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FEATURES State of the Industry: European Construction Equipment Market 13 Situation Europe: The downside of established economies
Filtration: Fuel filters 17 Clean fuel in, optimum engine performance out
Filtration: Engine air 21 Engines breathe easier with clean air
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Cover Story
Leave nothing to waste Hybrid technology captures and reuses energy that is normally wasted. 7
32 Market Forecast: European Equipment Market 35 Market Forecast: Fluid Power Industry
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COLUMNS EDITOR’S NOTEBOOK 2 The little European engine that could
Economic Outlook 4 Turn a negative to positive
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Edi t or’s No t e b ook
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The little European engine that could
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e focused heavily on Europe and its economy
the effect bauma can have on equipment
per the request of OEM Off-Highway’s
sales globally and what impact, if any, it
inquisitive readers. To do so, we again
could have for the European region this
enlisted the help of well-respected consulting
year. His digital exclusive column can be
firm AlixPartners to analyze this struggling
found on page 32.
region. The outlook is not bright for the
Once again, our expanded Economic
developed continent. Being developed is actually a large reason
Outlook section is available w ith
why the outlook is so dim in the first place, which came as a
additional charts for the defense, mining
surprise to me.
and trucking markets to offer a more
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During economic hardship, it can be difficult to combat a down
well-rounded perspective of the off- and
economy when there is not a large up-and-coming demographic of
on-road equipment markets we cover. You
future consumers, nor a need for new infrastructure development;
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almost a year in advance. Learn more about the show and the products and technologies set to launch in Munich starting
Editorial Publisher Editor & Associate Publisher Associate Editor Field Editor
Sean Dunphy sean.dunphy@cygnus.com Michelle EauClaire michelle.eauclaire@cygnus.com Sara Jensen sara.jensen@cygnus.com Curt Bennink
Sales Integrated Media Consultant Inside Sales Representative
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on page 25.
Kris Flitcroft Curt Pordes Debbie George Greg Udelhofen
Cygnus ExpositIons Senior VP Ray Bianchi OEM Off-Highway (USPS 0751-770 and ISSN 1048-3039 print; ISSN 2158-7094 on-line)
Our market forecaster Frank Manfredi also took a crack at dissecting the struggling European market and pointed out
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EC ONOMIC OU T LOOK
Turn a negative to positive
T
he first look at fourth quarter 2012
The euro area started
GDP growth was -0.1%. Very slow
2013 in a mostly stalled
growth was expected; a negative
state. Germany will lead
number was not. But not too much
the area toward recov-
should be made of the negative ele-
ery during the first half
ment. One-time drops in defense
of the year. But it will be
spending and exports were partly responsible.
the second half of the
The growth estimate may very well turn mod-
year before many areas
estly positive in subsequent revisions.
make notable progress.
U.S. Leading Indicator:
U.S. Total Industrial Production:
■ T his data series received its annual ■ ■
re-benchmarking; all historical data were revised. T he revised series has a slightly more positive tone to it. T his continued with the December report, which showed a 0.5 point gain. 100
93.1 92.6
Contact Steven Crane, Senior Economist at C3 Statistical Solutions, at scrane@c3stats.com.
■ P roduction advanced 0.3% during ■ ■
December. T hat left output up 2.2% from the yearago level. T he consumer durables groups have been primary contributors to industrial sector growth. 10.0
Actual Index (2004=100)
95 93.3 92.7
Questions?
93.1
93.4
93.4
93.9
Annual % Change in Quarterly Averages
7.5 5.0 4.7%
90
3.4%
2.5
4.2% 4.2% 2.4%
3.2% 1.8%
2.2%
85 0.0 80 75
-2.5 May ’12
Jun
Jul
Aug Sep Oct
Nov Dec
OEM Off-Highway | march 2013
-5.0
Jun ’12
Sep
Dec Mar ’13
Jun Sep
Dec Mar ’14
www.oemoffhighway.com
4
EC ONOMIC OU T LOOK
Farm Machinery & Equipment Shipments:
25 18
■ R eal shipment volume dipped ■ ■
2.7% in December. T his pales by comparison to the nearly 21% surge during November. S hipments remain depressed by any reasonable historical standard.
Annual % Change in Quarterly Averages
11 4
1.5%
-9.1%
-10
10.8%
-10
Jun ’12
Sep
Dec Mar Jun ’13
Sep
Dec Mar ’14
Sep Dec
Mar Jun Sep Dec Mar ’13 ’14
Private Nonresidential New Construction:
■ D ecember’s report on private
1.7% 1.1% 1.8% 0.1% 1.4%
0
■ -28.0% -27.8%
■
10.1%
-9.6%
-19.7%
■
nonresidential construction was quite encouraging. C onstruction rose 1.8% on top of notable upward revisions for the October and November estimates. T his was a nice way to end a year during which volume mostly moved sideways.
■ R esidential construction activity ■ ■
closed out 2012 on a strong note. S ingle-family starts rebounded 8.1%, after falling a revised 3.2% in November. F or the year as a whole, starts were up 18.5%.
OEM Off-Highway | march 2013
Millions of Single-Family
0.75 Units, Seasonally Adjusted Annualized Rates
0.60
0.52
0.55
0.59
0.62
0.65
0.68
0.70
0.74
13 6
2.8%
2.0%
-2.8%
0.30
-8
0.15
-15
0.00
Jun ’12
Sep
Dec Mar Jun ’13
Sep Dec Mar ’14
Jun ’12
Sep Dec
Mar Jun Sep Dec Mar ’13 ’14
-1.7%
-4.0%
Jun Sep ’12
Dec Mar Jun ’13
100
Sep Dec
Mar ’14
Annual % Change, in 12-Month Moving Total
75
(1982 Dollars)
50 25 21.6% 9.8%
0 -25
Jun Sep ’12
1.2% 0.4% 2.7%
3.4% 4.3% 3.4%
Dec Mar Jun ’13
Sep Dec
Mar ’14
Mining, Oil & Gas Field Machinery New Orders:
■ T he month-to-month volatility ■
-5.5% -10.8%
-2.0% -2.2%
-2.0% -2.2%
-5
2.7% 2.5%
-1
0.45
-0.3%
-3
during the final month of 2012. T his capped a strong second half of the year. O rder volume was very healthy as this sector entered the new year.
Annual % Change, in 12-Month Moving Total 12.7% (2003 Dollars)
1.1%
-1
■ R eal orders jumped nearly 12%
■
(1982 Dollars)
1
Construction Machinery, New Orders: ■
Annual % Change, in 12-Month Moving Total
3
public construction ended 2012 on a very weak note. R eported activity in December was down 1.4% on top of notable downward revisions to previous months’ estimates. A mong the major component categories, only highway and street construction showed a gain.
20
Housing Starts:
5
■ I n contrast to the private sector, ■
-3
20 18.0%
10
(1982 Dollars)
11.1%
Jun ’12
30
Total Public New Construction:
Annual % Change, in 12-Month Moving Total
15.4%
■
in real orders continued with December’s report. O rders rose 11.2% over a November estimate that was revised upward over 4%. A s a result, 2012 ended with volume well above trend growth levels.
www.oemoffhighway.com
5
EC ONOMIC OU T LOOK 45
Heavy-Duty Truck Shipments:
37.2%
■ A fter a difficult spring and fall, ■ ■
34
shipments rebounded during the final two months of 2012. R eal shipments gained 2.8% during November and 1.7% in December. P roduction volume was also quite strong during this period.
30
12.7% 10.0%
10.8%
■
6 -8.8%
-10 -13.4% Jun Sep ’12
■
-10.7% -9.6%
Dec Mar Jun ’13
Sep Dec
24.3%
23 12
5
-10
3.1%
3
2.4%
1 -0.1% -0.2%
-1 -1.7%
-3 -2.6% -5
-2.3%
-1.7%
Jun Sep Dec Mar Jun Sep Dec Mar ’12 ’13 ’14
OEM Off-Highway | march 2013
-5.1% -4.7%
-2.4%
Jun Sep Dec Mar Jun Sep Dec Mar ’12 ’13 ’14
■
taken a turn for the better. D ecember industrial production was up, as were new orders and business confidence. Y ear-over-year growth rates for the first half of 2013 will still lag due to strong year-ago benchmarks.
Annual % Change in Quarterly Averages
11 7
3.2% 3.4%
3 -1 -0.5% -1.6% -5
-1.5% -1.4% -2.5% -3.3% Sep Dec Mar Jun Sep Dec ’13
Jun ’12
Mar ’14
Mar ’14
105.0
One Company, Two Powerful Solutions
Monthly Index
103.6 102.2 100.8 99.4 98.0
99.73 99.63 99.53 99.45 99.41 99.41 99.47 99.56
May Jun ’12
Jul
Aug Sep
Oct
Nov Dec
Industrial Production, United Kingdom:
■ T he British industrial sector closed 2012 on a ■ ■
Click here to subscribe for our FREE monthly Economic Newsletter!
rose 67%. P re-ordering to beat expected funding cuts was almost certainly a contributing factor. T his distortive spike will keep the smoothed order growth estimates abnormally high during the first half of 2013.
gain following a no change in October. I t is looking more and more like the leading indicator has passed a turning point. T his fits the scenario of a recovery in Europe later in 2013. Annual % Change in Quarterly Averages
9.7%
-2.3%
■ D ecember’s reading was positive; this is the second
■
■
1
Euro Area Leading Indicator: ■
■ T he economic outlook for Germany has
(2003 Dollars)
■ D efense orders exploded in December; they
(1982 Dollars)
14
-2
34.6%
15
Defense Industry, New Orders:
Annual % Change, in 12-Month Moving Total 8.4%
22
Industrial Production, Germany:
Annual % Change, in 12-Month Moving Total
surprisingly strong note. O verall production rose 1.1%, and manufacturing gained 1.6%. T his improves the odds of Britain avoiding the feared “treble dip” recession.
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M A R K E T AT A GL A NC E : H Y BR IDS
Leave nothing to waste by Curt Bennink
C OV ER S T OR Y
T
he concept of hybrid technology is to capture wasted energy and
Hybrid technology captures and reuses energy that is normally wasted.
reuse it for productive purposes. Recently unveiled hybrid construction equipment designs claim fuel efficiency gains in
excess of 20% without any degradation in performance. Excavators and wheel loaders are at the forefront of this hybrid evolution. Komatsu was the first to introduce a hybrid excavator to the U.S. market, and it currently offers a second-generation model, the 23.8-ton HB215LC-1. Recently, Caterpillar announced its own unique hybrid technology with the Cat 336E H. And while it’s not currently offered outside of Japan, Hitachi, Tokyo, Japan, has its ZH200 hybrid excavator. This February, John Deere announced production of its 644K Hybrid wheel loader. The approach differs depending upon the type of equipment and how it is used. First, the location of where the majority of energy is wasted needs to be identified.
The 336E H captures the swing brake energy with a hydraulic accumulator. That energy is then used to accelerate the excavator upper structure back in the opposite direction.
OEM Off-Highway | MARCH 2013
For example, with an excavator, significant energy is lost as you swing the mass of the excavator upper structure back and forth
www.oemoffhighway.com
7
M A R K E T AT A GL A NC E : H Y BR IDS
C OV ER S T OR Y
on the undercarriage. Accelerating and decelerat-
which offers the same high level of performance
ing this upper structure consumes a lot of energy.
as its conventional counterpart, the PC200LC-8,”
With a hybrid excavator, the goal is to capture
Yureskes asserts. “In addition to the 25 to 40%
“It is 229 hp versus 232 hp. We run at a constant engine speed of 1,800 rpm, whereas a
this energy and put it back to use.
fuel savings, hybrid technology produces an
traditional wheel loader will run at 2,250 or 2,350 rpm. We are running at a more efficient
environmentally-friendly machine that reduces
point in the engine efficiency curve.”
Repetition is key to success
CO₂ and greenhouse gas emissions significant-
Hybrid technology is often beneficial in repeti-
ly. Noise levels are also reduced compared to a
tive applications. Consider the case of an exca-
conventional machine, making the HB215LC-1
vator. The more you swing the upper struc-
a suitable choice for urban areas or night work.”
ture, the greater potential benefit from hybrid
According to Pellegrini, “the Cat 336E H uses up
technology.
to 25% less fuel than the standard 336E without
— John Chesterman, Product Marketing Manager for Wheel Loaders at John Deere
The future of fuel efficiency There is an increasing emphasis on the develop-
as going back and forth, digging from one side and
“The Caterpillar 336E will deliver fuel savings
sacrificing power or productivity. Fuel efficien-
ment and implementation of technology that can
in all applications it was designed to perform;
cy—the amount of fuel used per ton of material
reduce equipment’s environmental impact on con-
however, the best fuel savings will come in high-
moved—is also a benefit. Compared to our 336D,
struction jobsites.
volume truck loading and trenching where the
the 336E H is 50% more fuel efficient. Using less
“The construction market and our customers are
machines. “Utility products are used differently and
machine is required to cycle frequently,” says
fuel per unit of work performed also results in a
taking the issue of the environment seriously, and
it wouldn’t be cost effective to use this technology
Kent Pellegrini, Product Application Specialist,
lower carbon footprint, and that benefits us all.”
it’s important for us to develop hybrid machines that
on small machines,” Larsson asserts. “However, I
Caterpillar Inc., Peoria, IL. “The more it swings
Hitachi also reports substantial fuel savings
significantly improve fuel efficiency and reduce emis-
believe that in the future we will see fully electri-
or cycles, the more opportunities there are to
(20%) from the hybrid system on its ZH200 com-
sions, as well as provide a cost-effective solution,”
fied utility machines. The electrification of construc-
store and reuse energy, which leads to more sav-
pared to the standard ZX200-3 excavator, with a
says Anders P. Larsson, Executive Vice President
tion will produce cleaner, quieter and more efficient
ings and quicker payback for customers.”
corresponding drop in CO₂ emissions.
of Volvo Construction Equipment’s Technology
products. This represents the future of our industry.”
The same applies to the Komatsu hybrid. “Since the HB215LC-1 utilizes the energy created dur-
How they work
ing the swing brake motion, applications that
function headquartered in Belgium.
loading on the other.” Consequently, the economics of hybrid technology currently favor larger production-oriented
Larsson also believes there are still efficiencies
There is no one-size-fits-all solution. Fuel efficien-
to be gained from conventional machine technol-
Hybrids capture wasted energy, which is then
cy gains, and the corresponding return on invest-
ogy. “At Volvo Construction Equipment, we put a
require a high amount of swinging maximize the
released at the appropriate time to produce
ment, are largely dependent on the application.
strong focus on fuel efficiency,” he states. “Each
effectiveness of the hybrid technology,” says Brian
useful work. A few key electrical components
“Some applications will benefit more than oth-
year, we invest a substantial amount of money in
Yureskes, Marketing Manager for Excavators,
form the backbone of Komatsu’s hybrid system.
ers by using hybrid excavator technology,” says
advanced engineering to drive the development of
Komatsu America Corp., Rolling Meadows, IL.
“The electric swing motor, generator motor and
Larsson. “The biggest gains will be found in the
new innovations, and improve conventional technol-
A common misconception about hybrid tech-
ultra-capacitor differentiate the HB215LC-1
production environment where there are a lot of
ogy by reducing the waste of energy.”
nology is that performance is sacrificed for fuel
from a conventional excavator,” says Yureskes.
repetitive cycles that use the swing function — such
savings. “This is not the case with the HB215LC-1,
“The machine body, undercarriage, hydrau-
OEM Off-Highway | MARCH 2013
www.oemoffhighway.com
8
M A R K E T AT A GL A NC E : H Y BR IDS
C OV ER S T OR Y
lics system and work equipment are identi-
rpm helps reduce fuel use between work cycles.
alongside the machine’s cooling pack. The elec-
The Caterpillar 336E H has all of the same
cal to those found on Komatsu conventional
The electrical engine assist helps the engine and
trical power is used to boost slew speed, and
advantages of the 336E, with the biggest dif-
excavators.�
hydraulic system quickly reach the necessary
also feeds a secondary hydraulic motor to assist
ference being greater fuel efficiency. Its design
speed to match hydraulic demand.
the diesel engine when there is a demand for
incorporates three building block technologies.
The electric swing motor recovers energy during each swing brake, and stores it in the capaci-
In a conventional machine, the engine would
tor to be used when needed. Energy can then be
lug down to peak torque. But with the hybrid
Caterpillar uses a different approach by cap-
(ESP) pump smoothly transitions between the
sent to either the swing motor or the generator
system, the engine ramps up to the needed engine
turing the swing brake energy with a hydraulic
hydraulic hybrid power sources, engine and accu-
motor to help the engine accelerate as engine
speed based on the hydraulic demand. There are
accumulator. A large accumulator, squeezed
mulator for efficient engine power management.
assist. This allows the hybrid to quickly respond
other benefits, such as reduced noise. Due to the
under the hood between the engine and coun-
It also matches pump and engine load to out-
to hydraulic power demands. Such responsive-
engine speed management and electrical engine
terweight, is pressurized by house-swing
perform the 336E, even at lower engine speed.
ness gives the hybrid the advantage over a con-
assist, the engine spends less time at high rpm,
braking. That energy is then used to acceler-
The Adaptive Control System (ACS) valve
ventional machine.
making its quieter operation ideal for noise-
ate the excavator upper structure back in the
intelligently manages restrictions and flows to
sensitive areas.
opposite direction.
control machine motion with no loss of power,
Proprietary machine control logic also contributes to fuel savings. The Komatsu hybrid has a
The Hitachi ZH200 also uses a hydraulic/elec-
different approach to engine speed management
tric swing motor to generate electrical power
during operation. A low engine idle speed of 700
under braking, which is stored in a capacitor
hydraulic power.
The Electronic Standardized Programmable
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OEM Off-Highway | MARCH 2013
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9
M A R K E T AT A GL A NC E : H Y BR IDS
C OV ER S T OR Y
and ensure operators experience no difference
going through those three cables.”
in control, hydraulic power or lift capability. The
The electric motor drives a simplified three-
ACS main valve takes the energy wasted in con-
speed transmission but the system has four
ventional excavators when flow dumps over relief
operating speed ranges in forward and reverse.
and directs it to circuits that can immediately
The transmission on the conventional 644 has
use the power. It reduces fuel consumption by
four or five forward speeds with three reverse.
preventing pressure loss.
Reverse gears are not needed on the hybrid. “The
The hydraulic hybrid swing system captures the
electric motor operates equally well [in] forward
excavator’s upper structure swing brake energy in
and reverse,” notes Chesterman. With the con-
accumulatorsandreleasestheenergyduringswing
ventional 644 you have to shift gears to change
acceleration.
directions. “We have eliminated that shifting [by]
The design of the Cat 336E H also allows it to
simply reversing the motor. It is very smooth and
run at reduced engine speeds, which saves fuel
very powerful.”
and reduces noise in and outside the cab.
The electric system also recaptures some of the
The John Deere 644K Hybrid wheel loader
energy that would normally be wasted. “If you
uses yet another variation of hybrid technology.
let off the accelerator and the machine is slow-
A diesel engine running at steady state turns
ing, that is actually backdriving the motor,” says
an electric generator. “This machine, compared
Chesterman. “When we backdrive the motor it
to our conventional drive 644, uses a smaller
acts like a generator. That power then lightens
engine (6.8-liter),” says John Chesterman, Product Marketing Manager for Wheel Loaders at John
On the Komatsu HB215-1 excavator, energy in the capacitor (lower left) can be sent to either the swing motor or to the generator motor to help the engine accelerate as engine assist.
Deere, Moline, IL. “It is 229 hp versus 232 hp.
the load on the engine and reduces fuel consumption. This is common in a tight V-pattern operation. During a V-pattern operation the operator
We run at a constant engine speed of 1,800 rpm,
all hydraulic flow and power is available at any
as experienced by the operator, a full 2 dB lower
is decelerating and reversing while at the same
whereas a traditional wheel loader will run at
time. “That is an advantage over a conventional
than our conventional machine. In the world of
time raising the boom. In a conventional machine
2,250 or 2,350 rpm. We are running at a more
drive machine.”
sound, a 3 dB reduction equates to cutting sound
the deceleration energy would be dissipated as
power 50%.”
braking heat, but in the case of the 644K Hybrid
efficient point in the engine efficiency curve.”
“Engines that run generators at constant engine
it is used to assist the engine in providing power
This provides several advantages. “First off, the
speeds have much longer lives than engines that
The John Deere power electronics are the
engine is always spooled up,” he explains. “We
are constantly hunting up and down the rpm
brains of the system. This is provided by John
don’t have to worry about response. We have
range to make power,” says Chesterman. Also,
Deere Electronic Solutions of Fargo, ND. Three
But this hybrid does not use an energy storage
all drivetrain power available.” The engine also
by turning at a lower rpm the noise generated is
cables connect the power electronics to the elec-
device. “Any excess electrical energy goes to the
runs the hydraulic pump at constant speed so
reduced. “The noise level of this machine is 68 dB
tric motor. “All of the power to turn the tires is
brake resistor,” Chesterman explains. “The brake
OEM Off-Highway | MARCH 2013
to the hydraulic system.”
www.oemoffhighway.com
10
M A R K E T AT A GL A NC E : H Y BR IDS resistor allows us to dissipate excess energy to
C OV ER S T OR Y The 644K Hybrid has also proven easier to use.
The hybrid technology also allows adaptation
says Chesterman. “It has four different settings.”
“Operating a conventional machine can be a chal-
of a few unique features, one of which is coast
When a conventional wheel loader starts digging,
The 644K Hybrid does not compromise perfor-
lenge because to effectively load the bucket the
control. With a torque converter machine when
it drops engine rpm to keep the wheels from spin-
mance. The average customer can expect about
operator has to actively manage engine speed
you let off the throttle, the loader free-wheels.
ning. For the 644K Hybrid, the system has been
a 25% reduction in fuel consumption. “That is a
which changes pushing force and hydraulic
With a hydrostatic machine when you let off the
expanded to Full Rim Pull Control. “We are not
mix of various activities—transport, stockpil-
speed,” says Chesterman. Since the engine on the
throttle you get dynamic braking. With coast
changing the speed of the engine. It is just not
ing, as well as V-pattern truck loading,” notes
644K Hybrid runs at a constant speed the opera-
control you can select from four settings—from
going to generate as much pushing force or rim
Chesterman. “But if they focus just on V-pattern
tor always has full driveline and hydraulic power.
no dynamic braking to dynamic braking similar
pull in certain settings.”
loading they will exceed that fuel consumption
“That really helps the novice operators be produc-
to a hydrostatic machine.
reduction. From an application standpoint, this
tive since they can very easily push the bucket
Another unique feature is Full Rim Pull
of the conventional 644. For instance, the frame
machine is not designed to do anything differ-
into the pile and they have the hydraulic power
Control. John Deere wheel loaders currently
is basically the same. “The axles and brakes are
ently than the typical 644.”
to curl the bucket and very quickly maneuver.”
come with Spin Control. “It is a reactive system,”
identical to the conventional drive machine,” says
prevent engine overspeed.”
The 644K Hybrid uses many of the components
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11
M A R K E T AT A GL A NC E : H Y BR IDS
We Turn Strong Machines into Clean Power Packs To satisfy the stringent guidelines for protection of the environment and climate, we have improved our clean solutions for construction and agricultural equipment: The air conditioning lines reduce CFC emissions by as much as 95% thanks to innovative technology – an extremely thin film barrier layer. And the SCR lines, equipped with heated quick connectors that ensure optimized contact, meet the latest emission limits specified for modern engines. Our hoses, hose lines and connection elements contribute substantially to the construction of future-proof and eco-friendly vehicles
C OV ER S T OR Y Chesterman. “We do some things to the counter-weighting of the
swing brake still represents a small portion of the work cycle, result-
machine, but this particular model we manufacture in Stage II
ing in a small window for capturing the energy,” says Yureskes. “By
emissions, Tier 3 emissions, Interim Tier 4 conventional and now
contrast, the automotive industry can use batteries, since the time
Interim Tier 4 hybrid. We always have to do some juggling based on
it takes to accelerate from a stoplight is a few seconds; therefore,
the engine and the aftertreatment device.” John Deere teamed up
the battery has time to convert the chemicals into electricity.”
with industry leading suppliers for the electric motors and drives,
Capacitors provide the necessary solution. “A capacitor has the
but it manufacturers its own inverters as well as the transmission
ability to capture the energy very quickly so the energy generated
to which the electric motor is attached.
in that small window of swing braking is able to be captured and
Will this technology be applied to other loaders in the John Deere
stored,” says Yureskes. “Due to the size of the machine, a large
wheel loader line? Chesterman indicates that this technology is
amount of energy is necessary to quickly decelerate the upper
scalable. “We are going to apply the correct technology to the right
structure, and these large forces directly correlate to the amount
machine. This technology is flexible.”
of energy that is stored. A capacitor allows the machine to convert
Evaluate options
and use this energy instantaneously.” Caterpillar weighed the electric and hydraulic options and took
With excavators, there are currently two ways used to capture
a different route. “We considered both the electric and hydraulic
the swing brake energy: electrically with a capacitor or hydrauli-
paths, and we built prototypes of both and tested them along with
cally with an accumulator. The Komatsu and Hitachi excavators
competitive machines,” says Pellegrini. “We determined that the
use capacitors, while the Caterpillar excavator uses a hydraulic
most efficient, least complex and easiest to service is the hydraulic
accumulator.
hybrid solution.”
The electric excavator hybrids share little in common with
By using this approach, there is very little difference between the
ContiTech Fluid Technology – the connecting force.
automotive hybrid technology. “The way construction equip-
Cat 336E H and a conventional 336E. “Nearly 98% of the machine
q www.contitech-online.com/ami
ment operates played a major role in the development of the
is made from the same proven and reliable components used on
electric hybrid technology,” says Yureskes. “Construction
our standard 336E,” says Pellegrini, “and that gives us economy
applications differ from the automotive industry because
of scale.”
and machines in many industries.
April 15-21, 2013 Munich Germany Hall B2 Stand 301/402 Fluid Technology info@fluid.contitech.de
ContiTech. Engineering Green Value
OEM Off-Highway | MARCH 2013
there is less time for energy to be captured and converted into usable energy.”
“Production machines have been tested by operators globally,” he continues. “Productivity studies and customer appli-
To illustrate, take a typical 90-degree boom swing:
cations have validated performance. The ‘brains’ of the sys-
• S wing starts/swing acceleration—approx. 40 degrees
tem, the ACS valve, has been in the field proving itself with
• S wing coasting—approx. 30 degrees
superior results for several years. In fact, the ACS and hybrid
• S wing braking—approx. 20 degrees
system have worked well together over thousands of hours
“Even if the swing is large (greater than 90 degrees), the degree of
of testing.” ●
www.oemoffhighway.com
12
S tat e of t he Indus t r y: E ur op e a n C on s t ruc t ion Eq uip men t M a r k e t
Situation Europe: The downside of established economies by Michelle EauClaire
Considering the high degree of development of Europe, the construction equipment and commercial vehicle manufacturers doing business in Europe must look internally to develop modular platforms and deliver cost reductions GDP is a key demand driver for construction equipment in developed markets, especially Europe.
to remain profitable.
E
AlixPartners
urope’s economic downfall and uncertain
Considering the period between 1981 and 2011,
recovery timeline are under constant eval-
the gross domestic product (GDP) in Europe has
uation by heavy equipment manufactur-
held a relatively consistent correlation to con-
ers. There are a number of economic indi-
struction equipment sales. “Simply stated, these
cators that can be tracked to help diag-
lines run almost in parallel, with a high correla-
nose the state of the market. Correlations
tion coefficient of 85%” says Barosi. “That strong
between the indicators and construction equip-
connection to GDP acts as both an indicator in
ment sales can then be drawn to better forecast
the moment, as well as a future forecast for the
market performance, according to Francesco
European construction equipment market.”
European Economy in Brief: • GDP is a key demand driver for Construction
• In order to cope with sales slow down, OEMs are
Equipment in developed markets, especially in
aggressively looking at rental capabilities as an
Europe, with a correlation of 0.85
area for growth, right sizing operations for lower
• Europe is expected to face moderate growth of GDP in the next few years • Overall CE industry sales are expected to drop
Barosi, Managing Director at AlixPartners LLP,
European GDP growth in 2013 is forecasted to
from 247k units in 2011 to 239k units in 2012
New York, NY, and global lead of the firm’s Heavy
be a marginal increase from the current near-zero
(final numbers still not reported by OEMs), with
Equipment Practice.
growth. “This is a clear reflection of the state of
moderate growth of 1.0% in the next few years.
OEM Off-Highway | MARCH 2013
production or expanding in new markets/products • Key indicators that OEMs should monitor: 1. G DP and General Government Expenditure 2. Eurostat Construction Production & Labor Index 3. Bloomberg Europe Building Materials Index 4. Country-specific investment trends
www.oemoffhighway.com
13
S tat e of t he Indus t r y: E ur op e a n C on s t ruc t ion Eq uip men t M a r k e t the market with low growth and low expecta-
ket. While there are a number of unique poli-
tion of year over year growth in the near future,”
cies at individual country levels such as France’s
continues Barosi.
recent loi scellier tax incentives for economical
“World GDP growth was essentially stable at 3
housing, the credit crunch continues to affect
to 4% between 2003 and 2007, while the European
private investment for housing starts across the
growth was running approximately 200 base
entire continent.
points lower. We observed the impact of the world
“When compared to other regions, Europe is a
recession in 2009 when we had retraction of the
much more predictable market with significantly
world economies by 2.2%. The recovery has been
lower year over year growth expectations,” Barosi
slow, especially in Europe, where growth in the
says. “In emerging economies such as China,
Old World is expected to be between 0.3 and
population growth, food needs and infrastruc-
0.4%,” says Barosi.
ture development drive economic growth. The
Other key indicators that OEMs should moni-
European countries are quite different; they are
After a decline in GDP in 2012, the European region is forecasted to have a marginal increase in 2013.
tor include the level of government expendi-
already developed and have limited space. At this
AlixPartners
tures, and private and public investments. In
point, the construction market in Europe is about
Europe, Eurostat—the statistical office of the
renewal—improving the current infrastructure,
European Union (EU)—publishes regional data
not developing one.” Compounding this situa-
which enable comparisons at the European
tion, investment in European infrastructure is
level between countries and regions. “If you look
well below historical levels seen in the mid-2000’s.
across the big regions like North America, Latin
The projected compound average growth rate
America and Asia-Pacific, you do not find infra-
(CAGR) for heavy equipment sales in Europe
structure spends and government investment
from 2012* to 2016 is 1%. Larger economies like
changing so drastically. What you find differs is
Germany, France and the U.K. are expected to
the order of magnitude and its impact on GDP—
see sales drop between 0.1% and 0.4%, while other
and that impact is much higher in Europe where
European countries (e.g., Eastern Europe) are
Government Spend accounts for 40% of GDP,”
expected to have slow growth. “The traditional
Barosi says.
larger developed economies are stable yet flat,
Break it down
while the non-traditional economies that are not typically monitored closely for GDP influ-
Low interest rates offset by low amounts of credit
ence are growing at a low rate. If they were grow-
available to borrowers affect the housing mar-
ing at 15 or 20% that may be worth mentioning,
OEM Off-Highway | MARCH 2013
Due to an expected marginal increase in 2013, construction equipment sales in Europe are expected to face moderate growth in the next few years, but still below 2011 volume levels. AlixPartners
www.oemoffhighway.com
14
S tat e of t he Indus t r y: E ur op e a n C on s t ruc t ion Eq uip men t M a r k e t its annual AlixPartners Global Commercial-
for all local and specific sector variants, which
Vehicle Industry Outlook.
can be assembled on a ‘variant-flexible’ local
The report projected a slump in sales of commercial vehicles globally and increased pressure
Excavators and mini-excavators, which account for ~55% of construction equipment sales, are expected to remain flat over the next few years. AlixPartners
assembly line.”
on the industry to consolidate. The long-term
Opportunities
analysis of the industry sees only those manu-
Unlike the situation in some emerging markets,
facturers who can capitalize on economies of
local European brands do not have state sup-
scale succeeding in the cost-driven market.
port to help them defend share or expand. “It’s
“[Cost] reductions can be achieved through
very difficult to penetrate the construction mar-
worldwide economies of scale in products and
ket and expand market share. The opportunity
in sourcing, including by adopting modular
really is to optimize equipment design inter-
strategies and using optimized processes in
nally,” explains Barosi. “Europe is currently a
cooperation with suppliers,” it states.
market in the process of stabilization, and large
The study anticipated that 2012 commercial
[construction] equipment manufacturers are
vehicle sales in Western Europe would decline
restructuring in the sense that they are reducing
15 to 20% as compared to 2011 sales, with pro-
their overall equipment footprint, consolidating
however comparatively their expected growth
same overall sales forecast. “One of the options
jected 2008 sales levels being achieved only by
production assembly lines and finding common
in low single digital is almost negligible,”
in Europe that we’ve seen is OEMs starting to
2015 at the earliest.
platforms to reduce internal manufacturing
explains Barosi.
leverage and focus on the rental market,” Barosi
According to the study, despite rising global-
costs.” The rental dynamic helps construction
So what can help Europe? Still on the table
says. “European OEMs are developing joint
ization, big manufacturers still must meet an
equipment OEMs to find another revenue out-
is relaxing the credit crunch. Unfortunately,
ventures and partnerships with a distribution
increasing variety of regional standards and
let without developing inventories of unsold
many financial institutions are carrying a lot of
model that is almost similar to an automotive
client requirements. Differences in regional
equipment.
debt causing their risk management policies to
model where not only commercial entities but
requirements range from emissions and safe-
AlixPartners predicts that commercial-vehi-
impact credit availability, “unless they develop
also individual end-users, can rent equipment.
ty requirements to duty cycle elements such
cle assembly from the chassis through elec-
a European-wide entity to provide funds,” sug-
There has been a large focus on developing
as distance, road quality, hours of usage and
tronics, as well as production processes, will
gests Barosi, “but that idea is far off.”
those capabilities and the infrastructure to
maintenance routines.
be modularized and standardized worldwide.
“In order to meet this high degree of complex-
Evaluations by the firm experts show that by
Looking beyond construction equipment, the
ity with minimum costs, parts standardiza-
doing this, OEMs could reduce 20% of produc-
Mini-excavators, excavators and loaders
current slow growth of the commercial vehi-
tion and modular design are necessary,” says
tion costs and 30% of development costs.
account for the majority of the heavy equipment
cle segment in Europe was predicted back in
Barosi. “The commercial vehicles of the future
The study also predicts that value commercial
sales in Europe and will basically follow the
September of 2012 when AlixPartners released
will be based on common modular strategies
vehicles—those currently being built by local
Markets
OEM Off-Highway | MARCH 2013
support them in the last 12 months.”
www.oemoffhighway.com
15
S tat e of t he Indus t r y: E ur op e a n C on s t ruc t ion Eq uip men t M a r k e t
After a sharp decline as a result from the global recession, the construction output slowly increased through 2011. AlixPartners
companies in developing countries—will for
costs. According to AlixPartners, Tier 1 suppliers
some time have major cost advantages over
are often not ready to take on the responsibility
Western commercial vehicles, even those built in
for a complete parts system, but OEMs often also
developing countries. “Value commercial vehicles
don’t want to relinquish the responsibility.
will have an impact on the market in Europe and
Just as was said of the U.S., the European econ-
on the U.S. as well,” says Barosi. “The opportuni-
omy will come to terms with and establish a new
ties for Europe lay within the company itself. They
normal. Streamlining processes and adopting
aren’t transformational or revolutionary. For con-
modular strategies are ways for European equip-
struction, it’s going back to basics and focusing
ment manufacturers of construction equipment
on the major product lines and perhaps removing
and commercial vehicles to survive a slow growth
low volume specialty equipment,” he says.
economy, while reducing product lines can ben-
A better-leveraged relationship with local sup-
efit OEMs in the suffering European construction
pliers instead of vertical technology integration
equipment market specifically. A close eye on GDP
is a potential opportunity for manufacturers to
and government investments will help OEMs bet-
find internal cost reductions. Greater transpar-
ter define production and sales strategies, but it
ency across the value chain could optimize joint
will take several years before the European mar-
planning and the steering of capacities, risks and
ket returns to strong growth. ●
OEM Off-Highway | MARCH 2013
www.oemoffhighway.com
16
F ILT R AT ION: F UE L S Y S T E M S
Clean fuel in, optimum engine performance out
Super Absorbing Polymer, an absorbent technology in Parker Velcon’s Aquacon diesel filters, removes water from fuel by chemically bonding it to a polymer so that it is no longer water. Parker Velcon Filtration Division
was in the 50 micron range (the human eye can see 40 microns and above). “We need to make sure the particulate removal is happening before it hits the pump or injector because it’s been shown that even sub 10 micron particles can wear on a high injection fuel pump…and clog [openings] of the
by Sara Jensen
injectors,” says Tom Muzik, Global Engineering
Fuel cleanliness needs are more stringent than ever before, putting an increased demand on a fuel filter’s ability to remove particulates for improved engine performance.
Colorado Springs, CO.
A
Manager at Parker Velcon Filtration Division, To capture larger amounts of microscopic particulate, fuel filter manufacturers have been working to develop new types of filtration media. While traditionally fuel filters have used cellulose
properly designed fuel filter prevents
implementation of Tier 4 engines. Because these
Thomas. “And the better it burns, the better the
and cellulose-blended media to remove solid par-
water or particles that may be in fuel
engines work at higher pressures and have small-
engine performs.” New fuel cleanliness standards
ticulate, this media type is no longer able to meet
from entering a vehicle’s fuel system
er injector openings, even the smallest amount
are now being implemented to guide filter design
the contaminant removal needs of newer engines.
and engine. Small pieces of dirt or
of water or particulate can cause the engine
in order to meet the needs of Tier 4 engines (see
“Inert inorganic bonded fixed pore fibers are
dust that don’t get filtered out of the
to underperform. According to Karl Thomas,
sidebar, pg. 18).
needed to capture finer particulate, plus maintain
fuel can get stuck in the openings of
Product Manager for Fuel Filtration at Schroeder
injectors, causing decreased engine performance
Industries, Leetsdale, PA, fuel for Tier 4 engines
Water and particulate removal
or system malfunctions. Ted Loftis, Director of
has to be 100 times cleaner than the fuel used in
Now, along with having to capture an increased
In early 2013, Cummins Filtration introduced
Engineering at Cummins Filtration, Louisville,
Tier 3 engines. Where Tier 3 diesel engines can
amount of particulate due to smaller injector
its latest filtration media, NanoNet, which
KY, says clean fuel enables an engine to consistently oper-
operate with between 1,300 and 2,500 particles
openings, fuel filters must also be able to prevent
uses smaller fibers to enhance a filter’s ability to
ate at its designed efficiency, emissions and economy tar-
greater than 4 microns in the fuel, Tier 4 engines
subvisible particulate from entering the engine.
capture subvisible particulates. “Smaller fibers
gets during its lifetime.
can only have between 20 and 40 particles greater
Fuel filters need to remove particulate in the 1
provide higher efficiency to capture smaller
Fuel cleanliness has become increasingly more
than 4 microns entering the engine. “The clean-
to 5 micron range—about the size of a red blood
particles while providing a greater [holding]
important within recent years due in part to the
er the fuel, the more efficient it will burn,” says
cell—whereas 20 years ago particulate removal
capacity for contaminants,” says Neha Takawale,
OEM Off-Highway | MARCH 2013
a reasonable element life,” says Tim Mills, Product Manager at Kaydon Filtration, LaGrange, GA.
www.oemoffhighway.com
17
F ILT R AT ION: F UE L S Y S T E M S Global Product Manager at Cummins Filtration.
Fuel cleanliness standards
Takawale further explains that the NanoNet fuel filters have 7 to 13 times greater retention of harmful particles within the filtration media
ISO 4406 is a method for measuring the
during engine vibration and fuel surge. This high
amount and size of particles within a fluid devel-
retention rate ensures particles don’t slip through
oped by the International Organization for Stan-
the filter or get knocked loose and make their
dardization (ISO) which uses a three-digit code
way into the fuel, engine or other vehicle systems.
to specify how clean a vehicle fluid should be.
With engines working at higher pres-
The three-digit code refers to a conversion chart
sures—15,000 psi and above—removing water
that gives a specific measurement of how many
from fuel is essential to maintaining the per-
particles of a certain micron size can be within
formance of an engine. While just 20 years ago
a 100 milliliter sample of fluid.
engines were able to burn water that entered
An ISO code of 12/9/6, for example, uses the
the fuel system, now even the smallest amount
12 in the three-digit code to specify that only 20
of water can cause an injector tip to blow and the
to 40 particles greater than 4 micron can be pres-
engine to need overhauling, says Dan Bigelow,
ent in a sample of fluid. The 9 indicates between
Chief Operating Officer at Separ Filter, Fort
2.5 and 5 particles greater than 6 microns can be
Lauderdale, FL. “We’re at an interesting point
present in the fuel, while the 6 specifies 0.32 to
where it is more important today to have quality
0.64 particles larger than 14 microns are allowed.
filtration on the equipment to protect the engine
Originally developed by the hydraulics indus-
than we ever have before,” says Bigelow.
try, ISO 4406 is now being applied more signifi-
For water removal, many filter manufactur-
cantly to diesel fuel. Fuel injection manufacturers
ers will use an absorbent technology to literally
have been some of the biggest proponents of
absorb water from the fuel. Once the absorbent
implementing a fuel standard. Because engine
can no longer absorb and hold water, the filter
injectors are working at higher pressures than
must be replaced. The Aquacon diesel filters
in the past and have smaller openings, they are
from Parker Velcon use an absorbent technology
more susceptible to problems caused by the
called Super Absorbing Polymer, which is in the
presence of contaminants in the fuel. To ensure
same family of chemical products as diapers. “It actually chemically bonds the water to a polymer
The SWK-2000 Series fuel filter/water separator uses five stages of filtration to remove the marjority of harmful particulates and water from fuel before it even reaches the filtration element.
and it’s no longer water at that point,” says Muzik.
Separ Filter
OEM Off-Highway | MARCH 2013
optimal engine performance, most Tier 4 engine manufacturers are specifying fuel meets an ISO 4406 code of 12/9/6 when it hits the injectors.
www.oemoffhighway.com
18
F ILT R AT ION: F UE L S Y S T E M S In conjunction with more absorbent filtration media, water separators and coalescers can be used to further enhance water and
change elements due to water,” says Schroeder
ent in the fuel. Glycerin is basically the same
Industries’ Thomas.
thing as soap and it will coat fuel filters as well as potentially deactivate coalescers, inhibit-
particulate removal. The SWK-2000 Series of
Changes in fuel
fuel water separators from Separ Filter, for
Though fuel quality has improved within
Muzik says this was more of an issue in the past
example, use five stages of filtration to sepa-
recent years, there are still many places around
“and [people] are being more diligent in speci-
rate water and the majority of particles prior
the globe where fuel quality is questionable.
fying the quality of the biofuel they’re putting
to the fuel passing through the filter media.
According to Cummins’ Loftis, 50% of the
into their engines.”
Coalescers, on the other hand, continually
world’s fuel supply does not meet current ISO
With ULSD, water removal is also a challenge
remove water by gathering droplets of water
fuel cleanliness standards. “In many of our
because the chemistry of the fuel changed
from the fuel and dropping them into a sump.
field experiences [we] have seen fuel samples
from the previous low sulfur version of diesel.
Unlike an absorbent which requires users to
30 times dirtier than the ISO 18/16/13 specified
ULSD contains 15 parts per million (ppm) of
replace the filter once it is no longer able to
by the fuel injection equipment manufactur-
sulfur, whereas low sulfur diesel contains 500
absorb and hold water, coalescers have a sump
ers,” adds Barry Verdgan, Research Fellow at
that needs to be drained on a periodic basis.
Cummins Filtration. ISO 18/16/13 states no
“Effectively, customers can have continuous
more than between 1,300 to 2,500 particles
Schroeder Industries’ bulk diesel filters use a combination of particulate filters and coalescing filters to ensure contaminants such as dirt and debris, as well as water, are removed from the fuel.
operation of [a] filter system without having to
greater than 4 micron can be present in the fuel.
Schroeder Industries
ing their ability to remove water from the fuel.
Some fuel suppliers have also been known to
ppm. Thomas of Schroeder Industries says the change in fuel chemistry “changed the surface tension of [the] diesel and made it harder to get water out of the fuel.” Challenges with ULSD can also arise from
dilute their diesel fuel with water in order to
pulls water [in] from the atmosphere and sur-
the additives used in them. Verdgan says some
trick customers into thinking they’ve received
roundings,” says Bigelow. In addition, Mills
blends use additives which can precipitate out
more fuel than they actually have. Because of
says as biodiesel grades increase, so does the
as soaps when metal ions are present, causing
practices like this, Muzik notes the importance
aggressiveness of those fluids, requiring differ-
injector sticking and in extreme cases plugged
While on-board filtration systems are an
of filtering fuel before it even enters a vehicle
ent metallurgy and filter media binders to be
filters.
important step in providing clean fuel to a
(see sidebar, left) in addition to using on-board
used in the filters. Bigelow says Separ Filters
vehicle’s engine, many filter manufacturers
fuel filtration systems.
had to change the type of materials its o-rings,
OEM collaboration
The benefits of diesel fuel filtration Whitepaper
emphasize the need for filtering fuel before it
Along with poor fuel quality, filter manu-
seals and other components used in the filtra-
Working together with an OEM or engine man-
even enters a vehicle. This can take the form
facturers have also had to contend with the
tion systems were made from to ensure com-
ufacturer on the design and integration of a
of adding extra filters at the point where fuel is
introduction of biofuels and ultra low sulfur
patibility with up to B100 biodiesel.
fuel filtration system is beneficial to all parties
sucked into the vehicle or using a kidney loop
diesel (ULSD). Biofuel is challenging because it
Poor quality biofuels can also be an issue,
involved. Muzik says each engine manufacturer
system to remove fuel from a bulk fuel tank, filter
is hygroscopic, which means it attracts water
notes Muzik. If a biofuel is not refined properly,
specifies the quality of fuel being delivered to
it and place the clean fuel back into the tank.
into the fuel. “It’s actually like a magnet and it
a bi-product called glycerin will become pres-
the engine at a certain volume, making col-
OEM Off-Highway | MARCH 2013
www.oemoffhighway.com
19
Intelligent Braking
F ILT R AT ION: F UE L S Y S T E M S laboration early on in the design
space parameters of the vehicle.
process vital to ensuring the cor-
OEM collaborations also enable
rect filter is used to meet the
filter manufacturers to further
manufacturer’s individual fil-
customize their designs for spe-
tration needs. Early engagement
cific application needs such as
allows filter manufacturers to
adding a heater to the filter for
develop filtration systems that
colder climates or developing
meet and exceed the require-
custom sensors for service noti-
ments of OEMs, adds Cummins’
fications. Bigelow says partner-
Takawale. “It allows us to design
ing with OEMs allows Separ
systems that fit the engine design,
Filter to connect water sensors
operating environment and appli-
to the engine control unit (ECU)
cation specific requirements,” she
in order to alert vehicle operators of the presence of water in the fuel.
injector performance as well as
The small fiber composition of Cummins Filtration’s NanoNet filtration media increases the filter’s ability to capture subvisible particulate.
enables the engine to meet its fuel
Cummins Filtration
need,” he says. “It’s a win-win to
says. Specifying the right filter for an engine helps maintain fuel
“We will customize our sensors to output directly what [OEMs]
economy and emissions targets. Many OEMs have their own stringent tests for
strive beyond simply a supplier relationship.”
performance in certain types of applications or
As engine technologies progress, many engine
real-world conditions. “Working with the OEMs
manufacturers foresee injection pressures dou-
upfront, we develop more real-world tests to
bling again, causing injector openings to decrease
design [a] product that meets these conditions,”
in size even more. This will further emphasize
says Takawale. Upfront collaboration with an
the need to have cleaner fuels running through
OEM also allows filter manufacturers to indicate
a vehicle. Muzik says fuel filtration is only going
auxiliary components such as fuel pumps, hous-
to grow in importance over the coming years
ings for the filter, coalescers and other compo-
to ensure engines run smoothly and efficiently.
nents that will create an entire system that meets
“[Engine manufacturers are] not going to get
the OEM’s fuel filtration needs. In addition, col-
their technology for a more efficient diesel engine
laborating on a filtration system design ensures
without filtration,” says Muzik. “It’s going to be
it will be configured correctly to fit within the
an integral part of the process.” ●
For a World on the Move The world of Mobile Machinery is on the move. Environmental Regulations, Energy Savings and Enhanced Vehicle Safety, and Operator Comfort and Efficiency are propelling new machine designs at a rapidly increasing rate. To stay ahead of the competition, you need to focus on machine differentiation, time to market, and cost competitiveness. MICO is uniquely positioned to help you lead and succeed in a world on the move. MICO engineers specialize in developing collaborative solutions custom tailored to the unique requirements of each machine.
Rapid development and prototyping processes ensure you get to market on time and on budget. The MICO Electrohydraulic Engineering Center brings new levels of intelligent braking integration to machine safety and efficiency while meeting and exceeding the latest regulations. MICO MOBEUS intelligent systems address your latest ABS, ESC and Traction Control requirements.
Talk with MICO today. We help you put your ideas into motion for a world on the move.
Innovative Braking and Controls Worldwide
mico.com • +1 507 625 6426
OEM Off-Highway | MARCH 2013
www.oemoffhighway.com
20
Visit us at Bauma in Hall A5 booth 424
F ILT R AT ION: ENGINE A IR
Engines breathe easier with clean air
Engine air flow rates, specifically those of Tier 4 engines, have increased by 20% or more in order to achieve the efficiency these engines are designed to provide. This has required air filter manufacturers to develop filtration media which can not only capture very small particulates but also enable the necessary amount of air to flow through the filter and on to the engine. Luber-finer
by Sara Jensen
To meet the needs of advancing engine technologies, air filter manufacturers are Business Development Manager for Air and
continually developing new filtration products that can provide improved
CCV Filtration Systems at Parker Hannifin
dirt-holding capacity and particle-removal efficiency, all in a smaller package.
P Removing particulates such as dirt and dust from air flow is integral to the performance of an engine. By improving air filters’ dirt-holding capacity, such as through the development of new filtration media, manufacturers can better guarantee optimal engine performance. Luber-finer Filters
OEM Off-Highway | MARCH 2013
Corp.’s Racor Division, Modesto, CA. To determine efficiency, ISO 5011 and SAE J726C
roper air filtration is an integral part
state manufacturers measure how much
of ensuring proper functionality of
particulate the filter collects (see sidebar,
a vehicle’s engine. Removing par-
pg. 22).
ticles—dust, dirt, leaves, etc.—from
The type of filtration media used in an air
the air which f lows through the
filter is the first step to ensuring an efficient
engine prevents premature wear and
filter design. One method for improving filter
fouling of components such as turbo chargers,
efficiency is through the use of nanofiber tech-
charged air coolers, cylinder walls, piston rings
nology (see sidebar, pg. 24). Nanofiber has an
and bearings, to name a few. Air filter manu-
ultra-fine fiber diameter that can be added to
facturers continue to research and develop new
filtration media, typically made from paper-
technologies to increase dirt-holding capacity,
like materials, to enhance efficiency of the
particle-removal efficiency, and reduce air flow
media while still keeping it open for higher
restriction for improved engine performance.
air flow. The fibers used in Baldwin Filters’
Most diesel engine manufacturers require
ProTura nanofiber technology, for example,
air filters to be at least 99.9% efficient at
have an average physical size of 90 nanome-
removing particulate, says Jon Wake, Global
ters (nm). Utilized in many of the company’s
www.oemoffhighway.com
21
F ILT R AT ION: ENGINE A IR heavy-duty air filters, the nanofibers enable the filtration media to capture contami-
New testing standards
nants in the submicron level. “The advantage
With so many new air filtration developments
[of nanofiber technology] is a higher initial
currently taking place and on the horizon, the
efficiency and a lower pressure drop which
SAE and ISO Filter Test Standard Committees
equates to a more efficient filter and a longer
have begun developing new testing procedures
service life,” says Rich Palmer, Vice President of
for air filters. John Gaither, Director of Heavy-
Original Equipment Sales at Baldwin Filters,
Duty Engineering at Luber-finer, says that while
Kearney, NE.
current test methods have served the industry
New filtration media developments have also
well for the last several decades, “the point
been brought about by the implementation of
has been reached where further information is
Tier 4 engines. Palmer says two of the most
needed to discern the highest performance air-
significant changes are increased air flow and
filters and materials from each other.”
higher operating temperatures. “For air flow,
Currently ISO 5011 and SAE J726C are the
requirements of most engines have increased
testing standards used to determine filter effi-
significantly, some by 20% or more,” he says.
ciency. These mass-based methodologies mea-
Meanwhile, increased underhood temperatures
sure how much particulate is captured by a filter
have necessitated the use of new materials for
and how much continues through the filter.
filtration media that can withstand the higher
Gaither says the new test methods being
temperatures.
developed will include specialized equipment
Andrew Shepard, Director of Global Market
to incorporate real-world properties such as
Management at Hollingsworth & Vose, East
vibration, cyclic flow pulses, thermal cycling and
Walpole, MA, says the heavy-duty equip-
more. “These upgraded standards will bring the
ment industry has begun adopting some of
laboratory bench test closer to the actual vehicle
the European standards for media smolder
operational environment in order to help pro-
resistance (SR) and flame retardency (FR) to
vide the tools to protect equipment for the long
improve vehicle safety. Shepard notes that
haul.” He adds that once finalized, the new test
not all FR and SR industry additives are the same. It is important to ensure the additives used in the media will continue to function after getting wet, especially for air filters that
OEM Off-Highway | MARCH 2013
Most commonly used in high-dirt applications, pre-cleaners are able to remove 75 to 96% of incoming dust and debris by spinning air inside the pre-cleaner and ejecting contaminants back out into the environment.
procedures will provide standardized information filter manufacturers can use to design even better filters.
Donaldson Company
www.oemoffhighway.com
22
F ILT R AT ION: ENGINE A IR typically ingest rain or snow. Palmer adds that this type of
they have a chance to build up on the air filter,” says Gaither.
media is typically found in forklifts operating in warehous-
“Keeping [larger particles] away from the air filter increases
es because of the potential backfiring that could occur and
service intervals and overall system efficiency.”
cause an air filter element to catch on fire. Underground min-
Pre-cleaners are able to separate and remove 75 to 96% of
ing applications benefit from the use of this type of media, as
incoming dust and debris from the air, says Anderson. Because
well, when working in hazardous environments where there
they can remove so much of the initial particulate that can get
is the potential for combustion and ignition of gases in an
trapped in airflows, pre-cleaners have been shown to increase
enclosed area.
filter life up to 20 times. A pre-cleaner’s ability to capture higher
Pre-cleaners
You’re a genius!
amounts of large particulate pieces makes it well suited for use in off-highway equipment working in high-dust environments.
As an additional means of removing contaminants from air flow,
Anderson adds that the greater a pre-cleaner’s efficiency, the
many filters will utilize pre-cleaners. While air filters physically
smaller an air filter can be, which is especially important for
filter and trap incoming contaminants in the air, pre-cleaners
vehicles with space limitations.
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separate and eject harmful contaminants from the air using inertial separation. A series of vanes within the pre-cleaner cause the air flow to spin as it passes through the vanes. While the air spins, dust particles and other contaminants are forced
Kawasaki is tough under pressure. For over 95 years, the Kawasaki Hydraulics Group has expanded around the world, close to our customers, close to you. Discovering the advantages of Kawasaki is your stroke of genius.
to the outer edges of a vane and ejected into the environment. The cleaner air then flows on to the air filter where any remaining particulate will be filtered out. “As a result, pre-cleaners
Contact us today.
require little to no servicing as they do not collect and store
• • •
[contaminants],” says Mike Anderson, Product Director in the Air Business Unit at Donaldson Company, Minneapolis, MN.
mobile marine industrial
Typically placed at the beginning of an air induction system, a pre-cleaner can be integrated into an air filter or be a separate component.
Kawasaki Precision Machinery (U.S.A.) Inc. Grand Rapids, MI www.kpm-usa.com 616.975.3100
According to John Gaither, Director of Heavy-Duty Engineering at Luber-finer, Albion, IL, pre-cleaners are able to remove the majority of the bigger particles, usually 30 micron or larger, found in the air flow. “In conditions with high airborne dust concentrations a pre-cleaner will remove the most massive particles before
OEM Off-Highway | MARCH 2013
Space for underhood air cleaners, such as the one pictured here, has become more limited within recent years due in part to the implementation of Tier 4 engines, requiring filter manufacturers to re-tool their filter designs to accommodate the space constraints. Parker Hannifin Corp., Racor Division
www.oemoffhighway.com
23
F ILT R AT ION: ENGINE A IR Hollingsworth & Vose
Space constraints One of the biggest challenges for air filter manufacturers is creating a filter which will fit into the ever-tightening space allotments of vehicles. In the past, the air filter was simply mounted to the top of the hood or close to where the engine was located.
Keep Your Engine Running
However, with the more streamlined design of today’s vehicles, which provides better visibility for operators, filters are being placed underneath the hood where space is a premium. “It’s always a challenge to be able to make an air cleaner smaller yet still accommodate the high air flow rates required by the engines,” says Wake.
With Superior Diesel Filtration The Separ Filter contains 5 stages of filtration that will: Increase the availability of equipment Ensure reliability Reduce downtime and warranty costs
The implementation of Tier 4 engine systems has reduced available space for air filters due to the larger cooling and exhaust aftertreatment systems the engines require. The ever tightening space constraints within vehicles have prompted air filter manufacturers to focus their research and development efforts on creating technologies which can fit into the smaller machine footprints while still providing the same—if not better—filtration performance. Working together upfront with an OEM or engine manufacturer, however, can help overcome these design challenges. Gaither says early input from an OEM is beneficial to the design pro-
Advantages of a new and advanced nanofiber coating technology for filtration media compared to the electrospinning process
cess to ensure filters will meet performance criteria and space
Whitepaper
dimensional specs for the air filtration system.
requirements. He notes that Luber-finer will begin working with powertrain engineers early in the design process, often three to four years out, to determine preliminary performance and
The use of nanofiber technology continues to increase within
As engine air filtration design continues to progress, improved
the filter industry. When added to traditional filter media types, the
efficiency and dirt-holding capacity will continue to be the key
ultra-fine diameter fibers which make up nanofiber help improve
drivers for optimal engine and vehicle performance. ●
Visit Us at bauma 2013 Hall A4, Stand 421
www.separfilter.com contact@separfilter.com (954) 523-9396
filter efficiency as well as air flow.
OEM Off-Highway | MARCH 2013
www.oemoffhighway.com
24
SP EC I A L SEC T ION:
b auma 2 013
bauma Fact Sheet for download!
Preview
Find out when the show is open, what to expect and where to be to get the most out of this triennial international tradeshow in
bauma is the world’s largest trade fair for the building industry. Established over 50 years ago, the show presents a comprehensive international product range in the area of construction machinery, construction equipment and vehicles, and mining machines. The 2013 show was fully booked 11 months prior to the opening day, impressive considering the fact that this year’s event had a record setting 570,000 square meters of exhibition space allocated.
Trends in construction machinery bauma 2013: New developments in construction machinery deliver
Munich, Germany. 1. Hours of Operation 2. Facts and Figures 3.
Quick Facts: Location: New Munich Trade Fair Centre
ever greater fuel efficiency
Munich (Muenchen), Germany
JCB uses new engines
efficient combustion. As well as the environmen-
Show Hours (in C.E.T.)
The British construction machinery manufac-
tal benefit from lower emissions, this new devel-
Monday, April 15 – Friday, 19
turer JCB is presenting its Ecomax engines for
opment gives customers improved torque across
the first time at bauma 2013. These engines meet
the whole range of speeds, which according to
the rigorous emissions standards Stage IIB and
the manufacturer significantly reduces fuel con-
Tier 4 Interim, without the need for diesel partic-
sumption. JCB is fitting the Ecomax engines to
ulate filters or emissions aftertreatment. Instead
excavators, loaders (backhoe/wheel/telescope/
JCB is using a new engine technology (patent-
telescopic-wheel/compact), telescopic handlers
Contact information:
pending) which enables particularly clean and
and rough terrain forklifts.
E-mail: info@bauma.de
OEM Off-Highway | MARCH 2013
Industry Trends and Charts
9.30 a.m. - 6.30 p.m. Saturday, April 20 8.30 a.m. - 6.30 p.m. Sunday, April 21 9.30 a.m. - 4.30 p.m.
www.oemoffhighway.com
25
SP EC I A L SEC T ION:
b auma 2 013
Cat presents its first hybrid excavator Caterpillar will be unveiling its new Cat hybrid excavator 336E H to the trade audience for the
Free Map!
first time in Munich. Instead of losing the kinetic
Download a free map of
energy when braking the upper structure, it is
the exibit halls and outdoor
captured in accumulators and re-used during
areas of bauma 2013 for
swing acceleration. According to this American
easier show navigation!
manufacturer, it has mastered the technically very difficult challenge of re-using hydraulic energy. The reward for the efforts of the developers, says the company, is a reduction in fuel consumption of approximately 25%. Another way of saving on operating costs is offered by the Cat wheel loader 966K XE, also on show in the Bavarian capital in April 2013. This has been fitted with a new, stepless powertrain system designed to minimize fuel consumption.
Liebherr lines up with a new hybrid crawler crane The German manufacturer Liebherr will be presenting a hybrid solution for heavy-duty applications at bauma—the HS 8300 HD Duty Cycle crawler crane. Weighing in at over 350 tons, it is fitted with a powerful and environmentally friendly hybrid drive on a hydraulic basis. According to the manufacturer, the storage and subsequent reactivation of excess energy increases handling rates and also significantly reduces fuel consumption. In addition, the tried
OEM Off-Highway | MARCH 2013
and trusted technology of hydraulic energy storage is low on maintenance as well as being highly reliable. The machine has hydraulic freefall winches offering approximately 50 tons of
and deliver higher efficiency. In addition, extra
already meets the EU IV/Tier 4 Final standards
sensors are fitted which ensure better electronic
which will come into effect in 2014. Two sepa-
control of the pumps, the engine and the main
rately controlled ventilators cool the charge air,
control valve. As a result, throughput, pressure
hydraulic oil and engine cooling fluid. In doing
and torque can all be precisely adjusted to suit
so the load-dependent control of the ventilator
the individual operating requirements.
for engine cooling saves fuel and reduces noise
Hamm saves fuel with loaddependent control
emissions. In addition, the rollers are fitted as standard with the Hammtronic engine management system, which, according to Hamm,
Hamm AG of Germany, part of the Wirtgen
ensures that the engine is always operated in
Group, is expanding its range of articulated
the right loading range. This optimizes perfor-
tandem rollers. The new models—HD+ 70i and
mance and minimizes consumption. Further
HD+ 80i—are fitted with engine technology that
information can be found at www.bauma.de ●
line pull.
Doosan balances productivity and fuel consumption Doosan Construction Equipment has brought out two new heavy-duty excavators in the 50-ton
INSULATION TECHNOLOGY FOR THE LONG HAUL New Emission Standards Mean Higher Temperatures. Higher Temperatures Demand Better Insulation Technology. THERMAL STRUCTURES IS THAT TECHNOLOGY. ISO 9001:2000 Certified
class, both of which meet the Stage IIIB emissions standard: the DX490LC-3 model, with an operating weight of 49 tons, and the DX530LC-3, with 52 tons. According to this Korean manufacturer, the ratio of productivity (excavated m3/h) to fuel consumption (l/h) in standard operating mode was increased by 9% in both these models as compared to the previous models. The secret to the lower overall fuel consumption, says Doosan, lies in improved cooling, a display to inform the driver about fuel consumption and optimized main control valves, which reduce energy losses
Call Thermal Structures and See How We Can Make Emission Standards Compliance Easy for You. Phone: 951-736-9911 Online: www.thermalstructures.com Email: Sales@thermalstructures.com
www.oemoffhighway.com
26
SP EC I A L SEC T ION:
b auma 2 013
Global Germany
This year’s partner country: Indonesia
Mining machinery continues to be in high demand due to high raw materials demand.
W
hat do the FIFA World Cup
of Mining Machinery
2014 and the Olympic Games
Manufacturers (a part
2016 in Brazil have to do with
of the VDMA, Germany’s
mining and the manufactur-
engineering federation)
ers of mining machinery?
have risen by an aver-
In the case of both of these
age of 13% per year. Dr. Paul
major events, the host country is committed to
Rheinländer, Chairman of this
an enormous ongoing program of investment,
trade association, is very happy with
which includes infrastructure projects. For this
this performance. “With these figures, we
they need raw materials. And to extract these,
are one of the few sectors in Germany that grew
specialist machinery is required.
right through the downturn.” The reasons for
In the medium to long term, too, the signs look
The higher the demand for mineral resourc-
this, believes Rheinländer, lie in rising demand
good for further expansion in business for the
es, the higher, too, is the demand for mining
for raw materials and in the high quality of the
mining machinery manufacturers. In increas-
machinery. At bauma 2013, the International
products themselves. The export ratio for this
ingly more countries around the world—above
Trade Fair for Construction Machinery, Building
sector in Germany is at around 92%. In 2012 the
all BRIC, i.e. Brazil, Russia, India and China—
Material Machines, Construction Vehicles and
value of machinery exports is put at €5.33 billion.
there is a growing middle class which has high
Construction Equipment, manufacturers from
The association expressly welcomes the raw
spending power and an appetite for consump-
all over the world will be showcasing their lat-
materials partnerships concluded with Mongolia
tion. Correspondingly, demand for raw materials
est machinery and technology for this branch
and Kazakhstan. These are aimed at not only
is rising to cater to these countries and the world
of industry. The next bauma takes place from
securing supplies of raw materials for Germany,
as a whole, where the population continues to
April 15 to 21, 2013 in Munich.
but also strengthening machinery sales in these
increase. The manufacturers of mining machin-
countries. Similar agreements with Australia,
ery are set to benefit from these trends.
Since 2007, sales by the mining machinery manufacturers in the German Trade Association
OEM Off-Highway | MARCH 2013
Canada and Chile are also in the pipeline.
Click here for more. ●
The partner country holds significant opportunity and growth potential due to its substantial raw materials. The present conditions in Indonesia are regarded as favorable for new ventures. As part of the general economic upturn in Asia, demand is rising for mineral raw materials, and this in turn is boosting activity in mining. As a result the requirement for mining machinery and technology is also increasing. bauma is an excellent meeting place for both investors in and companies from Indonesia. The Indonesian mining companies need expertise, technology and capital and they are looking to engage in cooperations with foreign partners. Adam Pamma, a representative of the Assn. of Indonesian Professionals for Science, Technology and Enterprises (AIPSE) in Germany, comments, "The mining sector in Indonesia is expanding rapidly, driven by good prospects for profit and rising demand on the international market. German partners are expressly welcomed, yet so far they seem not to have explored in any great depth the opportunities this market offers them.” Indonesia’s raw material reserves are the sixthlargest in the world. According to the Ministry of Energy and Mineral Resources, the republic ranks fifth worldwide for tin reserves, seventh for copper, and 15th for coal. Overall investment in the Indonesian mining sector was around $3,187 million US in 2010. Click here for more on Indonesia's presence at bauma 2013.
www.oemoffhighway.com
27
SP EC I A L SEC T ION:
b auma 2 013
An interview with Prof. Kunze Messe München discusses emissions-reducing driveline
A
THINK BIG! Live at bauma 2013 An extensive program for school children is being organized for the first time at bauma 2013. A 3,000 square meter display is being put on by the German Engineering Federation—the
technology with Professor Günter Kunze.
VDMA—in cooperation with Messe München GmbH and the agricultural machinery associa-
mong the many innovations at
ing components. Depending on the application,
Prof. GK: Traditionally combustion engines
bauma 2013, a key focus will be
a combination of technologies that reduce soot-
have been installed that can deliver the perfor-
7,500 pupils from 170 different schools have reg-
on drive technology for mobile
particle and nitrogen-oxide (NOx) emissions at
mance required. In other words, the manufac-
istered to take part.
construction machinery. Professor
the same time can be used to meet the low limits
turers work out the peak demand and design
All-out action
Günter Kunze, Head of the Dept.
of EU Stage IIIB and Tier 4 Final.
and build the engine to match. However, there
The aim of this initiative is to fill young people
tion LandBauTechnik Bundesverband. Already over
of Construction Machines and
With mobile machinery, attention must be
are many ideas and solutions concerned with
with enthusiasm for technology and the construc-
Conveying Technology at the Technical
paid to the special conditions in which the
the “average requirements” of the construction
tion and building material machinery sector in
University of Dresden, gives an insight into
machinery is used, to the variable operating
machine as a parameter in the design of the
current progress.
cycles and to the performance requirements
combustion engine. To cover peak loads, suit-
of the application in question. The enormous
able storage is then used, which is mechanically,
variety in off-road machinery makes it impos-
hydraulically or electrically operated. This is
Prof. GK: The limit values so far were observed
sible to have a standard solution for emissions
known as downsizing the installed engine per-
up THINK BIG booths, where they will show the
mainly by making adjustments inside the engine.
treatment. For this reason the manufacturers
formance. ●
schoolchildren just what working in the technol-
But in doing so, in some cases, the constructors
define the operating conditions—for example,
were confronted with the contradiction that a
temperatures—in order to enable on the one
Click here to read more with Professor Gunter
combustion process low on harmful emissions
hand filter cleaning in line with soot loading
Kunze as he discusses emissions reducing tech-
leads to higher fuel consumption. The require-
and on the other urea-dosing to reduce NOx,
nology options and his perspective of the prog-
ment for ever tighter limit values has empha-
depending on engine power. As these operating
ress of hybrid vehicles: “In the case of mobile
sized this “ecological conflict.”
conditions do not apply in every case with the
working machinery, the diversity, low production
application profiles in the off-road area, active-
quantities and high lifetimes lead us to assume
of these firms, young technicians and engineers
regeneration processes are used.
that developments will be slower still.”
and also sometimes even the top boss in person,
MM: What technologies can be used to adhere to Stage and Tier emissions regulations?
The limit values for off-road vehicles valid from 2014 require in most cases an additional treatment, downstream of the engine, with effective,
MM: Operating equipment also has to have
durable and low-maintenance emissions-reduc-
sufficient power. What is happening in this area?
OEM Off-Highway | MARCH 2013
particular. The program is aimed primarily at the age range of 13 to 18, across the spectrum of school types. It promises "action" for the entire duration of the show. In Hall B0, specially reserved for this program, twelve companies will be setting
ogy field can involve. For this they will be bringing along a variety of cranes, graders and digger simulators, presenting CAD workplaces, and inviting the youngsters to have a go at dismantling and re-assembling engines and to engage in experiments. On hand at these action stands will be employees from the human resources departments
all of them ready and willing to talk and answer questions. Continues on page 29
www.oemoffhighway.com
28
SP EC I A L SEC T ION:
b auma 2 013 P rod u c t P rev iew
from page 28
Workshop live! A part of the hall and the program is dedicated to a "Workshop live." Here trainees and their supervisors will be working in small groups on machinery, using tools and tool trolleys. Two presenters will be looking over the shoulders of these young technicians and asking some of them about their lives and career choices. Construction machinery companies will be supplying equipment for this workshop, comprising a wheel loader, a wheeled excavator, a site hoist, a vibratory plate, a concrete pump and a roller. The whole thing will be broadcast live on a big screen. Plenty of career information Between the presentations, a range of films will be shown about apprenticeships, study courses and careers. The youngsters will also be able to gather information at a number of classical "Infopoints": The VDMA, for example, is setting up one such information point about the construction and building material machinery sector, and – supported by the universities – about degree courses in engineering and other study routes in higher education. The LandBauTechnik Bundesverband and bbi, the German association of construction machinery hire companies and suppliers, will also be giving information and advice at a second "Infopoint," this time on apprenticeships in the various fields of technology. And, specially for girls, women involved in the MINT Initiative (which encourages young people’s interest in mathematics, IT, science and technology) will be presenting their offering.
Further information: www.facebook.com/thinkbigbub
OEM Off-Highway | MARCH 2013
Hydraulic Motor
Redundant Force Transducers
Engine Oil Management System
Bonfiglioli will present the 700CT, a travel drive gearbox coupled with an integrated hydraulic motor for closed circuit applications.
tecsis GmbH force transducers, used in cranes and other lifting applications, are now available in a redundant version with an additional safety electronic module.
• Compatible with the previous 700CK Series
• In case of error, electronics set analogue output to a preset level
• Features same chassis side and sprocket side dimensions, allowing designers to keep their present gearmotor drivetrain interface
• Fulfills requirements according to EN ISO 13849-1
The Groeneveld Oilmaster is an engine oil management system, originally developed for road transport and public transport, but now also increasingly used for construction and earthmoving equipment.
• Consists of two separate measurement links • Integrated safety module monitors the outputs of both sensors permanently
• Offers improved performance in terms of power transmission and reliability compared to conventional drives
• Features a 15-liter aluminium reservoir • Ensures motor oil will always be at the required level • Reduces risk of adding motor oil with incorrect specifications
• Available in sizes 702CT, 704CT, 705CT, 706CT • Speed sensor located in safe, protected position to avoid damage and malfunctioning
Wireless CAN Interface MICO Inc. introduces a wireless CAN interface for its MOBEUS electrohydraulic (EH) braking systems. The MICO EH wireless CAN bus interfaces with the MOBEUS ABS/TC/ESC ECU utilizing a CAN-Bluetooth connection to the service and diagnostic tool, LINC. • Compatible with SAE J1939 • Communicates with MICO MOBEUS LINC (Single Mode), as well as other vehicle controls utilizing the vehicle's CAN bus (Bridge Mode) • Offers up to 100 m transmission range (single mode) and up to 300 m in bridge mode • Compliant to Bluetooth specification V2.1 EDR • Features operating temperature range of -40 to 85 C • Receives power through vehicle battery power (9 to 30V DC) or an independent 9V battery
Vehicle Safety System The Greensight active safety system is an electronic detection system from Groeneveld Group which helps increase safety around trucks and other heavy-duty equipment. • Includes acoustic warning signal • Optional camera system provides machine operator with accurate and reliable information about free space behind or around the vehicle or machine • Available for construction equipment, trucks and trailers • Helps to prevent damage and personal accidents when reversing, even in bad weather conditions and when it’s dark
www.oemoffhighway.com
29
SP EC I A L SEC T ION:
And the winner is... The nominees are announced for the bauma Innovation Award 2013.
b auma 2 013 P rod u c t P rev iew on January 29, 2013 in Munich, by Johann Sailer,
Construction Equipment. See sidebar on
President of the VDMA Construction Machinery
Volvo’s Fume Extraction System on this
and Building Materials Machinery Association.
page and on page 31
The award is divided into five categories. Out
• AutoPilot Field Rover—3D system for con-
of a total of 156 submissions from Germany and
trolling offset slipform pavers, Wirtgen
abroad, the jury selected three groundbreaking
GmbH
Volvo CE’s Fume Extraction System a Candidate for 2013 bauma Innovation Award
innovations per category to go through to the final round. High-ranking international guests from busi-
Category: Construction Process • Monopile foundation for tidal engine
ness and politics are expected to attend the
turbine—offshore site in Scotland, Bauer
award ceremony, honoring the winners and
Spezialtiefbau GmbH
the nominees, on April 14 in the Allerheiligen-
• Using revolving tower cranes to
Hofkirche (Court Church of All Saints) in the
erect hybrid-energy wind towers—in
Residenz Palace in Munich. Most of the new
a fast construction time, Max Bögl
developments will also be on show at bauma.
Bauunternehmung GmbH & Co KG • “PAST”: reliable, automated road-
Category: Machinery • Revolution in underground mining—the
T
Mobile Tunnel Miner, Aker Wirth less method for installing pipelines,
Innovation Award 2013, which
Herrenknecht AG
is being presented as part of
• JFI Method—Fully automated production
bauma, the International Trade
of multi-layer concrete elements, Sommer
Fair for Construction Machinery,
Anlagentechnik
Bu i ld ing Mater ia l Machines, Category: Machinery Components
Kirchner Bauunternehmung GmbH
of three finalists in the machinery component category of the bauma Innovation Awards. The system,
Category: Research • Online grain size analyzer, Technical University of Clausthal • Parallel kinematics (HEXAPOD) for work-
which is available as an option on Volvo CE’s C-Series ABG pavers, introduces a new way of removing fumes from the operator’s working environment. By delivering 83% efficiency, the system exceeds
ing equipment on mobile machinery,
the National Institute for Occupational Safety and
Technical Univ. of Dresden
Health (NIOSH) guidelines which state that 80% of
• Computer tomography enables orien-
fumes should be captured. Behind the breakthrough
place to the construction machine, Bauer
forced concrete, Technical University of
“The pioneering system works by using a fume
Maschinen GmbH
Kaiserslautern
• Tablet PC—transferring the digital work-
(www.bauma-innovationspreis.de). The 15 nominated innovations were announced at the
OEM Off-Highway | MARCH 2013
revolutionary extractor for bituminous fumes is one
tation analysis of steel fibers in rein-
Construction Equipment, have been selected
press conference held at the bauma Media Dialog
Volvo Construction Equipment’s (Volvo CE’s)
whole building process chain, Hermann
• Pipe Express—a new semi-trench-
he nominations for the bauma
Mining Machines, Construction Vehicles and
building—improved function along the
• Fume Extraction System—Volvo
intake, with a fan located directly behind it, on both the left and right hand side of the auger channel,” Continues on page 31
www.oemoffhighway.com
30
SP EC I A L SEC T ION:
b auma 2 013 P rod u c t P rev iew from page 30
Category: Design • Liebherr Compact Loader, Liebherr-Werk Bischofshofen
explains Anders P. Larsson, Executive Vice President of Volvo CE’s Technology function. “The fan captures and transports the fumes via two tubes to
• Kaiser Walking Mobile Excavator 2013,
the top of the paver where they are then released.
Kaiser AG Fahrzeugwerk
This means that the air in the operator’s working
• EH 100 demolition breaker, Wacker
environment is significantly cleaner than was previ-
Neuson Vertrieb Europa GmbH & Co KG
ously the case.”
The criteria used by the jury of experts in
Volvo’s design is located at the back of the
reaching their assessment of the submissions
machine and features a very short distance
and innovations include the following: sustainability, practical use, contribution towards environmental protection and humanization of the workplace, economic benefit and performance capability combined with energy- and cost-efficiency, and the contribution towards
between the intake and the fan – eliminating the need for additional piping and funnelling in the auger channel. This increases efficiency, prevents any loss of power and ensures that there is no effect on the operator’s visibility into the auger channel. Because extra power is not needed, smaller fans are used. These can be installed horizontally instead
enhancing the image of the construction,
of vertically which offers a smaller, more compact
building-materials and mining industries or
architecture. This also helps to maintain visibility
the sector as a whole.
into the auger channel.
The Innovation Award is a joint project by the German Engineering Federation (VDMA), the German Construction Industry Assn. (HDB), the Central Assn. of the German Construction Industry (ZDB), the German Building Materials Assn. (BBS) and bauma.
During the majority of operating conditions, Volvo’s ABG pavers run on smart power which lowers the engine rpm and considerably reduces fuel consumption. The new fume extraction system continues this environmentally friendly and fuel efficient approach and works just as efficiently when the machine is
Click here for more information on the Innovation Awards for bauma 2013 in Munich
Innovative and efficient
●
operated in smart power mode as it does when the machine is working in max power mode. As well as increased efficiency and visibility, another benefit of the Volvo design is reduced noise. The difference in sound between the system being on or off is insignificant—just 0.3 decibels. Click here to read the full press release.
OEM Off-Highway | MARCH 2013
Dana Rexroth Debuting Modular, High-Efficiency Hydromechanical Variable Transmission at bauma 2013 The Dana Rexroth HVT R2 will be exhibited at bauma 2013 by Dana in hall A4, stand 314. Dana Rexroth Transmission Systems has unveiled the R2 hydromechanical variable transmission (HVT), the latest powersplit system resulting from the 50-50 joint venture between Dana and Bosch Rexroth AG. The R2 is a modular platform that delivers a full suite of configuration options and software controls, such as direct or remote mounting, flexibility in shift control and drive strategy parameters, and the deployment of up to three PTOs. Designed to maximize efficiency and reduce overall vehicle ownership and operating costs, the R2 is ideal for front-end loaders, motor graders, industrial lift trucks, reach stackers, forestry skidders and other off-highway applications requiring
Carraro Drive Tech Exhibiting Driveline Technologies at bauma 2013 The 2013 edition of bauma represents yet another opportunity for Carraro Drive Tech to demonstrate its leadership in drivelines for medium and light construction equipment. At the Munich event a range of solutions specifically designed for compact wheel loaders and compact wheel excavators, backhoe loaders, telehandlers and soil compactors will be presented. During the event, the high level of design and application flexibility of the construction equipment modular axle range, which provides extensive configurability both in the rigid and steering versions, will be highlighted, as well as drives for crawler excavators and winches. Click here to learn about more of the products Carraro is displaying at bauma 2013.
135 to 195 kW (180 to 260 hp) of engine output power. Initial tests on front-end loaders with Dana Rexroth HVT powersplit systems demonstrate fuel savings in the drivetrain of up to 25% when compared with the same vehicle outfitted with a conventional torque converter transmission. “The R2 is a truly innovative transmission platform that combines Dana’s and Bosch Rexroth’s deep knowledge of powertrains,” says Jeroen Decleer, Managing Director of Dana Rexroth Transmission Systems. “The R2 is unique in its ability to integrate hydrostatic, mechanical and control systems through a modular approach that can accommodate the application requirements and customer preferences demanded by the off-highway market.” HVTs from Dana Rexroth improve productivity by enabling sensitive, precise vehicle positioning and stepless drive with no interrupted acceleration. Click here to read the full press release.
Cummins Exhibiting Wide Horsepower Range of Engines at bauma 2013 Cummins Inc. will feature one of the most impressive engine line-ups ever seen at the bauma show with a “smallest-to-largest” engine display featuring the QSF2.8 at 49 hp (37 kW) and the QSK95 at up to 4,200 hp (3,132 kW). The 2.8-liter and 95-liter engines highlight the recent extension of Cummins power at both the low and high ends of the range, now the broadest and most capable in the industry of meeting Tier 4 Final emissions. The four-cylinder QSF2.8, with 49 hp to 74 hp (37 to 55 kW) output, is the smallest-ever Cummins engine to be introduced with full-authority electronic management and a High Pressure Common Rail (HPCR) fuel system. Small in size and light in weight due to the innovative use of composite materials, the QSF2.8 is ideally suited for highly compact equipment such as skid steer loaders and mini-excavators, offering easier installation for Tier 4 Final/Stage IV by utilizing Cummins Compact Catalyst (CCC) aftertreatment with a “fit-and-forget” advantage. Click here to learn about the other engines Cummins will display at bauma.
www.oemoffhighway.com
31
M A R K E T F OR EC A S T: E urop ea n Eq uip men t M arket
bauma 2013
80% 60% 40% 20%
-40%
2007
2008
2009
2010
2011
2012
May Sep
Jan
May Sep
Jan
Jan
May Sep
Jan JJaa
May Sep
May Sep
Jan
May Sep
Jan
Jan
2006
May Sep
-20%
Jan
0% May Sep
European market poised for two years of slow growth
DIGI TA L E XC LUSI V E
2013
-60%
by Frank Manfredi
% Change
A look into the European equipment market’s current situation and future projections for the next few years, as well as the economic influence and predictive nature of bauma 2013 in Munich, Germany.
T
Firwin HC
Hard-Coat Insulation for Engine Parts and Exhausts
NEW!
he good news is that the 2012
below the 2007 peak of slightly less than
European equipment market
200,000 units for at least the next five years.
was up 37% compared with 2009,
The forecast is based on slow economic
which was the worst year in many
growth expected in most of the European
decades. Retail sales in 2009 of
countries. The traditional economic power-
slightly more than 78,000 units
house economies of Germany, France, Italy
were down 60% compared with the 2007 peak.
and the U.K. are all coming off disappointing
Since 2007, the market has been crawling back
years. Italy has been in a deep recession. We
• Conforms tightly to part
with gains of 13% in 2010 and a gain of 14% in
expect negative GDP growth there again in
• Can be used in limited space applications
2011 compared with 2010. The growth rate is
2013.
expected to slow to just 2.8% in 2014 versus
The German economy slowed dramatically in
2012 and improve slightly by approximately
2012 and barely remained in positive territory
3.8% in 2014. We expect the market to remain
during 2012. We expect positive growth in 2013
OEM Off-Highway | march 2013
• Prevents fluids from igniting on hot engine and exhaust parts • High temperature performance Call Paul Herman today at 1.877.347.9467 firwin@firwin.com www.firwin.com
www.oemoffhighway.com
32
M A R K E T F OR EC A S T: E urop ea n Eq uip men t M arket
of 0.8% and acceleration to 2% in 2014 that is far below the 3 to
transparent and integrated financial markets) just downgraded
4% at the beginning of the decade. The German Construction
the U.K.’s domestic- and foreign-currency government bond
Equipment and Building Material Machinery association said
ratings by one notch based on its high debt burden and its
that construction activity actually decreased by 1% compared
view that the country is faced with a period of sluggish growth
with 2011. According to the association, 2013 will not see any
which Moody’s expects will extend into the second half of the
peaks. However, there is optimism among manufacturers who
decade, as well.
are participating in bauma 2013 in Munich, Germany, April
Generally the northern countries of the Euro region have
15 to 21. The event, which takes place every three years, has
fared better than the southern countries. Spain, Portugal and
always been a business trend barometer for the coming year
Italy are the laggards. Interestingly little has been mentioned
for many manufacturers.
recently about Greece. The European Central Bank was lurch-
The U.K. slipped back into a recession in 2012. Moody’s (an
ing from crisis to crisis with Greek debt last year. Perhaps debt
essential component of the global capital markets providing
markets have become inoculated to the news by now and are
credit ratings, research, tools and analysis that contribute to
looking at positive signs of growth beyond the next year or two.
OEM Off-Highway | march 2013
DIGI TA L E XC LUSI V E bauma 2013
www.oemoffhighway.com
33
M A R K E T F OR EC A S T: E urop ea n Eq uip men t M arket
DIGI TA L E XC LUSI V E bauma 2013
Manfredi & Associates
We estimate that product markets will grow in 2013 by approximately 2.8%. The articulated truck, wheeled excava-
in early 2012 and has been essentially flat for the last three quarters of the year.
tor and backhoe loader markets are expected to improve the
We expect a continuing positive trend for 2014 with retail unit
most due to expected improvements in housing markets. The
sales improving 3.8%. Our optimism for a continued positive
crawler excavator and mini excavator markets are expected
trend is based on statements by most European manufactur-
to remain at relatively high levels. We expect very low growth
ers that they expect equipment owners in the region to begin
rates in the wheel loader and rigid frame truck markets due
updating their fleets. For example, in a statement from Haulotte
to low demand in the mining and mineral extraction sector.
management, “Despite the European economic environment
Fourth quarter results have been announced by a number of
remaining difficult, the need for fleet renewal in Europe and
publicly traded manufacturers that report their sales by region.
the positive orientation of the emerging markets in which we
Volvo reported that its fourth quarter revenues in total were
operate support the business outlook for this year and should
down 7%, but revenues in its European region dropped slightly
allow Haulotte Group to show growth of around 10% of sales
more than 20%. Caterpillar reports a monthly survey of its
in 2013.”
dealers. The data is the average of three months. The January
Our machinery growth forecast is based on estimates by
report—the average of January, December and November—indi-
most economists and government officials of whom say that
cated that its dealer sales in Europe, Africa and Middle East
the worst news is behind us and normal growth will begin by
were up 1%. The percent change began trending downward
at least the second half of 2014. ●
OEM Off-Highway | march 2013
www.oemoffhighway.com
34
M A R K E T F OR EC A S T: F luid P ow er Industr y
DIGI TA L E XC LUSI V E Market Trends
Fluid power industry growth trend
T
he latest data published by the
month. The charts and table above are drawn
NFPA shows industry shipments of
from data collected from more than 80 manu-
fluid power products for February
facturers of fluid power products by NFPA’s
2012 increased 16.3% compared
Confidential Shipment Statistics (CSS) pro-
to February 2011, and slightly
gram. NFPA’s industry reports, outlook surveys,
increased 1.2% compared to last
Shipments – Cumulative year-to-date % change (2012 vs. 2011)
Total Fluid Power Shipments
Total Hydraulic Shipments
Total Pneumatic Shipments
Nov 2011
22.1
25.4
16.6
forecasts, and data sources allow our members
Dec 2011
21.2
24.2
15.8
month. Mobile hydraulics, industrial hydraulics
to understand trends and anticipate change
and pneumatics all showed growth in February
with a variety of trend graphs and data analysis
Jan 2012
16.4
13.9
17.7
2012 when compared to February 2011, and
for fluid power products, customer markets,
also slightly increased when compared to last
and economic indicators. ●
Pneumatic, Mobile and Industrial Hydraulic Orders Index 200.0
Total - Hydraulic and Pneumatic Shipments
180.0
120.0
160.0
110.0
140.0
100.0
120.0
90.0
100.0 80.0
80.0
60.0
70.0
Total Hydraulic
Feb-12
Dec-11
Oct-11
Aug-11
Jun-11
Apr-11
Feb-11
Dec-10
Oct-10
Jun-10
Aug-10
Apr-10
Feb-10
Dec-09
Oct-09
Total Pneumatic
Total Pneumatic
Mobile Hydraulic
Industrial Hydraulic
Each point on this graph represents the most recent 12 months of orders compared to the previous 12 months of orders. Each point can be read as a percentage. For example, 113.7 (the January 2012 level of the industrial hydraulic
This graph of 12-month moving averages shows that in February 2012, both pneumatic shipments and hydraulic
series) indicates that industrial hydraulic orders received from February 2011 to January 2012 were 113.7% of the
shipments increased. (Base Year 2008 = 100)
orders received from February 2010 to January 2011. (Base Year 2008 = 100)
OEM Off-Highway | march 2013
Dec-11
Oct-11
Aug-11
Jun-11
Apr-11
Feb-11
Dec-10
Oct-10
Aug-10
Jun-10
Apr-10
Feb-10
Dec-09
Oct-09
Aug-09
Jun-09
Apr-09
Feb-09
Dec-08
Oct-08
Aug-08
Jun-08
Apr-08
Dec-07
Total Fluid Power
Aug-09
Jun-09
Apr-09
Feb-09
Dec-08
Oct-08
Jun-08
Aug-08
Apr-08
Feb-08
Dec-07
50.0
Feb-08
40.0
60.0
www.oemoffhighway.com
35
OF F-HIGH WAY HER OE S
A tognum group BrAnd
Locomotive cranes by Thomas Berry, Archivist, Historical Construction Equipment Assn.
With the development of railroads as a major form of land transportation, it was only logical that a rail-mounted crane should be developed. This full-revolving crane, built by Industrial Works in 1886, was the first American-built true locomotive crane. Illustration from The Railroad Gazette March 1889 issue
U
ntil 1886, most railroad cranes con-
from a boom that revolved 360 degrees. It was
sisted of a hand-operated pedestal
also self-propelled, giving it the ability to move
crane on a flatcar, and the few loco-
the railroad car it was loading or unloading.
motive cranes used in America had
Soon, the locomotive crane resembled the full-
been imported from England. That
revolving crawler crane, in that all of its mechani-
was the year that Industrial Works of
cal and hoisting works were mounted on an
Bay City, MI, mounted an improved steam wharf
enclosed platform that revolved on its carrier.
crane on a four-wheeled flatcar for use around its
Crane capacity increased over the years; in 1912,
plant. Later that same year, the company intro-
Industrial Works’ locomotive crane line ranged
duced the first true locomotive crane to be built
from five to 30 tons capacity; in 1923, capacity
in America. This was a 15-ton capacity crane,
reached 60 tons. The company’s first 30-ton crane
with the boiler at the opposite end of the frame
was built in 1896, 50-ton in 1899, 100-ton in 1904,
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OEM Off-Highway | MARCH 2013
www.oemoffhighway.com
36
Scan to view video.
OF F-HIGH WAY HER OE S
POWER FACTS
150-ton in 1911, and 200-ton—the world’s largest
They trod cautiously on lightweight, temporary
at the time—in 1922.
track and trestles as they handled everything
Locomotive cranes travelled on four wheels
from excavation and pile driving to steel erec-
whose axles were attached directly to the crane’s
tion and concrete pours at bridges, dams, locks
lower frame, or on two four-wheel trucks. Some
and buildings. By the mid-1930s, locomotive
models were offered on either mount. While
cranes had been displaced from construction
more expensive, the eight-wheel crane had sev-
applications by more flexible mobile cranes, and
eral advantages over the four-wheel version: It
other types of lifting equipment replaced them
had greater lifting capacity, it was easier on the
in many industrial and railroad applications in
track and roadbed, and it could be moved over
more recent years. ●
the road on its own wheels whereas a four-wheel
The Historical Construction Equipment Assn.
crane could not. The eight-wheeled crane was
(HCEA) is a 501(c)3 non-profit organization
also more stable, an important factor when work-
dedicated to preserving the history of the
ing on temporary construction project trackage.
construction, dredging and surface mining
Although standard gauge was the norm, loco-
equipment industries. With over 4,300 members
motive cranes were built to whatever gauge the
in 25 countries, activities include operation of
customer ordered, with the understanding that
National Construction Equipment Museum and
capacity was directly proportional to track gauge.
archives in Bowling Green, OH; publication of a
Eventually, they were also offered on a variety of
quarterly magazine, Equipment Echoes, from
non-rail mounts.
which this article is adapted; and hosting an
Locomotive cranes were the only mobile, fullrevolving cranes being used in construction at
annual working exhibition of restored construction equipment.
the start of the twentieth century. They could be
Individual memberships are $30.00 within the
found on railroad spurs and sidings, loading or
USA and Canada, and $40.00 US elsewhere. HCEA
unloading equipment, supplies and construc-
seeks to develop relationships in the equipment
tion materials. They trundled about large aggre-
manufacturing industry and offers a college
gate plants, cement mills and quarries, loading
scholarship for engineering students. Information
product for delivery by rail, and they clammed
is available at www.hcea.net, by calling 419-352-
aggregates into batch plants situated at track-
5616 or emailing info@hcea.net.
side for convenient delivery of dry materials.
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www.oemoffhighway.com
37