acert presentation.ppt

CAT ENGINES WITH ACERT TECHNOLOGY

Off-RoadTier 3 / Stage IIIa Compliance

Caterpillar Innovations

EPA and European Union

Emissions Restricted by EPA StandardsCarbon Monoxide (CO) Hydrocarbons (HC)Non-Methane Hydrocarbons (NMHC)Particulate Matter (PM)Oxides of Nitrogen (NOx)

2005 Tier 3 / Stage IIIa1 Million Less Tons NOxby 2010

2005 Tier 3 / Stage IIIaEqual to 35 Million Passenger Cars

Tier 4 / Stage IIIbBeyond Tier 3Tier 2Stage IITier 3Stage IIIaTier 4Stage IIIb90%

Field Testing

Off-Road

Field Testing with

Customers and Dealers

DEVELOPMENT

Developing ACERT

With One Goal in Mind

Possible SolutionsCooled EGRNon-Cooled EGRWith Compromises

EXHAUST GAS RECIRCULATION EGR

Cooled-EGR

Variable Geometry Turbo-Charger

EGR Cooler

EGR VALVE

2002 On-Highway Launch

Bulldozer Technology?On-Highway Solution?

Engine Technology

Adaptable

Engine Technology

Comprehensive

Building Blocks

Core ConceptAdvanced Combustion

Advanced Combustion

ElectronicsProven, Reliable

Fuel DeliveryExtremely Accurate

Fuel DeliveryPrecisely Timed and Controlled

Air Management

Air ManagementProven Technologies

Air Management

Variable Valve ActuationAdjust for Engine Load and Speed

Series TurbochargingImproves Reliability, Extends Life

Series Turbocharging

Wastegate TurbochargingSmaller and Midsize Truck Engines

Aftertreatment

AftertreatmentResidual Emissions CO2 + H20

Future Technology

Multiple Injection

HEUIFor Smaller Engines

MEUIFor Larger Engines

ACERT TECHNOLOGY

ACERT TechnologyEnhances Combustion

ACERT TechnologyLong Engine Life

Challenges AheadAs We Move to Tier 4 / Stage IIIb

Flexible, Adaptable

Innovative, Effective

Welcome.

As you know, Caterpillar has a long history of innovation and technological advancement. Weve been at the forefront of machine technology since the day our company was founded.

To maintain that leadership, we continue to make a huge investment in research and development. Caterpillar now spends more than four million dollars each working day on R&D .

Today, Id like to introduce you to a brand new Cat innovation...in fact, one of the most significant technical achievements in Caterpillar history:Cat Engines with ACERT Technology.

ACERT Technology is one of the most effective and flexible diesel emissions reduction solutions available today.

ACERT Technology is already in service in our on-highway truck engines...where it has been proving itself since 2002.

Over the next few years, Caterpillar will expand ACERT Technology into all off-road product groups and throughout the entire Cat engine line...including engines for machine, marine, industrial, power generation and other applications...where ACERT will ensure compliance with Tier3/Stage IIIa emissions standards.

As well see in the course of this presentation, ACERT Technology enables Cat Engines to maintain engine performance and efficiency while meeting the strictest emissions reduction standards now in effect.

Well also see that ACERT offers long-term benefits that competitive solutions may not.Since 1931, Caterpillar has been a leader in diesel engine design and manufacturing. In fact, Caterpillar has pioneered many important innovations in diesel technology, such as the use of turbocharging on diesel engines way back in 1955.

Moving forward, aftertreatment, fuel injection and electronic control innovations followed.And in that time, weve made improving the environment an important strategic initiative, culminating with the development of ACERT Technology.

So its no surprise that, when the EPA and European Union passed a series of stringent new diesel engine emissions standards in the mid-90s, Caterpillar took a leading role in developing the technology to meet them.These new standards restrict the amounts of emissions, including carbon monoxide, hydrocarbons, non-methane hydrocarbons, particulate matter and oxides of nitrogen.But in 2005, the situation changes...because thats when far more stringent off-road standards take effect in the US.

Known as Tier 3 in the US...and Stage IIIa in the EU... these standards dramatically increase the level of emissions restrictions.

Tier 3/Stage IIIa standards represent a major push to improve worldwide air quality. In the US, the EPA estimates that, by 2010, Tier 3 standards will reduce NOx emissions by about a million tons per year the equivalent of taking 35 million passenger cars off the road.

Accomplishing these goals wont be a matter of refining current emissions reduction technologies. Meeting Tier 3/Stage IIIa standards will require more sophisticated technologies.

If that isnt enough of a challenge, in 2011 the stakes get even higher...when Tier 4/Stage IIIb standards begin to phase in. Tier 4/Stage IIIb standards call for reductions in NOx and other emissions that go as much as 90% beyond Tier 3/Stage IIIa levels.

No existing off-road diesel engine can even approach these low emission levels. In fact, the exhaust coming out of a Tier 4/Stage IIIb-compliant engine may, in some cases, have lower levels of emissions than the air going in.Off-road engines with ACERT Technology began field follow testing in industrial applications and various Cat machines in 2002. In 2005, about 300 Cat machines will have accumulated a total of 500,000 hours in field follow programs.

...so Cat machine customers, dealers and Cat engine users can breathe easy. Caterpillar ACERT Technology will lead the industry into the future of diesel emissions reduction technology.

In the process, Caterpillar tested a number of promising technologies.

In fact, Caterpillar explored all the technologies that competitors are currently relying on for Tier 3/Stage IIIa compliance...and determined that none could meet the mandated standards without compromises in engine efficiency, service life and performance.

As it happens, cooled-EGR can achieve emissions standards in on-highway applications. Because it was a known technology, it appeared to be the most obvious solution at the time, but after investing in the research of cooled-EGR, Caterpillar decided it did not provide the same value that has become synonymous with the Caterpillar brand.

At the same time, Caterpillar was also looking at one other promising technology, which was then in only the earliest stages of development.

The investment paid off, and in 2002, we introduced elements of ACERT Technology in our on-highway engine line. In early 2003, we introduced the first EPA certified engine with ACERT Technology. Today, well over 60,000 on-highway engines with ACERT Technology are in service, meeting the toughest emissions standards in effect right now. And customer response has been overwhelmingly positive.At the time, some on-highway competitors took potshots at ACERT and at Caterpillar...saying we were adapting a bulldozer technology for use in over-the-road trucks.

Today, some off-road competitors are pointing fingers and saying were applying an on-highway solution to off-road applications.On Tier 3/Stage IIIa-compliant off-road engines the basic elements of ACERT Technology include advanced electronic control, precision fuel delivery and refined air management.

To meet the more stringent on-highway emissions standards, current on-highway engines use additional air management refinement elements: Variable Valve Actuation, Series Turbocharging plus aftertreatment. Well cover these to provide a complete overview of todays ACERT Technology. These elements may or may not be used for off-road Tier 4/Stage IIIb compliance.

Its important to note that many of the elements used in engines with ACERT Technology have been around for years...and many were original Cat innovations. A lot of what makes ACERT work is advancements to proven technology. What makes it better is the way these improved technologies now work together in new, more integrated ways.

The core concept of ACERT is a highly advanced combustion process.

What ACERT does is carefully control the combustion process. It lowers combustion temperatures, resulting in reduced emissions levels while, at the same time, maintaining performance and efficiency.At the heart of the technology is a Cat A4:E4 electronic controller, building on the previous generation of ADEM 4.

Caterpillar was one of the pioneers of electronic engine control. In fact, the first electronic controller was introduced in 1993. Its a proven technology with millions of hours of service in the field.

The A4:E4 controller acts as the electronic brain of ACERT, precisely regulating fuel delivery, airflow and other engine functions.Most significantly, the controller regulates the performance of Cat HEUI or MEUI fuel injectors. These hydraulically- or mechanically-actuated electronic unit injectors are able to deliver extremely accurate volumes of fuel with very precise timing. Again, theyre proven components with a long history of field use...and once again they were developed by Caterpillar.

One of the unique features of ACERT Technology is the way the controller directs the injectors to deliver fuel to the combustion chamber.Instead of injecting all the fuel at once, the A4:E4 controller directs a series of controlled microbursts during the combustion cycle.

Each injection event is precisely timed and carefully controlled in volume.

This process regulates combustion temperatures and plays a key role in reducing emissions to Tier 3/Stage IIIa-compliant levels.Multiple-injection fuel delivery is one of the major breakthroughs that makes ACERT possible...but it isnt the whole story. The advanced fuel delivery system works in conjunction with air-management strategies that include crossflow cylinder heads and wastegate turbochargers again, all proven technologies.

ACERT Technology in on-highway engines uses two advanced air-management concepts: Variable Valve Actuation and Series Turbocharging.

Variable Valve Actuation (VVA) is another key breakthrough. It offers the ability to control exactly when and for how long valves open and close to let air in and exhaust out of the combustion chamber.

As with the multiple injection fuel delivery process, a Cat A4:E4 controller is programmed to continuously adjust valve timing for optimum performance under varying engine loads and speeds. While Variable Valve Actuation is a feature of ACERT Technology in on-highway engines. It is not used in ACERT for off-road applications to meet Tier 3/Stage IIIa.Series Turbocharging is another example of using an existing technology in an innovative way.

Series Turbocharging simply means using two turbochargers together in series that is, in a row, one feeding the next. Using two turbochargers together addresses a number of issues.A turbocharger essentially packs more air into the combustion chamber. The turbocharger is driven by the engines own exhaust gasses passing over a turbine.

As the exhaust gasses hit the turbine, it takes time for a turbochargers fan to get up to speed. This is the lag time.

Smaller turbochargers have less lag time than larger ones...but they dont deliver the volume of air that a big engine needs. You could make it spin faster to deliver more air, but higher speeds put more stresses on the turbine and can lead to reliability problems and shorter life.By using two smaller turbochargers in series, lag is kept to a minimum because the turbos are smaller... but air volume is increased because there are two working together.

In addition, both turbos spin at lower-than-normal speeds, which improves reliability and extends life.

Series turbocharging adds to the air management capabilities of ACERT Technology, enhancing its ability to regulate the combustion process for optimum performance under varying working conditions.Larger on-highway engines use Series Turbocharging because its the more appropriate solution - another example of ACERT Technologys building blocks flexibility. While Series Turbochargers are a feature of on-highway engines with ACERT Technology, they are not used in engines with ACERT Technology for off-road applications to meet Tier 3/Stage IIIa.

Not all on-highway engines with ACERT Technology use Series Turbocharging. Smaller and mid-size engines use a single wastegate turbocharger.

The wastegate is a governing system that kicks in at higher power levels. It vents some of the exhaust gases to keep the turbine from spinning too fast. Wastegate turbochargers are an ACERT Technology feature used in both on-highway and off-road applications.The final building block of ACERT is aftertreatment. For on-highway engines with ACERT Technology, Caterpillar developed a new Diesel Oxidation Catalyst. Placed in the exhaust path between the engine and the muffler, this Caterpillar exclusive system converts most residual emissions to carbon dioxide and water. Aftertreatment is a feature of ACERT currently used in on-highway applications.Series Turbocharging ,Variable Valve Actuation and advanced aftertreatment may be features of the off-road engine technology of the future.

Research continues on the application or adaptation of these elements to off-road engines. For example, Cat researchers are exploring an alternate aftertreatment solution for off-road use.For example, it has only recently become possible to achieve the level of control necessary to make the multiple injection process work. And once we developed the ability to control the process, we faced the challenge of how to make it work under widely different conditions.For example, smaller engines with ACERT Technology use hydraulically-actuated injectors......while larger engines use mechanically-actuated injectors. In all cases, elements can be selected and the A4:E4 controller programmed to optimize performance.

Optimum performance is a hallmark of ACERT Technology...and its something that sets ACERT apart from all other diesel emissions reduction solutions.

To see what a plus this is for Cat customers, we need to look at at least one of the alternative emissions reduction strategies.Taking in only cool, clean, fresh air, combustion temperatures are controlled by multiple injection fuel delivery.

ACERT Technology actually enhances combustion rather than suppressing it. As a result, engine performance and fuel efficiency are maintained to a much higher degree.The enhanced combustion process also maintains long engine life.

As weve seen, many of the technologies used in ACERT have been used in Cat Engines for years...and have already proven themselves over millions of hours of actual use.

There are still challenges ahead, but ACERT Technology provides Caterpillar with a clear line of sight to off-road Tier 4/Stage IIIb compliance.

Other competing emission reduction technologies do not have a sight line. Where other technologies may be reaching their limits, ACERT is taking on tomorrow.

With a flexible, adaptable building blocks approach......innovative use of existing engine technologies

... and breakthrough developments in controlling of the combustion process

...Cat Engines with ACERT Technology offer a solution that maintains engine efficiency, performance and value while providing a highly-effective, long-term diesel emissions reduction technology with a clear direction for the future.

acert presentation.ppt

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