1104D Transient Presentation 13.07.07 v1
Transcript of 1104D Transient Presentation 13.07.07 v1
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1104D Mechanical
Transient Performance Characteristics
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Introduction
The 1104D Mechanical represents a significant achievement in providing our customerswith a minimum-impact route to Tier 3 compliance and provides a market-leading level ofpower density & performance. However, Tier 3 emissions limits in this power range aresignificantly tighter than at Tier 2 and this effectively limits the range of possibleadjustment to optimise engine performance. Customers are likely to identify somechanges in the response characteristics of the engine, when compared to a comparable Tier2 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 bemore 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 informedselection of the most appropriate engine configuration for the application.
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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
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Product Positioning at Stage IIIA/ Tier 3
Selling the Range
Section 1
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Section Agenda
Tier 3 Product Positioning Overview
Electronic Positioning
Mechanical Positioning
Customer Expectations at Stage IIIA/ Tier 3
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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 wontprovide the performance benefits of the Electronic product
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Electronic Positioning
Electronic Control means Optimum Tier 3 Performance
Utilises proven components of Caterpillar ACERT technology
Common rail fuel system
Smart wastegate turbocharger
Performance optimised across theload and speed range
Optimised SFC
Minimised heat rejection
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Mechanical Positioning
Mechanical Control means Minimum Change from Tier 2
Ease of Changeover
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
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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
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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 resultsin some compromises (especially levels of visible smoke and low speedresponse)
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1104D Mechanical
Transient Response Characteristics
Section 2
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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
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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 tothe 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!
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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 themachine loaded
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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 FreeAcceleration Smoke (FAS) has been optimised for all ratings by theEngineering team at IPSD
Customers can increase low idle speed, or rematch machinetransmission and hydraulic demands, to further improve performance
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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 toapplication
Customers can increase low idle speed, or rematch machinetransmission and hydraulic demands, to further improve performance
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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 the1104C Stage II/ Tier 2 range
The product will feel more responsive in many circumstances
Naturally Aspirated product (1104D-44) will see a degradation ofaround 10% compared to Stage II/ Tier 2
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4) Free Acceleration Smoke (FAS)
Level of black smoke when blipping the throttle from idle with
the machine in neutral and any PTOs 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 FreeAcceleration Smoke (FAS) has been optimised for all ratings by theEngineering team at IPSD
Customer improvements can be made by optimising drive traininertias and managing engine acceleration
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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)
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IPSD Journey to Tier 3 Mechanical
Section 3
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Section Agenda
Emissions
Technology Choices
IPSD Tier 3 Solution
Performance Comparison: Tier 2 to Tier 3
1104D Mechanical Performance
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Tier 3 Emissions Challenge
Needham, J., 1991. "Engine Experience and EPA Regulations", University of
Minnesota Short Course Diesel Particulate Matter, October 1991
Tier 3 Off-Highway
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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
Technology Options at Tier 3 Mechanical
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IPSD Stage IIIA/ Tier 3 Solution
Engine 1104D-44TA 1104D-44T 1104D-44
Rating 68 83kW 55 75kW 54 56kW
Aspiration Turbo After-Cooled Straight Turbo Naturally
FIE Mechanical Rotary FIP
Rising Rate Injection
Dynamic AFR Control *
Mechanical Rotary FIP
Rising Rate Injection
Dynamic AFR Control *
Mechanical Rotary FIP
Rising Rate Injection
Combustion Re-Entrant Piston Re-Entrant Piston Re-Entrant Piston
General Hi-Efficiency WaterPump
Hi-Efficiency WaterPump
Hi-Efficiency WaterPump
* Patents applied for
IPSD has achieved Tier 3 emissions standards with minimal customerimpact and maximum carry over of todays proven design by innovativedevelopment of:
Air system strategies FIE Combustion chamber FIE boost control
SFC, heat rejection,and transient response
trade-off optimised
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Performance Comparison: Tier 2 to Tier 3400
300
200
1000 1400 1800 2200800 1600 20001200
380
360
340
320
280
260
240
220
Engine Speed [rpm]
Torque[Nm]
Tier 2
Tier 3
Full-load torque curves
are similar for Tier 2 andTier 3 ratings
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
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1104D Mechanical Performance
1104DMechanical
versus 1104C
Tier 3 Market Standardversus Tier 2 Market
Standard
BSFC + 5 % + 5 to +10 %
Heat Rejection + 5 % + 5 to +10 %
Noise -1 dBA -
Altitude 3000 m 3000m
Oil Change 250 to 500 hrs 250 to 500 hrs
Load Acceptance(from low idle)
TA 10%
Turbo 20%-10 to -25%
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
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Section 4
Selling Transient Messaging
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Section Agenda
Competitive Landscape
Transient Sales Messaging
Transient Response Practical Approach
What should I be doing?
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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 marketingMechanical product
Cummins QSB 3.3 Reduced displacement 4 Cylinder engine
Expect Load Acceptance from Low Idle degradation from StageII/ Tier 2 of around 25%
Competition using for example AVL TINER system
Expect Load Acceptance from Low Idle degradation from Tier 2 ofaround 10% to 25%
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Transient Sales Messaging
Product Benefits
Competitive MechanicalProduct Strategy
Strong Sales Proposition
Strong Steady StatePerformance
Responsiveness from PartLoad same or better thanStage II/ Tier 2
Lugging Capability same orbetter than Stage II/ Tier 2
Product Sensitivities
Low Speed Load Acceptance
Acceleration from Low Idle
Transient Smoke
Product sensitivities areapplication dependent.
Selection of the right product,and managing customer
expectations, is the key toavoiding transient issues
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Assessment of Transient Acceptability
Score Level of TransientOperation Customer BrandProposition EnvironmentalSensitivity to Smoke Typical Machine
1 Constant Speed Value Machine Outside / Ag Pump set
2 Lugging / Roading Ag Tractor
3 Shuttling / Pull-Away Mid-Range Machine Construction Site FLT
4 Digging Telehandler / BHL
5 Loading Premium Machine Indoor / Warehouse Wheeled Loader
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.
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Engine Selection: Practical Approach
1104DMechanical
1104DElectronic
5
4
3
2
1
54321
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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 thetransient 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
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Summary
1104D Mechanical is a highly competitive product with a strong sales
proposition
Transient concerns can be avoided by matching the engine to theapplication/ transmission and by managing customer expectationsrelative to Stage II/ Tier 2
Transient response characteristics of the 1104D are part of the StageIIIA/ Tier 3 Mechanical story for all suppliers in the industry sellingMechanical product
Applications Teams have been briefed on 1104D Transient
characteristics. Please contact your Applications Engineer if you haveany questions or concerns