Title: Development of a KPI-focused hybrid model for the Cummins QSB6.7 engine used in load haul dump vehicles

Authors: Bismarck Louw; P. Stephan Heyns; Stephan Schmidt

Addresses: Centre for Asset Integrity Management, Department of Mechanical and Aeronautical Engineering, University of Pretoria, Pretoria, South Africa ' Centre for Asset Integrity Management, Department of Mechanical and Aeronautical Engineering, University of Pretoria, Pretoria, South Africa ' Centre for Asset Integrity Management, Department of Mechanical and Aeronautical Engineering, University of Pretoria, Pretoria, South Africa

Abstract: Diesel engines are vital in mining operations, powering machinery in harsh environments where reliability is critical to avoid costly downtimes and economic losses. This study presents a hybrid model for the Cummins QSB6.7 turbocharged diesel engine to optimise predictive maintenance and operational efficiency in load-haul-dump vehicles. Controlled experiments generated key performance indicator (KPI) data under varied loads, capturing thermal, pressure, power, and efficiency metrics via QuantumX and CANedge2 systems. Physics-based models were calibrated using global and local optimisation, with complex metrics like turbocharger rotational speed as design variables. Neural networks mapped operational data, such as engine speed and load, to these variables, enabling accurate KPI predictions with minimal input. The model achieved MAPEs of 6.21% for thermal, 5.08% for pressure, and 4.12% for power, demonstrating strong predictive accuracy and practical applicability in mining contexts. These results underscore the model's potential to significantly reduce unplanned downtimes and associated economic losses.

Keywords: hybrid diesel engine models; key performance indicators; physics-based Cummins QSB; mining; vehicle performance.

DOI: 10.1504/IJVP.2025.149499

International Journal of Vehicle Performance, 2025 Vol.11 No.4, pp.446 - 482

Received: 26 Jan 2025
Accepted: 07 Jul 2025
Published online: 04 Nov 2025 *

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