7 Ways Cummins Goes High Tech to Power its Customers

Cummins commitment to technology means benefits for customers.

IN MANY WAYS, CUMMINS ENGINES AND RELATED PRODUCTS ARE MORE COMPLEX THAN YOUR SMART PHONE. HERE'S SEVEN WAYS CUMMINS PUTS HIGH-TECHNOLOGY TO WORK FOR YOU:

SUPER COMPUTERS

Clessie 2.0 enables Cummins to power increasingly sophisticated software for the design of engines and related products.

 

 

The Clessie 2.0 supercomputer is a critical asset to the company’s engineering function, accelerating innovation, improving productivity and reducing product development time as well as costs.

With approximately 1.4 petabytes of total storage, 8,584 cores, 355 teraflops of computational muscle, and built to double in capacity, it enables engineers to explore thousands of computer assisted design (CAD) options on demand. Traditionally, an engineer could only explore a small number of design options.

The combination of engineering expertise, robust software, and powerful computing enables Cummins to produce the best engines in the world.

3D PRINTING

Cummins 3-D Printing lab inside the Cummins Technical Center in Columbus, Indiana (U.S.A).

 

 

3D printers take extremely detailed instructions to make precise objects a layer at a time, with relatively little waste. The technology is primarily used at Cummins to help engineers make detailed prototypes of the engine parts they design, and do it faster and more accurately than ever before.

Prototypes can be made from materials strong enough to put in a working engine for testing, which ultimately means great ideas can get to market faster.

CONNECTIVITY AND BIG DATA

A new app is helping Cummins certified service providers get customers back to work faster.

 

 

Cummins is using the power of connectivity and big data to improve the lives of its customers and service providers in multiple ways.

Immediate Assessment, for example, enables service providers to wirelessly connect to an engine through their smart phones or tablets. A feature of Cummins’ new Guidanz™ mobile app, it can pull fault codes indicating the most likely cause for a check engine light and estimate repair time based on data from thousands of similar repairs. In the past, customers could wait hours just to learn what was wrong.

Telematics devices, meanwhile, allow Cummins to gather extremely large sets of data about how Cummins-powered products operate. Company experts can then analyze that data to create digital solutions to customer challenges. With this technology, we can also remotely monitor Cummins-powered products and send software updates to them over-the-air.

In June, Cummins launched a new company, ZED Connect, to help carriers and drivers use data and analytics to increase their bottom lines. The new company’s first product is a simple and low-cost electronic device, ZED ELD, to help fleets and operators log their hours electronically.

VIRTUAL REALITY

The Virtual Reality Team at the Cummins Technical Center in Columbus, Indiana (U.S.A) demonstrates the virtual reality system  based there.

 

 

There are some things that just can’t be captured on a computer screen. The CAVE at the Cummins Technical Center (CTC) in Columbus, Indiana (U.S.A.), is an especially popular spot for engineers who want to see their designs come to life before a prototype is ever built and customers who want to know how an engine will fit in their particular vehicles before one is ever manufactured.

Formally known as the CTC’s Advanced Virtual-prototyping Environment, the facility is one of several virtual reality centers across Cummins. Making it easier to see the intricacies of a big engine like those used in heavy-duty trucks or trains can be critical to engine uptime. It allows designers to know early on when a part is difficult to reach if a repair is necessary.

It can be important for engine components, too. The CAVE played a key role in development of Cummins’ ultra-efficient Single Module exhaust aftertreatment, helping engineers with both the design and the chassis installation requirements for the system, which is up to 60 percent smaller and up to 40 percent lighter than its predecessor.

ELECTRIFICATION

Indiana Gov. Eric Holcomb (third from left) stands with Cummins’ leaders beside a demonstration work truck testing electrification during a recent visit to the Cummins Technical Center in Columbus, Indiana (U.S.A.).

 

 

Cummins in early 2017 launched an electrification division in response to the growing interest in commercial electric vehicles, especially for buses and delivery vehicles used in urban areas. But the company has been working on diesel-electric hybrid engines for more than a decade.

Cummins is currently in the midst of multiple electric mobile and stationary power projects. In the spring of 2016, the company announced it was part of a project awarded a $4.5 million grant from the U.S. Department of Energy to develop a Class 6 commercial plug-in range extender electric powertrain that could reduce fuel consumption by at least 50 percent over a conventional Class 6/7 delivery truck.

ELECTRON MICROSCOPES

A team in the Cummins Technical Center’s Materials Science & Technology lab in Columbus, Indiana (U.S.A.) uses a powerful electron microscope to do its work.

 

 

Cummins researchers regularly use an electron microscope with enough magnifying power to read a newspaper sitting on the moon from earth.

Roger England, the Cummins Technical Center’s Director of Materials Science & Technology in Columbus, Indiana (U.S.A.), said that tool and others enable his team to work in the realm of atoms as it investigates problems like why a certain kind of oil might wear down an engine part and what metals might be less susceptible to damage.

OUR PEOPLE

Cummins engineers work in a lab in the Columbus Engine Plant.

 

 

Cummins strongly believes its people give the company a strategic advantage, with the technical know-how to help solve our customers’ toughest problems. As the only independent diesel engine manufacturer in the world, Cummins has the in-house capability to produce all the critical subsystems required to build an engine or generator.

About a third of the company’s professional staff has degrees in Science, Technology, Engineering or Math (STEM). Many at the company’s tech centers have PhDs.

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 Roars Back Into NASCAR Competition

The company looks to add to its rich racing heritage through a partnership with Stewart-Haas Racing and driver Clint Bowyer.

 

Cummins recently announced that it is returning to stock car competition, with the company inking a three race deal to sponsor the No. 14 Ford driven by Clint Bowyer of Stewart-Haas Racing (SHR) in the Monster Energy NASCAR Cup Series. 

Cummins will sponsor Bowyer’s No. 14 car at three of the most prestigious races on the NASCAR calendar: Bristol, Indianapolis and Talladega. While the sponsorship provides Cummins a unique opportunity to connect the company’s brand to innovation, dependability and success, it isn't Cummins' first foray into motorsports. Quite the contrary. In fact, the company's involvement in motorsports can be traced back to the founder of Cummins himself, Clessie Cummins

Read: "Cummins and the Indianapolis 500: A Time-Honored Tradition in Racing."  

The Cummins Diesel Special
The Cummins Diesel Special was an innovative Indy 500 Roadster that set a recording-breaking pole speed of 138 MPH at the 1952 Indianapolis 500 Mile Race. 

"Cummins has a nearly 100-year commitment of developing innovative technologies that enable our customers’ success," said Amy Boerger, Vice President of Sales, Cummins Inc. "We are pleased to partner with Stewart-Haas Racing, a company that shares this deep commitment to innovation and success, as we add another chapter to our rich heritage in auto racing. Personally, I cannot wait to see the Cummins brand back on the racetrack with Clint Bowyer and the No. 14 team."

The sponsorship is a homecoming of sorts for Cummins, which has deep motorsports ties in IndyCar and NASCAR. Cummins’ racing lineage dates back to the inaugural Indianapolis 500 in 1911 when Clessie Cummins, the company’s founder, served on the pit crew for Ray Harroun’s winning Marmon Wasp. A Cummins powered IndyCar also sat on the pole for the 1952 Indianapolis 500, the only diesel powered car to hold that distinction, and Cummins was the primary sponsor for Al Unser Sr. who won the Greatest Spectacle in Racing in 1987.

In the stock car world, Cummins adorned Mark Martin’s Ford in the 1990’s, often appearing on the Hall of Famers iconic red, white and blue paint schemes. Martin drove Cummins sponsored cars to 25 victories during the heyday of NASCAR. 

The sponsorship also provides the opportunity for the company to partner with one of Columbus, Indiana’s favorite sons, Tony Stewart. Stewart is a co-owner of SHR and echoed his excitement to see Cummins return to stock car racing. 

For as long as I can remember, Cummins and motorsports were one in the same, said Stewart, the three-time NASCAR Cup Series champion, 1997 IndyCar Series champion and four-time USAC champion.

"Cummins always had a presence in the Indianapolis 500 and I remember seeing their logo in NASCAR for years with Mark Martin," added Stewart. "To be able to team up with a hometown company and help Cummins grow its business with another SHR partner in Rush Truck Centers, is something I take a lot of personal pride in. I know what winning feels like as a driver, but this is what winning feels like when you’re a team owner." 

Be sure to tune-in and watch Clint Bowyer drive the Cummins sponsored car at the following races:

  • Saturday, Aug. 18 – Bristol Motor Speedway (NBCSN)
  • Sunday, Sept. 9 – Indianapolis Motor Speedway (NBCSN)
  • Sunday, Oct. 14 – Talladega Superspeedway (NBC)
Cummins Office Building

Cummins Inc.

Cummins is a global power leader that designs, manufactures, sells and services diesel and alternative fuel engines from 2.8 to 95 liters, diesel and alternative-fueled electrical generator sets from 2.5 to 3,500 kW, as well as related components and technology. Cummins serves its customers through its network of 600 company-owned and independent distributor facilities and more than 7,200 dealer locations in over 190 countries and territories.

The Cummins X15 Engine is Winning Friends and Influencing an Industry

A Cummins employee inspects an engine at the company's Jamestown Engine Plant in Jamestown, New York (USA). The plant, which produces several engine models, is nearing the production of its 2 millionth engine.
A Cummins employee inspects an engine at the company's Jamestown Engine Plant in Jamestown, New York (USA). The plant, which produces several engine models, is nearing the production of its 2 millionth engine.

The Cummins X15™ engine is off to an exceptional start since it went into full production last year, expanding the company’s industry leading market share for Class 8 heavy duty engines and winning praise for its durability and fuel economy.

The engine has won design awards, been embraced by truck makers and last month Cummins introduced a version for commercial marine segments.

“Cummins has always been a technology leader, helping us to meet new emission standards whether we’re operating in California or across the nation,” said John Savage, Executive Vice President of Savage Services, a transportation, logistics and materials handling corporation that participated in the early testing of the X15.  “When it comes to reliability, Cummins is progressive. They don’t sit back on their laurels.”

KEY QUALITIES

The X15 is today the best-selling engine for Class 8 trucks, the large trucks commonly seen on interstate highways in the U.S. Cummins supplied more diesel engines for that class than any other engine maker in 2017. Thanks largely to the X15, the company saw its market share increase from 35 percent in 2016 to 38 percent in 2017, according to WardsAuto.com.

Available in performance and efficiency configurations, the engine’s popularity stems from three key attributes: reliability, lower maintenance costs and fuel economy. Reliability was enhanced by a design that simplified some systems, backed by more than 10 million miles of testing. Total cost of ownership has been reduced by as much as 40 percent compared to a 2010 ISX15 engine. And the fuel economy numbers are particularly striking.

Compared to corresponding 2016 models, the X15 Efficiency Series has seen a 2 to 3 percent gain in fuel economy for the 400 to 450 horsepower (hp) range and up to a 12 percent increase for 485 to 500 hp ratings. Measured against comparable 2012 engines, it gets as much as a 20 percent bump in fuel economy.

That saves operators money and also translates into greenhouse gas (GHG) savings at a time many heavy duty fleets are trying to do their part to achieve climate-related goals. The X15 Efficiency Series reduces GHGs beyond the U.S. environmental standards established in 2017.

NEW DEVELOPMENTS

In just the past few months the engine has seen several new developments:

• In May, Cummins and Navistar announced the X15 was being paired with the Endurant transmission in Navistar’s International LoneStar and LT Series trucks. The first product of the new Eaton Cummins joint venture, Endurant weighs up to 105 pounds less than comparable automated manual transmissions, enabling smoother shifting and improved fuel economy.

• In June, Cummins announced a version of the X15 that uses the engine platform proven in heavy duty truck markets for marine segments. Designed to withstand long, continuous duty operation, the marine version meets Environmental Protection Agency Tier 3 and International Maritime Organization Tier II emissions standards. It utilizes the latest Cummins fuel system product to achieve an efficient fuel burn for clean emissions and optimized fuel economy.

A FAMILIAR TUNE

It looks like Cummins will stay atop the heavy duty market for a while. When the X15 was first introduced in July of 2016, it was unveiled along with the company’s new X12™ engine, the lightest heavy-duty engine in North America going into full production this year for vocational and coach duty.

The X12 was named to Heavy-Duty Trucking magazine’s 2018 Top 20 Products list for its innovation. That’s the same honor the X15 won in 2017.
 

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 Electronics and Fuel Systems China Celebrates its 10th Anniversary

The anniversary was marked with a celebration attended by Cummins executives, employees, end-user customers, suppliers and industrial media. 

 

Cummins Electronics and Fuel Systems (CEFS) recently celebrated the 10th anniversary of its China operations with production of the 2 millionth fuel injector and 800,000th Electronic Control Unit (ECU) in its Wuhan plant. Several Cummins executives, including Rich Freeland, Cummins President and COO; Steve Chapman, Cummins Group VP, China and Russia; Cary Chenanda, General Manager of CEFS; and Chen Hua, General Manager of CBU China; joined with representatives of CEFS China’s key OEM and end-user customers, suppliers, dealers, employees, and industrial media to witness the milestone.

Cummins Fuel Systems Wuhan was Cummins’ first fuel systems production base outside North America and Europe, starting operations in 2008. The electronic business was created in 2012, and in 2017 it merged with the Fuel Systems business unit to form Electronics and Fuel Systems business in China. Putting technology development and customer knowledge as its first priority, the Wuhan Components plant has sought continuous improvement, delivering leading products and proven services to its customers. In 2017, CEFS China achieved $238 million in sales: 

During the event, Freeland expressed his appreciation to end-users, customers and partners for their strong support during the past 10 years, and set high expectations for CEFS' future development: 

We are innovating for our customers to power their success and, in turn, improve the communities in which we live and work. This is the formula for our success in the past, now, and also for the future. 

"As China implements more stringent standards on emissions and fuel consumption, Cummins Electronics and Fuel Systems is uniquely positioned to provide the right technology to improve fuel efficiency while meeting tougher emissions," Freeland added. 

The achievements of CEFS are only possible with the strong support and effective collaboration from all of its stakeholders, including Cummins engine joint ventures in China, its dealers, suppliers, end user customers, and its 500 employees. During the celebration, Cummins awarded its customers and end-users with ‘best customer fleet’ and ‘business development’ awards, as well as showing appreciation towards employees through presenting 10-year service awards.

According to Pei Zhengwei, general manager from Sanjiang Logistics Co., Ltd, fuel economy is a key component when choosing who to do business with.

“When making a purchasing order, we are very cautious," Zhengwei said. "A critical reason for us to continuously choose Cummins engines to power our fleet is due to the best-in-class Cummins XPI fuel systems proving the way in fuel economy." 

Celebrating a Production Milestone As Well As An Anniversary

It would only seem appropriate that as representatives from Cummins leaders, partners, dealers and customers looked on, the 2 millionth injector and the 800,000th Cummins Common Rail (CCR) ECU rolled off the production line.

As one of the six major products of CEFS, the Fuel Lubricated System was specially designed for the China market. The system covers the fuel pump, fuel rail and fuel injector, with a maximum pressure is 2000Bar, ideal for 10-14L diesel engines with emissions requirements for National V and VI standards and future fuel consumption regulations.

CEFS products are featured on engines including Foton, Cummins 11-12L diesel engine; Dongfeng Cummins, 8.3-13L diesel engine; Chongqing Cummins 14-50L high horsepower engine platforms; Xi’an, Cummins 11L engine; and Guangxi Cummins off-highway engine platforms. Cummins Component products are also exported to other markets in Asia, Latin-America and Europe. The electronic products offer the customers with electronic hardware, tools, basic software, software development process, platform and services etc. They are widely applied in Cummins engines, after-treatment systems, fuel systems, power assembly and gensets.

Apart from offering the dependable and advanced products, CEFS China has also continuously expanded its aftermarket network, enhancing its service capabilities and developing cost-effective maintenance plans to better satisfy the requests from end-users. Since the end of 2017, CEFS and DBU China have worked together to authorize 45 dedicated dealers with strong fuel system service capabilities.

Cummins Office Building

Cummins Inc.

Cummins is a global power leader that designs, manufactures, sells and services diesel and alternative fuel engines from 2.8 to 95 liters, diesel and alternative-fueled electrical generator sets from 2.5 to 3,500 kW, as well as related components and technology. Cummins serves its customers through its network of 600 company-owned and independent distributor facilities and more than 7,200 dealer locations in over 190 countries and territories.

GILLIG and Cummins Celebrate Electrified Power Partnership

Early this month, GILLIG LLC and Cummins announced a new electrified power partnership at the American Public Transportation Association (APTA) show in Atlanta, Georgia (USA). The technical collaboration work focuses on integrating and optimizing new battery electric technology offered by Cummins that will soon power GILLIG zero-emissions transit buses. GILLIG is the leading manufacturer of heavy-duty transit buses in the United States.

Gillig - Electrified Bus.small_.jpg

“GILLIG has a very strong business relationship with Cummins, and now, with our new technical partnership, we have been able to share our respective technology roadmaps and jointly develop a vision to deliver the most comprehensive, advanced technology battery-electric bus in the market for our customers,” said Derek Maunus, President of GILLIG.

“We have leveraged our companies’ decades of heavy-duty transit experience in the design of the system, and will integrate this advanced technology into GILLIG’s industry-leading proven platform,” added Maunus. 

Amy Boerger, Cummins Vice President — Sales North America commented, “The Cummins electrified powertrain displayed here represents a major leap forward for the industry, and we are delighted that GILLIG will have first access to this important zero-emissions technology. The partnership enables a close technical collaboration so we can accelerate system integration and performance optimization work to leap ahead of others in the industry.” 

Initial development work for the new battery electric GILLIG bus plans for a 200-mile operating range on a single charge. The bus will feature a direct-drive traction motor with peak torque of 3,500 Nm (2582 pound-foot), and utilize energy recovered from a regenerative braking system. A package of e-accessories will be powered by the Cummins system. The initial bus deployment will use a plug-in charger. 

“Beyond the technical development work, the partnership will also encompass the full range of 24/7 service support, diagnostics, over-the-air connectivity, flexible warranty plans and training programs ready for when these GILLIG electric buses enter service,” said Boerger. 

“At Cummins, we see our customer support network equally as important as the technology we offer, and it will be a distinct advantage for us when we introduce electrified systems,” added Boerger. 

Cummins currently powers the GILLIG series of Low Floor, BRT, BRTPlus, Commuter and Trolley buses with a broad portfolio of clean-diesel, near-zero natural gas and diesel-hybrid power. The addition of Cummins electrified power systems to the bus range will align with transit customers looking to introduce zero-emissions buses to their fleets while still maintaining commonality with their existing GILLIG vehicles and service support provision.

“Cummins and GILLIG have been working together since the 1950s to introduce innovative bus power solutions — and I am really excited to be continuing that success forward into the new era of electric buses,” noted Maunus. 

Lauren Cole

Lauren is the Global Employer Brand Digital Communications Specialist for Cummins Inc, where she focuses on social media, employer branding, and digital media. Lauren joined the company in early 2017 while working on a B.S. in Marketing & Communications from Indiana University. She currently resides in Columbus, IN.

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