Bauma 2019: Engines and power generation

Perkins will be showcasing its complete EU Stage V engine range, future technologies and aftermarket services and digital solutions at Bauma.

Five engines meeting Stage V will highlight the Perkins 0.5 to 18 litre (4 to 597kW) engine range. Perkins will complement its range of off-highway diesel engines by showcasing a further three engines highlighting future hybrid offerings which will be shown for the first time.

Perkins has invested in hybrid engine research and development. At Bauma, the company is featuring a range of technologies that it said would add real value to OEMs as they design the next generation of off-highway machines.

The hybrid-electric, hybrid-mechanical and hybrid-hydraulic power technologies being shown by Perkins complement the existing 0.5 to 18 litre range of diesel engines.

Perkins is displaying a range of engines that meet the new Stage V emission standards which are being phased in from this year, such as the 1.7 litre mechanical 400 Series at 18.9kW, to the new Syncro 3.6 litre engine offering 100kW.

The company is showcasing a four-cylinder 1200 Series, designed for the electric power market.

The engine delivers 120kVA and meets Stage V emission standards for mobile generators. At the larger end of the Perkins range, the 1700 Series is a six-cylinder, 9.3 litre engine offering 340kW, while the 2400 Series, will be shown for the first time.

Perkins Stage V technologies include common rail fuel systems, selective catalytic reduction (SCR), diesel oxidation catalysts (DOC) and diesel particulate filters (DPF).

Volvo Penta will be showcasing its full range of engines, including the new Volvo Penta Stage V D5, D8, D11, D13 and D16 engines that offer power from 105 to 585kW.

Volvo Penta said its Stage V engine range for off-road applications had been developed with OEMs and end users in mind, delivering optimum productivity, uptime and total cost of ownership (TCO).

Volvo Penta has responded to the introduction of the toughest emissions regulations in the world, Stage V for Europe, valid from January 2019, with a new range of engines that it said offered easy installation, operation and maintenance.

One major driver in the development of the new Volvo Penta Stage V range has been ensuring that the engines and exhaust aftertreatment system worked seamlessly together, it said. Among other benefits, this is said to maximise passive regeneration during normal operation and, therefore, to remove the need for stand-still regeneration, boosting customers’ uptime, productivity and profitability.

In the D5 and D8 engines specifically, Volvo Penta has decreased cooling requirements by around 20%, meaning the size of the radiator can be reduced or power increased depending on customer need.

At the same time, Volvo Penta claimed to have succeeded in reducing fuel consumption, compared to Stage IV, across the entire range.

It said this meant that Volvo Penta could reduce the CO₂ footprint by around two fuel trucks per day. The company added that considering the average life of its engines was 10,000 to 12,000 hours or more, the savings in fuel consumption alone would pay for the engine over its lifespan.

Also, the oil change service interval was said to have been lengthened from 500 hours to 1,000 hours.

John Deere Power Systems (JDPS) will show a range of engines that have received Stage V certification, including its variable-speed engine families below 56kW, and above 130kW, as well as its constant speed engine families.

The industrial Stage V line up from John Deere offers ratings from 36kW to more than 500kW with displacements of 2.9 litres through the upcoming 13.6 litres.

The Stage V technologies used on these engines were said to be built on years of engine and application engineering expertise. As both an engine and machine manufacturer, John Deere boasts 1 billion hours of global experience with diesel particulate filter technologies.

Stage V aftertreatment technologies from John Deere claim to be optimised for flexible integration, and several offer reduced packaging and weight from previous Stage IV solutions.

Because the technologies are built on the same engine platform as current Stage IV solutions, the need for OEMs to re-engineer as a result of hardware or mounting changes is reduced, said John Deere.

Cummins will show a prototype electric mini excavator at its Bauma stand, the fruit of a co-operation with Hyundai that was first announced last October.

Powered by eight Cummins BM4.4E battery modules – 4.4kWh each – the 3.5 tonne Hyundai prototype is designed to operate for a full shift on a single charge, with recharging taking less than three hours.

The batteries are connected in a series configuration to provide a total energy of 35kWh. Mounted near the base of the excavator, the Cummins-designed and built battery pack uses Li-ion technology “to achieve a higher energy density and proprietary control technology to maintain the battery state-of-charge for a longer zero emission range.”

The modular design also allows for scalability to other applications and duty cycles, said Cummins.

The company unveiled its first Stage V construction engines at Bauma 2016 and is now in production with all engine models from the F3.8 to X15, with more than 200 machine installations completed or in progress.

At Bauma it will show the B6.7, which is said to offer 30% higher torque than the Stage IV equivalent, with 243kW of power. Cummins said this meant it could replace engines of higher displacement with no impact on machine operation.

Also at Bauma will be the Stage V F3.8 power unit. Delivered as a complete and ready-made power package, it comprises an engine, Single Module aftertreatment, radiator and cooling system – as well as auxiliaries such as mounting feet, hoses and an air cleaner.

Hatz has the world launch of its new E1 single-cylinder, electronically-controlled engines up to 12kW.

The German engine manufacturer said the E1 engines would be the world’s first single-cylinder units with electronically-controlled fuel injection system and a digital control unit.

This will allow them to be connected via the Internet iof Things (IoT), giving equipment users and owners access to data on machine use for smaller products such as mobile lighting towers and gensets.

Data from these small engines could be used by OEMs or fleet owners, such as rental companies, for fleet management purposes, in the same way that larger machines are already being equipped.

The company will have 5kW, 8kW and 12kW engines using the E1 platform ready for the start of 2020.

The company is also continuing to develop hybrid diesel-electric powerpacks for lighting tower and gensets. Its customers in this area include Atlas Copco and the UK’s TCP (Taylor Construction Plant).

Deutz will be exhibiting a modular product kit for diesel, gas, hybrid and electric drives at Bauma, on a stand measuring over 400m².

The company said it was diversifying its drive portfolio and would, in future, offer a modular range of different technologies to its customers in the construction equipment, fork-lift truck and lifting platform segments.

Based on its product modules, Deutz will design the optimum drive system individually for each customer and, it said that thanks to the company’s expertise gained over many years, it would “exploit and intelligently combine” the benefits of various technologies.

This applies both to combustion engines and to the electromobility segment. It said that electrification was an integral element of the Deutz development expertise, and that it had already successfully developed the first prototype machines as part of its E-Deutz strategy.

At the end of 2018, Deutz presented two fully working prototype machines. Two telescopic handlers which are normally powered by a 74kW Deutz TCD 3.6 diesel engine were converted – one to a hybrid drive and the other to a full-electric drive.

It said the E-Deutz hybrid achieved fuel savings of approximately 15%, recouping the investment costs after just one year of use.

At Bauma, Deutz plans to demonstrate under real-life operating conditions other prototype machines taken from actual E-Deutz customer projects. Together with the Manitou Group, Deutz has already assembled and delivered the first prototype machines to be fitted with electrified drives.

In addition to its electric solutions, Deutz will also be demonstrating the TCD 5.2 for the first time at Bauma, adding a powerful four-cylinder engine to its diesel portfolio.

From 2019, Deutz will also be making further additions to its higher output range portfolio, with four new in-line engines of between 9 and 18 litres capacity.

Deutz is extending its product offering in the lower power output range, not just as regards cubic capacity but in the choice of fuels.

From 2019, based on the successful four-cylinder TCD 2.9 (30 to 75kW), there will be a three-cylinder variant, the TCD 2.2, ranging in output from 22 to 56kW. Both these diesel engines will also be available as liquefied petroleum gas (LPG) versions, named G 2.2 and G 2.9. All the variants will be based on the same engine platform, generating extensive synergy effects, and the G 2.2 will be seen for the first time in Munich.

Yet another highlight to be seen at the Deutz stand at the fair will be a hydrogen variant of the TCD 7.8. The company said that adapting the traditional combustion engine so it could use alternative fuels – such as hydrogen – as a sustainable energy source was another promising area of its current research.

Kubota’s Business Unit Engine Europe (BUEE) plans to showcase its most comprehensive range of power systems to date at Bauma, saying that the line-up demonstrated the company’s belief that there was no one single fuel type for the future of the off-highway equipment industry.

Kubota said its long-term global business strategy has been to provide the markets with an engine platform for every fuel type and application – diesel, gasoline, liquid gas and natural gas – with the further option of duel fuel.

Kubota will also use Bauma to present a new pillar within its long-term business strategy, which is a further-developed version of the micro-hybrid prototype engine that was first showcased at Intermat 2018, Paris.

Highlights from the range of products on display at the show include the recently launched V1505-CR-T and D902-T.

Kubota will also feature its new 09 Series – which will enter service in 2020 as a global engine platform – which has been developed for upcoming Chinese non-road emissions regulations in addition to the EPA Tier 4 and European Stage V regulations.

Additionally, an evolved prototype of the new micro-hybrid engine, shown as a concept at Intermat 2018, will be showcased with the reference design.

Yanmar has developed gas-powered industrial engines that use LPG and meet US EPA Tier 2, CARB Tier 4 and EU Stage V emissions regulations.

It claimed two new clean burning and quiet industrial engine models in the 4TN88G – maximum output 45.0kW – and 4TN98G – maximum output 63.0kW. It also plans to introduce bi-fuel specification models that can run on both LPG and petrol.

Gas engines produce very little PM (particulate matter), it said, adding that they were comparatively quieter than diesels. It said this made them ideal for work indoors and in enclosed areas, where environmental concerns are a major consideration.

Yanmar has more than 30 years of experience working with gas engines. It said that it could now provide customers with a One-Stop Solution, whereby Yanmar could offer either a diesel or gas power source in one-stop sales contact, with maximum compatibility to the customer’s equipment.

Kohler-SDMO said it was quick off the mark in meeting the new Stage V emission limits, with a 50kVA Stage V model, the R50C5, on show in Bauma. That will be the first of its Rental Compact range (from 22 to 550kVA) to be Stage V compliant, with 20kVA and 330kVA gensets to follow later in the year.

Several more Stage V-compliant models will be available in 2020 – for 165, 220 and 550kVA power nodes – while 2021 will see gensets in the 66 to 110kVA range added.

The company will also show its new app for service engineers and users. Using Bluetooth technology, it will allow technicians to access data on a genset and also take them through maintenance steps. It will be available on sub-50kW gensets and fitted as standard on units of 6kW size and above, and optional on smaller sets. The app is free. Kohler-SDMO said the next step would be to offer the system on larger gensets.

FPT Industrial will show its Cursor X, the 4.0 power source concept, for the first time, and the company said it was characterised by four Ms – multi-power, modular, multi-application and mindful.

It is said to have been “designed for Planet Earth”, and FPT said the concept underlined its commitment to alternative fuels research and development.

The concept was developed jointly with sister-company CNH’s Industrial Design Centre. FPT said that Cursor X could adapt to provide the most suitable solution for the customer’s business, whether based on natural gas internal combustion, hydrogen fuel cell electric generation, or on battery-stored energy.

It said this allowed combinations from pure electric to parallel and serial hybrid. Energy transfer to the wheels would change accordingly, with the option of a mechanical transmission to be coupled with electric drivelines.

Bauma will also provide an opportunity for FPT to demonstrate its electric powertrain solutions, which include a customised solution for each specific mission, made up of two groups – electric propulsion and electric assist.

In addition to its own industry expertise, FPT Industrial said it could also count on the electrification heritage of CNH Industrial. Together with its sister brands, FPT has participated in electrification projects since the 1980s.

More recently, the brand announced its e-Powertrain team, a group inside the powertrain product engineering department entirely dedicated to the development of electric powertrain solutions.

FPT Industrial will present two solutions that consider electric power playing a direct role in vehicle propulsion – the E-Axle and the Transfer Box.

The E-Axle is described as a compact and flexible solution that transfers power and torque to the wheels through the gear unit, resulting in a modular concept that can be adapted to various vehicle layouts and weight capabilities.

It claims to be able to deliver power of up to 250kW and 98% efficiency.

FPT’s portfolio of Stage V engines for the off-road segment will be at Bauma. It will showcase some examples of its wide Stage V line-up, which is also ready to respond to worldwide emission standards, such as Tier 4 Final in North America and China IV.

MAN Engines said it wanted to detach itself from the “limiting” label of truck engine manufacturer and had further invested in its range of off-highway diesels. Its new D4276 six-cylinder inline engine is a special development for heavy-duty off-highway machines with an eye to construction vehicles.

The engine has been developed especially for applications that demand high power with full power operation at up to 70%. A maximum torque of 3280Nm is delivered at 1,100r/min speed and remains constant up to 1,500r/min. The output power is between 450 and 515kW depending on the power stage and, with a dry weight of just 1280kg, this engine has a high power-to-weight ratio.

Caterpillar’s range of industrial engines meeting EU Stage V emission standards will be on display, including the C2.2, C3.6 and C4.4, as well as the new C13B industrial power unit and the C27. The C7.1 and C9.3B engines will be featured in hall B6.

The XQP100 generator set can either meet EU Stage IIIA emission standards or provide low fuel consumption performance for customers in non-regulated territories. With a robust, rental- or mobile-ready construction, the product line is designed to be easily transported around project sites safely and efficiently.

Doosan Portable Power (DPP) will be showing several new portable compressor and generator products for the first time at Bauma 2019. They include the new Stage V-compliant 12/205 and 12/255 portable compressors, the new 7/53R portable compressor for the rental industry and the new G20 generator.

The 12/205 and 12/255 are part of a new generation platform of large Doosan Stage V portable compressors, with six models offering free air deliveries from 20.5 to 30.0m³/m at operating pressures from 8.6 to 21.0 bar.

These compressors are typically used to provide compressed air for drilling and boring machines in quarrying, mining, site investigation and water well construction work, and specialist applications such as abrasive blasting and temporary compressed air for industry.

The new rental-targeted 7/53R portable compressor, meanwhile, supplies 5.0m³/m of compressed air at a rated pressure of 7 bar. Designed to meet O1 trailer category requirements – the 750kg category – the new 7/53R is said to be suited for the rental market and also as a durable, cost-effective machine for the 5.0m³/m segment, covering the most common applications in construction, utilities and other markets.

In the generator sector, the G20 generator provides 19 kVA of power - driven by a Yanmar 4TNV88 18kW diesel engine – and meets EU Stage V engine emissions. More Stage V will be launched in the future.

Atlas Copco will be showcasing its latest innovations in clean drive technology at Bauma, and the company will be unveiling new portable air, power and flow equipment.

The new range of clean drive technology equipment on display will include the company’s E-air electric-powered compressors and its near-silent battery-powered HiLight Z3+ lighting tower.

Since they do not have a diesel engine, they do not require refuelling, noise levels are reduced and maintenance is simplified. Importantly, they also don’t produce emissions and so owners need not worry about emissions regulations.

These new clean drive technologies offer an alternative to diesel-driven units in metropolitan construction areas and at public events.

With the EU Stage V regulations introduced at the start of 2019, Atlas Copco will also use the exhibition as a forum to provide companies with guidance about the new regulations and how the company’s equipment can help users make a smooth transition towards compliance. Ahead of Bauma, Atlas Copco will launch a free e-guide outlining Stage V, its implications for operators and how it applies to the current and future design and use of portable compressors, dewatering pumps, lighting towers and generators.

Atlas Copco has integrated advanced fixed-speed and variable speed driven motors within its Stage V compliant diesel-powered construction equipment.

New innovations to be exhibited include the latest models from Atlas Copco’s QAS 5 generator range, as well as the new QAS VSG (variable speed generator). Both models were said to offer reduced consumption and emissions, as well as a smaller footprint.

The QAS 35 VSG has variable automatic speed control from 800 to 2550rpm and a built-in power management system that enables fuel consumption to be reduced by up to 40% compared with similar models.

Meanwhile, the QAS 5 offers quieter operation, a 20% smaller footprint than comparable models, reduced engine emissions and 24-hour autonomy.

On the digital side of things, the company will be showing its new Smart Air XC4004 compressor controller, which is IP67 rated, and visitors will also have the opportunity to learn about the latest extension of Atlas Copco’s FleetLink telematics system. It enables operators to track the location and usage of their assets in real-time.

Atlas Copco will also be launching its new LightThePower app to help customers correctly size their light and power equipment, and easily achieve paralleling.

Dana Incorporated recently introduced two new electric drivetrain solutions for off-highway vehicles, including the Spicer Electrified e-Axle and e-Gearbox, and they will be at Bauma.

These technologies are said to enable electrified propulsion within established vehicle architectures by leveraging the company’s portfolio of motors, inverters and controls.

Dana will debut its electrified drivetrain solutions at Bauma alongside e-Propulsion technologies from the SME Group, which the company acquired earlier this year.

The Spicer Electrified e-Axle combines Dana’s heavy axle design with a high-efficiency TM4 SUMO HP motor/generator and inverter combination for medium-sized load haul dumpers, medium-sized mining trucks and large lift trucks.

Supplying 139kW of continuous power and 193kW at peak power, the TM4 motor/generator and inverter are joined at the centre housing of the axle to provide the necessary torque and efficiency within the space typically allotted for an internal-combustion engine and transmission, according to Dana.

The Spicer Electrified e-Gearbox features a compact design that claims to manage high input speeds, and accommodates the installation of an electric motor. It offers a highly-engineered interface for connecting cost-effective motors used in electrification with conventional Spicer hydrostatic transmissions.

Meanwhile, Dana Incorporated has announced the development of the Spicer TE50 powershift transmission, which is designed for large load haul dumpers, trucks used in underground mining, and wheeled loaders.

Engineered for vehicles from 400 to 600kW, the Spicer TE50 transmission is said to offer superior performance through improved fuel efficiency, smoother shifting, more precise vehicle handling, and optimised braking.

It is engineered to fit within current vehicle design envelopes and is offered with a four- or eight-speed gearbox that is said to provide optimised shifting ratios. It is available with advanced automatic lockup, which improves fuel efficiency by enabling direct drive even at low speeds.

An integrated, automatic retarder claims to reduce brake wear and to enable smoother, quieter braking. Dana’s new transmission is also equipped with three heavy-duty, auxiliary pump drives.

The transmission will be launched with vehicle manufacturers in the second half of 2019, but will be at the Bauma show.