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.

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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.

Cummins introduces the Advanced Series 150 Holset Wastegate (WG) Turbocharger

Cummins introduces the Advanced Series 150 Holset Wastegate (WG) Turbocharger

For more than 60 years, Cummins has been powering their customers’ success with class leading air handling technologies. That legacy continues with the introduction of the next generation Series 150 Holset Wastegate (WG) turbocharger from Cummins Turbo Technologies (CTT). 

Engineered by Cummins Turbo Technologies and manufactured in Wuxi, China, the advanced Series 150 turbocharger will initially be available to the light-duty truck market in China in the second quarter of 2021.

Featuring the latest wastegate technology, the Series 150 caters to typical truck applications for the on-highway light-duty commercial vehicle market with engines ranging from 2.8L to 3.8L. This turbocharger has a standard pneumatic wastegate mechanism and can be easily integrated with electric wastegates.

The new turbocharger better supports low end torque requirements and offers improved fuel economy benefits at duty cycle zones for typical 4.5-6 Ton gross vehicle weight (GVW) applications.

The Series 150 turbocharger has achieved improved performance versus its predecessor and offers the following technological advancements:

  • Improved next generation turbine wheel design to provide superior performance.
  • Improved low end torque, which can support 350-380Nm at 1000rpm.
  • Higher turbo efficiency up to ~2% points at duty cycle.
  • Non-Map width enhanced compressor stage, which provides higher low flow performance and can meet engine altitude flow criteria.
  • The capability to integrate with an electronic wastegate actuator. 
  • The ability to work with exhaust throttle valve (ETV) architecture.

“In addition to improved turbo efficiency and fuel economy, these advancements also offer improved drivability, better altitude margin and can help in meeting more stringent emission regulations,” said Brett W Fathauer, Executive Director - Research & Engineering at Cummins Turbo Technologies. “We believe the pneumatic wastegate design found in the Series 150 will cater to light-duty commercial vehicle customers in India and China where compact turbochargers are becoming increasingly desirable and useful in powering our customers’ success.”

The Series 150 light-duty turbocharger offered by Cummins is the latest product development that will expand on the Company’s current market-leading position in the design and manufacture of turbochargers for the commercial diesel engine market.

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

Cummins Turbo Technologies News

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

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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.

Cummins introduces new compressor stage to Series 800 Holset Turbocharger

Cummins Holset Turbo HE800

Cummins Turbo Technologies (CTT) offers advanced improvements to the Series 800 Holset Turbocharger with an all-new compressor stage. The Series 800 Holset Turbocharger from CTT offers a world class product for its global customers that focuses on delivering performance and uptime in high-horsepower industrial markets.

Already a key component of CTT’s product catalogue, the Series 800 Turbocharger takes a leap forward and has been revitalized to deliver significant improvements in performance, flow range, temperature capability and seal robustness. The Series 800 turbocharger is designed for engines ranging from15L to 28L, but can be paired with two or four additional turbochargers for engines ranging from 28L up to 100L.

The Series 800 turbocharger has achieved its best-in-class results by introducing technological advancements like:

  • High Pressure Ratio Compressor 
  • Extended flow range 
  • Thin wall stainless steel compressor cover
  • Lead free bearings option
  • High temperature capable turbine housing option 
  • Improved seal and joint robustness

For the very first time we are introducing the High-Pressure Ratio Compressor (HPRC) technology on Series 800 Turbocharger. This product architecture increases flow range capability by up to 25% and is optimized for pressure ratios of up to 6.5:1. These capabilities have allowed our customers to uprate engines by 20-40% without the need to move to a 2-stage architecture. We have also enabled additional altitude capability for many applications. The HPRC offering also improves our product efficiency. These gains enable air handling architectures which have resulted in 5-7% BSFC improvements for existing applications during engine simulation work. 

The new Series 800 Holset Turbocharger is available with a thin walled stainless-steel compressor cover, enabling us to increase capability without adding to our weight or space claim. We also offer lead free bearings, high temperature capable turbine housings and have increased robustness of our joints and seals.

At Cummins, our continued investment in research and development enables us to engineer new solutions for this market. We are currently in development of an integrated electronic wastegate for optimal flow control as well as focusing on turbine stage efficiency improvement.  

“We are excited to be offering new innovative technologies to increase the capability of the HE800 product line without needing additional space claim. We have been able to leverage our technical engineering expertise and advanced simulation analysis to provide critical air-handling features such as higher-pressure ratios and improved efficiencies while offering more product robustness.” commented Brett Fathauer, Executive Director – Engineering and Research. 
The performance results of the upgraded Series 800 Turbocharger have been met with enthusiasm from off-highway customers who describe the Holset product as "class leading.”

The team at CTT has used the latest design practices to ensure this new product is superior to competition and drives value for customers. The upgraded Series 800 Turbocharger is available now and caters to a wide range of off-highway customer applications including power generation, agricultural, mining, oil & gas, rail, construction and marine. 

"At CTT, we continuously work to improve our products for on- and off-highway customers. The new Series 800 turbo is a class-leading product which exceeds performance expectations and provides excellent value for our customers around the globe," commented Matt Franklin, Director - Product Management and Marketing at Cummins Turbo Technologies.

Learn more and stay up to date on our latest advancements by signing up for our quarterly newsletter and email updates
 

Cummins Turbo Technologies News

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

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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.

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.

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
View the full infographic

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.

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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