Tier 4 QSK60 SS OEM Impact Presentation - · PDF file(2 per bank) New Piston with new rings 4x...
Transcript of Tier 4 QSK60 SS OEM Impact Presentation - · PDF file(2 per bank) New Piston with new rings 4x...
Tier 4 QSK60 SS OEM Impact Presentation
Cummins Confidential – Restricted *All information in this document is preliminary and subject to change
1
Cummins Confidential-Restricted
Introduction This purpose of this presentation is to highlight major
product differences between the QSK60 SS Tier 4 Industrial and Locomotive engine and today’s QSK60 SS MOH Tier 2 and Loco Tier 3/SIIIa engine (D593007CX03) – MOH Tier 2 and Loco Tier 3/SIIIa will be referenced as
‘previous emission certified product’ throughout the remainder of this presentation
These changes will likely affect how this engine is integrated into your equipment This presentation, along with the OEM Design Guide,
will help best integrate this Cummins Tier 4 product into your equipment and deliver a world-class product to your customers
NOTE: All references are made with respect to previous emission certified MCRS product
Cummins Confidential-Restricted
QSK60 Base Engine Architecture - Single Stage
‘4 No More’ turbocharger solution 4x HE800 ‘Low Flow’
New turbocharger support bracket
Revised Turbocharger coolant and oil plumbing
New Exhaust Manifold
Proprietary Fuel Filter Interface
4x CM2350 ECMs (2 per bank)
New Piston with new rings
4x External Wastegates
Revised fuel plumbing
Q60 Style Aftercooler Covers and Air Cross-overs
2200 Bar Bosch Fuel Injector
2200 Bar Bosch Fuel Pump
New Impactor Breather
Revised LTA Plumbing
NOTE: All references are made with respect to previous emission certified MCRS product
Cummins Confidential-Restricted Cummins Confidential
Figures in parentheses relate to Q60 previous emission certified product
Base Engine Sub Systems Single Stage initial packaging dimensions
1260mm 50”
(1180mm 46.5”)
1215mm 48”
(1135mm 45”)
2615mm 103”
1560mm/ 61.5”(1510mm/ 59.5mm) Across Aftercoolers
1590mm/ 62.6” Across ECM Guards
800mm 31.5”
Cummins Confidential-Restricted
QSK60 Tier 4 Loco Design/ Development plan
Unique Loco Options •Unique Loco hardware design integration with MOH engine hardware •Specific Loco Analytical tasks •Specific Loco QAP verification
Tier 4 Required Hardware •Base MOH Design Tier 4 unique components •MOH CPE Pre Alpha engine used for Rating development (Both MOH & Loco) •MOH Unique Tier 4 Analytical tasks •MOH Mech Dev engine QAP Validation testing to verify Tier 4 hardware robustness. •MERGE MOH & LOCO
+
Cummins Confidential-Restricted
Locomotive Tailored Components: Loco Tier 3 options shown
Reinforced Flywheel housing – FH 6102
Similar to FH 6082 modified brackets to accommodate oil pan
Grade 10.9 capscrews
support, engine (10) 3641779 – E phase support, engine (10) 3641780 – E phase
Eliminator – New LF option required – unique eliminator bracket 3642349 filter,lubricating oil (21-1) - e phase 3642350 bracket,filter (13) - e phase 3642351 piece (10) - e phase 3642352 piece (10) - e phase Prelube PL 6771 off
engine
Oil heaters - OH 6003
Released into config on QGD1611
Unique Architecture QSK60 Loco
Cummins Confidential-Restricted
Locomotive Fuel System Schematic Loco Tier 3 Config
Locomotive Fuel tanks
Fuel pre filter (FS 6042)
Lift pump (FS 6731)
Deaeration reservoir (FS 6731)
MCRS fuel pump
Stage 1 fuel filters
MCRS fuel system
Customer supplied Customer mounted Cummins Supplied Cummins mounted Cummins remote mounted
Deaeration tank overflow drain to main locomotive fuel tank
Inje
ctor
dr
ain
Unique Architecture QSK60 Loco
Cummins Confidential-Restricted
Overview – Tier 4 certified QSK60 production start date is 2014 – Will integrate Selective Catalyst Reduction (SCR) exhaust
aftertreatment hardware to meet U.S.EPA Tier 4 Final regulations
Base Engine / Performance – Base engine and MCRS fuel system architecture remains the same – Will continue with existing ratings from 1875 – 3000hp – The engine will continue with 2 pump 2 loop aftercooling – Turbochargers will be external wastegate architecture – Turbos will increase in size over previous emission certified product.
Single stage turbos will be HE 800. – Altitude derate schedule is planned to remain the same as previous
emission certified product levels – Transient response will be the same or better than previous emission
certified product
Fuel Economy – Fuel economy target is to be better than previous emission certified
product – Combined fuel + DEF consumption will be comparable to previous
emission certified product fuel consumption
Platform Overview
Tier 4 Wastegate Valve
Cummins Confidential-Restricted
Packaging – Engine weight will increase by approximately 100 kg plus
the weight of aftertreatment hardware. – Engine height will increase by approximately 3 inches
and engine width will increase by approximately 2 inches over previous emission certified product.
– SCR will target the muffler space claim and also serve as the silencer.
New customer options will be released with the Tier 4 engine
– Heat shields are being considered for offering as an option at start of production
– An air shut off valve is planned to be provided as a factory option
– To meet Tier 4 regulations non-burn Centinel options will be provided
Service and Durability Impact – Fuel filter change interval targeted at 500 hrs
(improvement over 250 hr previous emission certified product filters)
– The design life of the aftertreatment module is equal to that of the engine
Platform Overview (cont’d)
T4 Aftertreatment
Cummins Confidential-Restricted
Mechanical Interface Impact
OEM will need to integrate SCR aftertreatment hardware into chassis.
Water inlet and outlet connections remain the same
Fuel inlet and drain connections will remain on intake manifold and fuel pump respectively, although the fuel pump envelope has changed.
Turbocharger inlet and exhaust outlet connections will move vertically upwards by approximately 3-4 inches.
Exhaust collector centerline moved up vertically 75 mm will point inwards at a 45 degree angle from vertical rather than the side and top out arrangement of the existing options
Inlet and exhaust plumbing – Exhaust plumbing sizes are still being evaluated – Exhaust plumbing must be of stainless steel construction
Fuel cooler may be required (depends on tank size and duty cycle)
NOTE: All references are made with respect to previous emission certified MCRS product
Cummins Confidential-Restricted
Fuel Cooler Requirement
Fuel return heat rejection is estimated to be increased for Tier 4 when compared to current product MCRS fuel systems
Refer to the fuel rating datasheet for heat rejection to fuel values
Due to the increased heat rejection, engines operating with a high load factor and small fuel tanks will likely require a fuel cooler
This includes applications such as underground mine trucks, drills, and excavators
AEB 24.07 provides detailed guidelines for fuel cooler design and testing
Cummins Confidential-Restricted
Five Primary OEM Interface Connectors Base Engine Connectors (Same as previous emission
certified product)
– Signal Connector #1 (Deutsch 31-pin) – Signal Connector #2 (Deutsch 23-pin) – Power Connector (Deutsch 16-pin)
OEM Electrical Interface Connectors Left Bank Rear Base Engine Connectors
(same as T2/ LocoT3/S IIIa)
Right Bank Rear Aftertreatment Connectors
(New for T4)
12
New Aftertreatment Connectors for Tier 4
− Signal Connector #3 (Deutsch 47-pin) − Signal Connector #4 (Deutsch 31-pin)
To be connected to these two connections: −Urea quality sensor, ambient air sensor, line heater relay, DEF supply module, SCR temperature sensors, coolant control valve electric heater (if applicable), etc…
Cummins Confidential-Restricted
Electrical Interface Impact Same as previous emission certified product
– Three OEM chassis connectors and location will remain the same • 16 pin power connector • 23 pin signal connector • 31 pin signal connector
Different from previous emission certified product
– Harness from aftertreatment components to the ECM will be the responsibility of the OEM. • DEF tank heaters • DEF line heaters • DEF temperature sensors • DEF level sensor • NOx sensor • Dosing module
*more details will be provided in the Aftertreatment Requirements AEB
Cummins Confidential-Restricted
Selective Catalyst Reduction (SCR) Key Features
Exhaust enters SCR module
Integrated DEF doser
SCR Module will replace muffler (sound attenuation target approximately 25 dB)
Exhaust exits SCR module
Cummins Confidential-Restricted
SCR Aftertreatment
15
Preliminary packaging details Model 6000
– 17” x 25” x 70” overall dimensions – 8” inlet & outlet pipe – 470 lbs
Packaging Models are available
All QSK60 ratings will be Tier 4F certified with an SCR catalyst with integrated DEF dosing system (1 / bank).
Preliminary packaging details Model 8000
– 17” x 25” x 85” overall dimensions – 10” inlet & outlet pipe – 660 lbs
Packaging Models are available
Cummins Confidential-Restricted
Inlet / Outlet Configurations (Under Investigation)
Model 6000 – End-In and End-Out is the only configuration
need identified at this time. – Side-In and End-Out with Inlet currently being
evaluated and designed • 9 O’Clock Inlet position currently being evaluated
– Looking for further input from specific applications
– Development of alternatives would be based on requirement and business case
– Inlet designation described viewing the SCR canister from the exhaust inlet end with dosing module placed at the top.
3 O’Clock Inlet Position
9 O’Clock Inlet Position
Dosing Module location
End in End Out Configuration
Side in End Out Configuration
View Direction
Cummins Confidential-Restricted
SCR System Component Responsibilities CMI Supplied
SCR Catalyst Assembly SCR inlet and outlet connections DEF (Urea) pump & dosing injector DEF Line Heater Controls NOx Sensors NOx ECUs SCR Temperature Sensors
OEM Supplied Exhaust Piping: Turbo to SCR Tailpipe Assembly DEF Tank Assembly
Tank vent, tank filter, tank drain DEF Heating Related
DEF tank heater DEF line heaters DEF line heater relays Coolant lines to/from DEF tank from engine Coolant lines to/from dosing pump Coolant flow valve
DEF Sensors DEF level, temperature, and quality sensors
Ambient Air Sensor DEF Lines
DEF line from DEF tank to dosing pump DEF line from dosing pump to dosing injector DEF line from dosing injector to DEF tank
DEF Electrical System Wiring Vehicle to Aftertreatment Wiring DEF indicator lamps and gauges SCR and Dosing Pump Mounting
Brackets/Fasteners Insulation of Exhaust Piping (if necessary)
Cummins Confidential-Restricted
Investigating SCR Canister Mounting Requirements Primary direction is OEM supplied mounting components OEM will have to design mounting system for SCR catalyst and
Dosing Supply Module (DSM) to limit maximum transmitted shock and vibration (May require vibration isolated mounting in some applications)
Studies in progress: – ‘End in-end out’ 6000 Unit adding a mounting bracket to facilitate mounting in
OEM equipment – 8,000 Unit mounting still not decided, most likely a bolted hardware configuration
which will be embedded into the SCR assembly to enable OEM mounting
Allowable canister orientation is a function of the doser orientation (the doser cannot be mounted in a vertically upward orientation)
Dosing Injector
Supply Pump
Cummins Confidential-Restricted
DEF Issue Detection Requirements Based on preliminary U.S. EPA provided guidance
Three DEF related issues require a machine response to effect operator behavior 1. Empty DEF tank
• DEF tank level sensor broadcasting fault via engine/AT integrated control system
2. Poor Quality DEF • Expected direction is: DEF quality sensor broadcasting fault
via engine/AT integrated control system
3. DEF system tampering • Affected AT system component broadcasting fault via
engine/AT integrated control system
Cummins Confidential-Restricted
Required Machine Response to DEF Issues Based on preliminary U.S. EPA provided guidance
Operator Warnings – Mandatory to alert operator visually and/or audibly
Operator Inducements – Reduction in engine torque output and/or speed to negatively
influence the vehicle’s operating characteristics – 3 available levels
• Mild Inducement (Optional) – Supplement to Operator Warnings, reduced machine functionality
• Severe Inducement (Mandatory) – Disable primary functionality of machine, but not prohibit mobility
• Proposed – Ultra-Severe Inducement (Optional) – Disable all machine functionality except “limp home” type mobility
Engine Shutdown – Engine stop (Mandatory)
• Also classified as “final inducement”