not initially automatically close.
TruckWings are designed with smart sensors to fully track fuel and carbon savings and provides uptime reports	TrailerTails does not track savings or provide reporting.

How Innovation is Keeping Fuel Costs Down, Drivers Comfortable

TruckLabs VP of Product Andrew Kelly sees an increasing need for truck fleet operators to reach emissions reduction goals while tackling increased fuel costs and driver shortages. Thankfully, technology and product innovations are now speeding solutions for keeping fleets online and drivers comfortable. Kelly shares his insights on the latest innovations sparking the future for fleets and top solutions helping the trucking industry face unprecedented disruption.

Q: What trends and innovations are most exciting for the trucking industry, especially against the backdrop of ongoing challenges, including rising fuel costs and driver shortages?

A: Sensor technology, the enabling of IoT through connected devices, and the pursuit of aerodynamics are among advancements paving the way for the future of trucking fleets, said Kelly, who oversees the design of TruckWings, a key product offering from TruckLabs. The tractor-mounted active aerodynamic device automatically closes the gap between a truck cab and the trailer at highway speeds to reduce drag, improve handling, and save fuel.

Trip data that can now be collected along a truck’s route is providing increased visibility into how to optimize routes, economize on fuel, improve driver satisfaction, and increase the operational efficiency of entire fleets. New platforms can measure a truck driver’s performance while accounting for real-world complications, including weather, traffic and load. Data systems and sensors provide minute-by-minute data that can pick apart stories about truck performance to see how a truck operates, noted Kelly.

Truck design and the adoption of leading-edge aerodynamics are also shaping the future of the industry, Kelly added. Aerodynamics are one of the most cost-effective means of improving a truck’s efficiency. Improvements in aerodynamics for trucks are going beyond fuel efficiency design to the frontier of EV capabilities.

Q: What does the future hold when it comes to the adoption of electric truck fleets?

A: For sure, we can hear the silent roar of electrification, said Kelly. Designing electric trucks addresses the dependence on fossil fuels and the increasingly important issues of carbon emissions and fuel efficiency. But, there is a lot of apprehension from an operational standpoint, and massive adoption is still well around the corner, Kelly noted.

Aerodynamics is critical for America’s trucking fleets. While EV manufacturers continue to address issues around battery weight and range, aerodynamics is one of the most critical factors in achieving range targets in electric trucks. Aerodynamic losses are irreversible in EVs, whereas energy spent on acceleration can be partially recovered with regenerative braking in trucks, for example, Kelly said.

We see the aerodynamic choices of passenger car EVs on the market today that stand apart, including flush door handles, digital side view mirrors, and 3D wheel covers. Truck manufacturers have to make the same leap in aerodynamic efficiency to hit their range targets for market appeal. As manufacturers continue to put R&D investments into battery technology, the first generation of electric trucks will look much like their diesel counterparts. That leaves room for aerodynamic design to help in this first stage of adoption.

Right now the fastest way that a truck manufacturer could reduce drag on an existing truck model is to apply TruckWings, said Kelly.

Q: How does the TruckWings product address fuel efficiency and aerodynamics, while making the lives of fleet managers easier?
A: TruckWings closes the gap between the truck cab and trailer, where airflow commonly creates drag and stability issues. The product can be quickly installed and requires zero driver input to operate. Using vehicle speed and a smart sensor to detect trailer clearance, the patented folding panel design automatically deploys and retracts for easy use and maximum maneuverability without being prone to damage from user error. Common aerodynamic product offerings on the market today include long side extenders, which can limit turning radius during in-town driving. TruckWings retracts automatically at speeds under 50 mph without driver input, so trucks can be easily maneuvered for all driving conditions.

TruckWings traces its origins to a visit company founder Daniel Burrows made to a truck stop. Inspired by his work with climate change, Burrows noticed the gap between the truck and trailer and wondered if there was a better way to create energy and performance efficiency for commercial trucks.

The latest generation of the TruckWings solution automatically fits about 90% of trucks that are being manufactured and can be customized for others. That allows TruckLabs to buy parts in bulk to have on hand for delivery and service for any make and model of truck and cut down on lead time.

TruckWings works for all major OEM tractor models, a symbol that our customers have already pushed the limit and are keen on what makes a tractor most efficient and are looking to unlock best in class trucking aerodynamics, said Kelly.

Q: How do aerodynamic solutions for trucks help with driver retention?
A: Driver shortages have kept the trucking industry scrambling as supply chain and logistics issues have gone from one-time “black swan” events to an ongoing global challenge. Trucking fleet operators have responded by working to improve driver retention and the comfort of long-haul drivers.

Aerodynamic solutions like TruckWings can help. Product reviews and studies show that TruckWings helps reduce buffeting and improves the stability of a truck traveling in crosswinds, which can reduce fatigue associated with fighting crosswinds. Drivers also have reported feeling that TruckWings helped with straighter driving, said Kelly. The product operates automatically, so drivers don’t have the hassle of another device to maintain or operate.

Trucking companies today are looking for just about anything that can keep drivers happy and comfortable, but also need to take advantage of the latest technology to improve fleet operations and stay competitive.

So much is changing for the industry, yet the basics of driver comfort, safety and optimizing routes remains at the core of doing good business.

Ready to learn more about TruckWings? Reach out today and receive a complimentary product introduction and information.