Cummins’ Hedgehog: Big Can Still Be Green

Mark Levett, Cummins Vice President and General Manager – High Horsepower Business, talks about the QSK95 engine at its unveiling in Seymour, Ind.

It’s hard to imagine something eight feet tall, 14 feet long and capable of producing 4,000 horsepower could ever be considered “green.”

But Cummins’ new 16 cylinder QSK95 engine, the largest high-speed diesel engine the Company has ever built, has a number of environmentally friendly qualities.

Foremost among them: the engine, nicknamed “Hedgehog,” will meet the most stringent emissions standards, including U.S. Environmental Protection Agency (EPA) Tier 4 Final regulations that take effect in 2015. The EPA regulations cover the off-highway, marine, locomotive, and power generation markets.

“A key achievement of our combustion analysis-led work is that the QSK95 makes no performance compromise to meet very low emission standards – an advantage that few, if any other, large high-speed or medium-speed engines will be able to claim for Tier 4,” said Jim Trueblood, Vice President – Cummins High Horsepower Engineering.

The Hedgehog platform was unveiled Nov. 1, 2011 at the Seymour, Ind. Engine Plant where it was fired up for Cummins employees, reporters and potential customers. The engine is being marketed for use in passenger and freight locomotives; boats, including tugs and towboats; mining and off-shore drilling and power generation systems.

To meet the very low emission standards in the EPA’s Tier 4 Final, the diesel Hedgehog will use Cummins’ Selective Catalytic Reduction (SCR) aftertreatment system, which has a proven track record for significantly reducing the Oxides of Nitrogen (NOx) associated with air pollution and smog.

The SCR system also achieves diesel fuel savings of five to ten percent with a corresponding reduction in carbon dioxide (C02), a key contributor to greenhouse gases

In addition to those environmental benefits, the Hedgehog was designed with remanufacturing in mind. Remanufacturing is big at Cummins. Some 50 million pounds of Company product were reclaimed in 2010 to be put back into use.

Working from a “clean sheet” on Hedgehog, designers were able to consider remanufacturing in almost every aspect of the engine.

For example, the engine block is made with a little extra metal so when it comes time for milling during remanufacturing, it will be easier to bring the block back to original specifications.

Electronic Control Modules in the engine can detect stresses and in some cases alter engine operations to reduce that stress. And snap-in parts designed to absorb wear can extend the life of other more critical parts.

“High horsepower customers demand that high horsepower parts are used until they are at their full life limit,” said Doug Free, a Senior Technical Advisor on Hedgehog who formerly worked in remanufacturing at Cummins. “Then, they insist we remanufacture them for even more life. They want their money’s worth out of every part!”

Creating a new engine platform also allowed engineers to design Hedgehog with cleaner-burning natural gas in mind.

Abundant supplies of natural gas are becoming more readily available at lower prices than diesel. That is expected to significantly increase demand for spark-ignited natural gas engines over the next several years. Leveraging the base architecture of Hedgehog’s diesel engine, the gas platform will be fully optimized to deliver market leading performance.

“The gas engines will not be just a derivative of the diesel engines, but uniquely designed for gas,” said Mark Levett, Cummins Vice President and General Manager – High Horsepower Business.

“The Hedgehog team has done a remarkable job of translating the voice of the customer into key design features,” added Srikanth Balasubramaniam, Director – High Horsepower Natural Gas Business.

About 150 engineers have been working on the engine project and over $100 million will be invested to establish a new production line and test facilities at Seymour.

And this Hedgehog will be growing even larger. Plans are in the works for the QSK120, adding four cylinders while using the same platform to achieve over 5,000 horsepower.

blair claflin director of sustainability communications

Blair Claflin

Blair Claflin is the Director of Sustainability Communications for Cummins Inc. Blair joined the Company in 2008 as the Diversity Communications Director. Blair comes from a newspaper background. He worked previously for the Indianapolis Star (2002-2008) and for the Des Moines Register (1997-2002) prior to that. [email protected]

 

Cummins Turbo Technologies gears up to launch the 8th Generation Holset Series 400 Variable Geometry Turbocharger

8th generation HE400VGT

As emission regulations become more stringent, Cummins Turbo Technologies (CTT) is committed to helping customers reduce emissions and advance fuel economy through innovative new air handling technologies.

Built on 70 years of innovation and dependability, CTT and Holset have introduced a wide range of industry leading air handling technologies. In 2021, CTT launched the 7th generation 400 series Variable Geometry Turbocharger (VGT) to help engine manufacturers meet future emission standards and offer best in class fuel economy. At Cummins, innovation never stops as we continue to advance our current technologies, while developing new ones. With this philosophy in mind, CTT is now preparing to introduce the 8th generation HE400VGT. It is specifically engineered to have top of class performance, reliability and durability for the 10-15L heavy-duty truck market.  

CTT has made significant improvements in turbocharger performance with its latest generation of products. The 8th generation turbocharger will have 5 percent improved efficiency over the previous 7th generation turbo.

In addition to offering improved turbocharger efficiency, which helps customers in engine downsizing, the HE400VGT will have a better transient response, enhanced compressor side oil leak robustness and dual sourcing on key components for supply chain flexibility.

Key highlights of the Holset HE400VGT include a new bearing system and near zero clearances to enhance performance and transient response. These enhancements are achieved by tighter clearances on the compressor stage, lower radial movement on the turbine stage, improved surface finish and new aero designs.

Scheduled to be launched in 2024, this turbocharger incorporates a next generation smart electric actuator and speed sensor with the latest chipset to enhance performance and durability. The dual sourcing strategy helps mitigate any unforeseen electronics shortages that have recently plagued the industry.

Along with the performance enhancements, the latest generation turbocharger will offer best-in-class performance for on-highway heavy-duty trucks coupled with improved fuel economy at key vehicle running points.

“CTT has incorporated exciting new technologies in our latest HE400VGT to help engine customers meet strict emissions requirements and reduce their total cost of ownership,” said Matthew Franklin, Director – Product Management & Marketing. As customers establish their strategies for upcoming emission regulations, CTT continues to build on the success of previous turbocharger launches to deliver innovative products that meet the challenges of our customers’ engine development needs without compromising on performance. 

Want to learn more about CTT’s products and technical innovation? Sign up for our quarterly newsletter today.

Cummins Office Building

Cummins Inc.

Cummins, a global power technology leader, is a corporation of complementary business segments that design, manufacture, distribute and service a broad portfolio of power solutions. The company’s products range from internal combustion, electric and hybrid integrated power solutions and components including filtration, aftertreatment, turbochargers, fuel systems, controls systems, air handling systems, automated transmissions, electric power generation systems, microgrid controls, batteries, electrolyzers and fuel cell products.

Rebuild masterstroke pays off for miners

belt buckle with text reading "Cummins 300th QSK60 MCRS Upgrade"

A masterstroke by Cummins engineers in Australia and the US has resulted in major cost reduction and environmental benefits for mining companies electing to rebuild their QSK60 engines under a special upgrade program.

The engineers focused on rebuild possibilities for the early generation QSK60, and how it could be upgraded to the latest diesel technology at overhaul time with no major change to the base 60-litre V16 design – a feat that eluded other engine manufacturers.

The key technology upgrade is to fuel injection, with the early unit injection system (HPI) replaced with the high-pressure modular common rail system (MCRS) that is now featured on all of Cummins’ latest generation high horsepower engines.

The 300th upgraded engine, rated at 2700 hp, recently rolled off the production line at the Cummins Master Rebuild Centre in Brisbane, highlighting yet another successful step in the evolution of the QSK60 and why it is the foremost high-horsepower diesel engine globally in mobile mining equipment.

“Reduced fuel consumption and longer life-to-overhaul are keys to lower total cost of ownership, and they were the initial aims behind the engineering of the upgrade program for the QSK60,” says Greg Field, mining business development manager for Cummins Asia Pacific.

“Innovation is at the core of Cummins’ long history, and it has certainly played its part in the QSK60 rebuild options we can offer our mining customers.”

The bottom line is impressive: Diesel particulate emissions are slashed by up to 63% through in-cylinder combustion technology with no aftertreatment. There’s also a plus for maintenance with less soot loading in the oil.

Fuel savings up to 5% are consistently reported in the field for significant greenhouse gas emissions reduction, while life-to-overhaul is extended by 10%, translating to fuel consumption of more than 4.0 million liters before rebuild is required.

Apart from the fuel system upgrade to MCRS, the QSK60 with single-stage turbocharging also features other Cummins innovations in combustion technology that were engineered for Tier 4 Final and Stage V emissions compliance, the most stringent off-highway emission standards in the world.

The rebuild upgrade package can be applied to the two variants of the QSK60 – one with single-stage turbocharging (known as ‘Advantage’) which can be rated from 1785 to 2700 hp, the other with two-stage turbocharging which can be rated at 2700, 2850 or 3000 hp.

The 300th upgraded QSK60 went to Boggabri Coal in the NSW Gunnedah Basin for installation in a Komatsu 930E haul truck. The engine has proved its worth in both coal and iron ore mining in Australia.

yellow QSK60 engine

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Cummins Inc.

Cummins, a global power technology leader, is a corporation of complementary business segments that design, manufacture, distribute and service a broad portfolio of power solutions. The company’s products range from internal combustion, electric and hybrid integrated power solutions and components including filtration, aftertreatment, turbochargers, fuel systems, controls systems, air handling systems, automated transmissions, electric power generation systems, microgrid controls, batteries, electrolyzers and fuel cell products.

Hurricane Sally no match for Florida couple and their home standby generator

Family with dog standing next to Cummins home standby generator

Three months. That’s how little time Macy and Sherry Summers had between the installation of their new Cummins QuietConnect™ home standby generator and its first major test: the arrival of Hurricane Sally.

The Category-2 hurricane stalled over the Pensacola, Fla. area for nearly 12 hours in September 2020, bringing 110-mph winds, torrential rain and major power outages. While many of their neighbors worried about their home flooding during the storm, the Summers were secure, knowing their Cummins generator would help pull them through.

“I was very concerned that if too much water got near the house, it could come in,” said Macy. “Without power, we couldn’t run our pumps, we couldn’t take the water away from our pool. That was the big fear for me.”

The new Cummins generator came through big time, powering their home and three sump pumps during the storm and running nearly 90 hours with one break for an oil change before power was restored.

Its performance was no surprise for Macy, a former Lockheed Martin engineer. Upon moving permanently into the home in 2019, he used his research acumen to find the best way to power their home through a storm. After 18 months, he decided on a Cummins QuietConnect Home Standby Generator because of the brand reputation, build quality and support.

“The brand was really important to us. We wanted to have a good support system from a large company we knew would be there if we needed it. It turns out that Cummins was the right one for us,” said Macy.

“I would certainly recommend Cummins over the brands that most people have heard of. Cummins is a stronger solution for somebody who wants that reliability.”

For the installation, the Summers contracted with Emergency Standby Power, their local Cummins dealer in nearby Fort Walton Beach, which also services and maintains the generator for them.

Said Raul Perez who oversees generator installations for Emergency Standby Power, “We try to partner with a product we know is going to be reliable that we’re comfortable servicing, that we’re comfortable installing and that we’re comfortable standing behind. That means a lot. We do like working with Cummins, because when we call and we need support, they’re always there.”

According to Sherry, the QuietConnect generator lives up to its name. “It’s amazing that when we hear it come on, we’ll always say, ‘Oh, there’s the generator. The power must be off.’ We just keep going about whatever we’re doing,” she said. 

After the hurricane, the Summers have complete confidence in their Cummins generator. Sherry says she no longer worries about food spoiling, keeping the house cool and keeping the pool pumps running. 

Macy adds, “If a hurricane comes, my peace of mind really is around these systems we’ve put in to protect our home. They’ll now have constant power, enabled by the generator.”

Find the perfect generator for your home by visiting Cummins generator size calculator.


To hear the Summers tell their own story, watch the video of them below.
https://www.youtube.com/watch?v=Lv9jxX7PFGU

Cummins Office Building

Cummins Inc.

Cummins, a global power technology leader, is a corporation of complementary business segments that design, manufacture, distribute and service a broad portfolio of power solutions. The company’s products range from internal combustion, electric and hybrid integrated power solutions and components including filtration, aftertreatment, turbochargers, fuel systems, controls systems, air handling systems, automated transmissions, electric power generation systems, microgrid controls, batteries, electrolyzers and fuel cell products.

Cummins launches new twinpack rental power diesel generator

Cummins logo at the entrance of Fridley plant

Cummins Inc. (NYSE: CMI) has launched a new 1MW twinpack rental generator, the C1000D6RE, which offers a competitive rental power solution for a diverse range of applications throughout North America. Manufactured by Cummins, a company that has been synonymous with technology, reliability and service since 1919, the new C1000D6RE model will be built in Fridley, Minnesota.

As a twinpack, the C1000D6RE combines two Cummins 15L, 500kW generators into a single, 40ft power unit, complete with aftertreatment. This enables the C1000D6RE to meet Tier 4 final emissions regulation while delivering reliable, high output performance. The generator can be used in parallel with other rental power solutions and is capable of masterless load demand.

The C1000D6RE offers a 1000kW power rating as per ISO 8528 and is powered by 2 x U.S Tier 4 Final certified QSX15 Cummins engines. The QSX15 engine meets the stringent EPA standards without the need of a Diesel Particulate Filter (DPF) which offers ease of serviceability, lower emissions and greater performance.

A new heavy-duty trailer and hitch design ensures even greater reliability for rugged mobile power applications. The generator’s container is capable of withstanding extreme weather conditions, while a full sound attenuation package minimizes the generator’s noise levels. For faster and cleaner oil changes, a ‘Quick Fit’ oil evacuation system option is also provided.

Weighing in at 69,000lbs with fuel, the C1000D6RE comes equipped with a front-end stabilizer and mobile air-ride to reduce the impacts of travel, minimizing potential down time.

The C1000D6RE is suitable for use across a wide range of large-scale industries requiring rental power, including: construction sites, emergency power, large scale events, industrial buildings and utilities located in remote locations or urban areas.

John Gibbons, Rental Power Markets Director at Cummins, said: “We’ve listened to our customers and developed the C1000DR6RE specifically to meet their demands. We also wanted to prioritize the production of a generator that continues to provide reliable power solutions, regardless of climate, location or industry. We believe this product will provide markets with greater reliability, improved performance and increased flexibility.” 

The 1MW twinpack model can be used for a diverse range of industries requiring mobile power; ranging from construction sites, industrial buildings and utilities located in remote locations or urban areas. The remote start and stop contact functionality allows the generator set to be switched on and off upon demand without the need of local maintenance support. As a result, customers can expect more stability, greater uptime and lower labor costs leading to lower total cost of ownership.

To ensure continued performance, Cummins offers customers servicing and maintenance of its mobile power generator range. Cummins aftermarket capabilities are provided through a network of over 200 local sales and service locations across North America; supported by a global system of service technicians, engineers and part distribution centers, experienced in offering mobile power solutions to fit any power requirement.

Cummins Office Building

Cummins Inc.

Cummins, a global power technology leader, is a corporation of complementary business segments that design, manufacture, distribute and service a broad portfolio of power solutions. The company’s products range from internal combustion, electric and hybrid integrated power solutions and components including filtration, aftertreatment, turbochargers, fuel systems, controls systems, air handling systems, automated transmissions, electric power generation systems, microgrid controls, batteries, electrolyzers and fuel cell products.

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