Turbocharger innovation: Enhancements to improve compressor performance

Turbo charger

Enhancing product capabilities through continuous innovation and improvement is the corner stone of Cummins Inc.'s effort to offer customers solutions that lower emissions without compromising engine performance. As part of the Destination Zero strategy, Cummins strives to lower carbon and other emissions for the trucking industry with its wide range of products and solutions. As the industry-leader, Cummins has the incredible opportunity and responsibility to lead the energy transition to alternative fuels and be part of the solution to the world’s climate challenges.

In the current scenario, there is an immediate need to lower emissions production from internal combustion engines (ICE). The low-carbon fuels available today, including biodiesel, renewable natural gas, and hydro-treated vegetable oil are all cost-effective means to reduce carbon emissions with immediate benefits and without requiring changes to the current transportation infrastructure. The transition towards reducing carbon and other emissions is becoming more prevalent in heavy-duty applications. This means that lower-emission trucks using ICE need to reduce their carbon footprint to contribute to the overall reduction in carbon emissions.

Continuous improvement in turbocharger technology is essential to meet the challenging demands of diesel and alternative fuel engines that strive to comply with stringent emission standards. Compressor performance is one of the most critical parameters in a turbocharger for delivering rated power and ensuring emission compliance. Cummins Components and Software’s (CCS) latest compressor stage enhancements increase compressor performance, complementing other innovations developed for Holset® turbochargers. The enhanced compressor stage from CCS consists of several new technologies coupled with the existing Super Map Width™ (SMW). This combination is suitable for applications across both on-highway and off-highway markets.

What are the benefits of the new compressor stage?

Key Improvements

Benefit(s)

Customer Benefit(s)

Improved surface finish

Higher Efficiencies

Improved performance variation

Improved Brake-specific fuel consumption (BSFC)

Improved vehicle performance variability

Lower wheel to housing clearances (abradable coating)

Higher Efficiencies

Improved BSFC

Optimized air handling

Tailored efficiencies characteristics

Improved BSFC

Enhanced oil sealing capability

Higher reliability

Less downtime

Optimized compressor stage

For matching on Hydrogen ICE or Fuel cell engines

Improved air handling

Manufacturing process

Improved quality

Improved durability/reliability

On-going projects include innovations in the low noise compressor stage and surface finish improvement to further enhance the compressor stage performance in alignment with customer requirements.

What experience does Cummins have with this type of improvements?

Cummins Components and Software has been continuously improving and adopting new technology for more than 60 years. The latest compressor designs utilize advanced Computational Fluid Dynamics (CFD) simulations, which, when combined with optimizer software, allow engineers to explore more design parameters to deliver improved performance, durability, and reduced noise.

“A key part of Cummins' strategy to facilitate energy transition will be how we continue to develop products to support lower emissions for ICE applications. As a part of this initiative, I am excited to be able to offer our customers improved compressor performance, building on our design capabilities to provide the customer with higher efficiencies and wider compressor maps. We have been able to leverage our global engineering expertise and advanced simulation analysis to develop these higher-performing stages while maintaining product robustness, which is also a key requirement in emission-leading markets.” - John Clark, Executive Director - R&E, Cummins Components and Software

Cummins' ongoing commitment to innovation and improvement ensures that these advanced compressor stage technologies can be seamlessly integrated across all product lines to meet evolving customer requirements. This dedication to enhancing product performance is evident in the latest Gen7 and Gen8 turbocharger models, which incorporate these cutting-edge improvements. As Cummins continues to innovate, the focus remains on delivering solutions that drive higher efficiencies, lower emissions, and unmatched reliability for customers.

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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