Acert Chuck Wills

Chuck Wills
Industrial Power Systems

Marketing Manager
Caterpillar Confidential: GREEN

Non-Road Emission Regulation
>750
>750 <19
25 -50 50-100
25-100 25 -75
50-100 100-300 100-175 >175
100-175 175-300 75-175

600-750
300-600 <25
175-750
300-750
Tier 3 Tier 4
Tier 1 Tier 2
‘9 6 ‘9 7 ‘9 8 ‘9 9 ‘0 0 ‘0 1 ‘0 2 ‘0 3 ‘0 4 ‘0 5 ‘0 6 ‘0 7 ‘0 8 ‘0 9 ‘1 0 ‘1 1 ‘1 2 ‘1 3
Stage Stage II Stage III A

25-50
100-750 25-50 100-750
175-750
50-100 175-750
100-175 50-100
100-175
50-100
Stage III B
50-100

Non-Road Emissions
Levels & Technologies
0.6
Timing Retarded Unregulated
JWAC / ATAAC Engines
Combustion Optimization
Particulates - g/hp-hr
0.5 Higher Injection Pressure

Limited Electronics
0.4
Tier 1/Stage I
0.3
0.2
Tier 2/Stage II Electronics
0.1 SCAC / ATAAC
Tier 3/Stage IIIa
Tier 4/4aStage IIIb ACERT
0.0
0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0
NOx - g/hp-hr
Emissions Challenge
Develop the best

customer solution
that meets the
Tier 3/ Stage IIIa
Emissions

Option #1: Cooled EGR
Exhaust Gases are Re-introduced

Depleting the Oxygen Density
Recycled exhaust gas is externally
cooled

Cooled-EGR Experience
Heat Rejection?
Reliability?
Durability?
Operating Cost?
Cat Testing with Cooled EGR
• Originally our path for truck

• Never considered for non road
• Selected one path - ACERT

Option #2: Internal EGR
Exhaust Gases are Re-introduced

Depleting the Oxygen Density
By early opening of intake valve
capturing exhaust gas in manifold
before intake stroke

Cat Testing with Internal EGR
• Effectively reduces engine

displacement
• Significant impact on performance
• Very significant response impact
• Concerns on engine wear

ACERT was a better solution
Mark Craig- Product Mgr.
The SOLUTION:
Innovative
Combustion
Science
The missing
Alternative piece to the
puzzle!

ACERT Technology
Engines

What does ACERT Technology Mean?

The World’s Best

Emissions Solution

Integrated Electronics
Precise injection control
Advanced air management
Deep integration of key technologies

How about Others with Enhanced
Combustion Alternatives?

Only Cat has ACERT Technology
How about Others with Enhanced

Combustion Alternatives?
Optimized Single Solution

Cat has history of Innovations

Technology Revolution ……..
…….. Through Evolution



Over $500 Million Invested
Over 500 Engineers working full time

247 Patents

Caterpillar Engine Business
• US $23 Billion Corporation

• US $8 Billion Engine Company
– Worlds largest engine company
– One engine company with multiple brands
– 500,000 engines per year
• Worldwide Dealer Service & Parts Network
• Growth oriented company
– Engines leading toward $30B target

Diverse Markets

OEM System Solutions from Cat
Transmissions
Electro-hydraulic control
Load-sensing steering
On-board monitoring
Electronic engines
System integration
Understanding Customer Needs
Beyond engine supply
Off-Road
Tier 3/Stage IIIa
Compliance

Tier 3 / Stage IIIa Product Launch
C18 ACERT– 429-585 kW
C15 ACERT – 328-444 kW
C13 ACERT – 287-388 kW
C11 ACERT – 242-336 kW
C9 ACERT - 205-280 kW
C7 ACERT -130-224 kW
C6.6 ACERT - 89-186 kW

Engine Availability*
C6.6
C7
C9
C11
C13
C15
C18
Date Q1 ‘04 Q2 ‘04 Q3 ‘04 Q4 ‘04 Q1 ‘05 Q2 ‘05 Q3 ‘05 Q4 ‘05 2006
Fit-up Engines Pilot Engines Production

*Subject to Change

Engine Availability*
C6.6
C7
C9
C11
C13 C9 Production in
C15 Gosselies will be the
C18 First ACERT Engine
Production in Europe
Date Q1 ‘04 Q2 ‘04 Q3 ‘04 Q4 ‘04 Q1 ‘05 Q2 ‘05 Q3 ‘05 Q4 ‘05 2006
Fit-up Engines Pilot Engines Production

*Subject to Change

ACERT Validation Plan
• 40,000 hrs lab testing • 85,000 ACERT

• Thermal abuse Engines in operation
• Cold start qualification • 20 million km/day
• Over speed • 39 Industrial Test
qualification Engines
• Crankshaft structure • 60 Cat Earthmoving
• Head/block structure machine engines
• Emissions Certification

Cummins – M11 July production
"With the certification of the QSM completed

early, our development will focus on further
improvements in fuel economy and reliability to
exceed our commitments to customers," said
Vedak of Cummins.

Cummins Announcement – M11
"With the certification of the QSM completed early,

our development will focus on further improvements in
fuel economy and reliability to exceed our commitments
to customers," said Vedak of Cummins.
Does this really mean “We rushed our certification

to get the headline, but the engine still sucks so we
need to keep working on it?”

ACERT Engine Displacement +14.6%
+4.1%
20 +4.6%
Displacem ent (L)
15 +8.25%
+10%
10
5
0
Current 3056E 3126B C-9 C-10 C-12 C-15 C-16
ACERT C6.6 C7 C9 C11 C13 C15 C18

ACERT Engine Power
+17%
600 +3%
+4%
500
P o w er - kW
+5%
400 +12%*
+43%
300
200
100
0
Current 3056E 3126B C-9 C-10 C-12 C-15 C-16
ACERT C6.6 C7 C9 C11 C13 C15 C18
*New C9 ACERT “D” Rating Caterpillar Confidential: GREEN

Power Band Performance
• High rpm provides

¾ Widest operating range A
¾ Easiest changeover B
POWER
C
• Lower rpm provides D
E
¾ Best fuel economy
¾ Best heat rejection
¾ Less noise
1300 1500 1700 1900 2100
RPM
Full Power for wide rpm range

®
ACERT Engine
Technologies for Tier
3 / Stage IIIa
Engine Overview

Advanced Combustion
Tana Utley – ACERT Development Manager

Why ACERT Technology?

Building Blocks
Tier 3 / Stage IIIa

Building Blocks
Tier 3 / Stage IIIa

Building Blocks
Tier 3 / Stage IIIa

Building Blocks
Tier 3 / Stage IIIa

Electronics
Tier 3 / Stage IIIa

Electronics
Tier 3 / Stage IIIa

Cat ADEM 4 Electronics

TM
ADEM 4 Electronic Engine Control
Generations of Experience
1987 1991 1993 1998 32-bit 2004 32-bit

8-bit Advanced Two 8-bit ADEM III
8-bit ADEM II ADEM 4
PEEC II
PEEC III

ADEM 4 Testing in Extremes
• Extreme
temperature test
• Vibration test
• Salt spray test
• Electrostatic test

ADEM 4 Developments
• Processing speeds and

memory increased
¾ Up to 300 fuel maps to
optimize combustion
¾Better performance
¾Better efficiency

ADEM 4 Features for the OEM
¾No change in OEM / machine interface

¾Worldwide service now!!!!
¾Use Cat ET just like Tier 2
¾Common electronics C4.4 – C32
¾Better machine integration

New ADEM 4 Features
• Better Throttle input strategy
– Multi-throttle capability
– Configures throttle input priority
• Engine control system options
– Full range governor
– Min max governor
• Speed Droop Control
– Simulates mechanical performance
– Adjustable from 0-10% droop

New ADEM 4 CAN J1939 Data Link
• High Speed 2-way communications

• Standard SAE link for all C-series engines
• Broadcasts engine performance, status and
diagnostic information

Fuel Delivery
Extremely Accurate
Fuel Delivery
Extremely Accurate
ACERT – Multiple Injection Technology

ACERT Technology
Fuel
Injection
Combustion
ACERT Multiple Injection Capability
MEUI, HEUI, HEUI single fluid fuel systems

• Multiple injection
• Variable injection timing
• Controls quantity of fuel
• Rate shaping of fuel delivery

Engine Operating Map Optimization
Pilot + Ramp
Engine Load
Pilot + ERS
Square on Accels Engine

Torque
Ramp + Post Curve
Square Splits Pilot + Square

Idle Splits
Engine Speed

Split Injection Simulation

Air Management

Air Management
Tier 3 / Stage IIIa

Wastegate Turbocharging


•Single wastegate turbocharger except C18

•Provides higher boost over wide range
¾Improves engine response
¾Outstanding low end performance
¾Improved peak torque

Cylinder Head Technology
• Cross flow design and

refined port geometry
– Improved breathing
– Reduce pumping loss
– Better combustion

Optimizing ACERT Technology
• Increase Peak Cylinder Pressures

– Improved Engine Structures
– Many new materials
– Improved joints and clamping forces
– Includes many leak reduction improvements

Optimizing ACERT Technology
• Increase Compression
ration to 16.5 to 18:1
¾ Improves cold start
characteristics
¾ Improves white smoke
clean up time
¾ Optimizes ACERT
performance

Piston Technology C7-C18 (except C9)
• Monotherm/steel piston
– Forged Steel Design
– High strength
– Light weight
– Tighter tolerance
– Narrower rings conform to liner
¾ Better oil control
¾ Reduced blow-by
¾ Less liner wear

Hardened plateau honed liner
Two Step Honing Process:
- Cuts deep grooves for oil retention
- Smoothes the tops off to reduce wear Smooth Surface
and better contact
Deep Cuts
¾Reduces blow by
¾Improves oil control and consumption

Noise Reduction Technologies
• Isolated covers
• Multiple injection strategy
• Insulated timing case cover
• Sculpted crankcase
• Gear Train refinements

Maintenance Information
• Maintain 250 hour for now but develop 500

hour oil change solution
• Same oil specifications as Tier 2/Stage II
– CH-4 Oil recommendation
• Maintain durability of Tier 2 / Stage II

High Efficiency Oil Filters
• Revolutionary filter
design
¾Increased
contamination control
¾Double the efficiency
without increasing the
changing interval
¾Reduces wear on all
oil lubricated surfaces

Challenges Ahead
Tier 4/ Stage IIIB

Tier 4/Stage IIIb

ACERT Tier 4 / Stage IIIb Products
C18 ACERT
C15 ACERT
C13 ACERT
C11 ACERT
C9 ACERT
C7 ACERT
C6.6 ACERT

Future Technology
Tier 4/ Stage IIIB

Future Technology
Tier 4/ Stage IIIB

Series Turbocharging
Tier 4/ Stage IIIB

Tier 4/ Stage IIIB

Tier 4/ Stage IIIB

• Reliability
– Proven technology
• Durability
– Slower shaft speed
– Longer life
• Performance
– Better combustion
– Emissions reduction
– Fuel economy
– Improved response
Tier 4/ Stage IIIB

Variable Valve Actuation
Tier 4/ Stage IIIB

Tier 4/ Stage IIIB

Variable Inlet Valve Actuation
• Variable Inlet Valve

Actuation (VIVA)
• Cam provides
mechanical energy
• VIVA holds valves
open until signaled
to close
Leverage HEUI Actuator

• Reduces compression work required

• Optimized for each speed and load
• Reduced in-cylinder temperatures
• Works with Series turbo to maintain pressure
Exhaust Inlet
Valve Valve

Aftertreatment
Tier 4/ Stage IIIB

Aftertreatment
• Cat technology
• Specialist in Diesel
Oxidation Catalyst
• Developing particulate
trap for future off road
needs
Tier 4/ Stage IIIB

Rich Thompson – Engine Division Group President

Key ACERT Technology Values
Proven
reliability and durability

Meet or exceed
Tier 2 / Stage II
performance

Seamless changeover
to Tier 3 / Stage IIIa and
future

Global supportability
available now

Industrial ACERT
Technology Engines
available early
(mid-2004)

ACERT Launch
Plans

ACERT Press Activities
• Meet with Diesel Progress – January
• Press event in Brussels – 78 editors
• Press Event Bauma – 28 NA editors
• Griffin and Mine Expo later this year

IPS Cat Industrial Bauma Layout
5 show engines with Simulated Test Cell showing Tier 4

Badge on Cat ACERT Engines

Support Materials
• Product presentations
• ACERT Technology CD 20-25 min
• ACERT Technology Engine Brochure
• Emissions Brochure
• Ratings Guide
• Industrial Power Report
• Preliminary Spec Sheets

ACERT Technical Brochure
© 2003 Simantel
Regulations Education
Brochure
© 2003 Simantel
Key messages
BREATHE EASY
TAKING
TAKING ON
ON TOMORROW
TOMORROW
OUR
OUR DIRECTION
DIRECTION IS
IS CLEAR
THE POWER TO LEAD
Caterpillar Engines with ACERT Technology

Advertising Activities
• Advertising Campaign
– Diesel Progress
– OEM Equipment (award winner)

ACERT Awareness Ad

Selling Skills Training Program
• TrainOne – Jeffery Gitomer

• Powerful - innovative online tool
• Customized for Industrial
• One hour per week for 50 weeks

Dealer Sales
Training Kit
© 2003 Simantel
Leverage with your OEMs
Cat Machines price increase – so can your OEMs

Griffin OEM Days
• September 13th week

• Objectives
– Perkins – Shibaru momentum
– C27/C32 Launch
– Gain ACERT commitments
• Target 150 Accounts
– Changeover and Conquest

THE POWER TO LEAD
Caterpillar Engines with ACERT Technology


Acert Chuck Wills

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Acert Chuck Wills

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Verfügbare Formate

Chuck Wills

Industrial Power Systems

Caterpillar Confidential: GREEN

50-100 100-300 100-175 >175

100-175 175-300 75-175

Stage Stage II Stage III A

Caterpillar Confidential: GREEN

0.5 Higher Injection Pressure

Develop the best

Caterpillar Confidential: GREEN

Exhaust Gases are Re-introduced

Caterpillar Confidential: GREEN

• Originally our path for truck

Caterpillar Confidential: GREEN

Exhaust Gases are Re-introduced

Caterpillar Confidential: GREEN

• Effectively reduces engine

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

The World’s Best

Caterpillar Confidential: GREEN

Deep integration of key technologies

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

How about Others with Enhanced

Optimized Single Solution

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

…….. Through Evolution

…….. Through Evolution

…….. Through Evolution

Over 500 Engineers working full time

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

• US $23 Billion Corporation

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

Caterpillar Confidential: GREEN

Fit-up Engines Pilot Engines Production

Caterpillar Confidential: GREEN

Fit-up Engines Pilot Engines Production

Caterpillar Confidential: GREEN

• 40,000 hrs lab testing • 85,000 ACERT

Caterpillar Confidential: GREEN

"With the certification of the QSM completed

Caterpillar Confidential: GREEN

"With the certification of the QSM completed early,

Does this really mean “We rushed our certification

Caterpillar Confidential: GREEN

ACERT C6.6 C7 C9 C11 C13 C15 C18

Caterpillar Confidential: GREEN

ACERT C6.6 C7 C9 C11 C13 C15 C18

*New C9 ACERT “D” Rating Caterpillar Confidential: GREEN

• High rpm provides

Full Power for wide rpm range

Caterpillar Confidential: GREEN

Tana Utley – ACERT Development Manager

Tana Utley – ACERT Development Manager

Tier 3 / Stage IIIa

Tier 3 / Stage IIIa

Tier 3 / Stage IIIa