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1104D Mechanical

1104D Mechanical. Transient Performance Characteristics. Introduction

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1104D Mechanical

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  1. 1104D Mechanical Transient Performance Characteristics

  2. Introduction The 1104D Mechanical represents a significant achievement in providing our customers with a minimum-impact route to Tier 3 compliance and provides a market-leading level of power density & performance. However, Tier 3 emissions limits in this power range are significantly tighter than at Tier 2 and this effectively limits the range of possible ‘adjustment’ to optimise engine performance. Customers are likely to identify some changes in the response characteristics of the engine, when compared to a comparable Tier 2 model. In many cases, these changes will be insignificant, or may be overcome by fine-tuning of the installation/ driveline; in other cases, the customer requirements may be more effectively satisfied through the selection of a different engine configuration.This presentation is the front piece to a package of information that sets out to: • Reinforce the positioning of the 1104D Mechanical product within the range; • Define areas where customers might see a change in machine operating characteristics; • Identify areas where compensating adjustments could be made to machines; • Provide guidance as to the sensitivity of various application types to these issues; • Suggest the most suitable engine configuration for specific customer sensitivities The objective is to ensure that the customer has enough information to make an informed selection of the most appropriate engine configuration for the application.

  3. Presentation Overview • Section 1: • 1104D Product Positioning • Customer Expectations at Stage IIIA/ Tier 3 • Section 2: • What is Transient Response? • 1104D Transient Characteristics • Section 3: • IPSD Journey to Stage IIIA/ Tier 3 Mechanical • Section 4: • Selling the transient message

  4. Section 1 Product Positioning at Stage IIIA/ Tier 3 ‘Selling the Range’

  5. Section Agenda • Tier 3 Product Positioning Overview • Electronic Positioning • Mechanical Positioning • Customer Expectations at Stage IIIA/ Tier 3

  6. Tier 3 Product Positioning Overview • Transient concerns (smoke & response) can be avoided by selecting the right product for the application • Strong 4.4L product range at Stage IIIA/ Tier 3 • Electronic & Mechanical offering • Power range overlap • Unique sales propositions • Mechanical offering = Minimal change • Electronic offering = Optimum Stage IIIA/ Tier 3 performance • Mechanical product offers significant commercial benefits but won’t provide the performance benefits of the Electronic product

  7. Electronic Positioning • Utilises proven components of Caterpillar ACERT™ technology • Common rail fuel system • Smart wastegate turbocharger • Performance optimised across the load and speed range • Optimised SFC • Minimised heat rejection Electronic Control means Optimum Tier 3 Performance

  8. Mechanical Positioning • Design goal to maintain as close to Stage II/ Tier 2 performance with minimal external changes • Development focus on internal improvements: • Combustion chamber • Air system (camshaft & cylinder head) • Fuel Injection • Cooling system Mechanical Control means Minimum Change from Tier 2 Ease of Changeover

  9. Mechanical Positioning • Package virtually identical to Tier 2 & Tier 0 • Identical major hook-up points • Minimal visible external changes • Common front and rear ends • Many components carried over (95%) • Product reliability • Minimised additional parts inventory • Streamlined training • Consistent serviceability • Low OEM investment costs • Minimised engineering costs

  10. Customer Expectations at Tier 3 • ‘The next generation is always better’ • ‘The engine will be more responsive at Tier 3’ • ‘The engine will have less visible smoke at Tier 3’ • General Customer Expectations: • Driveability = Tier 2 or better • Smoke = Less visible smoke • Power/ Torque = Tier 2 or better • Fuel Consumption = Minimal change • Package Size = Drop-in solution • General Performance = Improvements • In reality, achieving a Mechanical offering at Stage IIIA/ Tier 3 results in some compromises (especially levels of visible smoke and low speed response)

  11. Section 2 1104D Mechanical Transient Response Characteristics

  12. Section Agenda • Transient Performance Overview • What is Transient Response? • 1104D Mechanical Transient Response Characteristics • Load Acceptance from Low Idle • Loaded Acceleration from Low Idle • Acceleration from a Loaded Condition • Free Acceleration Smoke (FAS) • Loaded Acceleration Smoke

  13. Transient Performance Overview • Emissions • Challenge was significant for Mechanical products at Stage IIIA/ Tier 3 • Challenge is shared by the competition • Transient characteristics are different at Stage IIIA/ Tier 3 due to the technologies employed to achieve emissions legislation • Customer Management • Understand the transient characteristics of the 1104D • Manage customer expectations accordingly • Match the right product to the right application • Utilise the full product range, it is a key strength!

  14. What is Transient Response? • Responsiveness of the Machine • Load acceptance from low idle • How the engine responds when applying sudden load • Loaded acceleration from low idle • How the machine performs accelerating from a standing start • Acceleration from a loaded condition • How the machine feels accelerating through the speed range • Smoke • Free Acceleration Smoke (FAS) • Level of black smoke when blipping the throttle from idle with the machine in neutral and any PTO unloaded • Loaded Acceleration Smoke • Level of black smoke generated during acceleration with the machine loaded

  15. 1) Load Acceptance from Low Idle • How the engine responds when applying sudden load? • Load Acceptance from Low Idle degradation from equivalent Stage II/ Tier 2 model • 1104D-44: -10% • 1104D-44T: -20% • 1104D-44TA: -10% • The trade-off between low speed, un-boosted torque and Free Acceleration Smoke (FAS) has been optimised for all ratings by the Engineering team at IPSD • Customers can increase low idle speed, or rematch machine transmission and hydraulic demands, to further improve performance

  16. 2) Loaded Acceleration from Low Idle • How the machine feels to the operator when accelerating from a standing start with a heavy load? • Loaded Acceptance from Low Idle degradation from Tier 2 • 1104D-44NA: -10% • 1104D-44T: Dependent on machine loading characteristics • 1104D-44TA: Dependent on machine loading characteristics • Atmospheric Boost Control (ABC) will improve performance • IPSD offers two variants of low pressure options to best match to application • Customers can increase low idle speed, or rematch machine transmission and hydraulic demands, to further improve performance

  17. 3) Acceleration from a Loaded Condition • How the machine feels to the operator when accelerating through the speed range? • 1104D will achieve boosted fuel at lower manifold pressure than the 1104C Stage II/ Tier 2 range • The product will feel more responsive in many circumstances • Naturally Aspirated product (1104D-44) will see a degradation of around 10% compared to Stage II/ Tier 2

  18. 4) Free Acceleration Smoke (FAS) • Level of black smoke when blipping the throttle from idle with the machine in neutral and any PTO’s unloaded? • FAS will be higher than 1104C but within legislation requirements (including Switzerland & Austria) • There will be visible black smoke at Stage IIIA/ Tier 3 Mechanical • Smoke acceptability is highly subjective • Manage customer expectations relative to Stage II/ Tier 2 product • Certain markets will be more sensitive to smoke than others • The trade-off between low speed, un-boosted torque and Free Acceleration Smoke (FAS) has been optimised for all ratings by the Engineering team at IPSD • Customer improvements can be made by optimising drive train inertias and managing engine acceleration

  19. 5) Loaded Acceleration Smoke • Level of black smoke generated during acceleration with the machine loaded? • Loaded Acceleration Smoke will be higher than 1104C • Smoke levels are highly subjective and will need to be assessed at the customer level • Flag the issue to Applications if… • The customer is in a highly smoke sensitive market (e.g. Scandinavia) • The environment the machine is operating in requires no visible smoke (e.g. indoor) • The machine will be performing a lot of complex operations (e.g. Shovel Loader)

  20. Section 3 IPSD Journey to Tier 3 Mechanical

  21. Section Agenda • Emissions • Technology Choices • IPSD Tier 3 Solution • Performance Comparison: Tier 2 to Tier 3 • 1104D Mechanical Performance

  22. Heavy-Duty Diesel NOx-PM Trade-Off By Technologies and Legislation Tier 3 Off-Highway <75kW Needham, J., 1991. "Engine Experience and EPA Regulations", University of Minnesota Short Course “Diesel Particulate Matter”, October 1991 Tier 3 Emissions Challenge Experience from on-highway development shows that Tier 3 levels of NOx would typically require Electronic FIE strategies. Some engine manufacturers have achieved Tier 3 levels with rotary mechanical FIE, using innovative technological approaches. IPSD will offer a full range of mechanical products between 54.5 and 83kW, from NA to TA to meet the needs of each customer.

  23. Technology Options at Tier 3 Mechanical • Air System • Charge-Air Cooling • Variable Geometry Turbo (VGT) • Fuel System • Multi-Shot Injection • Injection Rate Shape • Injection Retard • Combustion System • Re-Entrant Piston Bowl • Quiescent Combustion (with high-pressure FIE) • Optimised port swirl • General • Reduce Engine Parasitics • Optimise Torque Curve Shape

  24. IPSD Stage IIIA/ Tier 3 Solution • IPSD has achieved Tier 3 emissions standards with minimal customer impact and maximum carry over of today’s proven design by innovative development of: • Air system strategies • FIE • Combustion chamber • FIE boost control SFC, heat rejection, and transient response trade-off optimised * Patents applied for

  25. 400 380 360 340 320 Torque [Nm] 300 280 260 240 220 200 800 1000 1200 1400 1600 1800 2000 2200 Engine Speed [rpm] Performance Comparison: Tier 2 to Tier 3 Tier 2 Full-load torque curves are similar for Tier 2 and Tier 3 ratings Tier 3 However, un-boosted torque is lower on Tier 3 due to emissions control strategies The penalties of low un-boosted torque have been offset to some extent by management of fuelling control to transition to fully-boosted torque at lower speed • Tier 3 Concerns: • Low-speed load acceptance • Acceleration from low idle • Operating close to smoke limit • Tier 3 Strengths: • Competitive mechanical strategy • More responsive from part load than Tier 2 • More lugging capability than Tier 2

  26. 1104D Mechanical Performance • Performance Features: • BSFC and heat rejection believed to be highly competitive • Noise reduction over Stage II/ Tier 2 will be noticeable • Load acceptance and response believed to be competitive • Reliability and durability as Stage II/ Tier 2

  27. Section 4 Selling Transient Messaging

  28. Section Agenda • Competitive Landscape • Transient Sales Messaging • Transient Response – Practical Approach • What should I be doing?

  29. Competitive Landscape • Competition will have a similar, or greater, challenge with Transient Performance at Stage IIIA/ Tier 3 • Technology choices are the same for all competitors marketing Mechanical product • Cummins QSB 3.3 • Reduced displacement 4 Cylinder engine • Expect Load Acceptance from Low Idle degradation from Stage II/ Tier 2 of around 25% • Competition using for example AVL TINER system • Expect Load Acceptance from Low Idle degradation from Tier 2 of around 10% to 25%

  30. Product Benefits Competitive Mechanical Product Strategy Strong Sales Proposition Strong Steady State Performance Responsiveness from Part Load same or better than Stage II/ Tier 2 Lugging Capability same or better than Stage II/ Tier 2 Product Sensitivities Low Speed Load Acceptance Acceleration from Low Idle Transient Smoke Transient Sales Messaging Product sensitivities are application dependent. Selection of the right product, and managing customer expectations, is the key to avoiding transient issues

  31. Assessment of Transient Acceptability • Transient acceptability is largely subjective. The following criteria should be considered in relation to a specific customer requirement: • Level of transient operation • Customer brand proposition • Sensitivity to visible smoke This information is graphically represented on the next slide.

  32. Engine Selection: Practical Approach 5 1104D Electronic 4 3 2 1104D Mechanical 1 1 2 5 4 3

  33. What should I be doing? • Determine if any of your customers are sensitive to smoke or response based on territory and application • Make customers aware that the transient characteristics of the 1104D are different from Stage II/ Tier 2 • Manage customer expectations accordingly • Smoke, although highly subjective, is worse than Stage II/ Tier 2 • Machine responsiveness will be different at Stage IIIA/ Tier 3 • Sell the strong product benefits, there is a positive side to the transient story • Steady state performance has improved over Stage II/ Tier 2 • Product is more responsive from part load • Product has additional lugging capability • Strong position vs. other mechanical offerings in the marketplace

  34. Summary • 1104D Mechanical is a highly competitive product with a strong sales proposition • Transient concerns can be avoided by matching the engine to the application/ transmission and by managing customer expectations relative to Stage II/ Tier 2 • Transient response characteristics of the 1104D are part of the Stage IIIA/ Tier 3 Mechanical story for all suppliers in the industry selling Mechanical product • Applications Teams have been briefed on 1104D Transient characteristics. Please contact your Applications Engineer if you have any questions or concerns

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