Stage V-ready engines take center stage at Bauma

  • 23-Mar-2016 12:21 EDT
Cummins_Single_Module_Aftertreatment_System.jpg

The Stage V engines in the 4- to 9-L range will be supplied as an integrated system with the Single Module exhaust aftertreatment, newly developed by Cummins Emission Solutions to fit increasingly space-constrained equipment.

Mid-April in Munich marks the 31st edition of the largest trade fair in the world, Bauma. With more than 3400 exhibitors and 530,000 visitors at the last iteration in 2013—not quite the draw of Oktoberfest but impressive nonetheless—the event offers something for everyone in the construction-machinery and mining industry.

One topic drawing pre-event attention is the European Union’s Stage V emissions regulations for off-highway equipment that could commence in 2019. Stage V will further reduce allowable limits on criteria emissions and place limit values on particulate number (PN). For engines between 19 and 560 kW (25 to 750 hp), PN cannot exceed 1x1012 per kW·h.

At Bauma, Cummins plans to showcase engines across a 74- to 400-hp (55- to 300-kW) output range that “go beyond meeting Stage V near-zero emissions regulations to bring an increase in power and torque of up to 10%.” Enhancements involve combustion, airflow, and fuel-injection systems, allowing Cummins to optimize its four-cylinder QSF3.8 and QSB4.5, and six-cylinder QSB6.7 and QSL9, without increasing displacement.

“Cummins is taking the opportunity offered by the introduction of Stage V regulations in 2019 to redefine engine performance in terms that our customers care about, with easier installation, simplified servicing, and more responsive power delivery,” said Hugh Foden, Executive Director – Cummins Off-Highway Business.

The Stage V engines in the 4- to 9-L range will be supplied as an integrated system with the Single Module exhaust aftertreatment, newly developed by Cummins Emission Solutions to fit increasingly space-constrained equipment. The company claims the Single Module will provide up to a 50% reduction in envelope size and a 30% reduction in weight compared with the existing Stage IV and Tier 4 Final aftertreatment systems.

A critical enabler of the Single Module’s reduced weight and size is the Compact Mixer, a helical urea decomposition chamber developed in conjunction with Faurecia Emissions Control Technologies. The Compact Mixer enables optimal urea mixing while minimizing the risk of urea deposits.

Cummins’ QSG12, which powers equipment up to 512 hp (382 kW), and the QSX15 with a 675-hp (503-kW) top rating, are ready to meet Stage V regulations by retaining the DPF and selective catalytic reduction (DPF-SCR) aftertreatment system used for Stage IV and Tier 4 Final applications. “For those larger, high-output machines, the Cummins DPF-SCR provides an established installation package with ongoing continuity for equipment manufacturers as they transition their machines to Stage V compliance in 2019,” the company states.

The increase in peak power and torque achieved at Stage IV and Tier 4 Final by the QSG12 and QSX15 will carry forward to the Stage V certified engines with no modification required to the existing engine architecture. But the engines will be renamed, the X12 and X15, for Stage V applications.

Rolls-Royce Power Systems also will be presenting its Stage V-ready engines in Munich. MTU Series 1000 to 1500 engines are based on Daimler commercial vehicle units and are currently undergoing advanced development by MTU and Daimler for EU Stage V. Covering the 100- to 480-kW (135- to 645-hp) power range, these engines are scheduled for availability in advance of Stage V initiation.

The MTU engines meet the new emissions limits for soot particles using advanced internal engine technology, an SCR system, and an additional DPF. Two six-cylinder Series 1000 and 1500 engines will be on display at Bauma, along with the associated exhaust aftertreatment system. For MTU Series 1000 engines, the aftertreatment system will be available as a 1-Box as well as a 2-Box solution to enable flexible installation.

Deutz is using the occasion to not only show its existing Stage V-ready product range, which comprises the TCD 2.9, 3.6, and 4.1 four-cylinder models and the six-cylinder TCD 6.1 and 7.8, but also to reveal its new TCD 2.2 diesel and liquefied petroleum gas (LPG) engines as well as a new LPG version of its 2.9. The new TCD 2.2, a three-cylinder variant of the TCD 2.9 four-cylinder engine, expands the company’s offering in the lower output range.

With a rating of up to 55 kW (74 hp), the TCD 2.2 will be particularly suitable for applications in material handling and compact construction equipment. The LPG-fueled variant will produce up to 42 kW (56 hp). The TCD 2.2 is planned to go into series production in 2019, coinciding with Stage V's expected start.

Also producing up to 55 kW, the LPG variant of the TCD 2.9 engine will have a similar size and configuration to its diesel equivalent. The new gas variants—called G 2.2 and G 2.9—have a three-way catalytic converter that allows them to meet the EU Stage V standard without an exhaust aftertreatment system.

Deutz engines with capacities of 4 L or more are fitted as standard with a diesel oxidation catalyst, DPF, and SCR. DPF, which currently is available as an option for the 2.9- and 3.6-L models, will be mandatory when Stage V comes into effect. The size and configuration of the Stage V-ready engines with DPF will remain “virtually identical as the industry transitions from the current EU Stage IV to EU Stage V,” the company notes, meaning no expensive changes will have to be made to customers’ equipment.

Now that’s something to raise a stein to—even if it’s not Oktoberfest.

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