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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 finetuning 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.
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
Section 1
Section Agenda
Mechanical Positioning
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 wont provide the performance benefits of the Electronic product
Electronic Positioning
Utilises proven components of Caterpillar ACERT technology Common rail fuel system
Performance optimised across the load and speed range Optimised SFC
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 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
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)
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Section 2
1104D Mechanical
Transient Response Characteristics
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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
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!
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
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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
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
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
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 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
Level of black smoke generated during acceleration with the machine loaded?
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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Section 3
Section Agenda
Emissions Technology Choices IPSD Tier 3 Solution Performance Comparison: Tier 2 to Tier 3 1104D Mechanical Performance
Needham, J., 1991. "Engine Experience and EPA Regulations", University of Minnesota Short Course Diesel Particulate Matter, October 1991
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 highpressure FIE) Optimised port swirl General Reduce Engine Parasitics Optimise Torque Curve Shape
Combustion General
360
Tier 2 Tier 3
Full-load torque curves are similar for Tier 2 and Tier 3 ratings However, un-boosted torque is lower on Tier 3 due to emissions control strategies
The penalties of low unboosted torque have been offset to some extent by management of fuelling control to transition to fully-boosted torque at lower speed
Torque [Nm]
340 320 300 280 260 240 220 200 800 1000 1200 1400 1600 1800 2000 2200
Tier 3 Strengths: Competitive mechanical strategy More responsive from part load than Tier 2 More lugging capability than Tier 2
Oil Change
Load Acceptance (from low idle)
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 Industrial Power Systems Division
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Section 4
Section Agenda
Competitive Landscape Transient Sales Messaging Transient Response Practical Approach What should I be doing?
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%
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 are application dependent. Selection of the right product, and managing customer expectations, is the key to avoiding transient issues
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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
Summary
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