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]

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.

Cummins CEO says company positioned for success at Annual Meeting

Cummins CEO Tom Linebarger addresses the company's Annual Meeting in Indianapolis.
Cummins CEO Tom Linebarger addresses the company's Annual Meeting in Indianapolis.

Chairman and CEO Tom Linebarger pronounced 2017 a success and said Cummins is well positioned for the future at the company’s Annual Meeting today in Indianapolis, Indiana (U.S.A.).

“Looking ahead, we are confident that the investments we made in our people, our products and services in 2017 will ensure that the company continues to help our customers win in their markets and create long-term value for our shareholders,” Linebarger said at the meeting at the company’s Distribution Business headquarters.

“We were able to grow profitably and generate record operating cash flow while investing in new products and technologies, new partnerships and positioning for the future,” he added.

Linebarger said 2017 was the first year of broadly improving markets since 2012. Full year revenues were a record $20.4 billion – a 17 percent increase over 2016. Revenues increased 15 percent in North America and 19 percent internationally.

Cummins Indianapolis Distribution Headquarters
The 2018 Annual Meeting was held in Indianapolis at the Cummins Distribution Headquarters (pictured here). 

Excluding charges related to U.S. tax reform, Earnings Before Interest and Taxes for 2017 was 2.4 billion or 12.2 percent of sales compared to $2 billion or 11.4 percent of sales in 2016.

He said an improving focus on Cummins’ core business should prepare the company for future success, including:

*Strengthening the company’s market positions with the launch of innovative new products across markets and around the world.

*Improved customer support through the company’s Distribution Business, which is now organized to better serve customers.

*Reduced costs and improved productivity at every operation in the world.

*New processes and methods to improve product quality at launch and in the field.

This year’s Annual Meeting was held in Indianapolis because the Corporate Office Building in Columbus, Indiana, including the Board Room, was under renovation.
 

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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 TEC Program Launches in Brazil

Rogéria Varella Almeida, coordinator of FAETEC, the educational institution that supports Cummins TEC, addresses a ceremony to celebrate the start of the initiative.
Rogéria Varella Almeida, coordinator of FAETEC, the educational institution that supports Cummins TEC, addresses a ceremony to celebrate the start of the initiative.

Cummins’ global strategic community initiative, Cummins TEC: Technical Education for Communities, recently expanded into a new country with the inauguration of a TEC site in Brazil.

First launched in 2012, Cummins TEC targets the technical skills gap around the world through local vocational education programs. In Brazil, Cummins is partnering with French multinational energy management and automation company Schneider Electric to bring the program to the Foundation for the Support of Technical Schools (FAETEC), along with support from the state government.
 
“The TEC program was created from the need to raise the opportunities of low-income youth for the labor market, and also to fill the gap of skilled labor,” said Luis Pasquotto, president of Cummins Brazil, speaking at a ceremony April 20 to celebrate the initiative. “It is a program of global importance. We are proud to inaugurate it here in Brazil.”

TEC Classroom in Brazil
A Cummins TEC classroom is ready for the new initiative in Brazil.

Mary Titsworth Chandler, Vice President of Corporate Responsibility at Cummins and Chief Executive Officer of the Cummins Foundation, said the mission of corporate responsibility at the company is to “build prosperous communities.”

“Cummins TEC aims to help employers fill jobs that pay good wages by teaching students the technical skills needed to be successful in those jobs,” she said. “Cummins looks forward to working with our Cummins TEC partners in Brazil.”
 
Cummins TEC is built on a five-element framework that helps education partners deliver effective, market-relevant curriculum, teacher training, guidance counseling and the practical experience students need. It is the company’s first global strategic community initiative and today operates in 14 countries around the world at 22 sites.
 
“For us at Schneider Electric it is fundamental to contribute to initiatives like Cummins TEC, which is totally aligned with our company’s mission,” said Cleber Morais, president of Schneider Electric for Brazil. “Causes like these generate positive social impacts by preparing a growing number of youngsters to enter the labor market.”
 
Thirty students have been selected for the first class in Rio de Janeiro through a public examination conducted by FAETEC, whose Vice President Miguel Badeneso, also attended the ceremony. The TEC program will take three years.

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 puts Electrification Progress on Display

Cummins displayed an electric system for bus applications at the Busworld show in Izmir, Turkey.
Cummins displayed an electric system for bus applications at the Busworld show in Izmir, Turkey.

Cummins is moving quickly to develop the company’s new electrification business, displaying technologies it’s working on at trade shows this month in Paris and Izmir, Turkey.

The company’s Electrified Power business unveiled an electric system for city bus, shuttle and intercity bus applications at Busworld in Izmir, Turkey, last week (April 19-21). And the business is displaying its first electrified off-highway powertrain concept suitable for cranes, excavators and wheeled loaders at Intermat in Paris through Saturday (April 23-28).

Both could potentially deliver zero emissions technology to customers on a broad scale before the end of the decade or sooner.

“With our recent acquisitions of Brammo and Johnson Matthey Battery Systems (two battery companies), we are building capability across the entire range of electric storage,” said Julie Furber, Executive Director, Cummins Electrified Power. “We want to be as transparent as we can about where we’re headed so customers can see what’s coming and think about the Cummins technology that will work best for them.”

Cummins believes there is no single answer to the world’s power needs. Instead, the company wants to offer customers a range of technologies to help them succeed while addressing global needs such as reducing greenhouse gases.    

The displays at Busworld in Turkey and Intermat in France are merely the latest signs Cummins is determined to be the electrification leader in every market it serves. Less than a year ago the company unveiled AEOS, a fully electric, heavy-duty demonstration truck Cummins is using to study electrification. And it’s been less than six months since the company announced it was starting its Electrified Power business.

AEOS - Cummins heavy duty electric concept truck
Cummins' all-electric demonstration truck AEOS will help the company study electrification.

“We’re moving quickly, but we have a big advantage in that Cummins has been working on electrification for more than a decade,” Furber said. “We’ve manufactured hybrids like diesel-electric engines. We’ve brought to market engines using stop-start technology. So that gives us a significant head start compared to smaller companies without much experience scaling up a new product.”

Cummins has pledged to have an all-electric powertrain for the urban bus market by 2019, and off-highway applications will follow at a later date.


BUSWORLD IN TURKEY

The system that was on display at Busworld is configurable for either a full battery electric vehicle (BEV) or a range-extended electric vehicle (REEV), incorporating an engine-generator with a battery pack.

It uses a new Cummins 74-kWh battery pack with more space-efficient packaging, enabling easier bus integration with a format expandable to eight batteries. That would provide an operating range of up to 385 km (240 miles) on a single charge.
 
The Cummins designed and built batteries achieve a higher energy density and use a proprietary control technology to maintain battery charging for a longer range. Operational flexibility is provided with an integral plug-in connection for overnight or route-end charging, and options for on-route charging where the proper infrastructure exists.

“Our BEV and REEV electric architecture was designed to be fully adaptable for today’s diesel bus models,” said Cenk Yavuz, Cummins Territory Leader in Turkey. “This allows transport authorities to specify the same buses that work so well for them today with an electric system.”  

 

INTERMAT IN PARIS

Cummins is using virtual reality to demonstrate its first electrified off-highway powertrain concept at Intermat. Visitors will see how REEV would power a wheeled loader, used for excavating and carrying bulky material. The loader could be charged overnight, allowing two hours of operation per 35 kWh battery. More batteries would be required for longer zero emission operation.

REEV offers a balance of battery power with a compact engine-generator.  It has an F3.8 Stage V powered generator, giving much more flexibility where charging infrastructure is not available. Cummins’ BEV system is intended for the most environmentally challenged locations, suitable for applications such as drills, underground mine trucks and terminal tractors.

“Cummins is developing a portfolio of alternative power for the industrial market, including full electric and range extending electric drivelines,” Furber said. “These complement our Stage V clean diesels and enable us to offer the best solutions for our customers, whatever their needs.”

 

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]

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