Making a splash with hydrogen internal combustion engines

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The search for power solutions to decarbonize commercial vehicles and off-highway equipment took an exciting turn last summer with an announcement from Cummins

Cummins and Hydrogen Internal Combustion Engine (ICE) Development

Our hydrogen-fueled engine development program is one of our latest steps to advance zero-carbon technology. Customers are taking notice and so are governments

Indeed, judging by some reactions, it's almost as if Cummins has just reinvented the internal combustion engine (ICE).

Test Cell - Cummins Hydrogen Internal Combustion Engine (ICE)
Test Cell - Cummins Hydrogen Internal Combustion Engine (ICE)

Of course, product development is in the early days, but the truth is, it looks very promising and I am excited about the capability of a hydrogen engine to virtually eliminate CO2 emissions.

According to the EPA's Greenhouse Gas Emissions Model (GEM) for Medium- and Heavy-Duty Vehicle Compliance, a model year 2027 Class 8 sleeper cab semi, powered by a hydrogen ICE would generate 144 fewer metric tons of CO2 per year versus its diesel-powered counterpart.
 
That adds up to saving 1,437 metric tons of CO2 over the life of that one vehicle —that’s equal to nearly 575 full size hot air balloons filled with CO2 in the sky. Can you imagine what a fleet of hydrogen ICE vehicles can do if that is just one vehicle?

Why hydrogen ICEs?

Hydrogen ICEs will provide a low cost zero-carbon solution for high load factor and high utilization applications where battery-electric solutions cannot meet the operational requirements and fuel cells are not yet economically viable.
 
A hydrogen ICE fits in today's trucks, works with today's transmissions and integrates seamlessly into the industry's existing service networks and practices. End users are responding positively to the potential for a hydrogen engine because of the zero-carbon fuel and its familiar technology. 

Likewise, launching the hydrogen engine also benefits other paths to reach a zero-carbon future, such as hydrogen fuel cells. By creating a viable use case and demand for hydrogen in the near term, we can accelerate hydrogen infrastructure build-out and increase scale production of vehicle storage tanks. Both advances are necessary for the widespread adoption of fuel cell powertrains.

How will the hydrogen ICE make it to market?

Built on decades of experience and as a major player in natural gas engines worldwide, you can say that we at Cummins have an inherent advantage in getting this program off the ground.   

There is significant reuse of appropriate engine components, which drives economies of scale while also providing reliability and durability equal to diesel.

But it's also important to note that with decades of experience in spark-ignited engines comes the knowledge that we will harness to bring differentiating technology to the forefront. 

For example, our hydrogen-fueled engine development program plans to utilize all-new engine platforms that offer flexible overhead cam systems, improved cooling, and reduced friction which aims to achieve a more efficient and higher power density product. 

These platforms are being developed to avoid the performance limitations and other compromises associated with converting today's diesel or natural gas engines over to hydrogen fuel.  

In addition, we have designed an advanced optimized combustion chamber for fuel mixing, charge motion, and turbulence generation that we believe is critical for fast hydrogen combustion to maximize power density and efficiency. It’s also important to note that this combustion system will synergize with our next-generation high power density, high-efficiency natural gas engines. 

Early testing on these and other advanced solutions are quickly validating our expectations.

What's next for Hydrogen ICE development?

The next step in our hydrogen engine innovation is to match the performance capability of the powertrain with the applications most struggling to find viable zero-carbon solutions in the near term. 

Hydrogen ICEs will create a new and attractive solution where high load factors and high equipment utilization are critical to customers. With a wave of excitement and possibilities on the horizon, the hydrogen-fueled engine development program has the potential to expand the customers' powertrain of choice. 

Taking on significant challenges is nothing new to Cummins. We have been doing just that for over a century, and innovation is in our DNA. 

Over the last 25 years alone, we have achieved remarkable reductions in engines' criteria NOx and particulate matter (PM) emissions. Improvements in fuel efficiency have also been impressive and a corresponding decrease in CO2 emissions.

Now, over the next few years, our hydrogen-fueled engine development program will take on the challenge of delivering zero-carbon fuel while retaining all the performance attributes our customers have come to expect from Cummins. 

Add this to our already diverse set of technologies available, the path towards the mass adoption of more environmentally sustainable solutions is within reach.

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Srikanth Padmanabhan

Srikanth Padmanabhan

Srikanth Padmanabhan is Vice President and President of the Engine Business, the largest of Cummins’ four business segments. In this role, he pushes the boundaries of customer-focused innovation to position Cummins as the leading powertrain supplier of choice, with its portfolio ranging from diesel and natural gas to hybrid and electric powertrains. Read more about Srikanth's more than 30 years at Cummins.

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 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.

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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