1104d transient presentation 13.07.07 v1

7/28/2019 1104D Transient Presentation 13.07.07 v1

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Industrial Power Systems DivisionConfidential Green

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 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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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


Dynamic AFR Control *

Mechanical Rotary FIP


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

1104d transient presentation 13.07.07 v1

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