2014Komatsu to Start Commercial Production of New Emission Regulations-compliant Engines
Jan. 7, 2014
Komatsu Ltd. (President and CEO: Tetsuji Ohashi) (hereinafter
"Komatsu") has developed new engine technologies designed to comply
with new emission regulations in Japan, North America and Europe
effective 2014, and is going to start commercial production in January
Emission regulations for diesel engines for use in construction equipment, announced in 2004, require a challenging reduction of NOx(nitrogen oxides) and PM (particulate matter) emissions to one tenth of, or below the preceding regulations1 and specifies enforcement in two phases, 2011 and 2014. Emission regulations, enforced since 2011, have required the reduction of PM emissions to one tenth of the preceding regulations. In response, Komatsu has developed and adopted the next-generation high-pressure common rail fuel injection (HPCR) system, high-efficiency exhaust gas recirculation (EGR) system, variable geometry turbocharger (VGT) system and diesel particulate filter (DPF), which have been well received on the market. New regulations effective in 2014 require the reduction of NOx emissions to one tenth or below from the preceding regulations. In addition to refining the above technologies, Komatsu has developed a new selective catalytic reduction (SCR) device in-house.
From displacement of 3.3 to 46 liters, respectively, for small construction equipment to large mining equipment, Komatsu has been consistently2 engaging in research, development, and manufacture of diesel engines over the years. With respect to construction and mining equipment on which new engines will be mounted, Komatsu will also continue to take advantage of in-house development and manufacturing capabilities for other key components, such as hydraulic devices and control systems, in order to achieve both reduction of environmental impact and improvement of fuel economy at the same time.
1) Regulations applied to diesel engines (130 – 560kW) for construction equipment manufactured in 2006 through 2010.
2) Including some engine models jointly developed and manufactured with Cummins Inc.
[New engine designed to meet new emission regulations in Japan, North America, and Europe]
[Technologies Applied to New Engine]
1.Heavy-duty aftertreatment system
This new system combines a diesel particulate filter (DPF) and a selective catalytic reduction (SCR). The NOx reduction device equipped with SCR injects optimal amount of urea based solution at optimal timing, thereby decomposing NOx into nontoxic water (H2O) and nitrogen gas (N2). We have also succeeded in in-house development of the entire system which includes control software for optimal injection of urea based solution and exhaust gas temperature, the critical technology to ensure effective operation of the aftertreatment system. As a result, we have demonstrated our commitment to the reliability and durability of construction equipment in use under demanding conditions.
2. Heavy-duty cooled exhaust gas recirculation (EGR) system
The system recirculates a portion of exhaust gas into air intake and lowers combustion temperatures, thereby reducing NOx emissions. Furthermore, while EGR gas flow is increased, by incorporating a high-efficiency and compactly designed cooling system, the system achieves a dynamic reduction of NOx, while helping reduce fuel consumption.
3. Electronic Control System
The electronic control system performs high-speed processing
of all signals from sensors installed in the vehicle and engine to
ensure total control of equipment in all conditions of use. While
keeping the powerful and quick response of Komatsu equipment, the system
helps reduce NOx and PM emissions to a great extent and improve fuel
consumption and noise.
Conditions of the engine are displayed via an on-board network on the monitor inside the cab, providing necessary information to the operator. Furthermore, managing the information via KOMTRAX helps customers engage in appropriate maintenance.
4.Variable geometry turbocharger (VGT) system
The VGT system features Komatsu-original hydraulic technology for variable control of air-flow and supplies optimal air according to load conditions. The upgraded version realizes better exhaust temperature management. Along with high-efficiency combustion, the system achieves both further purification of exhaust gas and improved fuel economy.
5. Heavy-duty high-pressure common rail (HPCR*) fuel injection system
The system is designed to achieve an optimal injection of
high-pressure fuel by means of computerized control, thereby bringing
close to complete combustion to reduce PM emissions. While this
technology is already used in current engines, the new system realizes a
higher-pressure injection, thereby reducing both PM emissions and fuel
consumption at entire engine operating conditions.
*High-Pressure Common Rail
- The information described is at the time of presentation and may be subject to advance notice.