Engine Performance and Fuel Consumption Monitoring

What are manufacturers offering ?

Presented by: Bryson Robertson FERIC West

Presentation Outline

Tiered emissions vs. Fuel consumption. Detailed review of manufacturer ECM systems. Common features and discrepancies. Problems and accuracy issues. Recommendations

Overview of Tier 3 Regulations

Engine Power 37 kW < 75 (50 hp < 100) Tier Tier 1 Tier 2 Tier 3 75 kW < 130 (100 hp < 175) Tier 1 Tier 2 Tier 3 130 kW < 225 (175 hp < 300) Tier 1 Tier 2 Tier 3 225 kW < 450 (300 hp < 600) Tier 1 Tier 2 Tier 3 450 kW < 560 (600 hp < 750) Tier 1 Tier 2 Tier 3
Not adopted, engines must meet Tier 2 PM standard.

Year 1998 2004 2008 1997 2003 2007 1996 2003 2006 1996 2001 2006 1996 2002 2006 -

CO -

HC -

NMHC+NOx

NOx 9.2 (6.9) 9.2 (6.9) 9.2 (6.9) 9.2 (6.9) 9.2 (6.9) -

PM

5.0 (3.7) 5.0 (3.7) 5.0 (3.7) 5.0 (3.7) 11.4 (8.5) 3.5 (2.6) 3.5 (2.6) 11.4 (8.5) 3.5 (2.6) 3.5 (2.6) 11.4 (8.5) 3.5 (2.6) 3.5 (2.6)

7.5 (5.6) 4.7 (3.5) 6.6 (4.9) 4.0 (3.0) 6.6 (4.9) 4.0 (3.0) 6.4 (4.8) 4.0 (3.0) 6.4 (4.8) 4.0 (3.0)

0.4 (0.3) - 0.3 (0.22) - 0.54 (0.4) 0.2 (0.15) - 0.54 (0.4) 0.2 (0.15) - 0.54 (0.4) 0.2 (0.15) -

1.3 (1.0) 1.3 (1.0) 1.3 (1.0) -

Tiered Fuel Consumption

Generally, the higher the emission standard, the higher the fuel

consumption Baseline based on Series 60 Detroit Diesel (Klassen Diesel)

Manufacturer ECM Program

Cummins:

INSITE Powerspec Electronic Technician Global Monitoring System DDEC Reports Diagnostic Link Machine Information Centre Diagnostic Display Unit JDLink Matris Komtrax May 07

Caterpillar:

Detroit Diesel:

John Deere:

Volvo:

Komatsu:

Linkbelt:

ECM Monitoring Benefits

Maximize equipment utilization Monitor fuel consumption of machinery. Improve maintenance scheduling and reduce costs Measure productivity Streamline logistics Enhance machine security with geo-fence & machine lock offs. Improve future bidding by having detailed numbers. Operator analysis for future training purposes on most effective working procedure.

How the Satellite systems work

GPS Satellites

Analog / Digital Cellular

Equipment with Satellite Terminal Network Operations Center

Internet End User through Machine Satellite Application

Cummins PowerSpec / INSITE

Cummins Shift Information

Information can be displayed as the table above or downloaded to Excel and analyzed further. MPG Fuel not applicable to Harvesting Operations (All programs started as Trucking applications)

Cummins Trip Information

Powerspec data can be exported from the program into Microsoft Excel for further analysis (.csv file) The Excel data below is just a snippet of the information that can be taken from the Engine ECM. Other information that can be downloaded: Fuel Rate, Fuel Temperature, Long Term Fuel Usage
All Trips (Cumulative) ECM Time Engine Average Load Engine Hours (Engine Run Time) Fuel Used Idle Fuel Idle Time PTO Fuel Used PTO Time 0:03:07 55.21 0:03:07 0.3 0 0:00:41 0 0:00:00 HH:MM:SS Percent HH:MM:SS gal gal HH:MM:SS gal HH:MM:SS

More Cummins info.

Need an INLINE cable adapter to download information. Downloads all ECM information but no alterations allowed. INSITE program is available to only the dealers and mechanics. Shift based information, no hourly breakdown of fuel usage. Cummins Western Canada has designed a build an onboard live display unit.

Caterpillar Electronic Technician

Used to program, alter and read engine performance characteristics. Used to retrieve trip information, check fault codes and can be use to track fuel consumption. Combines with Global Maintenance Service (GMS) to allow satellite access to ECM data. Context-sensitive help options to guide every task Tentative in releasing ET information

Caterpillar Electronic Technician

Detroit Diesel Diagnostic Link

It is a maintenance and troubleshooting software program which can:

View and Clear Active and Inactive Diagnostic Codes View Fuel injector Response Times, Injector Calibrations and Cylinder Cut-Out Tests View Total Engine Data and Engine Trip Data

Diagnostic Link has many additional features that save time & money Ability to log instantaneous fuel economy Ability to Graph and Analyze data with the Diagnostic Link program.
Diagnostic Link software package

DDEC Reports: Trip-based reporting tool

Diagnostic Link: Trouble-shooting & maintenance tool

Detroit Diesel Diagnostic Link

Detroit Diesel Diagnostic Link

Detroit Diesel Diagnostic Link

Playback function allows detailed analysis. Highest resolution data Custom screens/displays available to ensure relevant data is displayed together. Unfortunately no satellite based systems in the works. Yet may work with other manufacturers systems. DDEC reports are easy to produce and cover most necessary fields.

John Deere DDU and MIC

John Deere has two ways to access machine ECM information:

DDU = Diagnostic Display Unit MIC = Machine Information Centre Machine Performance

MIC provides a history of:

Alarms and Faults Histograms RPMs, Temperatures, Pressures Idle vs. Operation time Travel Time vs. Swinging and Processing Fuel Consumption Hourly, Daily, Weekly, etc. Life

Machine Utilization

Machine Operation

John Deere Display Unit

Currently only mining and construction versions. Forestry - Mid 2007 Display unit is customizable and visible to operator DDU will provide fuel consumption in Gallons per hour reading (Instantaneous and Total) Requires the machine serial number to initialize. Designed and created by Hitachi Japan.

John Deere JDLink

John Deere and Qualcomm teamed up to create 24/7 satellite machine monitoring software. 4 Versions: Standard, Advanced, Ultimate and Direct. Ultimate will provide the most detailed and useful data for the forestry industry.

Volvo Matris

Satellite based machinery monitoring tool Not Volvo specific! Works with other machines. A detailed report and analysis of the machines operating history

History on use of the engine, transmission, front and rear axles as well as fuel consumption. The information is displayed graphically in tables, circle and bar graphs. This gives you the possibility to continuously check and correct your operating techniques. By keeping a constant eye on your machine, you also keep an eye on your business efficiency and profitability.

Lower costs and longer service life

Gives you control of your profitability and efficiency

Volvo Matris

All graphs use color that are easy to analyze for most effective running procedures:

Green = correct use, Blue = lower than optimal operating temperature Yellow = warning Red = alarm (Machine is too warm or being operated incorrectly).

Volvo Matris

Examples of the many graphs and tracking features possible with the Volvo Matris system.

Volvo Matris

Machine Independent. Geofence capable Pre-program service plan intervals. Start Volvo Demonstration

Komatsu Komtrax

Komtrax is Komatsus wireless monitoring systems. Features:

Location Geofence and Operating Maps Average hourly fuel consumption Machine Operating Information Monthly and Annual Machine reports Loading Frequency Working Hours

Ability to graph and analyze data within program No need to connect to ECM and download data, therefore less equipment downtime and employee costs. Available anytime anywhere any machine

Komatsu Komtrax
SMR Working Hour (Total) Working Hour (>1000rpm) Working Hour (<1000rpm) ECO Lamp Hours Consumed Fuel Date Operation Map For & Rev Time Avg. Fuel Consumption

Additional Komtrax info

-

Data is downloaded once a day, or whenever a fault/alarm/service set point is reached. Daily resolution is the best available for fuel. Free for 5 years Movement is done by hydraulic pressures, not my vibrations. Less operator disturbance and is automatic. Can lock the machine remotely. For alternate machines approximately $4000 cost for everything. Equipment, installation.

Accuracy concerns of entire line

Input flow meter Calibrations. Temperature sensors. Injector timing.

ECM Monitoring Benefits

Maximize equipment utilization Monitor fuel consumption of machinery. Improve maintenance scheduling and reduce costs Measure productivity Streamline logistics Enhance machine security with geo-fence & machine lock offs. Improve future bidding by having detailed numbers. Operator analysis for future training purposes on most effective working procedure.

Conclusions

Trends show increasing fuel consumption with lower emissions. Large amount of tools and monitoring software available to manage fleets and operations to the highest level. Detroit Diagnostic Link provide most detailed machine information for analysis. Volvo Matris and Komatsu Komtrax at the forefront of satellite based monitoring. Brand new technology. Will become the standard and common within the industry in years to come.