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The paper describes a process for the design of fuel-efficient diesel engine powertrains for heavy-duty commercial vehicles. A System Engineering approach is described that delivers optimal fuel efficiency by taking into account interactions among engine, exhaust aftertreatment, and vehicle systems. The primary objective of this approach is to develop a properly integrated system that delivers the lowest total cost of ownership (TCO) while maintaining high sociability, reliability, and performance. The paper will also discuss the role of competitive analysis and benchmarking, in-use duty-cycle analysis, design, simulation and final confirmation tests. System optimization is performed at critical steps in the process for engine hardware, control software and calibration, aftertreatment, engine accessories, powertrain components and vehicle interfaces.

This paper presents an overview of the process Cummins uses to integrate the engine and aftertreatment systems with the vehicle. This is a system integration process which assembles various subsystems such as the engine, aftertreatment, drivetrain, electronics, and cooling systems into one vehicular end product. It requires close collaboration with vehicle manufacturers and their suppliers. Given the wide range of vehicle types and applications, a robust process is needed. A synopsis of this vehicle integration process is included.