Cummins Turbo Technologies prepares to launch 7th generation Series 400 Variable Geometry Turbocharger

7th generation Cummins 400 series Variable Geometry Turbocharger

Cummins Turbo Technologies (CTT), a leading manufacturer of commercial turbochargers, has developed the 7th generation 400 series Variable Geometry Turbocharger (VGT) to help engine manufacturers meet upcoming emission standards and offer best in class fuel economy. Originally revealed at IAA in Hannover in 2018, the 7th generation 400 series VGT will be launched with major customers in Europe and North America in the first quarter of 2021.

Though the latest product line is focused on the on-highway heavy-duty market with engines ranging from 10L to 15L, it can also be applied to smaller engines in the medium-duty space. Customers will find the 400 series VGT in a variety of applications, including line haul, vocational, transit bus and firetruck, to name a few.

The next generation 400 series VGT has 5% higher turbocharger efficiency compared to its predecessor. “The leapfrog innovation is the combined effect of a multi-clearance shroud design (patent pending) and new wheel options to provide higher turbine efficiency,” explained Lisa Prentiss, Director – Heavy Duty Engineering. The multi-clearance shroud provides significant performance gains - specifically at lower flows and adds value through improved engine down speeding and better fuel economy. CTT has conducted more than 7,000 hours of rigorous testing, which is the equivalent of driving from New York City to San Francisco 159 times and have collaborated with customers to optimize performance and fuel economy.

With more than 20 years of experience in the heavy-duty VGT space, CTT frequently upgrades turbocharger performance and durability. With the latest generation, along with the performance enhancements, the turbocharger durability has been improved using an optimized Variable Geometry mechanism (nozzle ring, shroud plate) and center housing designs.

Matthew Franklin, Director – Product Management & Marketing highlighted that “CTT understands that Total Cost of Ownership (TCO) is a key requirement of our customers. The 7th generation 400 series VGT further delivers on this need by lowering fuel costs through improved performance and improving uptime through product robustness."

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

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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.

Turbocharger innovation: small changes that make a powerful difference

Oil leakage of a turbocharger is a failure mode which can lead to reductions in performance, oil consumption, and emission non-compliance. Cummins' latest oil sealing innovation reduces these risks through the development of a more robust sealing system which compliments other leading innovations developed for Holset® turbochargers.  

The redefining oil sealing technology from Cummins Turbo Technologies (CTT) celebrates nine months of being available to market. The revolutionary technology, currently undergoing international patent application, is suitable for applications across on-highway and off-highway markets.

Unveiled in September 2019 at the 24th Supercharging Conference in Dresden in the whitepaper, "Development of an Improved Turbocharger Dynamic Seal," the technology was developed through Cummins research and development (R&D) and was pioneered by Matthew Purdey, group leader in Subsystems Engineering at CTT. 

The research came in response to customers demanding smaller engines with greater power density, along with lower emissions, and the turbocharger remained one of the most critical components on a vehicle driveline. Due to this, Cummins has continuously remained dedicated to delivering excellence to customers through continually exploring innovative ways to improve turbocharger performance and by considering improvements which affect durability, as well as performance and emission benefits. This new technology further enhances the oil sealing capability to offer a wide range of benefits to customers.

What are the benefits of the new oil sealing technology?

The new sealing technology for Holset® turbochargers allows turbo down speeding, downsizing, oil leakage prevention on two-stage systems and enables CO2 and NOx reductions for other technologies. The technology has also improved thermal management and reliability of the turbocharger. In addition, due to its robustness, it has positively affected the frequency of maintenance of a diesel engine. 

Other key elements were also taken into consideration when the sealing technology was in the research and development stages. These include allowing for optimisation of the compressor stage diffuser and a drive for closer integration between the aftertreatment and turbocharger, an integration which has already been subject to significant R&D from Cummins and forms a significant part of the Integrated System concept.

What experience does Cummins have with this type of research?

Cummins has more than 60 years of experience developing Holset turbochargers and uses in-house testing facilities to conduct stringent testing and repetitive analysis on new products and technologies. 

“Multi-phase Computational Fluid Dynamics (CFD) was used to model the oil behavior in the seal system. This led to a much deeper understanding of the oil/gas interaction and physics at play. This deeper understanding influenced design improvements to deliver the new sealing technology with unmatched performance,” said Matt Franklin, Director – Product Management & Marketing. 

Due to this rigorous testing regimen, the final product exceeded the seal capability by five times the projects initial target. 

What further research should customers expect to see from Cummins Turbo Technologies?

The continued investment in research and development for diesel turbo technologies is ongoing and demonstrates Cummins’ commitment to delivering industry leading diesel solutions across the on-highway and off-highway market.  

For further information about Holset technology improvements, join the Cummins Turbo Technologies quarterly newsletter. 

Cummins Turbo Technologies News

Stay up to speed on the latest turbocharger technology by signing up for the Cummins Turbo Technologies quarterly newsletter.

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.

Cummins continuing to supply critical filtration material for personal protective equipment

Cummins Filter Media
To date, Cummins has provided more than 14 tons of its filtration media to mask manufacturers across the globe.

In this Q&A, Amy Davis, Vice President of Cummins Filtration, shares an update on the company's progress to provide filter media to mask manufacturers around the globe. 

As the world began to grapple with COVID-19, employees at Cummins were working on innovative solutions to help supply PPE that was in high demand. On April 6, Cummins announced plans to use their filter technology to supply critical materials for N95 respirator masks, an essential piece of personal protective equipment for front-line healthcare workers.

Following the N95 announcement, on April 14, Cummins announced an additional partnership with 3M, which would include the utilization of equipment typically used for producing diesel engine filters to manufacture high-efficiency particulate filters for use in 3M’s powered air purifying respirators (PAPRs).

To date, Cummins has provided more than 14 tons of its filtration media to mask manufacturers across the globe, which has been used to produce more than eight million masks. Amy Davis, Vice President of Cummins Filtration, recently shared an update on the company’s progress to date.

Cummins Filter Media -  Covid - By the Numbers - 1
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Q: First, can you share more about the Cummins Filtration business and your core products?

DAVIS: Our core expertise is designing, manufacturing and selling air, fuel, hydraulic and lube filtration, as well as chemical technology products for diesel and gas-powered equipment around the world. 

Q: How did Cummins Filtration get involved in supplying media for masks?

DAVIS: The need for masks, especially N95 respirator masks, skyrocketed in March and April in response to the COVID-19 pandemic. We learned that many of the world’s leading mask manufacturers needed the critical materials to assemble masks and were struggling to meet demand. We realized that the NanoNet® and NanoForce® Media technology typically found in filtration products for diesel engines could also be used in surgical masks and N95 respirator masks worn by healthcare professionals to help stop the spread of COVID-19. Once we made that connection, we began exploring partnerships to apply the filter material to masks. 

 

Cummins Filter Media - Covid - By the Numbers - 2

Q: How has Cummins been able to partner with 3M in an additional effort to meet the surge in demand for PPE due to the COVID-19 outbreak?

DAVIS: We needed to move fast and saw an opportunity to use our existing workforce at our Neillsville, Wisconsin facility to meet this demand. We acquired, commissioned and tested a new pleater in a matter of weeks and have already produced more than 41,000 filters for 3M’s PAPRs since mid-April. Internally, we talk a lot about employee empowerment and decision making and this project is a testament to our employees’ ability to adapt quickly to fill an important supply void in a totally different market. 

Q: What has the response been like from mask manufacturers?

DAVIS: Demand has been strong – in fact, it’s getting to the point where demand will exceed our capacity. Seeing so many organizations inquire about the media reinforced how critical the need for masks was globally. We’ve talked with Universities, health care systems, other automotive companies and mask manufacturers large and small about our media. To date, we’ve supplied 6 tons of the complete composite multilayer media that can be used in N95 masks, and we’ve shipped 8 tons of a simpler polypropylene media that can be used in surgical masks. 

 

Cummins Filter Media - Covid - By the numbers - 3

Q: Do you plan on selling media for masks long-term, or is this a temporary measure to respond to the COVID-19 pandemic?

DAVIS: We’ve added manufacturing capacity and capability to our plants and plan on continuing to supply media for masks as long as there is demand and a need to protect our communities from COVID-19.  

Q: What has been the most interesting thing about this project for you?

DAVIS: Our employees always want to help, and it wasn’t a surprise when they demonstrated how quickly we could pivot from supplying filters for diesel engines to supplying the media that is critical to manufacturing medical PPE. It only took us one month to go from concept to production on this project! Cummins Filtration employees across the globe have taken immense pride in being part of the solution to help our communities, and the entire initiative is a great example of how Cummins embodies our mission of making people’s lives better by powering a more prosperous world.

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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.

Counterfeit turbos turn dream cruise into a nightmare

Rick Renfroe spent years diligently planning for a dream cruise. Little did he know, he had been deceived by counterfeit parts that were going to cause his trip to go horribly wrong.

Rick Renfroe had been planning a cruise to Key West and the Bahamas for well over a decade. The day he finally got his keys to a Sundancer 440 with twin Cummins diesels, that dream was on its way to becoming a reality.

No stone was left unturned in his boating preparations. Every mechanical element was checked and tested ahead of time, and if there were any doubts about a part’s reliability, it was replaced. 

This included the Holset® turbochargers mounted to the Cummins 6BTA5.9-M2 engines. Right before the big trip, Renfroe was wrapping up months of trouble-free performance sea trials when smoke started to appear from the port engine. 

Rather than taking any risks, Renfroe and his diesel mechanic decided to replace the turbochargers in both engines. 

The Start of a Vicious Cycle 

Counterfeit TurboThe local marina did not have the correct turbo model in stock, so Renfroe searched online and found a dealer in Atlanta, 600 miles (965 km) away, that did. With the trip fast approaching, he quickly drove to Atlanta to pick up the turbos and brought them back to be installed immediately by his trusted technician. 

The new HX40M turbos were advertised as “genuine Holset.” They looked right. They fit right. However, when the owner fired up the engines for a shake-down cruise in nearby waters, it took less than two minutes for the turbo on the port engine to have a significant failure. 

Assuming a manufacturing defect was the issue, Renfroe got back in his car, drove to Atlanta and exchanged it for another unit. He shrugged it off as an anomaly. Little did he know, this was only the beginning of his troubles. 

With the second replacement turbo installed, the family embarked on the first leg of the journey. All was going according to plan, and they spent a delightful week cruising the Bahamas and back to Key West. They started up the western coast of Florida, and just as they were leaving a fuel stop in Venice, the turbo on the starboard engine died, forcing them to idle for 14 miles (about 23km) to the nearest marina. 

A postmortem on the turbo revealed a seal failure and oil leak in the turbo, which caused the shaft to snap. The family rented a car to get home and a slip for their boat. Renfroe once again drove back to the dealer who sold him the first three units to get yet another replacement. Finally, back at his home port, Renfroe noticed oil seeping out of the housing. Fed up, he sent the turbos to Holset, where it was discovered the entire lot of turbos were counterfeit.

Hurricane Michael 

An ugly situation took a disastrous turn when Hurricane Michael suddenly started bearing straight down at the port. With no turbo on one side, there was no way to escape the hurricane’s path in time. Renfroe had no other choice but to remain docked and hope for the best. Unfortunately, the entire Panama City Marina took a direct hit and was completely destroyed – including Renfroe’s Sundancer 440. 

Hurricane Michael
During Hurricane Michael, the entire Panama City Marina took a direct hit and was completely destroyed - including Renfroe's Sundancer 440. 

Despite the situation, Renfroe appreciated the Holset team that made every effort to remedy the situation once they were contacted. He learned firsthand that to be absolutely positive you are getting a Genuine Holset turbocharger, with Holset reliability, durability and performance, you must always buy from an authorized Holset distributor. 

To learn more about Genuine Holset turbochargers and parts, visit Holset.com to find your local authorized Holset distributor
 

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.

Cummins Turbo Technologies launches exhaust throttle valve

Cummins Exhaust Throttle Valve - ETV

A new Exhaust Throttle Valve (ETV) for aftertreatment thermal management and exhaust braking has been developed by Cummins Turbo Technologies (CTT). ETV helps engine manufacturers meet stringent emission requirements.

"With more than 60 years of experience in engine air handling innovation, CTT is uniquely positioned to integrate ETV with engine systems that provide customers with a complete system level solution. Cummins’ knowledge of air handling systems combined with experience in control systems technology has achieved a cost effective, high performing ETV to meet the needs of our customers," commented Matt Franklin, Director – Product Management & Marketing.

Initially, the launch of the ETV was developed for medium-duty engine applications in India and China, and has since grown to Brazil, Europe and Mexico. ETV applications include on-highway truck, transit bus, refuse and tipper trucks. 

The ETV not only helps engine manufacturers meet stringent emission requirements, but also offers flexible design needs. Cummins’ Original Equipment Manufacturers (OEM) have options to configure the product with heat shields, coolant fittings and locator features. Bespoke ETV products can be designed with customized flap diameter for tailored pressure control and unique end connections for easy integration. These flexible design offerings help OEM’s meet their packaging and performance requirements. 

"We have validated the product extensively on more than 130 applications with five different engine families. At the end of 2019, the total field mileage accumulation exceeded ten million kilometers - equivalent to circling the earth 250 times. The extensive engine and vehicle validation pursued by CTT has ensured a reliable and durable product," explained Brett Fathauer, Executive Director, Research & Engineering. 

A modular service strategy was also put in place to allow selected components to be serviced, rather than replacing the entire ETV. Thus, lowering the total cost of ownership. Additionally, CTT has leveraged its global supply chain to minimize product costs and support global market needs. The ETV is currently in production and is available now for customers.
 

Cummins Turbo Technologies News

Stay up to speed on the latest turbocharger technology by signing up for the Cummins Turbo Technologies quarterly newsletter.

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.

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