DYNAMIC WHEEL LOADS FROM HEAVY VEHICLES Dr Lloyd Davis PhD, Grad Dip(Control), BEng(Elec), Cert(QMgt), CEng, RPEQ, FIET Abstract Research was undertaken to determine the forces exerted on pavements from an instrumented triaxle group of a semi-trailer. A combination of accelerometers and strain gauges was used to determine both static and dynamic wheel forces. A novel roughness value of the roads during testing was derived. Dynamic pavement forces are presented according to the range of novel roughness of pavement surfacings encountered during testing. Left/ right imbalances of wheel forces are presented for varying speeds. A conclusion drawn from research indicates that pavement models need to be revised as instantaneous dynamic wheel forces are not generally considered in contemporary pavement designs. The mean and standard deviation of heavy vehicle wheel forces do not correlate with pavement roughness however peak wheel forces do. Introduction This article is a combination of earlier work presented at the Transport and Main Roads Technology Forum 2009 combined with subsequent results from a recent research project, Heavy Vehicle Suspensions –Testing and Analysis. Pavement design life calculations are based on repetitive loadings arising from repeated passes of a theoretical heavy vehicle (HV) axle. Conceptually, this pavement life design parameter is based on the number of passes of a standard axle over a pavement. This measure is, in turn, based on tests conducted after the World War II by the US military where trucks were driven repetitively over a pavement until the pavement became unserviceable (6). The number of passes that the trucks made (i.e. the number of axle repetitions including some dynamic forces) determined the design parameter for pavement life. The terms “equivalent standard axle” (ESA) and “standard axle repetition” (SAR) came into use to allow pavement life to be correlated to axle repetitions or passes at different axle masses. The physical size of vehicles, number of axles and axle loads has increased historically as a result of technology and the push for more freight efficient vehicles. As the need for a vehicle driver is a given, costs are reduced in these freight efficient vehicles by utilising more axles, more mass per axle and more trailers. Increased wheel loads have added additional stress to the road surfacings. Continued pressure is maintained on road authorities for increases in HV mass limits and other HV changes. Nonetheless, the basic theory for determining pavement life as a value of vehicle passes has not altered significantly since the US military experiments last century (1,22). Australia’s accelerated loading facility (ALF) and New Zealand’s Canterbury accelerated pavement testing indoor facility (CAPTIF) have been used to determine pavement life in a similar manner to the original US testing, that is; repeated passes of a test wheel at a particular increased load over a pavement (22,23). Much work has been done using the CAPTIF to correlate dynamic wheel forces with axle passes (13,14,15). Further, a considerable body of work has been undertaken in the UK (3,4,5,6) on dynamic wheel loadings from HVs. Results of that work have not yet been incorporated into general pavement design, particularly in Australia (22,23). Unofficial estimates put the number of road friendly suspensions (RFS) sold in Australia per year at 90% to 95% (28) of the total HV fleet1. RFS in Australia generally incorporate air springs, although there are some steel-sprung RFS emerging onto the market. A body of work has already been performed some time ago on dynamic HV wheel forces. However this previous research focused mainly on the suspension types of the day such as Hendrickson and simple leaf spring suspensions with inter-leaf friction dampening. 1 Actual numbers are not readily available as commercial sensitivity and competitive forces between manufacturers limit reporting more accurately. Because of the current predominance of air spring suspensions in HVs, there exists a need to understand the fundamental characteristics of air spring suspensions and determine the corresponding dynamic interaction between the vehicle tyres and the road pavement. A semi-trailer with air springs was chosen for the testing and the axles instrumented to measure dynamic wheel forces. Although other HVs were tested as part of the project (7,10,11,12), the semitrailer test is the subject of this article. The semitrailer tri-axle group spacing was 1.4m. The wheel forces were measured on typical pavements at various roughness levels and at different road speeds. The instrumentation installed on the semi-trailer allowed a novel roughness measure to be derived together with the mean, dynamic range and peak dynamic pavement forces. This article presents heavy vehicle dynamic wheel-forces at the pavement according to the range of novel roughness of pavement surfacings encountered during testing. of the axle as close as possible to the wheel hub. These gauges were calibrated to measure the vertical shear force, Fshear. The strain gauges in this position could not detect the inertial component of wheel forces further outboard from the point where they were mounted. These inertial forces were measured by mounting an accelerometer outboard of the strain gauges and as close as possible to the hub of interest. Dynamic wheel forces were determined by combining the accelerometer and strain gauge signals as indicated in equation (1). (1) This is sometimes termed the “balance of forces” technique (6,8,13,21,29,30) and is illustrated diagrammatically in Figure 1 where: a = acceleration experienced by the mass outboard of the strain gauge Determining dynamic wheel forces Measuring dynamic wheels forces directly at the wheel is not an easy task. In this project the wheel forces were calculated by the use of a combination of accelerometers and strain gauges mounted onto the axle. The strain gauges were mounted on the sides m = Fshear = mass outboard of the strain gauge shear force on the axle at the strain gauge Axle Shear forces - Fshear Strain gauges Wheel force - Fwheel Figure 1. Instrumented HV axle used to derive tyre forces (8) Accelerometer Bins loaded with scrap steel were used to load the semi-trailer (Figure 2) to the maximum allowable mass for a tri-axle group — 3.3t per set of duals or 1.65t per tyre. HV air spring suspensions have very little internal damping. Hence dampers (shock absorbers) play a very important role in an air suspension’s performance characteristics. All suspension dampers were renewed for the testing. New tyres were fitted and inflated to the manufacturer’s specification. Auxiliary roll stiffness and Coulomb friction within the HV suspension were in accordance with the manufacturer’s specification and remained consistent during the tests. Tests were performed in the Brisbane area on both highway and suburban roads and at different speeds. The roads chosen had a mix of speed, roughness and surface textures and were representative of what may be expected during typical low, medium and highspeed HV operation. Novel roughness Road roughness is usually designated by a standard measure - the international roughness index (IRI). This measure is the sum of vertical oscillation movement distance of a calibrated vehicle relative to the horizontal distance travelled along the road during the test run. The units of this roughness measure are mm/m or m/km. This measure is now standardised for use around the world (25,26). Early Australian efforts need to be recognised (18) - Figure 3 shows a device for measuring roughness developed in Australia in the early 1970s by NAASRA 2. Roughness was derived from the positive-going movements between the chassis and rear axle of a calibrated vehicle (usually a Ford Falcon station sedan). Each count was proportional to approximately 15mm of movement. Modern techniques measure roughness by a combination of height measuring lasers and accelerometers. Sprocket with one-way clutch 2174 Spring Revolution counter Differential Figure 3. Diagram of the NAASRA novel roughness meter Figure 2. Test weights on semi-trailer vehicle The dynamic signals from the on-board instrumentation were recorded over a 10s sample time at a 1kHz sample rate resulting in 10,000 data points per test. Detailed testing procedures are documented elsewhere (7,9,10,12). Each semi-trailer hub had acceleration data recorded during the on-road testing. Net vertical acceleration measured at the hub was used after compensation for the constant gravity component. A double integration was performed on the vertical acceleration data. This yielded a novel roughness value of positive vertical movement of the axle for a given horizontal distance travelled at a constant speed. The horizontal distance travelled during each 10s sample period is dependent on vehicle speed; hence the HV speed during each test was recorded and included in the derivation of the roughness results. 2 NAASRA was the National Association of Australian State Road Authorities. Its name changed and later became Austroads. distinguish between contributory forces from the axle-to-body dynamics of the test vehicle compared with those from the surface irregularities of the pavement (25,26). Even so, the novel roughness value provided an independent variable against which to plot wheel force as the dependent variable. Equation 2 provides a mathematical derivation of the novel roughness value used. novel roughness = ªn a f º «³ ³ a» ¬ 0 a 0 ¼ x 1000 mm/m v (2) where: Wheel forces vs. novel roughness = net upward hub acceleration during the The data plotted from Figures 4 to 6 shows the peaks, standard deviations and means of the wheel forces vs. novel roughness values for the front axle of the tri-axle group of the semi-trailer. The front axle plots were very similar to those of the other two axles. recording period in ms-2 v = velocity in ms-1 per 10s sample period n = the number of data points recorded per 10s sample period The linear regression correlation coefficients for the relationship between semi-trailer wheel force parameters and novel roughness (Figures 4 to 6) were derived and are summarised in Figure 7. Note: Only the positive values of acceleration are integrated, in line with the philosophy of the IRI measure. This novel roughness value should not be equated to the IRI value as the novel roughness is determined for a very short length of road while IRI tends to be calculated over longer distances. It was derived to provide an indicative measure of roughness as experienced by representative hub accelerometers. It arose from the unsprung mass dynamics combined with road surface irregularities, wheel load and speed. In this way, it was similar to the methodology for determining IRI; that methodology does not In general, the semi-trailer’s increasing peak wheel forces, exemplified in Figure 4, corresponded to increasing “novel roughness” values with linear regression correlation coefficients well above 0.707. Neither the standard deviation, nor the mean of the wheel forces, correlated to increasing novel roughness, even though Figure 6 may have indicated this on visual inspection. Peak wheel forces vs. Novel roughness - front semi-trailer axle 9000 LHS wheel force - semi-trailer axle RHS wheel force - semi-trailer axle 7000 6000 5000 4000 Novel roughness (mm/m) 0 XXX 0000 Figure 4. Semi-trailer axle peak wheel forces vs. novel 5.89 5.22 4.3 3.8 3.51 2.55 2.53 2.46 2.31 3000 2.03 Wheel force (kg) 8000 2.62 a Std. dev. of wheel force vs. Novel roughness - front semi-trailer axle 1000 900 700 600 500 400 300 200 5.89 5.22 4.3 3.51 2.55 2.53 2.46 2.31 2.03 0 3.8 LHS wheel force - semi-trailer axle RHS wheel force - semi-trailer axle 100 2.62 Wheel force (kg) 800 Novel roughness (mm/m) Figure 5. Semi-trailer axle mean wheel forces vs. novel roughness Std. dev. of wheel force vs. Novel roughness - front semi-trailer axle Std. dev. of wheel force vs. Novel roughness - front semi-trailer axle 1000 1000 600 500 400 300 200 5.89 5.22 4.3 3.8 3.51 2.55 2.53 2.46 600 2.31 0 2.62 LHS wheel force - semi-trailer axle RHS wheel force - semi-trailer axle 100 2.03 700 700 Novel roughness (mm/m) 500 400 300 200 0 XXX 0000 Novel roughness (mm/m) 5.89 5.22 4.3 3.8 3.51 2.55 2.53 2.46 2.31 0 2.62 LHS wheel force - semi-trailer axle RHS wheel force - semi-trailer axle 100 2.03 Wheel force (kg) 800 800 Wheel force (kg) 900 900 Document7 Figure 6. Semi-trailer axle std. dev. of wheel forces vs. novel roughness The linear regression values for the three derived parameters on the left side did not vary from those on the right. Accordingly, whole-of-axle results are shown in Figure 7. A t-test (Figure 8) was performed for variations of the left and right hand sides of the axle with respect to standard deviation, mean and peak wheel forces against increasing novel roughness values. A t-test is one test for confirming, or otherwise, a hypothesis where the test results follow a Student’s t distribution if the null hypothesis is supported (20). The shaded areas of Figure 8 indicate that the only forces that varied per side were the mean wheel forces with a 90% confidence value. Correlation coefficient, R, of wheel force parameters over novel roughness range – semi trailer axle group Std. dev. per axle Mean per axle Peak per axle Rear Mid Front Rear Mid Front Rear Mid Front <0.707 <0.707 <0.707 <0.707 <0.707 <0.707 >0.707 >0.707 >0.707 Figure 7. Correlation coefficients for wheel forces vs. novel roughness Left/right wheel force t-test table for range of novel roughness – semi trailer axle group Std. dev. per axle Mean per axle Peak per axle Rear Mid Front Rear Mid Front Rear Mid Front 0.923 0.852 0.840 0.0406 1 x 10-4 1 x 10-4 0.527 0.194 0.537 Figure 8. t-test results for left/right wheel force variation over “novel roughness” range. Speed (km/h) Left/right wheel force t-test table – semi trailer axle group Std. dev. per axle Mean per axle Peak per axle Rear Mid Front Rear Mid Front Rear Mid Front 40 0.576 0.883 0.768 0.633 0.016 0.018 0.801 0.434 0.344 60 0.978 0.867 0.887 0.591 0.001 0.003 0.801 0.544 0.943 80 0.851 0.809 0.767 0.290 0.028 0.036 0.624 0.631 0.831 90 0.881 0.909 0.885 0.063 0.010 0.019 0.795 0.684 0.804 Figure 9. t-test summary table for left/right variation axle forces vs. speed Wheel forces left/right variation vs. speed Semi-trailer wheel forces were subjected to a t-test for left/right position correlation vs. speed; the results are shown in Figure 9. The t-tests indicated that the mean wheel forces on the front and middle axles of the semi-trailer varied per side for all speeds and with a 90% confidence value (shaded). This was predominantly on the left but was biased toward the right for one-way right lane test sections. It is likely that these variations resulted from the centre-of-gravity (CoG) of the semi-trailer shifting to the left or the right, depending on cross fall. This result was not too dissimilar from that for the mean forces being dependent on side as in Figure 5. The semi-trailer’s front and middle axles were particularly affected by left/right variation but the rear axle was only affected at the highest test speed. This would seem to indicate that the front two axles on the semitrailer had left/right imbalances where the CoG was thrown to one side or the other by the cross-fall of the road for suburban up to intermediate speeds. The rear axle was not so affected until highway speeds were reached. by the adoption of road friendly suspensions but the efficacy of these in reducing wheel forces is still open to debate, especially when these are not maintained (5, 8, 27). When a vehicle’s tyres hit imperfections in the road surface, dynamic wheel forces result. These dynamic wheel forces have various frequencies of vibration. There are two predominant types of vibrations axle-hop and body bounce. Body bounce has the lower vibration frequency of the two. As semi-trailer axle-hop and body-bounce frequencies are the inverse of a signal’s period, this may be translated back into a value of wavelength as measured on the road. The result of these cyclic variations in axle loads may be seen as road damage at regularly spaced intervals. This cyclic length is dependant on vehicle speed and may be derived from the fundamental relationship between speed and distance as follows: Distance travelled = velocity x time for one cycle (3) Time for one cycle Road damage wavelength Government Acts and Regulations, pavement design manuals, etc tend to refer to vehicle static axle loads. Indeed, when HVs are weighed for regulatory purposes they are weighed statically not dynamically. When Transport and Main Roads installs in-road dynamic weight systems for survey information, particular care is exercised to ensure the road prior to the weighing device is smooth and flat. Similarly, lay-bys for enforcement weighing and the decks and approaches of static weighbridges are smooth and level. Measuring dynamic wheel forces directly is complex, as shown above. Dynamic forces are considered, to some extent, Vehicle/axle group Semi-trailer tri-axle group 1 frequency Combining equations 3 and 4 gives: Distance travelled velocity frequency (5) Applying equation 5 to the test data, the HV’s suspension wavelengths were derived after examining the dominant axle-hop and body-bounce frequencies at the corresponding test speeds (12). For brevity only wavelengths for highway speeds are shown in Figure 10. Speed (km/h) Bodybounce frequency (Hz) Axle-hop frequency (Hz) Suspension wavelength distance corresponding to the body-bounce frequency (m) Suspension wavelength distance corresponding to the axle-hop frequency (m) 80 90 80 90 1.7 1.7 1.7 1.7 10.03 10.0 12.04 12.0 13.1 14.7 13.1 14.7 2.2 2.5 1.9 2.1 Figure 10. Predominant suspension frequencies and wavelength distances 3 lower bound for semi-trailer axle-hop. 4 upper bound for semi-trailer axle-hop. (4) Discussion The measures of standard deviation, mean and peak dynamic wheel forces all combine to show a picture of pavement forces in the real world. Instantaneous values of these forces can be up to double those of the static force for which the pavement was designed. Pavement damage models use a “power law” damage exponent to account for the variation in empirical pavement life correlated to axle load (Equation 6). § Load on test axle · Pavement damage ¨ ¸ © Standard axle load ¹ N (6) Pavement life calculations are based on standard axle loads with equal wheel loads. However, in practice, equal wheel loads from one side of a vehicle to the other are rarely achieved. As an indicative exercise, a 3% cross-fall with a conservative CoG height of 1.5m causes a variation in wheel loads of approximately 4.5 % when compared to the theoretical value for a flat surface (Figure 11). This 4.5% variation correlates conservatively with the results as indicated in Figure 5. Wheels on the left of the vehicle will add additionally to pavement distress in two ways. 1. Moisture related pavement distress is caused The value of N is dependent on the type of materials used in the pavement construction. The current pavement models that use a number of quasi-static passes of a HV axle at a theoretical loading to determine pavement life do not always consider peak dynamic forces; usually they consider some nominal static force with an allowance for standard deviation of the dynamic forces. On-board mass research has found that mean wheel forces of HVs in travel mode are not equal to static wheel forces (19). The quasi-static application of pavement loads from HV wheel forces in these models for pavement design should be reviewed in light of the dynamic data from the research presented here and by others (3,4,5,6). More realistic dynamic pavement loads from HVs need to be considered. The semi-trailer wheel force standard deviations and mean wheel forces did not correlate with increasing novel roughness values. However, peak wheel forces from the semi-trailer did correlate to increasing values in novel roughness. Indicatively, the semitrailer exhibited variation per side in mean wheel forces. These results obtained in this project make a case for micro-profiling or pavement overlays on roads which have gone beyond some threshold roughness value. Perhaps beyond some threshold roughness, additional accelerated deterioration occurs beyond normal predicted values due to the increased dynamic wheel forces. Roughness increases dynamic wheel forces which in turn cause accelerated road damage (roughness) and so on — a vicious circle. by water infiltration from road shoulders and embankment edges. Hence moisture content is typically higher in the LHS or outer wheel path. Higher pavement moisture content accompanies reduction in pavement strength. Seasonal rainfall has thus more effect on the outer wheel path than the inner wheel path. One consequence of these effects is increased wheel rutting in the outer wheel path which further leads to water ponding in ruts and depressions with increased moisture penetration and accelerated pavement degradation. 2. For a standard road formation with a cross-fall toward the LHS, a vehicle’s centre-of-gravity will be closer to the LHS wheel than the RHS wheel (Figure 11). The amount of weight increase on the LHS will be matched by a decrease in weight on the RHS wheel. The increase on the LHS wheel load will be correspondingly accompanied by an increased probability of greater dynamic wheel forces. Accordingly, further unpredicted accelerated deterioration will occur when more heavily-loaded LHS wheels combine with higher moisture content pavements. 1500mm 3% crossfall Rav + 4.5% 948mm Rav - 4.5% 1038mm Figure 11. Effect of crossfall on wheel loads As indicated in equation 7 below, a 4.5% increase in wheel load over a standard ESA wheel load will result in a 20% increase in road damage. This increase is very conservative as a damage factor of 4 is used with no other allowance for dynamic effects. Even using existing, conservative models, an indicative 20% increase in damage on the LHS of the lane would indicate the need for a different design standard on that part of the running lane. The model in Figure 11 does not take into account dynamic vehicle roll or the additional load transfer as a result of fifth wheel interaction, tyre deflections, chassis and suspension interaction. Geotechnical domain experts should consider the above factors in combination with a higher damage power value. 4 ª1.045 º Pavement damage v « » | 1.2 or 20% increase ¬ 1.0 ¼ (7) A solution to this issue that was proposed some years ago was to replace the uniform thickness base layer with a tapered base layer. The base would be thinnest at the crown and thickest at the shoulders. This solution was not put into practice. The contribution that body-bounce force makes to pavement force is approximately equal to that of axlehop force (12). Accordingly, two sets of suspension wavelengths need to be examined as they both 5 27.7m for 10Hz @ 100km/h contribute to peak pavement forces from HV wheels. Wheel forces from body bounce at highway speeds will be repeated at approximately 15 - 28 m spacings5. Axle-hop repetitive forces will occur at approximately 2 - 2.5 m intervals, depending on speed of travel. This is termed “spatial repetition” and has been well documented (17). Should a particular suspension have its axle hop frequency (i.e. axle hop force repetition) as a multiple of its body-bounce frequency, a doubling of the instantaneous pavement force will occur where the two coincide at a common wavelength node. Conclusion The results of the testing indicate that augmentation of existing pavement models should be examined. Some pavement damage models that use static load values have been mentioned above. Further, neither roughness values nor peak wheel forces are included in Australian pavement design models (2,22,23). The results here indicate that the correlation of wheel forces to roughness needs to be explored further, as noted in other research (24). Further, the adherence to HV suspension dynamic metrics containing only standard deviations (16,27) needs to be re-examined since the peak wheel forces of one of the workhorses of the Australian HV fleet, the semi-trailer, varied proportional to novel roughness in a statistically significant manner whereas neither the wheel force standard deviations nor the mean wheel forces so varied. Augmentation of pavement models should account for: 4. Cebon D. Interaction between heavy vehicles • actual dynamic wheel loading effects 5. Cebon D. Tyres, Suspensions and Road Damage. • a more complex set of considerations than simply the static loads and roads. Paper presented at the 39th L Ray Buckendale lecture. 1993 5th Brazilian Congress on Roads and Concessions. 2007 6. Cebon D. Handbook of vehicle-road interaction. • the issue that neither standard deviation nor mean wheel forces are dependant on roughness • changes of wheel loads due to pavement cross fall and vehicle dynamics. In particular, the left/right variation apparent in mean wheel forces and the highly-dependent relationship between novel roughness values and peak wheel forces needs to be investigated further by pavement technologists, geotechnical engineers and other domain experts. Particular attention needs to be made to the indication that the pavement under the outer wheel path may need a different design standard from that of the inner wheel path pavement. The cause and effect relationship between roughness, dynamic wheel loads and accelerated pavement deterioration are other areas worthy of further research. Lisse, South Holland, Netherlands: Swets & Zeitlinger. (Ed.) 1999 7. Davis L. Further developments in dynamic testing of heavy vehicle suspensions. Paper presented at the 30 th Australasian Transport Research Forum (ATRF). 2007 8. Davis L, Bunker J. Heavy Vehicle Suspensions – Testing and Analysis. A literature review. Brisbane, Queensland: Queensland Department of Main Roads; Queensland University of Technology. 2007 9. Davis L, Bunker J. Heavy vehicle suspensions testing and analysis: Phase 3 - eigenfrequency peak loads. Test plan. Brisbane, Queensland: Queensland University of Technology. 2008 10. Davis L, Bunker J. Larger air lines in heavy Acknowledgements I would like to acknowledge the contribution and advice from various officers of the Department of Transport and Main Roads, Dr. Jon Bunker, Dr. John Fenwick, Greg Hollingworth, Dr. Hans Prem, Tramanco, Volvo Australia, RTA, Mylon Motorways and Haire Truck & Bus. References 1. Alabaster D, Arnold G, Steven B. The equivalent standard axle approach and flexible thin surfaced pavements. Christchurch New Zealand: Transit New Zealand, Pavespec Limited, University of Canterbury. 2004 2. Austroads Pavement design: A guide to the structural design of road pavements. Sydney, NSW, Australia: Austroads. 1992 3. Cebon D. Assessment of the dynamic wheel forces generated by heavy road vehicles. Paper presented at the Symposium on Heavy Vehicle Suspension Characteristics, Canberra, Australia. 1987 vehicle suspensions – differences in wheel and air spring forces. Paper presented at the 31st Australasian Transport Research Forum (ATRF). 2008 11. 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