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Our focus throughout the entire testing process is to ensure that the transmission will meet our customers’ expectations for performance, durability and reliability. First, we use computer models to analyze the strength of the mechanical components. Computer simulations are used to fully understand the dynamic behaviors. Then, we start testing physical parts. Smaller subsystems are built up and tested individually. These are then built up into larger and larger systems until the full transmission is assembled. The full transmission is then tested in multiple ways on a dynamometer. Once we have confidence in transmission by itself, we integrate the transmission into a vehicle and test it again. This is also where we tune it for a specific engine and chassis. Finally, we put the transmission in customer field test trucks for testing and final validation in real world conditions.
Customer input plays a crucial role in ensuring that our products meet the needs of our users. One key method we use is customer councils, which function like focus groups. We carefully select representative fleets from various sectors within our industry and bring them together for multiple sessions over the course of the development program. During these sessions, we provide updates on future product plans, seek feedback on their experiences with our products and competitors' products, and discuss their needs and priorities. The council members even drive trucks with the engineering development transmissions in them to provide feedback and ensure we are on-track to meet their expectations.
Prior to the start of production, we conduct a field test with customers. These customers use the trucks in full-time revenue service just like a production truck. The only difference is each truck has a data logger to record and monitor the performance of the transmission, and that at defined intervals, we remove the transmission and inspect it for any early signs of problems.
On the production side, we conduct pilot builds and limited volume builds with each OEM. This allows everyone to work out any kinks in the production systems prior to larger volumes being built. This is especially important on a product like Endurant XD, where there are body builders and upfitters downstream of the OEM who will be adding equipment such as PTOs to the transmission.
Most applications are tested at the truck level, where field test selection is crucial. The goal is to have representative trucks from the target segments or vehicle applications, whether it is a dump truck, dry van, or logging truck, and from different geographical regions. We also work with our OEM partners to copy specs of real world customer trucks when spec’ing engineering trucks. That way, our trucks replicate real trucks in the market.
We complement this with discrete use cases like slamming into loading docks and driving on ice and in muddy conditions at our Proving Grounds or as part of the multi-year field testing. This is done to demonstrate durability of the transmission on trucks in real applications.
Advanced technology plays a crucial role in our transmission testing process, ensuring top-notch reliability and performance. On the hardware front, we utilize the latest in Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) software to simulate everything from the loading of a gear tooth to the cooling performance of the lubrication system. Other cutting-edge techniques such as CT scans are used to inspect components like the cast aluminum housings. This allows us to ensure that there are no internal defects in the components.
The software in our transmission control module is critical to the performance of the transmission and undergoes its own development process. Software is first tested in a virtual environment on what is basically a small supercomputer. We run thousands of tests on each build of software before it is moves on to testing in the real world. We use engineering grade data loggers on all our development and field test trucks to record hundreds of signals. Powerful data analysis tools process all this data looking for both discrete problems with the transmission (a missed shift, for example) or trends that would indicate a durability problem.
We also use automated test cells to conduct longevity testing. A typical test uses electric motors on the input and output of the transmission to perform tests that would be impossible to do with a human driver. Some of the longest tests that we’ll run in these test cells will be up to 4,000 hours long and will take over six months to complete. Imagine driving a truck for over 6 months without ever stopping!
The transmission test cells replicate what the vehicle will experience in extreme conditions such as operating at peak torque climbing a hill. I sometimes explain it to people as if you’re driving up an infinite hill. We will pull that mountain grade for hundreds or thousands of hours in each gear to build up cumulative wear on the gears, shafts and bearings.
Advanced technology permeates every aspect of our testing process, from hardware and software evaluations to real-world simulations and longevity tests. This comprehensive approach guarantees that our transmissions meet the highest standards of functionality and durability, ensuring optimal performance in diverse conditions.
I would say the most important thing for fleets to understand about our testing process is that we take our testing process seriously. To ensure that our transmissions meet the highest standards, we subject them to rigorous testing protocols that include real-world conditions. We test our products mile after mile across diverse terrains and weather conditions. We want to make sure our transmissions can handle whatever the road throws at them, whether it's scorching hot or freezing cold.
And we're not just sitting in some lab running tests. Customer feedback is an important part of our testing process. By actively incorporating customer insights into our testing process, we not only address specific concerns but also gain a deeper understanding of how our transmissions perform in the field. This customer-centric approach allows us to refine our products, making them more reliable and better suited to our customers' evolving needs.
Our dedication to reliability extends to every component of our transmissions. We meticulously test each part, ensuring that even the tiniest components meet our stringent quality standards. From individual gears to the entire transmission system, every element is thoroughly scrutinized to guarantee flawless operation and durability.
