02-10-2012, 03:10 PM
Cleaner, Greener Engine Design
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the phrase “environmentally responsible” doesn’t seem to fit into a sentence with the terms 18-wheel tractor trailer
and heavy-duty truck. As a world-leading manufacturer of
commercial engines and related systems, Cummins Inc. is
working to change that perception one design at a time, developing next-generation technologies that are revolutionizing
the international trucking industry.
using software from ANSYS, Cummins is developing and testing radical improvements in engine design, including the use of alternative materials and smaller engine footprints that reduce weight, improve fuel economy and reduce emissions — while also boosting performance. the work of the corporate research and technology organization focuses on developing new, environmentally responsible technologies for the company’s core engine business.
Cummins’ recent product development efforts target a
great deal of attention on fuel economy and emissions —
and with good reason. government environmental standards grow more challenging every year. because
commercial trucking is a low-margin business, every improvement that Cummins makes in fuel economy adds to its customers’ successes. beyond these practical considerations.
Building the Truck of the Future
In recognition of its environmental technology leadership, Cummins recently received nearly $54 million in funding from the u.S. department of energy (doe) to support two projects aimed at improving fuel efficiency in
both heavy- and light-duty vehicles.
About $39 million will fund Cummins’ development of
a new “supertruck” — a highly efficient and clean diesel-
fueled Class 8 (heavy-duty) truck that is expected to set a
new industry standard for green technology. Another $15 million in funding will support the development of advanced-technology powertrains for light-duty vehicles. the resulting improvements in engine system efficiency will mean significantly lower fuel and petroleum consumption by these vehicles as well as a significant reduction in greenhouse gas emissions.
though details of this work are proprietary, Cummins is using software from ANSYS to simulate engine performance and achieve the ambitious goals defined by the doe: Improve Class 8 vehicle freight efficiency by 50 percent and achieve a 40 percent improvement in fuel
economy in light-duty vehicles
Using Simulation to Rev Up Ongoing Engine Improvements environmental standards and customer needs are an ever-evolving target. So the Cummins team uses engineering simulation to improve engine features and boost performance. design changes that reduce emissions and fuel consumption often result in higher temperatures and pressures within the engine, which require Cummins engineers to continually test the limits of
conventional engine designs.
most materials used in diesel engines exhibit reduced
strength as temperature rises. the combination of high pressure/temperature and reduced strength places stress
on components such as the cylinder head, a geometrically
complex casting that serves many functions including transferring engine oil and coolant, intaking air and exhausting gas. the head also houses the fuel injector and valve train components; it must contain hot combus-
tion gases during the cylinder firing event. to address the
multiple forces that come into play, Cummins engineers use multiphysics software from ANSYS to combine thermal and structural analyses in their work on this sophisticated engine component.