New Technologies Revealed at IAA Hannover Ignites Fuel Efficiency Debate

The global engineering leader in turbocharging technologies chose IAA Hannover to unveil several near-market solutions, which it believes reflect the changing priorities of global engine and vehicle manufacturers whose future products are being developed to insulate customers from rising fuel prices.

Speaking at the event, Executive Director for Product Line Management & Marketing, Mark Firth commented: "With fuel prices rising steeply we foresee the trend in engine downsizing - making them smaller and lighter - gathering pace.

"In parallel both engine and vehicle manufacturers are striving to maintain or increase the power outputs from their products. We have therefore developed a suite of next generation technologies and enhancements to meet this significant engineering challenge."

Cummins Turbo Technologies' close working relationship with its customers means it has developed an enviable reputation for bringing the right products to market at the right time. This was crucial in determining when the emissions versus economy balance shifted. Three of the turbomachinery solutions being revealed are:

1. A Next Generation Variable Geometry Turbocharger (VGT) that features a common platform capable of being tailored to meet the needs of individual customers without re-engineering. The VGT also features: a high efficiency compressor stage (delivering improved fuel economy) integrated actuator cooling, enhanced load balance, improvements to the turbine seal rings and oil slinger and an ability to apply a new actuator for reduced packaging and plumbing on heavy duty applications. The corresponding reduction in complexity and materials contributes to a 2kg weight reduction and a 20% cost reduction over the model it replaces.

2. Advanced Waste Heat Turbine Expander prototypes which use an organic rankine cycle to capture what would otherwise be lost energy, in the form of heat. It turns this into useful mechanical (25kW) or electrical (5kWe) power that is capable of reducing vehicle fuel consumption by 5% and delivering fuel savings of up to 4500 euro per annum.

3. Two-stage Turbocharging Systems with a flexible architecture capable of efficiently integrating and packaging two fixed geometry, wastegate or variable geometry turbos in series to deliver: higher power density, ultra high boost, superior air flow and extend altitude air handling capabilities through the Holset Rotary Turbine Control (RTC) – a patented flow channelling technology that directs exhaust gas to selected ‘ports’ for limited exhaust control capability and is integrated into the turbine housing within the Modulated 2 stage (M2) and Serial 2 stage (S2) products. with a flexible architecture capable of efficiently integrating and packaging two fixed geometry, wastegate or variable geometry turbos in series to deliver: higher power density, ultra high boost, superior air flow and extend altitude air handling capabilities through the – a patented flow channelling technology that directs exhaust gas to selected ‘ports’ for limited exhaust control capability and is integrated into the turbine housing within the Modulated 2 stage (M2).

Mark Firth added: "The head of engine development at a major European manufacturer told me recently that ‘priority number 1 is fuel efficiency; priority number 2 is fuel efficiency and priority number 3 is fuel efficiency.

"So, whilst there will undoubtedly be more high profile product launches at IAA Hannover, we believe none will have the far reaching implications for the commercial vehicle industry as our next generation technologies. Only in time will their influence become clear but that goes with the territory when you're pushing technological boundaries."

Cummins Turbo Technologies, which is currently celebrating its 60th Anniversary, is known for providing a wide range of innovative, reliable and durable turbochargers and will also be exhibiting its latest Euro 6, Tier 4 Final and US13/14 compliant products for customers seeking more immediate solutions to forthcoming emissions targets.