Dear ,

In addition to the fact that SmartTruck products are more technologically advanced and optimized than any competing aero solution, one of the most exciting areas of the SmartTruck design process is durability testing.  
 
SmartTruck uses a regimented design process for defining and releasing high quality product into the industry. From defining the design intent, to evaluating and specifying requirements, to testing and releasing, the engineering design lifecycle is taken very seriously.
 
Below is a brief outline of the engineering tools SmartTruck uses to continue to push the envelope, and provide customers with optimal drag reduction and improve fuel performance.
 
To learn more about SmartTruck product development, visit our website. 
 
Please don't hesitate to contact the  SmartTruck engineering team  or your local  SmartTruck representative  if you'd like to learn more.  For sales inquires or to purchase a SmartTruck System call (864) 236-4970 or click HERE to contact your local sales  representative
FINITE ELEMENT MODELING AND ANALYSIS

Finite Element Analysis (FEA) is one of the tools utilized once the initial design intent and first modeled pieces are produced. FEA gives SmartTruck the capacity to initially find approximate solutions to real world behavior, which could be a result of effects such as mechanical stress, vibration, and in some cases fatigue.
The diagram above is an example of the stress concentrations that can occur under varying load cases.


This diagram is an example view of the stress-induced ARG metal only, mounted on a generic trailer. The colors can represent stress or deflection, depending on settings.
The diagram above is an example of the stress concentrations that can occur at the rear, roadside area of the trailer during a simulated impact.
MATERIAL SELECTION AND MECHANICAL PROPERTY EVALUATION
 
Another engineering tool used to evaluate design solutions is material evaluations. This is typically done using several methods such as material-testing machines (tensile and compression), material composition testing, mechanical property research, engineering hand calculations, hardness tests, impact tests, corrosion resistance, and others....
 
Below are pictures of testing procedures SmartTruck routinely uses in evaluation of the ARG product and Side Fairing product. SmartTruck additionally takes advantage of third party material testing resources for support.
 
The diagram above shows the Side Fairing mounted on a table with loads attached at strategic points.
 
These points are provided by the aero engineers giving a specific load and position, translated from the aero lift it experiences on the trailer at specific speeds.
The SmartTruck Product Engineer, shown above, will use CMM to measure the fairing in a 3D coordinate system as a result of the static loads affect.
 
The data is then copied and transferred into SolidWorks, from which a surface model is created to show behavior changes.
DESTRUCTIVE TESTING
From a product durability standpoint, one of the most important product development processes performed is destructive testing. This is where the finalized concepts are subjected to worst-case environmental scenarios, to observe and evaluate the robustness of the application. This process also provides a method of comparing actual life behavior to computer-simulated behavior.

The test above shows the rivets used to install the Side Fairing brackets, being specifically tested for ultimate strength.

The testing is based on specified rivet mechanical properties and installation method.
Above, an R&D and Testing technician tries to prove his strength, while attempting to test the crush and fastening strength of the LeadEdge kit on the front of the trailer.

The LeadEdge won.

Destructive testing also involves accounting for small failure modes that could cause large issues after time.
 
Below is a water test being done on various Side Fairing bracket rivet installations. That water jet can spray up to 1600 psi.