Developing Next Generation Innovations to Improve Diesel Engine Efficiency

Electrical WHR

Highly Durable, Highly Efficient and Compact Turbochargers Are Becoming Increasingly Desirable
Over the past few years, the market has seen global engine and vehicle manufacturers shift their focus from emission driven regulations to fuel economy improvements to insulate their customers from rising fuel prices. With fuel prices remaining high, Cummins Turbo Technologies is committed to focusing on developing next generation technologies to improve diesel engine efficiency. This trend in engine downsizing, in parallel with both engine and vehicle manufacturers striving to maintain or increase the power outputs from their products, is proving an engineering challenge.

Working Together
Working in partnership with many engine and vehicle manufacturers Cummins Turbo Technologies can offer bespoke products and versatile solutions using our global expertise and market knowledge. These close working relationship have informed the research and development that is shaping our future product range, leading to the creation of a new generation of technologies. We don’t simply provide off-the-shelf products, we develop advanced technological solutions that are ‘fit for market’, in partnership to meet customers’ specific requirements.

Next Generation Innovations
Cummins Turbo Technologies recently unveiled at IAA Hannover 2014, a selection of next generation innovations capable of improving the fuel efficiency of modern diesel engines by at least 10%, whilst also giving the customer a diverse range of technical options to help achieve the next stage of legislation.

Next Generation HE300VG
Variable geometry turbochargers provide optimum power output with efficient fuel consumption. This next generation HE300VG design has been enhanced specifically to improve efficiency, and its features and benefits include:

  • Improved turbocharger efficiencies of up to 12% enabling improved fuel efficiency and reduced CO2
  • 10% lighter than its existing counterpart creating greater fuel economy
  • Enhanced integration with the engine system due to a new actuator
  • Improved durability and optimized performance through the patented moving shroud variable geometry mechanism

Holset M2 Two Stage Systems with Rotary Turbine Control (RTC)
This bespoke technology sits within our specialist Modulated 2 stage (M2) product range and has been developed in partnership with the Cummins Engine Business Unit. The RTC technology is used to channel exhaust to the required areas for complete exhaust control capability. Its features and benefits include:

  • Enables our customers meet performance levels whilst still meeting stringent emissions target within light-duty market
  • RTC helps enable air flow range to reduce turbo lag whilst maximizing horsepower range
  • Optimized Aftertreatment operating conditions for emissions control
  • RTC enables thermal management control for exhaust regeneration functionality

Electric Waste Heat Recovery Turbine Expander
This prototype captures what would otherwise be lost energy, in the form of heat. It turns this into useful electrical (5kWe) power that is capable of offering a supplementary way of feeding a hybrid system with additional power. Its benefits include:

  • Reduces fuel consumption
  • Reduces CO2
  • Supplementary way of feeding a hybrid system with additional power

As the industry rapidly shifts to greater efficiency and reduction in CO2, innovative solutions are becoming increasingly desirable to engine and vehicle manufacturers.

As the global market leader in the design and manufacture of turbochargers for the commercial diesel engine sector, Cummins Turbo Technologies will continue to develop and expand on its innovative solutions to meeting todays and the future industry challenges

Cummins Turbo Technologies YouTube Channel

Watch the video on the Cummins Turbo Technologies YouTube Channel that showcases our next Generation Technologies capable of improving the fuel efficiency of the modern diesel engine.

Cummins Office Building

Cummins Inc.

Cummins, a global power technology leader, is a corporation of complementary business segments that design, manufacture, distribute and service a broad portfolio of power solutions. The company’s products range from internal combustion, electric and hybrid integrated power solutions and components including filtration, aftertreatment, turbochargers, fuel systems, controls systems, air handling systems, automated transmissions, electric power generation systems, microgrid controls, batteries, electrolyzers and fuel cell products.

Cummins Custompaks are being used for water management as Thailand struggles with its water crisis

CustomPak on site

Water crisis

Sixty Cummins Inc. CustomPaks are in service in Thailand as part of a critical water management plan aimed at easing the country’s water crisis – a crisis that has caused enormous economic and social damage and stirred conflict among communities.

Over the past several decades, Thailand has continually faced water problems caused by severe drought. Water reserves in dams and reservoirs are insufficient while water resources are often contaminated with toxins caused by urban communities and the industrial and agricultural sectors.

Severe flooding is a threat, too, at a time when the realities of climate change are hanging over the country.

As a result, the allocation of precious water resources, which must be shared among various stakeholders including new and existing industry, large and small agriculture, and cities and villages has become a flashpoint.

Kittithanapat Engineering Co. (KTP), has been involved in the water management system since 1996, working closely with authorities such as the Royal Irrigation Department, Department of Water Resources, Bangkok Metropolitan Authority and others.

CustomPaks on site

600 hp CustomPaks

To help KTP meet its often urgent requirements, Cummins DKSH (Thailand) has recently supplied 60 Australian-built CustomPaks – 45 powered by Cummins’ X15 engine rated at 600 hp, and 15 powered by the QSL9 rated at 325 hp. These fully self-contained powerpacks are emissions certified to Tier 3.

The CustomPaks are coupled to hydraulically-driven, large-volume submersible water pumps sourced by KTP from US company Moving Water Industries (MWI); KTP is the exclusive distributor in Thailand for these MWI Hydroflo pumps.

Prior to Cummins’ involvement, KTP was using another diesel engine brand but service support wasn’t up to the standard required.

Long-serving KTP engineer Kittisak Thanasoot says Cummins DKSH’s reputation for technical and aftersales support along with the reliability of the Cummins product were a key reason behind KTP’s decision to specify the CustomPaks for the Royal Irrigation Department.

The ability of Cummins DKSH to respond to short delivery times was also important.

“Supplying large quantities of high horsepower diesel engines for emergency situations such as flash flooding can be a challenge for KTP,” says Kittisak Thanasoot.

“Responding to the needs of the government agencies to manage such problems in a timely manner and with least impact on communities, KTP has found the answer in our partnership with Cummins DKSH.”

Power, pride and passion

Parked semi truck

The switch back to Cummins power has been beneficial for iconic New Zealand company Uhlenberg Haulage. It's all about whole-of-life costs.

Uhlenberg Haulage is closing in on 60 years in business, having been founded in 1966 by Mike and Carol Uhlenberg.

Based in Eltham, Taranaki, in New Zealand’s North Island, the operation is today owned and operated by their sons Chris, Daryl and Tony Uhlenberg.

Describing the Uhlenbergs as “old school family truckies”, Daryl talks about the company’s time-honored journey with a definite tone of pride, especially the work of his parents in laying the foundations for what is today an iconic fleet in its own right.

Cummins Inc. made its debut in the Uhlenberg fleet in 1971 with an NH250 powering a second-hand Kenworth K923 used in logging. A second Kenworth, a new W924 with a Cummins NTC335, followed soon after hauling an LPG tanker.

The Uhlenberg operation today comprises 40 prime movers and a variety of trailing gear to cater for the myriad of a jobs the fleet is involved in.

A number of Peterbilts feature in the fleet although Kenworth is now the brand of choice with six new units to be delivered over the next 12 months to cater for business growth.

Cummins’ X15 Euro 5 engine rated at 550 or 600 hp is the preferred power specification, with 18 red engines currently in the fleet.

Uhlenberg family in front of truck

Whole-of-life support

“The switch to Cummins has been a very good experience for us. We have nothing but praise for the Cummins organization,” says Daryl.

“The whole-of-life picture is the key thing for us and we’ve got that nailed with the support we get from Cummins – parts availability, scheduled maintenance, life expectancy and in-frame rebuilds.

“So the red engines turn up, we run them to life, which is 900,000 to 1.2 million kilometers, and then Cummins does an in-frame overhaul in a timely manner. If there’s an issue, parts and support are close by.

“The support we get from Cummins Palmerston North is fantastic, second to none.”

Daryl recently looked under a Kenworth that was in the workshop for a service and was surprised to see no oil leaking from the one-million-kilometer X15. “I remember when I was a fitter we had to wear a raincoat when working under a truck,” he jokes.

Fuel agnostic

Acknowledging that the push to decarbonize is now “very real”, Daryl likes the idea of Cummins’ fuel agnostic concept where one base internal combustion engine, optimized to run on diesel, can also be customized to run on ultra-low and zero-carbon fuels like renewable natural gas and hydrogen.

“My father was a pioneer of linehaul trucking in New Zealand and he always embraced new technology. He was never scared of it,” he says.

“I tend to be a little more cautious but I can see where a 500 hp natural gas or hydrogen engine would work for us in short haul applications,” he admits. “We’re certainly willing to look closely at these alternative fuel technologies when suitable infrastructure is in place.”

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