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Mark James

Energy Now Expo 2013
February 22, 2013
40

Mark James

Reducing carbon emissions - its more than just the engine!

Energy Now Expo 2013

February 22, 2013
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Transcript

  1. Energy Now Expo – February 2013 3 Items to consider

    • Where to focus? • Power consumers in the agricultural tractor • What can we do? • Quantifying the possible gains • Future technologies
  2. Energy Now Expo – February 2013 4 Emission reductions –

    Where to focus? Engine arguably offers limited short term potential: • Must offer correct mix of performance & fuel economy – VITAL! • Tied in to stringent iT4 or FT4 NOX / Particulates standards • Engine development is expensive & has a LONG lead time! A modern tractor has MANY other systems consuming power! • Focus on the WHOLE VEHICLE could offer cost effective improvements!
  3. Energy Now Expo – February 2013 5 Potential power loss

    or inefficiency • Hydraulic system • Brakes: • Service brake • Secondary brake • HVAC system • Transmission: • Architecture • Operation • Cooling package • Air flow management • Parasitic losses & drag
  4. Energy Now Expo – February 2013 6 Cooling package Cooling

    fans are “Power hungry” • Uses 5 to 10Kw in normal running! • Optimizing the cooling fan offers immediate savings in fuel consumption! 1. Vari-Cool or Vistronic fans • Single cooling fan with accurate temperature-related speed control 2. Distributed cooling with 2 fans 1. Active Charge Air Cooler 2. Main cooling package • Each fan runs at optimum speed • 50% reduction in total power requirement • 1.3% Lower fuel consumption 1 2
  5. Energy Now Expo – February 2013 7 Cooling Air Flow

    Restricted air flow can easily DOUBLE the power requirement and fuel use! • It is VITAL to have: • A Free air inlet • Clean outwards air flow • Fully ducted air flow • Planned air paths • Precise under hood temperature management • Less likelihood of debris issues • Increased fuel efficiency
  6. Energy Now Expo – February 2013 8 Transmission architecture •

    Synchromesh • 2-speed Hi-Lo • Partial Powershift • Full Powershift • Infinitely Variable RELATIVE EFFICIENCY HIGHER PRODUCTIVITY MORE MECHANICAL MORE HYDRAULIC
  7. Energy Now Expo – February 2013 9 Dual Clutch –

    the Best of both Worlds High Productivity • 8 speeds shiftable under full load • Wide overlap between ranges – no need to change ranges under load • High Efficiency • 100% mechanical power flow • No hydraulic drive • Few hydraulic clutches • 4% Fuel efficiency increase • 10gKwH lower fuel consumption than an IVT transmission. • More efficient even than a Powershift
  8. Energy Now Expo – February 2013 10 “Efficiency Managers” Electronic

    driver aids for most efficient operation • Automatic optimisation of engine & transmission • Engine RPM & Gear selection • According to speed • According to load • IVT, Dual Clutch and Powershift transmissions • No operator input required
  9. Energy Now Expo – February 2013 11 Parasitic losses or

    Windage Oil splash and oil drag • Up to 30Hp in power losses at high speed on a large tractor! • Don’t overfill the transmission! • Active Oil Management • Oil level in transmission compartments kept low • Gears and shafts NOT oil immersed • Baffles and Windage covers • Oil prevented from pooling around fast moving components • Large efficiency increases
  10. Energy Now Expo – February 2013 12 Oil Management Dry

    Sump - The ultimate oil management • Oil stored in a separate compartment or tank • Transmission is pressure lubricated • Oil returned to separate reservoir after use. • Eliminates oil splash and oil drag. Oil temperature control • Thermostat control of oil cooling flow. • Faster warm up • Reduced cooling load
  11. Energy Now Expo – February 2013 13 Charge Pump Main

    Pump. Sensing Line Sensing Line Charge / Main Pump PFC hydraulic system Item PC hydraulic system Gear type Charge pump type X Axial piston pump Main pump type Gear type Pressure and flow LS compensates:… Pressure 114 l/min Max. oil flow 65 or 80 l/min 200 bar Rated pressure 200 bar 27 – 32 Liters (aux. tank) Oil take out 15 – 20 liters Hydraulic Systems
  12. Energy Now Expo – February 2013 14 Hydraulic Systems •

    Pumping oil all the time is wasteful and unnecessary! • Pressure Flow Compensated (PFC) systems only pump when needed! • Variable main hydraulic pump • Variable charge pump ? PFC Load Sensed Monitoring of the hydraulic load No hydraulic load Main Pump on standby mode Reduced load on engine
  13. Energy Now Expo – February 2013 15 Brakes & brake

    optimization 1. Brake retractors • Brake pistons actively pulled away from friction disc on pedal release 2. Secondary Brake • Electric or spring-loaded secondary Brake/Steering pumps • Only engaged when hydraulic pressure drops to zero. 1. Air Brake compressor with Electric Clutch • Compressor driven only when air pressure is low.
  14. Energy Now Expo – February 2013 16 Potential savings &

    reductions? Fuel use reduction (%) Annual CO2 reduction (Kgs) Optimized Cooling package 1.3% 1,139 Transmission Architecture 4% 3,504 Windage Reduction Oil Management / Dry sump Windage Covers Brake drag reduction/optimization 8% 7,008 Hydraulic system design 2% 1,752 TOTAL 15.3% 13,403 Kgs An ESTIMATE based on an “average” 100Kw tractor! • Average fuel consumption of 293gKwH (DLG Powermix average) • 1000 hours annual use. • 2.68Kgs CO2 per Kg diesel fuel used. Full benefits may not be seen in every situation!
  15. Energy Now Expo – February 2013 17 Engine 20Kw Generator

    Power Control Box 2x Implement connectors Mobile power Outlets Electric Implement drives 20Kw to drive attached implements • 2 plug & play outlets with Q-R couplers • 240v & 400v mobile power outlets • Efficient • 10% more efficient than mechanical drives • Output independent of engine speed • 15% more efficient than hydraulic drives • As much power as required and no more • Precisely controllable • Ideal for accurate implement controls or targeted applications • Eg sprayers & spreaders EMI Filter
  16. Energy Now Expo – February 2013 18 Electric Traction Drives

    Assisted Drive - Fliegl “PowerDriveElect” • 12.5Kw electric trailer drive axle • More efficient alternative to ground-speed mechanical drive Full Electric drive - Ropa “EuroTiger EMO” • 280Kw electric traction drive • Replaced 340Kw mechanical drive system Electric drive sprayers, dozers & tractors are in development & production!
  17. Energy Now Expo – February 2013 19 The Future? The

    “All Fuel” tractor • Multiple fuels in a single tank • Biodiesel; Mineral oil; Pure plant oils (PPO) eg. Rapeseed oil • Tank sensor monitors fuel type • Engine settings automatically set according to fuel quality • Servicing requirement as standad model. • 60% reduction in CO2 output • According EU Renewable Energy directive • Meets Final Tier 4 emissions level • SIMA 2013 Gold medal winner!
  18. Energy Now Expo – February 2013 21 To Conclude... •

    A wider focus than just the engine is needed to reduce emissions & increase fuel efficiency on complex machinery. • Ancilliary & accessory systems offer plenty of scope for optimization & efficiency gain. • New technologies are in the pipeline that will have a HUGE impact on emissions from farm equipment! •BUT REMEMBER – other factors can also conspire to reduce efficiency or increase emissions – including: • Working conditions • Operational factors • Implement settings • Tyres, ballasting & wheelslip PLUS MANY MORE