POWERTRAIN International 2024-2
Among the topics… AUTOMOTIVE SHIPPING: emissions according to the Big Five FOCUS FPT INDUSTRIAL: Andrea Abbà tells us about the XC13 13-LITER ENGINES FOR TRUCKS: who are the nine challengers? PREVIEWS INTERMAT PARIS: digitalisation and energy will be the keywords COMPARISONS 5L INDUSTRIAL ENGINES: AGCO, Deutz, Isuzu, Kubota, mtu, Volvo REPORTS HUNGARY: it is becoming Europe’s battery hub ELECTRIFICATION TELESCOPIC HANDLERS: Claas, Dieci, Faresin, JCB, Kramer, Manitou, Merlo SHOWS AGRITECHNICA, COMPONENTS: Comer Industries, MTA, Bosch Rexroth, UFI OFF-HIGHWAY ABB to electrify heavy-duty applications COLUMNS Editorial; Newsroom; Sustainable Techno
Among the topics…
AUTOMOTIVE
SHIPPING: emissions according to the Big Five
FOCUS
FPT INDUSTRIAL: Andrea Abbà tells us about the XC13
13-LITER ENGINES FOR TRUCKS: who are the nine challengers?
PREVIEWS
INTERMAT PARIS: digitalisation and energy will be the keywords
COMPARISONS
5L INDUSTRIAL ENGINES: AGCO, Deutz, Isuzu, Kubota, mtu, Volvo
REPORTS
HUNGARY: it is becoming Europe’s battery hub
ELECTRIFICATION
TELESCOPIC HANDLERS: Claas, Dieci, Faresin, JCB, Kramer, Manitou, Merlo
SHOWS
AGRITECHNICA, COMPONENTS: Comer Industries, MTA, Bosch Rexroth, UFI
OFF-HIGHWAY
ABB to electrify heavy-duty applications
COLUMNS
Editorial; Newsroom; Sustainable Techno
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Powertrain<br />
INTERNATIONAL<br />
On the<br />
e-WAY<br />
Hungary is going to be the European battery hub - FPT XC13<br />
and 13L truck engines comparison - 5L offroad engines -<br />
Preview from Intermat Paris - Electric telescopic handlers<br />
VADO E TORNO EDIZIONI<br />
www.vadoetorno.com<br />
www.powertraininternationalweb.com<br />
www.dieseloftheyear.com<br />
ISSN 0042<br />
Press Register n. 4596 – April 20th 1994<br />
Poste Italiane Inc. – Mail subscription<br />
D.L. 353/2003 (mod. in L. 27/02/2004 n° 46)<br />
Art. 1, subsection 1, LO/MI<br />
<strong>POWERTRAIN</strong>-Diesel SUPPLEMENT<br />
March <strong>2024</strong><br />
1
MARCH <strong>2024</strong><br />
powertraininternationalweb.com<br />
CONTENTS<br />
READY TO<br />
POWER<br />
GENERIC<br />
ICE<br />
H2 HYDROGEN<br />
kWe ELECTRIC<br />
GAS<br />
10<br />
AUTOMOTIVE<br />
8. SHIPPING<br />
Emissions according to the Big Five<br />
FOCUS<br />
10. FPT INDUSTRIAL<br />
Andrea Abbà tells us about the XC13<br />
14. 13-LITER ENGINES FOR TRUCKS<br />
Who are the nine challengers?<br />
PREVIEWS<br />
16. INTERMAT PARIS<br />
Digitalisation and energy will be the keywords<br />
FOLLOW <strong>POWERTRAIN</strong> INTERNATIONAL ON:<br />
COMPARISONS<br />
20. 5L INDUSTRIAL ENGINES<br />
AGCO, Deutz, Isuzu, Kubota, mtu, Volvo<br />
REPORTS<br />
24. HUNGARY<br />
It is becoming Europe’s battery hub<br />
ELECTRIFICATION<br />
32. TELESCOPIC HANDLERS<br />
Claas, Dieci, Faresin, JCB, Kramer, Manitou, Merlo<br />
ENERKIT<br />
SHOWS<br />
36. AGRITECHNICA: COMPONENTS<br />
Comer Industries, MTA, Bosch Rexroth, UFI<br />
RELIABLE, SUSTAINABLE, PRE-ASSEMBLED POWER SOLUTIONS<br />
ENERKIT DIESEL FROM 1500 kVA – 4000 kVA<br />
UPTIME INSTITUTE COMPLIANCE | HVO TESTED | BEST IN CLASS LEAD TIME<br />
GLOBAL SUPPORT NETWORK | TAILORMADE OPTIONS<br />
32<br />
44<br />
OFF-HIGHWAY<br />
44. ABB<br />
To electrify heavy-duty applications<br />
COLUMNS<br />
4. Editorial 6. Newsroom 48. Sustainable Techno<br />
Editorial: Tom ‘Stage VI’ and Jerry ‘Euro 7’<br />
“The shadow of phase out has fallen on the NRMM<br />
ecosystem players. Thus, the prospect of applying<br />
Stage VI appears ethereal and intangible”<br />
DURABLE. ROBUST. BUILT TO LAST.<br />
BAUDOUIN.COM<br />
VISIT US AND EXPERIENCE OUR EXCITING<br />
NEW PRODUCT LAUNCHES - STAND S3.B40<br />
3
EDITORIAL<br />
by Fabio Butturi<br />
TOM ‘STAGE VI’ & JERRY ‘EURO 7’<br />
POWER TO<br />
MAXIMIZE<br />
PRODUCTIVITY<br />
More power with less complexity and less weight. The Cummins<br />
B6.7 engine delivers the productivity you need to keep your<br />
equipment running. The power increases up to 326 hp / 243 kW<br />
and peak torque up to 1014 lb-ft / 1375 Nm, enabling<br />
replacement of engines with higher displacement<br />
with no impact on productivity.<br />
Stage V is now in full swing. Recall that the<br />
approval dates back to 2016. Therefore, the time<br />
for some OEMs, some applications and some<br />
markets to digest it is not so snapshot-like. In the<br />
meantime, the shadow of phase out has fallen<br />
on the NRMM ecosystem players. Thus, the prospect<br />
of applying Stage VI appears ethereal and intangible.<br />
Yet, the European Union has this “antidote” in store<br />
to mitigate the impact of exhaust emissions. Reducing<br />
CO 2<br />
means reducing fuel consumption. Will hybrid<br />
powertrains and BEVs be the vectors of Stage VI? David<br />
Phillips, Engineering Director, Eminox, commented: “Our<br />
teams are driving forward new exhaust aftertreatment<br />
system (EATS) technologies to support anticipated Stage<br />
VI requirements and have been conducting extensive<br />
research and concurrent projects for some time now to<br />
fully understand the integration of a range of alternative<br />
fuels as power options.” Will aftertreatment be a lever to<br />
reconcile upcoming European regulations for off-highway<br />
applications? In the meanwhile, the EU Council and<br />
Parliament have found agreement on the CO 2<br />
emissions<br />
reduction roadmap for heavy-duty vehicles. The aim is<br />
to further reduce CO 2<br />
emissions in the road transport<br />
sector and to introduce new targets for 2030, 2035 and<br />
2040. The proposal also aims to encourage an increasing<br />
share of zero-emission vehicles in the EU-wide heavyduty<br />
vehicle fleet. Truck and bus manufacturers fully<br />
support an ambitious decarbonisation agenda. However,<br />
the agreed implementation timeline remains extremely<br />
challenging in the absence of vital enabling conditions,<br />
stated the European Automobile Manufacturers’<br />
Association (ACEA). “Electric charging and hydrogen<br />
refilling infrastructure, comprehensive carbon pricing<br />
schemes, and meaningful support measures for transport<br />
operators to invest quickly: these are the key ingredients<br />
for rapidly decarbonising the heavy-duty transport sector,<br />
in addition to zero-emission vehicles,” emphasised<br />
Sigrid de Vries, Director General of the ACEA.<br />
“We cannot continue boldly setting ambitious targets<br />
for vehicle manufacturers and expect swift and smooth<br />
implementation to follow. Without an enabling framework<br />
to shore up demand for the zero-emission models,<br />
achieving targets will be impossible, especially with<br />
the envisaged timeline.”<br />
4<br />
©<strong>2024</strong> Cummins Inc.
NEWSROOM #INTERACTANALYSIS #BATTERY<br />
BY INTERACT ANALYSIS<br />
MAGIC YEAR<br />
2035<br />
THE POWER<br />
TO PERFORM<br />
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According to the latest<br />
research by Interact<br />
Analysis, battery electric<br />
vehicle powertrains<br />
will become the<br />
favored powertrain<br />
for commercial vehicles<br />
by 2035<br />
Battery electric is expected to<br />
replace ICE as the leading<br />
powertrain type for commercial<br />
vehicles by 2035, according<br />
to global market intelligence<br />
firm, Interact Analysis. It is expected<br />
that almost 2.5 million battery electric<br />
commercial vehicles will be sold<br />
in 2035 compared with fewer than<br />
500,000 forecast to be sold in 2025.<br />
Currently, the battery pack accounts<br />
for more than half (55%) of battery<br />
electric vehicle powertrain revenues,<br />
with price erosion forecast over the<br />
coming years, driving growth and<br />
increasing the appeal of battery electric<br />
commercial vehicles. Taking a<br />
look at the commercial vehicle market<br />
as a whole, fuel cell vehicles are<br />
expected to represent a small share<br />
because they are best suited to vehicles<br />
that travel long distances. Hybrid<br />
vehicles will also comprise a small<br />
share of the market due to a lack of<br />
focus on the technology from manufacturers<br />
and a shortage of regulatory<br />
support, which provides no compelling<br />
argument for adoption. Battery<br />
electric appears to be the clear winner<br />
for commercial vehicle powertrains.<br />
This is largely due to low operating<br />
costs (which make up for the high<br />
upfront cost), alongside regulations<br />
and subsidies which appeal to customers.<br />
For battery electric vehicles,<br />
the battery pack accounts for most<br />
of the powertrain revenue – around<br />
55% in fact. This component has the<br />
greatest impact on the overall cost of<br />
a commercial vehicle, while motors,<br />
inverters and the transmission have<br />
little influence on the overall vehicle<br />
price. In contrast, for fuel cell vehicles,<br />
the fuel cell system accounts for<br />
a much higher proportion of the total<br />
cost, while the transmission accounts<br />
for a higher proportion of the overall<br />
cost of hybrid vehicles. The use of e-<br />
axles is a growing trend but one that is<br />
currently an expensive alternative to a<br />
separate motor, transmission and axle.<br />
Interact Analysis expects this to change<br />
over time as volumes increase. One<br />
of the key advantages that e-axles offer<br />
is space saving, making it possible<br />
to add battery capacity and range to<br />
the vehicle, or have a smaller vehicle<br />
with the same battery capacity, reducing<br />
production costs. Depending<br />
on the customer’s viewpoint, e-axles<br />
may pay for themselves through the<br />
advantages they offer, despite having<br />
a higher initial upfront cost.<br />
Jamie Fox, Principal Analyst at Interact<br />
Analysis, comments, “Currently,<br />
the upfront cost of a battery electric<br />
vehicle is high, and this is mainly due<br />
to the cost of a full electric powertrain.<br />
For a heavy-duty battery electric<br />
truck, the complete battery electric<br />
powertrain can cost as much as<br />
$100,000, but this can be as low as<br />
$2,000-$3,000 for a mild hybrid light<br />
duty truck. Despite this, we expect to<br />
see price erosion over time due to production<br />
innovation and economies of<br />
scale.”<br />
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6
AUTOMOTIVE<br />
#COP28 #EMISSIONS #ECA<br />
SHIPPING VS ONROAD<br />
IS LNG<br />
THE ONLY<br />
WAY?<br />
In fact, the Green<br />
Shipping Challenge<br />
at COP28, held in the<br />
presence of the CEOs<br />
of the five largest<br />
shipping companies,<br />
ended in a dead heat.<br />
The comparison with<br />
the four-wheeled world<br />
is ruthless. Large<br />
commercial marine<br />
applications work on<br />
almost a continuous<br />
cycle, and have a very<br />
exorbitant CO 2<br />
balance<br />
Five shipping companies control<br />
the world’s 2,300 largest<br />
container ships. This fleet<br />
is the backbone of planetary<br />
logistics, transporting around 80% of<br />
the world’s goods. Greenpeace’s cry<br />
of alarm goes back to 2020: “The contribution<br />
of international shipping is<br />
about one billion tonnes of CO 2<br />
equivalent<br />
per year, more than double the<br />
UK’s emissions or almost half those of<br />
Brazil”. At COP28 in Dubai, Maersk<br />
CEO Vincent Clerk announced a<br />
methanol container ship. However,<br />
LNG is still very much in vogue,<br />
despite the many adverse opinions.<br />
Most recently, UMAS, associated<br />
with UCL (University College of London),<br />
pointed out that methane-related<br />
emissions – 80 times more potent than<br />
CO 2<br />
itself in terms of greenhouse effect<br />
– have risen by 150% in the past<br />
two years as a result of the expanding<br />
fleet of dual-fuelled (Bunker Oil/<br />
LNG) ships. “The only realistic way<br />
to achieve zero emission targets by<br />
2050 for a sector that accounts for<br />
2-3% of global greenhouse gas emissions<br />
is to switch from fossil fuels to<br />
green fuels quickly and on a large<br />
scale” is the final statement of the<br />
shipping industry, which highlights<br />
the gap to the automotive industry. By<br />
2027-28, Toyota will market models<br />
with solid-state batteries that will provide<br />
a thousand kilometres of range<br />
and recharge times in the order of 10<br />
minutes. China’s CATL, the world’s<br />
largest automotive battery manufacturer,<br />
responded by announcing the<br />
conclusion of tests for its new CIIC<br />
(CATL Integrated Intelligent Chas-<br />
sis) for A/B-segment models with fuel<br />
consumption of 10.5 kWh/100 km, a<br />
range of a thousand kilometers and a<br />
recharge time of five minutes for 300<br />
km of extra mileage. A few days before<br />
New Year’s, the Sino-German<br />
JAC group (50% VW) started pre-series<br />
deliveries of the Yiwei E10X, a<br />
four-door city car that makes its debut<br />
with sodium-ion batteries. These<br />
are less expensive than batteries with<br />
lithium-ion cells, albeit at the expense<br />
of energy density, limited to 120 Wk/<br />
kg, but with decidedly higher performance<br />
both in terms of charging<br />
at low temperatures and number of<br />
life cycles. Instead, shipping remains<br />
bogged down in evoking multi-fuel<br />
strategies and calling for green fuels.<br />
Even the Clean Shipping Coalition’s<br />
proposal to make the Mediterranean<br />
an ECA area, despite being approved<br />
at the end of 2022, will not see the<br />
light before May 2025. And this is not<br />
to dramatise the situation gratuitously.<br />
As Greenpeace points out, the emission<br />
load of large container ships is almost<br />
perpetual: ships operate 24 hours<br />
a day every day of the year; even if in<br />
port the main engine remains “idle”,<br />
there are dozens of generating sets that<br />
have to guarantee service operation<br />
without cold ironing services going<br />
beyond experimentation. On the occasion<br />
of the launch of a recent cruise<br />
super-ship, the online group of motoring<br />
enthusiasts Rollingsteel.it had fun<br />
“prying” into Royal Caribbean’s Wonder<br />
of the Seas’ affairs. It is one of the<br />
top five leisure vessels in the world:<br />
362 meters in length, capable of accommodating<br />
just under 7,000 pas-<br />
sengers and 2,300 crew members. The<br />
six Wärtsilä engines at its disposal,<br />
totalling over 93 thousand kW, would<br />
consume something like 19 thousand<br />
litres of bunker oil per hour if fully<br />
utilised. Without going into too many<br />
technical details, research conducted<br />
in 2015 by the German environmental<br />
association Nabu, Naturschutzbund<br />
Deutschland, estimated the daily emissions<br />
of an average cruise ship using<br />
those of a petrol-powered Golf Euro6<br />
as a unit of measurement. The result is<br />
striking: reasoning with the equivalent<br />
number of cars, we are talking about<br />
CO 2<br />
equivalent to 83,678 Euro6 Golfs,<br />
NOx in the order of 421,153, particulate<br />
matter in excess of one million<br />
and sulphur oxides amounting to 376<br />
million (the entire car fleet of the EU<br />
27 is estimated at 250 million).<br />
8<br />
9
AUTOMOTIVE<br />
#FPTINDUSTRIAL #XC13<br />
FPT INDUSTRIAL<br />
LET'S GO,<br />
XC13<br />
In the picture, the XC13 and Andrea Abbà, product marketing<br />
manager at FPT Industrial: “We expect ICEs to remain the<br />
benchmark for a long time.”<br />
The XC13 is the quintessential<br />
expression of FPT Industrial’s<br />
soul: common rail and thermodynamic<br />
parameters that<br />
are Diesel cycle-optimized, with the<br />
HVO option; a significant upgrade of<br />
the natural gas unit, historically rooted<br />
back to Turin; a hydrogen version<br />
that looks forward to the (not-so-distant)<br />
future. It turns its gaze to the onroad<br />
with this version, that is, however,<br />
naturally inclined towards mobile<br />
industrial applications.<br />
After all – as Andrea Abbà will tell<br />
us – field tests are being carried out<br />
on a Prinoth snow groomer, right in<br />
a hydrogen incarnation. Introduced in<br />
Barcelona, where Iveco said it would<br />
be investing a billion into renewing<br />
their entire range, the XC13 reaffirms<br />
internal combustion engines’<br />
The XC13 surely<br />
sounds agnostic<br />
in FPT Industrial’s<br />
unofficial<br />
nomenclature;<br />
it comes, indeed,<br />
with a tripartite<br />
certification: Euro<br />
6E (winking an eye<br />
at the upcoming<br />
Euro 7), methane<br />
gas and also<br />
biofuel, with a link<br />
to hydrogen<br />
prominence in the heavy range. At<br />
the headquarters in Turin they firmly<br />
believe BEVs are not an option for<br />
long-haulage.<br />
Speaking of which Luca Sra, heading<br />
Iveco Group’s Truck Business unit –<br />
was absolutely unequivocal. “Let’s<br />
think of a carrier working on international<br />
routes: it simply can’t work<br />
without the fuel autonomy it needs to<br />
ensure its business stays productive.<br />
It comes just naturally, then, to think<br />
that we need time, we need the transition<br />
to be guided. Ours is neither a<br />
critical nor an opportunistic stance,<br />
but rather the affirmation of a strong<br />
sense of practicality.”<br />
Andrea Abbà, FPT’s product marketing<br />
manager, told us about dialoguing<br />
with Iveco upon conceiving the XC13<br />
for the Model Year <strong>2024</strong>.<br />
Could you tell us about Iveco’s demands?<br />
In other words, about the<br />
genesis of the XC13?<br />
“Reducing fuel consumption was our<br />
North Star. To stick to this input, we<br />
revolutionized the engine starting<br />
from the very engine block, whose<br />
material changed from cast iron to<br />
compacted graphite iron. Displacement<br />
per cylinder was our cornerstone,<br />
given that bore and stroke had<br />
remained unchanged, compared to<br />
the Cursor 13. We also implemented<br />
a new valve actuation system to maximize<br />
braking power, which allows<br />
vehicle engineers to avoid fitting a<br />
retarder on many applications. That’s<br />
an expedient that enables end customers<br />
to get a pretty considerable saving.<br />
This project enabled us to shed over<br />
100 kg. I know we’re talking about a<br />
44-ton truck, but this means the carrier<br />
will have a 100kg of extra payload.<br />
We resized the crankshaft and used<br />
connecting rod journals and crankpin<br />
journals of a smaller diameter; plus,<br />
we added an electronically controlled<br />
dual flow ball bearing turbo, which<br />
optimizes air flow and thus also fuel<br />
consumption. We modified the common<br />
rail: pressure gets from 2,200 to<br />
2,500 bar. We also made variations to<br />
the Peak Cylinder Pressure, raising it<br />
to 250 bar. We were asked to provide<br />
a base engine that could work with a<br />
variety of fuels – diesel, natural gas,<br />
bio, and also hydrogen, in the future.<br />
Another key demand was about fuel<br />
consumption, that has a direct impact<br />
on CO 2<br />
emissions. We have to comply<br />
with the goals set for 2025 for truck<br />
drivers. XC13 will be one of the pri-<br />
mary contributors to the Iveco Group<br />
mission. The engine consumes 7%<br />
less diesel compared to Model Year<br />
2022 and as much as 9% less compared<br />
to the Model Year 2019, which<br />
is the baseline against which the impact<br />
set for 2025 is measured. The<br />
natural gas/biomethane version uses<br />
8% less fuel compared to Model Year<br />
2022 and 10% less compared to MY<br />
2019. We were clearly asked to align<br />
with competitors’ performance. So<br />
in particular, we worked to close the<br />
torque gap at low revs, so hard we can<br />
now say we’re the best in class, both<br />
in terms of max torque and of downspeed,<br />
hence at low revs.”<br />
Could you expand a little on performance,<br />
ending with a note on MEP?<br />
“In terms of performance, we equalled<br />
10<br />
11
AUTOMOTIVE<br />
#IVECO #DIESEL #NATURALGAS<br />
Iveco announced a historic partnership with Rock & Roll Hall of Famers Metallica<br />
during the launch event of its full range renewal in Barcelona. The brand will<br />
support the band during the European leg of the M72 World Tour, from May<br />
to July <strong>2024</strong>.<br />
the top of the range. The max engine<br />
capability is 600 hp/2850 Nm, but to<br />
date we have certified the 580 hp/2800<br />
Nm version. If we compare the 500 hp<br />
XC13 with the 480 C11 and the 490<br />
C13, thanks to downspeeding, in addition<br />
to achieving a remarkable increase<br />
in max torque up to 2600 Nm<br />
(versus 2300-2400) max torque is<br />
reached already at 840 rpm, versus<br />
the 930/970 rpm of the previous versions.<br />
The mean effective pressure<br />
gives us an idea of the amount of useful<br />
work achieved with the same displacement.<br />
The MEP went from 24.4<br />
to 27.8 bar, meaning a 14% increase.”<br />
114 kg lighter than the Cursor 13. Is<br />
this only explained with the use of<br />
compacted graphite iron?<br />
“That’s certainly one of the key improvements,<br />
as we changed the engine’s<br />
core – that is, the cylinder head<br />
and the block. In addition, we downsized<br />
a few components, namely the<br />
crankshaft, the conrods and the piston,<br />
to reduce both size and friction.<br />
We halved the number of counterweights<br />
– we went from 8 to 4. That<br />
laid the groundwork for the 114-kilogram<br />
weight reduction.”<br />
When discussing with Iveco, what<br />
inputs were you given as to performance,<br />
considering that internal<br />
combustion engines are steadily<br />
under the spotlight? Specific curve<br />
increase or fuel reduction?<br />
“No doubt reducing consumption. To<br />
achieve which, downspeeding is a key<br />
step. And this brings us back to what<br />
we were able to reap: 300Nm more<br />
and 150 rpm less, as I mentioned earlier.”<br />
Will these same parameters be applicable<br />
to the hydrogen version,<br />
too?<br />
“Hydrogen is less efficient, after all is<br />
the Otto cycle we’re talking about, so<br />
we can draw a comparison with natural<br />
gas technology. We have to think<br />
of efficiency and performance similar<br />
to those in the gas and biomethane<br />
versions. The NG version’s max capability<br />
is 500 hp at 2200 Nm. Torque<br />
and power curves meet the needs of<br />
this segment’s core – long-haul applications.<br />
As you know, we launched a<br />
prototype jointly with Prinoth, fitted<br />
on a snow groomer, tested last winter.<br />
We’re setting ourselves the target of<br />
achieving start-up production of the<br />
hydrogen-fuelled XC13 by the end of<br />
the decade. This is not a very shortterm<br />
project, but we do have a few<br />
engines being field-tested so that’s<br />
a realistic option. We have changed<br />
all components on the NG version,<br />
too, in addition to introducing the<br />
new valve actuation system to maximize<br />
braking power, the same applied<br />
to diesel, with the differences<br />
in performance that are inherent to<br />
the individual technologies. The main<br />
changes, compared to the diesel version,<br />
are the turbocharger, an electronically<br />
controlled wastegate – no<br />
longer a VGT – and the addition of<br />
EGR. Recirculation suits more powerful<br />
engines in that it enhances performance:<br />
natural gas entails temperatures<br />
that are much higher than<br />
with diesel engines, which the EGR<br />
can lower, thus improving efficiency.”<br />
Are the axles by FPT, too?<br />
“In Turin we’ve been producing axles<br />
and transmissions since the Seventies,<br />
we manufacture about 260,000<br />
a year for commercial medium and<br />
heavy vehicles. To the MY24 we provide<br />
the front and rear axles. On the<br />
rear axle, the rear axle ratio was sped<br />
up to 2:06 to optimize downspeeding.”<br />
What about friction reduction?<br />
“It helps mitigating CO 2<br />
emissions as<br />
well as fuel consumption. To achieve<br />
it, we used smart auxiliaries, such as<br />
variable water and oil pumps, and<br />
also donwnsized the components.”<br />
One of the take-home messages<br />
from Barcelona is that Iveco was<br />
brave enough to state that for the<br />
time being electric vehicles are no<br />
solution for long haulage. How did<br />
you come to this conclusion?<br />
“Being very practical. Currently, legal<br />
requirements are clear, and so<br />
are thresholds, and the penalties applied<br />
in case the goals are not met.<br />
Everything else is still a chapter left<br />
unfinished: for example, where’s the<br />
fuelling infrastructure for hydrogen,<br />
a carrier that holds promise for long<br />
haul transportation? And what’s the<br />
rationale, considering that the circulating<br />
fleet in Italy is more than 10<br />
years old?”<br />
Vehicle registration data for 2023<br />
have just been issued and the percentage<br />
share of diesel vehicles is growing.<br />
FPT Industrial too expects ICEs<br />
to remain the benchmark for a long<br />
time.<br />
12<br />
13
COMPARISONS PREVIEWS<br />
#TRUCK #CUMMINS #FORD #COMMONRAIL #FPT #MAN #HVO #MERCEDES #POWERPACK #RENAULT #OFFROAD #SCANIA #CHECKAPP #VOLVO<br />
12L TO 12.9L TRUCK ENGINES<br />
FOR THE<br />
NOMINAL<br />
SPEED<br />
This table is taken from a comparison<br />
made two years ago.<br />
Preceded by the interview with<br />
FPT Industrial, it provides an<br />
intuitive mirror on the evolution initialed<br />
XC13, which appears in place<br />
of the Cursor 13. Scania’s Super engine<br />
is leader in efficiency and Diesel<br />
of the Year 2023, in the industrial version.<br />
What’s more, it is also confirmed<br />
as top in the Diesel Index, just one<br />
decimal point behind Cummins’ X12,<br />
which makes its way mainly because<br />
of its “slim” mass, and the XC13’s<br />
own. Scania’s engine management<br />
system is the tried-and-true EMS,<br />
which oversees the XPI’s nozzle, and<br />
interacts with the VGT. Timing is<br />
handled by the double overhead camshaft.<br />
Compared with the Cursor 13,<br />
it has made a significant leap forward<br />
especially in maximum torque and<br />
related values. The key to the climb<br />
to the Diesel Index can be attributed<br />
to weight reduction and that efficiency-functional<br />
goal of reducing rpm. In<br />
short, reaching the apex torque value<br />
at less than 900 rpm is certainly a significant<br />
milestone. The other 6-cylinder<br />
at the top is the Cummins, which<br />
in Europe we will see on harvesters<br />
more than on trucks. Of course, when<br />
we’re talking about ICE.<br />
Hyundai is present in Switzerland<br />
with the Xcient fuel cell truck and<br />
other manufacturers from Far East<br />
are probably set to land in Europe.<br />
Other familiar faces of industrial<br />
comparisons, with turbocharging,<br />
injection and revs tuned to heavy-duty<br />
performance are Man’s D26 and<br />
Mercedes’ OM 471, as the 6R 1300<br />
from Rolls-Royce Power Systems.<br />
The 12.77L from Volvo Trucks and<br />
Renault, too, hides the familiar looks<br />
of Penta’s Tad13VE. More unusual is<br />
Ford’s Ecotorq, a typically long-haulage<br />
application.<br />
BRAND<br />
MODEL<br />
CUMMINS<br />
X12<br />
DAF<br />
MX 13-530<br />
FORD<br />
ECOTORQ 12.7L<br />
FPT INDUSTRIAL<br />
CURSOR 13<br />
MAN<br />
D2676 - 500<br />
MERCEDES<br />
OM 471 - 530<br />
RENAULT<br />
DTI 13 - 520<br />
SCANIA DC13 173 VOLVO D 13 K-540<br />
I. D.<br />
B x S mm - S/B 134 x 142 - 1,06 130 x 162 - 1,25 130 x 160 - 1,23 135 x 150 - 1,11 126 x 166 - 1,32 132 x 156 - 1,18 131 x 158 - 1,21 130 x 160 - 1,23 131 x 158 - 1,21<br />
N. cil. - dm 3 6 - 12,01 6 - 12,90 6 - 12,74 6 - 12,88 6 - 12,41 6 - 12,80 6 - 12,77 6 - 12,74 6 - 12,77<br />
Maximum power kW - rpm 373 - 2.000 390 - 1.800 368 - 1.800 419 - 1.900 368 - 1.800 390 - 1.850 390 - 1.900 412 - 1.800 397 - 1.800<br />
Mep at max power bar 19,0 20,6 19,6 21 20,1 20,1 19,7 22,0 21,1<br />
Piston speed m/s 9,5 9,7 9,6 9,5 10 9,6 10 9,6 9,5<br />
Maximum torque Nm - rpm 2.305 - 1.000 2597 - 1.000 2499 - 1.000 2400 - 950 2499 - 930 2597 - 1.100 2548 - 1.050 2.803 - 900 2597 - 1.000<br />
Mep at max torque bar 24,6 25,8 25,2 23,9 25,8 26 25,6 28,2 26,1<br />
% power at max torque (kW) 51,8 56,6 58 47,3 58 56,6 55,4 58,1 55,4<br />
Torque at max power Nm 1.784 2.068 1.950 2.107 1.950 2.009 1.960 2.185 2.107<br />
DETAILS<br />
Specific power kW/dm 3 31 30,2 28,8 32,5 29,6 30,4 30,5 32,3 31<br />
Specific torque Nm/dm 3 191,8 201,2 196,1 186,3 201,2 202,7 199,4 219,9 203,2<br />
Areal spec. power kW/dm 2 44,09 48,99 46,23 48,78 49,20 47,50 48,21 51,76 49,07<br />
RULES AND BALANCE<br />
Dry weight kg 930 1.000 - 1.197 1.114 1.126 1.115 1.100 1.134<br />
L x W x H mm 1.294x931x1.002 1.375x825x1.150 - 1.360x1.008x1.171 1.630x893x1.046 1.375x980x1.260 1.285x1.100x1.301 1.710x780x1.430 1.285x1.100x1.301<br />
Volume m 3 1,21 1,30 - 1,61 1,52 1,70 1,84 1,91 1,84<br />
Weight/power kg/kW 2,5 2,6 - 2,9 3 2,9 2,9 2,7 2,9<br />
Weight/displacement kg/dm 3 77,4 77,5 - 92,9 89,7 87,9 87,3 86,3 88,8<br />
Power density kW/m 3 308,3 300 - 260,3 242,1 229,4 212 215,7 215,8<br />
Total density t/m 3 0,77 0,77 - 0,74 0,73 0,66 0,61 0,58 0,62<br />
Displacement/volume dm 3 /m 3 9,93 9,92 - 8 8,17 7,53 6,94 6,67 6,94<br />
INDEX<br />
Torque 13,1 11,3 - 12,5 11,9 10,9 11,8 12,4 11,3<br />
Performance 6,9 7,2 7,1 6,9 7,3 7,3 7,2 7,7 7,3<br />
Stress 11,4 11,8 11,6 11,1 11,9 11,9 11,9 12,6 11,9<br />
Lightness 10,2 10,2 - 12,8 11,9 11,6 11,5 11,5 11,7<br />
Density 10,5 10,2 0,0 8 8,6 7,9 7,2 7,6 7,3<br />
DIESEL INDEX 8,0 7,8 - 7,7 7,7 7,7 7,8 7,9 7,7<br />
14<br />
15
EVENTS<br />
#INTERMAT #WORDLOFCONCRETE<br />
INTERMAT PRESS DAYS<br />
DIGITALIZATION<br />
AND<br />
ENERGY<br />
On August 31, 2023, Christophe Lecarpentier (left), has been<br />
appointed head of the Comexposium group’s Agro Equipment<br />
and Construction division, which includes SIMA, SITEVI and<br />
Intermat.<br />
Digitalisation and energy will<br />
be the key words at Intermat<br />
<strong>2024</strong>, which will take place<br />
from April 24 to 27 in Paris<br />
Nord Villepinte. France leads the<br />
continent in fission energy. In 2023,<br />
the French parliament approved the<br />
construction of six more nuclear power<br />
plants by 2025. The construction<br />
sites in urban areas are one of the<br />
most testing grounds for electrification<br />
in the industrial segment. A lot<br />
of energy is needed to accomplish<br />
this mission. Intermat has the systemic<br />
credentials to restructure itself<br />
as the hub of electrification in the<br />
construction industry. And, guess<br />
what?, electric technology will be the<br />
widespread protagonist on the OEM<br />
stands. Some examples? Liebherr’s<br />
T33-10 telescopic handler, Amman’s<br />
It’s going to be an<br />
“electric” event,<br />
at least from the<br />
point of view of the<br />
OEMs. Certainly<br />
stimulated by<br />
the drivers of<br />
digitalization<br />
and energy,<br />
as Christophe<br />
Lecarpentier, the<br />
event’s director,<br />
confirmed to us<br />
eAMX-15 mini-excavator, and Develon’s<br />
DL250-FCEV wheel loader.<br />
Liugong will even exhibit only<br />
BEVs.<br />
Who better to talk to than Christophe<br />
Lecarpentier, director of the<br />
agricultural and construction equipment<br />
division at Comexposium?<br />
“First of all, I would like to focus on<br />
the name Intermat, which is known<br />
in the French-speaking world and<br />
beyond. This event is industry-oriented<br />
from the very beginning, so<br />
we have emphasised the issue of<br />
decarbonisation. In this production<br />
ecosystem, it is a truly epochal transition.<br />
It was and remains crucial,<br />
now more than ever, that the organisation<br />
of this event follows industry<br />
trends. The first way involves endothermic<br />
systems. Digital tools can<br />
help improve the fuel consumption<br />
of diesel engines. Biofuels are the<br />
second step, which however calls<br />
into question the availability of these<br />
fuels. Let me say that, with due proportion,<br />
it is easier to electrify cars.<br />
The earthmoving sector cannot rely<br />
on a single solution. There are small<br />
machines as well as extremely large<br />
ones (key factors such as work cycle,<br />
peak load and energy absorption,<br />
possible transit on the road, use of<br />
tools, etc. come into play). Intermat’s<br />
role is to work hand in hand with the<br />
French and European federations<br />
of the industrial machinery sector,<br />
whether they represent OEMs, hirers<br />
or end users. They are able to intercept<br />
the industry’s most authentic<br />
challenges and understand how to<br />
bring supply and demand together<br />
during the event and how to meet<br />
visitors’ needs”. A strategy game<br />
called energy transition? “We represent<br />
the different solutions of decarbonisation,<br />
coming from the implementation<br />
of endothermic efficiency,<br />
for some applications from electric<br />
motors or alternative fuels, with hydrogen<br />
more in perspective. This is<br />
why we created the Energy sector.<br />
We don’t just deal with machines,<br />
we analyse infrastructure, storage,<br />
regulations governing new energies,<br />
and the operators’ training. The<br />
<strong>2024</strong> edition intends to take up the<br />
challenges of our industry, not only<br />
through the traditional exhibition<br />
formula, but also through seminars<br />
and meetings, television popularisation,<br />
and networking. Visitors must<br />
leave the show ‘enlightened’ about<br />
new technologies. The show evolves<br />
both in terms of exhibitors and solutions,<br />
organisations involved, topics<br />
on the table. Digitalisation is a<br />
truly crucial factor, which concerns<br />
the huge amount of data collected<br />
and its use in reducing the carbon<br />
footprint. Stakeholders wonder how<br />
best to use machines to increase<br />
productivity, reduce consumption,<br />
etc. This is the first real step in decarbonisation.<br />
There is the World of<br />
Concrete, which massively involves<br />
electric machines and the use of materials<br />
with a low carbon footprint.<br />
In short, we take a holistic view,<br />
which does not only embrace propulsion<br />
systems. There is legislation<br />
to comply with, which requires us to<br />
speed up the roadmap. How can we<br />
take action to reduce emissions from<br />
16<br />
17
EVENTS<br />
#CUMMINS #NPROXX<br />
New for <strong>2024</strong>, the Industry Forum’s BFM Business TV set, featuring a series<br />
of round tables, will provide an opportunity to take a broad look at societal,<br />
energy and economic issues, the challenges of decarbonisation and digitalisation,<br />
and also raise public authority awareness of the fundamental role of our sector<br />
in achieving net zero.<br />
ICE-equipped machines, which will<br />
be such a large part of the circulating<br />
fleet in the coming years. At the<br />
same time, the demand for electric<br />
machines is increasing and, consequently,<br />
so are the problems with<br />
recharging. To us, as well as to the<br />
Ministry, it seems that there is no<br />
single solution; efforts must be made<br />
on several fronts: reducing emissions<br />
on diesel machines, spreading biofuels,<br />
and electrifying part of the fleets.<br />
Intermat remains a construction and<br />
building event, as well as demolition<br />
and what goes around this sector. We<br />
are definitely not mining-oriented.”<br />
Finally, a look at Intermat’s target<br />
markets. “Our trade show remains<br />
international in scope and strongly<br />
oriented towards European countries.<br />
We clearly have a strong link<br />
with French-speaking visitors, such<br />
as Canadians and Africans. We have<br />
a special top buyer programme from<br />
Africa and the Middle East. Intermat<br />
India will be held in April <strong>2024</strong> and<br />
is going to be tailor-made for that<br />
specific market. Finally, we have<br />
Chinese exhibitors, who are gaining<br />
increasing market shares in Europe.”<br />
Laurent Di Vito is Manager Engines<br />
Sales, Application and Production,<br />
New Power Leader, at Cummins<br />
France. “Our strategy up to now has<br />
been focused on engines,” De Vito<br />
confirms, also for the French side.<br />
“Currently we have differentiated<br />
ourselves with a range of proposals,<br />
for example electrified axles, after<br />
the acquisition of Meritor. When we<br />
offer a complete package, we do not<br />
limit ourselves to the propulsion part,<br />
we also provide support for storage.<br />
There are indeed those who demand<br />
a complete ecosystem from us. In<br />
France, for example in Champagne<br />
and Bordeaux, we have some interesting<br />
projects: some wind turbines<br />
are connected to an electrolyser for<br />
the production of hydrogen. This will<br />
power the fuel cells of grape harvesting<br />
machines.” What about the market?<br />
we ask. This is almost a naive<br />
question... “We record a strong push<br />
for hydrogen from decision makers,<br />
at least from the Covid-19 pandemic<br />
onwards. Throughout the last two<br />
decades, the main topic of discussion<br />
has been ‘what is the next emission<br />
level for my endothermic engine?’.<br />
Today, while waiting for Euro 7,<br />
Stage VI, what do we need? In the<br />
truck industry there is a need for ap-<br />
plications with electric recharging,<br />
but if there is a lack of electricity...<br />
In the off-highway sector, on the other<br />
hand, we are seeing a strong push<br />
towards hydrogen. You know our<br />
agnostic, diesel, gas and hydrogen<br />
engine. We have developed a common<br />
platform with a strong focus on<br />
each specific technology. Hydrogen<br />
requires spark ignition, albeit with<br />
different energy requirements than<br />
gas, with which it shares a head and<br />
spark plug. From the supercharging<br />
point of view, more air is needed than<br />
the diesel cycle. Cummins presents<br />
itself as a flexible and comprehensive<br />
supplier of propulsion solutions.<br />
You, the OEM, manufacture your<br />
machine, Cummins supports you<br />
with the Stage VI solution, since 80-<br />
90% of the market will remain diesel.<br />
We assist you in integrating hydrogen<br />
solutions, with specific 700 bar<br />
tanks, derived from our collaboration<br />
with NPROXX. Cummins allows<br />
OEMs to design a diesel machine<br />
with a hydrogen engine or fuel cell<br />
option at hand, should the availability<br />
of hydrogen increase. Cummins is<br />
already producing fuel cells, thanks<br />
to the acquisition of Hydrogenics”.<br />
When will fuel cell technology be<br />
mature for construction sites? “The<br />
fuel cell is very sensitive to air. Not<br />
only to environmental impurities, but<br />
also to chemical factors. In addition,<br />
it needs low vibrations. At present,<br />
excavators are not a congenial application<br />
for this technology. In the<br />
future, diesel machines will continue<br />
to perform their function outside the<br />
urban perimeter, in quarries, con-<br />
struction sites and mines. The city<br />
will be the preserve of electric and<br />
hydrogen technology, at this stage<br />
possibly applied to the combustion<br />
engine, which reduces design costs.”<br />
How to overcome the insuperable<br />
limits of Stage VI? “The question is<br />
how to reduce CO 2<br />
and thus reduce<br />
consumption? There are basically<br />
two ways: redesigning the engine,<br />
strengthening after-treatment. Without<br />
EGR, AdBlue consumption is<br />
higher, although with Stage V, Cummins<br />
has managed to reduce fuel<br />
consumption. Or, we can resort to<br />
hybrid solutions. At the trade show<br />
we will have the opportunity to see<br />
Deutz and Volvo Penta’s vision for<br />
this market. We will see who will enter<br />
the list of suppliers of propulsion<br />
solutions.”<br />
18<br />
19
COMPARISONS PREVIEWS<br />
#COMMONRAIL #OFFHIGHWAY #HVO #POWERPACK #4CYLINDERS#OFFROAD #AGCOPOWER #CHECKAPP #DEUTZ<br />
5 TO 5.2 LITERS<br />
CORE IS<br />
50<br />
TOO<br />
ter. We can’t, then, rule out that the<br />
5 litre will be available in a wider<br />
range of cylinder number options<br />
depending on captive needs and its<br />
impact on the free market. Cylinder<br />
displacement is modular and the engine<br />
block was designed with the<br />
same engineering features; we will,<br />
therefore, repeat what we already<br />
said in May’s comparison, with all<br />
due exceptions. Under the lens, the<br />
1.25L cylinder displacement in the<br />
6-cylinder configuration; an engine<br />
block – as we said back then<br />
– that does not make it to the podium<br />
based on the comparison’s indices,<br />
and yet stands out for torque,<br />
reaching second place behind mtu<br />
and climbing the ranking thanks<br />
to torque at max power. Compared<br />
to the three top positions, it pays<br />
a toll in power curve comparison<br />
– 20% less, precisely, compared<br />
to Friedrichshafen’s fastest horse,<br />
the 6R1000. A conservative choice<br />
embodied in piston speed, stuck<br />
at only 7.5 metres per second. Af-<br />
It was 2019, at Bauma Munich.<br />
Kubota was crowned Diesel of<br />
the Year with its V5009; a 5 litre<br />
that gained a following. Indeed,<br />
there are six 4 cylinders all<br />
lined up for a comparison on these<br />
pages. So, let’s start with the newest<br />
entry, the Core50 by AGCO<br />
Power. It completes the bottom section<br />
of the newly introduced Core<br />
range that’s recoded the language<br />
of AGCO Power Group’s engine department.<br />
A network that got a fresh<br />
boost from TAFE (Tractors and<br />
Farm Equipment limited) becoming<br />
a significant shareholder in the<br />
Corporation. The Indian group is<br />
the third largest agricultural OEM<br />
in the world. There is no shortage<br />
of synergies, then, as confirmed to<br />
us by Massimo Ribaldone, TAFE’s<br />
CTO and Business Development<br />
President. “Today, India’s industrial<br />
base provides for manufacturing<br />
at a reasonable cost with proven<br />
technologies; yet, quality comes at<br />
a price and costs also stem from the<br />
need to provide a centralized European<br />
sales and marketing structure<br />
to support importers across<br />
different countries. Ours is, therefore,<br />
a global range with a shared<br />
platform for all markets and scalable<br />
upgrades based on the relevant<br />
region. 75hp Stage V engines<br />
are manufactured in India based on<br />
the Tier 4 Final units equipping the<br />
Massey Fergusons”.<br />
Spearheading the Finnish renewal is<br />
Core75. Announced in a low-speed<br />
mode embodiment, it was followed<br />
by a medium speed one shortly af-<br />
AGCO Power’s Core<br />
family expands. The<br />
1.25-liter cylinder<br />
displacement also<br />
applies to 4-cylinder<br />
Diesel engine and<br />
throws down the<br />
gauntlet in this<br />
micro-segment.<br />
Veterans mtu and<br />
Volvo Penta are<br />
joined by the Finns,<br />
Deutz, Kubota and<br />
Isuzu<br />
BRAND<br />
MODEL<br />
AGCO POWER<br />
POWER CORE50<br />
DEUTZ<br />
TCD 5.2<br />
ISUZU<br />
4HK1<br />
KUBOTA<br />
V5009<br />
MTU<br />
R4 1000<br />
VOLVO PENTA<br />
TAD572VE<br />
I. D.<br />
B x S mm - S/B 110 x 132 - 1,20 110 x 136 - 1,24 115 x 125 - 1,09 110 x 132 - 1,20 110 x 135 - 1,23 110 x 135 - 1,23<br />
N. cil. - dm 3 4 - 5,01 4 - 5,17 4 - 5,19 4 - 5,01 4 - 5,13 4 - 5,13<br />
Maximum power kW - rpm 165 - 1.700 170 - 2.300 145 - 2.100 157 - 2.200 170 - 2.200 160 - 2.200<br />
Mep at max power bar 23,7 17,5 16,3 17,4 18,4 17,3<br />
Piston speed m/s 7,5 10,4 8,8 9,7 9,9 9,9<br />
Maximum torque Nm - rpm 950 - 1.200 951 - 1.300 686 - 1.200 882 - 1.500 951 - 1.400 902 - 1.200<br />
Mep at max torque bar 24,3 23,6 16,9 22,5 23,8 22,5<br />
% power at max torque (kW) 47,7 46 37,3 46 46 46,3<br />
Torque at max power Nm 921 706 657 686 735 696<br />
% power at max torque (kW) 72,4 (119) 76,20 (130) 59,50 (86) 88,30 (139) 82,10 (140) 70,90 (113)<br />
Work range rpm 500 1.000 900 700 800 1.000<br />
DETAILS<br />
Specific power kW/dm 3 32,8 32,8 27,9 31,3 33,1 31,2<br />
Specific torque Nm/dm 3 189,3 183,9 132,1 175,7 185,3 175,7<br />
Areal spec. power kW/dm 2 43,42 44,74 34,94 41,32 44,74 42,11<br />
RULES AND BALANCE<br />
Dry weight kg 590 530 470 620 540 560<br />
L x W x H mm 923x664x1.171 921x695x902 1.019x776x1.034 898x656x972 818x755x1.033 772x859x995<br />
Volume m 3 0,72 0,58 0,82 0,57 0,64 0,66<br />
Weight/power kg/kW 3,6 3,1 3,2 3,9 3,2 3,5<br />
Weight/displacement kg/dm 3 117,6 102,5 90,5 123,6 105,2 109,1<br />
Power density kW/m 3 229,2 293,1 176,8 275,4 265,6 242,4<br />
Total density t/m 3 0,82 0,91 0,57 1,09 0,84 0,85<br />
Displacement/volume dm 3 /m 3 6,97 8,91 6,33 8,80 8,02 7,78<br />
20<br />
21
COMPARISONS PREVIEWS<br />
#ISUZU #KUBOTA #ROLLSROYCEPOWERSYSTEMS #VOLVO<br />
BRAND<br />
MODEL<br />
AGCO POWER<br />
POWER CORE50<br />
DEUTZ<br />
TCD 5.2<br />
ISUZU<br />
4HK1<br />
KUBOTA<br />
V5009<br />
MTU<br />
R4 1000<br />
VOLVO PENTA<br />
TAD572VE<br />
INDEX<br />
Torque 7,9 12,9 11,2 9,9 11 12,8<br />
Performance 6,8 6,8 5,4 6,5 6,8 6,5<br />
Stress 10,6 11,3 8,6 10,7 11,2 10,8<br />
Lightness 14,4 12,6 11,2 15,4 12,7 13,5<br />
Density 16 19,5 10,3 18,9 17,8 16,3<br />
DIESEL INDEX 7,1 7,7 7,1 7,2 7,6 7,5<br />
ter all, the first application of this<br />
1.25 dm 3 single cylinder was Fendt<br />
728 Vario, winner of Tractor of the<br />
Year 2023. But there’s more to this<br />
engine’s architecture than just thermodynamic<br />
performance. Quoting<br />
AGCO Power Marketing Manager<br />
Tommi Puomisto we approached<br />
at Bauma Munich: “It’s a fact that<br />
the technology on the market is not<br />
100% ready for carbon neutrality,<br />
but we need to take all steps to get<br />
it closer to it. Specific consumption<br />
is 188 g/kwh – we’ll be happy<br />
to compare it to that of any other<br />
competitor with publicly accessible<br />
technical datasheets. Specific consumption<br />
values are often higher<br />
than 200 g/kwh”.<br />
Are these similarities also found in<br />
performance? Specific power moves<br />
from 29.6 kW per litre to 32.8. Specific<br />
torque is slightly lower and yet<br />
it becomes best in class when com-<br />
pared to the five equally sized competitors.<br />
Head-to-head with its big<br />
brother, the Core50 dashes forward<br />
tanks to torque reserve and it knocks<br />
out the contenders in the max power<br />
curves comparison. Out of 950 Nm<br />
recorded at peak power – an asset<br />
that allows AGCO to flank Deutz at<br />
the top – no less than 921 are still<br />
available as power reaches the peak<br />
value, right when one would expect<br />
the curve to start declining; instead,<br />
it stays basically stable from 1200<br />
to 1900 rpm.<br />
AGCO Power too has chosen to remove<br />
the recirculation valve so as<br />
to minimize heat, make the radiator<br />
more compact and avoid a negative<br />
impact on specific fuel consumption.<br />
The Diesel Index is instead rewarding<br />
for Deutz’s 5.2L, the most muscular<br />
of the group. Size-wise the<br />
AGCO gets close to the approach<br />
of the 5.2; since the Cologne engine<br />
gained a millimetre in bore – from<br />
109 to 110 – and two in stroke (from<br />
134 to 136), the 5.2 litre was among<br />
the first to give up on the EGR, one<br />
of the German mechanical engineering<br />
dogmas. That’s an engine that<br />
has a lot to say to the market of mobile<br />
working machinery, including<br />
when considering mean effective<br />
pressure, leaving room for action<br />
on the piston to achieve overall efficiency.<br />
We were speaking about<br />
Kubota, that went past the 110kW<br />
pillars of Hercules right with its 5<br />
litre. Looking at the Japanese 4 cylinder<br />
one gets impressed with its<br />
extremely compact size. The Osaka-based<br />
engine maker pushed hard<br />
on MEP – contrary to what’s customary<br />
for Kubota, for which the<br />
monobloc’s robustness comes prior<br />
to any excess within the combustion<br />
chamber. With 17.4 bar, the 1.250<br />
DEUTZ MTU VOLVO PENTA<br />
litre cylinder displacement can support<br />
performance and boost specific<br />
curves without “pressuring” the piston<br />
too much. As mentioned, rpms<br />
are in line with those of its talented<br />
contenders and piston linear speed<br />
well set below the fatidic value of<br />
10 metres per second.<br />
As pointed out during the V5009<br />
awarding ceremony at Bauma Munich,<br />
“since the middle of the last<br />
decade, and increasingly more often<br />
as of III B, the true driving force of<br />
internal combustion engines have<br />
been emissions standards. No manufacturer<br />
was able to find an alternative<br />
to the DPF – SCR combo. EGR<br />
was the only distinctive element.<br />
Kubota’s strategy – improving on<br />
the after-treatment system and combustion<br />
parameters – was a winning<br />
one”. Isuzu now moved this unit<br />
into the Tier 4 Final/Stage V territory,<br />
but without altering its mood.<br />
Low stress, no gambling with performance<br />
characterizes this engine<br />
that’s basically designed to work at<br />
construction sites.<br />
Rolls-Royce Power Systems and<br />
Volvo Penta are placing their bets<br />
on two thoroughbreds, widely tested<br />
and reliable. The mtu 1000 Series<br />
confirms its sophisticated architecture<br />
that shows painstaking care for<br />
boosting as well as fuel supply. The<br />
4R becomes a party of four: 115,<br />
129, 150 and 170 kW at 2200 rpm.<br />
This series, up to series 1500, will<br />
be marketed by Deutz, while waiting<br />
for 2028 when the agreement<br />
with Daimler Truck is set to enter<br />
into force. The heavy-duty engines<br />
will keep being built by Daimler<br />
Truck at the Mercedes-Benz plant<br />
in Mannheim and sent to Deutz for<br />
the final assembly, while the medium<br />
speed range will be manufactured<br />
entirely in Cologne.<br />
The Swedes, too, are taking sophisticated<br />
solutions pretty seriously.<br />
The variable geometry turbo is a<br />
legacy of research into the on road<br />
heavy duty domain; the EMS – Engine<br />
Management System – control<br />
unit governs the system and can be<br />
controlled remotely.<br />
Fine particles are taken care of<br />
through the high temperature within<br />
the chamber. The unavoidable<br />
nitrous oxides trade-off is handled<br />
by the EGR-SCR duo, upstream<br />
and downstream of the combustion<br />
stage, respectively. The aftertreatment<br />
system then gets shorter and<br />
freed from the burden of regeneration.<br />
22<br />
23
AUTOMOTIVE<br />
#AUDI #BMW #MERCEDES #OPEL #STELLANTIS #SUZUKI<br />
HUNGARY FOR BATTERY<br />
EUROPEAN<br />
ELECTRIC<br />
HUB<br />
EV BATTERY CELL, MODULE AND PACK MANUFACTURERS IN HUNGARY<br />
NAME<br />
ORIGIN<br />
TOTAL ANNUAL<br />
PRODUCTION<br />
OUTPUT<br />
LOCATION<br />
STARTING YEAR<br />
OF OPERATION<br />
Samsung SDI South Korea 40 GWh+ Göd 2017<br />
SK Innovation South Korea 47,3 GWh* Komárom, Iváncsa 2019<br />
CATL China 100 GWh Debrecen 2025<br />
BYD China t.b.a. Fót t.b.a.<br />
EVE Power China 28 GWh Debrecen 2026<br />
Sunwoda China t.b.a. Nyíregyháza 2025<br />
*possibility to be increased to 53,5 GWh<br />
One of the key products of the future<br />
are traction batteries, essential<br />
components of any electric – or<br />
even fuel cell powered – vehicles.<br />
Within the European Union, Hungary<br />
puts a particularly high stake on EV battery<br />
plants. As automotive industry gradually<br />
turns to more sustainable – practically<br />
electric – drivelines, fear of change<br />
(and the loss of the combustion engine<br />
market) also increases in Hungary, whose<br />
economy is currently highly dependent<br />
on automotive industry. Today, according<br />
to the estimations of the government,<br />
the conventional automotive sector is responsible<br />
for nearly 20% of the country’s<br />
total GDP, which comes not only from<br />
the large OEMs present at the country –<br />
namely Suzuki, Audi, Mercedes-Benz,<br />
Stellantis (Opel), with a new BMW assembly<br />
plant being under construction –,<br />
but also the many local and multinational<br />
industry suppliers settled in Hungary during<br />
the last decades. However, producing<br />
traction batteries in large amounts seems<br />
to be a good card to remain part of the<br />
game in the future as well.<br />
For the above reasons, the establishment<br />
of factories related to the EV battery<br />
industry (including supplier products)<br />
enjoys huge financial and political support<br />
from the Hungarian government - a<br />
reason often mentioned by the battery<br />
manufacturers themselves when they are<br />
asked about their reasons why choosing<br />
Hungary as the location of their newest<br />
plants. The central position of the country<br />
within the region, the local big car factories<br />
and the relative proximity of others<br />
in the neighbouring countries – such as<br />
Slovakia, Romania or even the Czech<br />
Republic – also contributes to making<br />
Hungary a considerable place for such<br />
investments. Márton Nagy, Minister for<br />
National Economy minister of Hungary,<br />
stated at a press event in September that<br />
the government has plans to build up an<br />
annual battery production capacity of 250<br />
GWh in the next few years, which, according<br />
to him, would cover 35% of the<br />
European needs and would put the country<br />
to the fourth place worldwide in this<br />
comparison, right after China, the United<br />
States and Germany. Indeed, by November<br />
2023, battery production capacity in<br />
Hungary reportedly already reached 87<br />
GWh/year, not including the newest SK<br />
Innovation plant, which is expected to<br />
begin production soon and to provide an<br />
additional output of 30 GWh/year alone<br />
when operating on full throttle. It is also<br />
worth mentioning that not only battery<br />
cell and module producers, but also all<br />
concerns include the tremendous energy<br />
and water consumption of the manufacturing<br />
process, and the significant use of<br />
foreign labor. A frequently heard criticism<br />
of the investments is that the newly<br />
built plants of foreign-owned companies<br />
only bring health-risky work processes to<br />
Hungary with low added value, instead of<br />
R&D activities from which the country<br />
itself would benefit in the long run. Some<br />
analysts also note that the country does<br />
not really have the necessary raw material<br />
resources, neither accessible cheap energy<br />
to support the needs of the factories.<br />
Similar to the practice observable worldwide,<br />
EV battery cell and module manufacturers<br />
currently present at Hungary<br />
come from the Far East – namely South<br />
Korea, Japan, and, first of all, China. The<br />
supplier segment is also dominated by<br />
these countries, for whom setting up a loparticipants<br />
of the whole supply chain,<br />
such as electrolyte, anode, cathode, aluminum/copper<br />
foil, separator foil and battery<br />
part manufacturers, as well as industrial<br />
waste recycling firms are welcomed<br />
by the Hungarian government, which is<br />
well demonstrated by the various recent<br />
local investments of these companies.<br />
Moreover, there are even plans for local<br />
lithium extraction, by exploiting geothermic<br />
deposits. However, the construction<br />
of more and more battery plants is also a<br />
quite sensitive topic in the Hungarian political<br />
field, due to the many arising technical<br />
and environmental issues. Demonstrations<br />
and protests against the planned<br />
battery plants are common by the locals,<br />
who are afraid of health issues, airborne<br />
pollution, contamination of groundwater<br />
and noise emission the factories may<br />
cause in their neighbourhood. Further<br />
cal production base in a relatively cheap<br />
but well-located EU-member state provides<br />
an entrance to the European market.<br />
While these companies are strengthening<br />
their positions as key employers<br />
and become such important part of the<br />
country’s economy with the dedicated<br />
support of the Hungarian government,<br />
some political concerns raise at European<br />
level, especially in case of China. At the<br />
moment most customers of the battery industry<br />
products produced in Hungary are<br />
coming from the passenger car business.<br />
Some of the OEMs representing the main<br />
customer market also operate in Hungary,<br />
while the local Hungarian bus industry –<br />
which is currently a shadow of its former<br />
glory, although some developments have<br />
been done the last years – plays a negligible<br />
role for now. The only exception is<br />
BYD, which operates (among others) a<br />
24<br />
25
AUTOMOTIVE<br />
#SAMSUNGSDI #SKINNOVATION<br />
On the left, you can see a picture of the Samsung SDI plant,<br />
located in Göd, near the Hungarian Capital, Budapest.<br />
bus assembly plant in Hungary and uses<br />
its own batteries. In below, we provide<br />
a slight overview about the EV battery<br />
producer companies which already operate<br />
manufacturing plants in Hungary<br />
or announced to do so in the near future.<br />
We also take a look at their products and<br />
manufacturing capacity.<br />
SAMSUNG SDI<br />
The Korean company can be considered<br />
as a pioneer of the traction battery industry<br />
in Hungary, as it started to construct its<br />
first traction battery plant in the country<br />
as early as 2016, located in Göd (sometimes<br />
written as “Goed” in the international<br />
media), a town about 25 kilometers<br />
north of the capital, Budapest. In fact, it<br />
was a brownfield investment by converting<br />
Samsung’s own former cathode ray<br />
tube factory. The new battery plant’s inauguration<br />
ceremony was held in 2017,<br />
quickly followed by a further expansion<br />
investment of 1.2 billion euros in the<br />
same year. As a result, the second unit<br />
was completed in 2019 and reached full<br />
production capacity (more than 6 million<br />
cells/month) by January 2022. By now<br />
the total manufacturing output increased<br />
to 40 GWh/year. Prismatic battery cells<br />
produced here are used in electric cars of<br />
BMW, Volkswagen and Stellantis. The<br />
Hungarian plant will also supply sixth<br />
generation P6 prismatic NCA cells for<br />
Hyundai Motor’s electric vehicles dedicated<br />
for the European market, starting<br />
from 2026. However, the plant often appears<br />
in the Hungarian media in a negative<br />
sight due to the complaints of the<br />
people living around it. These complaints<br />
include safety issues, significant noise<br />
emission and assumed responsibility of<br />
an alleged groundwater poisoning.<br />
In January 2023, there were reports that<br />
Samsung SDI would expand its operations<br />
in Hungary with a new production<br />
plant, with a similar output as the previous<br />
two. According to the rumours, this facility<br />
would produce 46120-type cylindrical<br />
cells, to be used exclusively in BMW<br />
cars – more precisely, the planned new<br />
manufacturing unit is expected to supply<br />
the also recently announced BMW<br />
battery module assembly plant in Debrecen,<br />
Hungary. From an e-bus perspective,<br />
Samsung SDI cells are used in the traction<br />
battery packs of Akasol, which itself<br />
is a supplier of Mercedes-Benz, Van Hool<br />
and Industria Italiana Autobus. The current<br />
Hungarian market leader, Credobus<br />
will also use these packs in its all-new<br />
zero emission bus family, scheduled to be<br />
introduced in <strong>2024</strong>. Also, battery technology<br />
of Samsung SDI is used in Webasto<br />
batteries, which can be found in Otokar<br />
e-buses.<br />
SK INNOVATION<br />
Another major player from South Korea,<br />
battery industry giant SK Innovation operates<br />
three plants in Hungary by now.<br />
Two of them are located in Komárom –<br />
the same north-western Hungarian town<br />
which is the home of BYD’s now-only<br />
European bus assembly plant –, while<br />
the newest, third unit recently started operation<br />
at Iváncsa, with an almost twice<br />
higher production output than the former<br />
two combined. The original Komárom<br />
plant – which was the first European<br />
plant of the company, operating since the<br />
end of 2019 – produces third-generation<br />
pouch battery cells, with a manufacturing<br />
capacity of 7,5 GWh/year, on a total<br />
of five assembly lines. Capacity was<br />
increased by a further 9.8 GWh with the<br />
commission of the second manufacturing<br />
unit in 2022, which has a capability<br />
to be scaled up to even 16 GWh/year.<br />
The number of employees, originally<br />
475, was also boosted by another 1000.<br />
These two plants mainly supply battery<br />
cells for the electric vehicles of Daimler<br />
and Volkswagen. The company’s newest,<br />
third factory in Hungary will operate<br />
at Iváncsa, a small town 51 kilometers<br />
southwest of Budapest. At the time of<br />
its official announcement in early 2021,<br />
it was considered to be not only the largest<br />
green field investment in the history<br />
of Hungary up to that point (value: 1.9<br />
billion euros), but also the largest EV<br />
battery plant in Europe. Although the factory<br />
buildings are ready and production<br />
is expected to start soon, various works<br />
are still remaining around the plant, such<br />
as the construction of road and industrial<br />
railway connections, and setting up service<br />
infrastructure. When operating at<br />
full capacity (expected from mid-<strong>2024</strong>,<br />
although the plant’s full completion is<br />
only scheduled for 2028), the plant will<br />
provide an annual production output of<br />
30 GWh, with a workforce of 2500 people.<br />
SK Innovation has ambitious plans<br />
to increase its global annual production<br />
output to 125 GWh by 2025 and to 500<br />
GWh by 2030, in which they assign a<br />
large role to their Hungarian manufacturing<br />
capacities, along with their facilities<br />
in South Korea, China and the United<br />
States. SK Innovation’s Hungarian plants<br />
were also involved in some safety issues:<br />
in June 2023, dozens of workers experienced<br />
sickness during the construction<br />
of the Iváncsa plant after inhaling an unknown<br />
chemical. This incident was also<br />
widely reported in the local media.<br />
26<br />
27
AUTOMOTIVE<br />
#CATL #BYD # EVEPOWER #SUNWODA<br />
Left , the assembly of CATL batteries on some commercial vehicles.<br />
Above, SK Innovation’s current plant in Hungary. Another plant is<br />
under construction.<br />
CATL<br />
The largest EV battery maker of the<br />
world for six consecutive years by now<br />
(according to the 2022 report of the SNE<br />
Research market research and consultant<br />
company from South Korea), CATL is<br />
a well-known supplier of many electric<br />
cars and buses worldwide. The Chinese<br />
industry giant is also considered to be<br />
one of the most important companies in<br />
the Hungarian economy in the future.<br />
Although not operating yet, it is already<br />
decided and officially announced that<br />
CATL will establish a huge battery cell<br />
manufacturing plant in Debrecen, the<br />
second most populous city of Hungary.<br />
This will be the second battery manufacturing<br />
base of the company outside<br />
China, after commissioning the first such<br />
unit in Erfurt, Thuringia, Germany. The<br />
project, which is the biggest greenfield<br />
investment to date in Hungary with its<br />
total value of 7.34 billion euros, enjoys<br />
great support from the Hungarian government,<br />
in order to create an estimated<br />
9,000 jobs locally. According to the available<br />
industry news, CATL’s Debrecen<br />
plant will produce NMC cells in prismatic<br />
and cylindrical format. Production<br />
output in the first phase will be an impressive<br />
40 GWh/year, with plans already announced<br />
to increase it to even 100 GWh/<br />
year in the near future. Trial production<br />
is planned to start at the beginning of<br />
2025. Modules and cells produced at the<br />
Debrecen factory will appear in electric<br />
models of approximately 30 different car<br />
manufacturers, including BMW, Daimler,<br />
Volkswagen, Toyota, Volvo and Tesla.<br />
CATL traction batteries are also widely<br />
used by e-bus manufacturers, among<br />
others the world’s largest bus and coach<br />
manufacturer Yutong and the Hungarian<br />
brand Ikarus.<br />
BYD<br />
An internationally well-known and respected<br />
Chinese company, BYD has<br />
special connections in Hungary. Its already<br />
mentioned bus assembly plant in<br />
Komárom started operations in 2017,<br />
and now is the only foreign-owned bus<br />
factory in the country which has a huge<br />
heritage in bus and coach manufacturing.<br />
BYD is also the current leader of the<br />
local e-bus market, but buses will not be<br />
the only vehicles that roll off the production<br />
lines in Hungary with the company’s<br />
logo. On December 22, 2023 it was officially<br />
confirmed that BYD will build up<br />
its first European electric passenger car<br />
assembly plant in the city of Szeged, in<br />
the south-eastern corner of Hungary. Last<br />
but not least, BYD’s battery business<br />
branch also plans to establish a manufacturing<br />
unit in the country, namely at<br />
Fót, in the north-eastern agglomeration<br />
of Budapest. It is important to note that<br />
unlike the previously mentioned EV battery<br />
makers, BYD would not manufacture<br />
battery cells in Hungary, but would<br />
establish an assembly plant for battery<br />
packs, without the use of harmful chemicals.<br />
When officially announcing the<br />
new plant’s arrival in June 2023, Péter<br />
Szijjártó, Minister of Foreign Affairs<br />
and Trade of Hungary stated that the total<br />
value of the investment is 10 billion<br />
HUF (nearly 27 million euros), with a<br />
financial support of 1 billion HUF from<br />
the Hungarian government. The initial<br />
plans include a workforce of 100 people.<br />
The battery modules and packs would be<br />
assembled from cells based on LiFePO4<br />
chemistry, which themselves would<br />
come to Fót from other facilities of BYD.<br />
The Hungarian-assembled batteries are<br />
intended for use in various electric vehicles,<br />
including e-buses. However, neither<br />
the exact vehicle types, nor the factory’s<br />
planned production output has been confirmed<br />
yet.<br />
EVE POWER<br />
In May 2023, another major battery<br />
industry investment was officially announced<br />
in the Hungarian media: EVE<br />
Power, another powerful Chinese participant<br />
of the EV battery industry, will establish<br />
its first European production plant<br />
in Debrecen. It will supply 6 th -generation<br />
cylindrical lithium-ion battery cells, most<br />
probably in a 4695 format, for the future<br />
BMW battery module assembly plant located<br />
also in the same city, with a massive<br />
production capacity of 28 GWh/year. The<br />
total value of the investment exceeds 1<br />
billion euros (from which 37.5 million<br />
euros come from the Hungarian government<br />
as financial support). The factory is<br />
expected to start operating in 2026, with a<br />
workforce of more than 1000 people.<br />
SUNWODA<br />
At the end of July – confirming the rumours<br />
that surfaced a few months before<br />
– Sunwoda also officially announced that<br />
it would build a new battery plant in Hungary.<br />
The Chinese company’s first European<br />
manufacturing unit will be built up<br />
at Nyíregyháza, a city in the north-eastern<br />
region of the country, with an initial investment<br />
of 245 million euros. However,<br />
in medium to long term this may increase<br />
to even nearly 1.5 billion euros, creating<br />
more than 1,000 jobs locally. The size of<br />
the planned production capacity and the<br />
type of battery cells to be produced have<br />
not yet been announced. Construction of<br />
28<br />
29
AUTOMOTIVE<br />
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According to Bloomberg (9 January <strong>2024</strong>): “Hungary will undertake<br />
a 700 billion forint ($2 billion) infrastructure development project in<br />
Debrecen that will help transform the country’s second-largest city<br />
into one of Europe’s biggest battery production hubs.”<br />
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the factory will start in <strong>2024</strong>, production<br />
is expected to begin at the end of 2025.<br />
Sunwoda is considered among the top 10<br />
EV battery manufacturers in the world<br />
based on market share, and is a supplier<br />
of Volkswagen, the Renault-Nissan<br />
group and Dongfeng, among others.<br />
However, customers of the products to<br />
be manufactured in Hungary have not yet<br />
been named, it was only communicated<br />
that the new plant will work for the “international<br />
market”.<br />
LOW-VOLTAGE BATTERY<br />
Apart from the industry-flagship traction<br />
batteries, producers of low-voltage<br />
starter batteries also enjoy considerable<br />
support from the Hungarian government.<br />
Japanese battery manufacturer GS Yuasa<br />
opened its first European factory in Miskolc,<br />
north-eastern Hungary in 2019,<br />
where 12V automotive lithium-ion batteries<br />
are produced. The initial production<br />
capacity of 500,000 units/year is planned<br />
to be increased soon, but the company’s<br />
future vision also includes installation of<br />
lithium-ion cell manufacturing process in<br />
the plant. Jász-Plasztik – which is an exception<br />
in the sea of the Far Eastern companies,<br />
since it is a Hungarian-owned<br />
firm – also received state financial support<br />
in recent years to increase its production<br />
capacity.<br />
SUPPLIERS<br />
As mentioned before, not only the main<br />
cell and battery manufacturers, but also<br />
many supplier companies are already<br />
present in Hungary with manufacturing<br />
capacities, producing vital components<br />
of EV batteries. Just to list a few: cathode<br />
material (EcoPro, Huayou Cobalt, Toyo<br />
Ink), electrolyte (Soulbrain), separator<br />
film (LG Toray, Semcorp, W-Scope),<br />
aluminium and copper foil (Lotte Aluminium<br />
and Volta Energy Solutions/<br />
Doosan, respectively), housing (NICE<br />
LMS, Sangsin) and various other battery<br />
parts (Bumchun Precision, HALMS,<br />
INZI Controls, Mektec, Sang-A Frontec,<br />
Shenzen Kedali, Shinheung SEC), while<br />
recycling industry is represented by companies<br />
like Dongwha Electrolyte, JWH<br />
and SungEel Hitech.<br />
To sum up, the building up of the new<br />
industry is well on its way in Hungary,<br />
ensuring that the country is committed to<br />
green mobility not only for environmental<br />
considerations, but also for economic<br />
reasons. The number of the settled companies<br />
is expected to increase even more<br />
in the near future, for example there are<br />
rumours about the possible arrival of<br />
Hangke Technology, another EV battery<br />
industry player from China.<br />
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kind of vanguard of electrification<br />
in the agricultural and construction<br />
sectors.<br />
The CLAAS Scorpion range of telescopic<br />
handlers is manufactured by<br />
Liebherr. At Agritechnica Claas introduced<br />
its first battery-electric model,<br />
built based on the chassis of the smallest<br />
among Scorpion internal combustion<br />
models. The Scorpion 732e<br />
uses two independent 90kW electric<br />
motors, a 64kWh modular battery that<br />
can run up to 4 hours and a 22kW onboard<br />
battery charger to provide for<br />
a maximum traction power of 53 kN<br />
and a maximum speed of 30 km/h. It<br />
can reach a max lifting height of 6930<br />
mm and it can handle up to 3200 kg of<br />
100% electric<br />
models are<br />
carving their place<br />
among telescopic<br />
handlers. The major<br />
manufacturers’<br />
offers in a nutshell:<br />
the challenge is<br />
playing out in the<br />
compact models<br />
arena but technology<br />
is ready for higher<br />
classes. Claas,<br />
Dieci, Faresin, JCB,<br />
Kramer, Manitou,<br />
Merlo<br />
weight. The size is the same as its internal<br />
combustion counterpart, so not<br />
exactly compact, with a width of 2380<br />
mm and a height of 245 mm.<br />
After the launch of DIECI Agri Farmer<br />
Hybrid – powered by a Kubota<br />
hybrid engine – Dieci pulled out the<br />
Mini Agri-e, a compact-sized full<br />
electric telescopic handler equipped<br />
with a battery pack that can be expanded<br />
in the aftermarket, too, to adapt<br />
the unit to its operational requirements.<br />
Basically, the Mini Agri-e can<br />
be fitted with one or two lithium batteries<br />
that can also be inserted at the<br />
worksite, for a maximum output of<br />
up to 44kWh – enough power to complete<br />
a whole day’s work on a single<br />
charge. The maximum lifting height<br />
is 5680 mm, and the maximum load<br />
capacity is 2600 kg.<br />
In Hannover FARESIN introduced<br />
its FS Middle range featuring extendable<br />
booms ranging from 7 to 10 m<br />
in height with capacities from 3.5 to 4<br />
tons. There are four models available<br />
in 6 versions powered by a 4-cylinder<br />
Stage V Deutz with a 75, 102, 115 and<br />
136 hp power output. The Full Electric<br />
range has been including the compactsized<br />
6.26 model for a long time now,<br />
and as many as three Big Range models<br />
– 14.42, 17.40 and 17.45, whose<br />
lifting height can reach up to 17 m,<br />
designed with the construction sector<br />
in mind. Figures speak volumes: the<br />
6.26 can haul 2600 kg up to 6 metres,<br />
the other three can lift 4200, 4000 and<br />
4500 kg, respectively, up to a height of<br />
14 and 17 metres. The 6.26 (featuring a<br />
capacity of 2600 kg and a lifting height<br />
of 5.9 metres) was the first Full Electric<br />
telescopic handler to go into mass<br />
production. It works with an 80 V,<br />
24kWh battery but 32 or even 43kWh<br />
battery are also optionally available. It<br />
features 5 charging systems: integrated<br />
(standard), integrated rapid, external<br />
rapid, external three-phase, for charging<br />
in 3 hours with built-in rapid charger<br />
and autonomy up to 10 hours with<br />
a larger battery with interrupted cycle.<br />
The transmission with the 30kWh<br />
electric motor allows transfers as fast<br />
as 12 km/h, while the hydraulic system<br />
has an 80 l/min gear pump.<br />
JCB has long been engaged in developing<br />
carbon neutral solutions, so while<br />
designing a hydrogen powered engine<br />
for more powerful units it definitely<br />
aims at going electric with compact<br />
models. Alongside its 525-60E, a telescopic<br />
handler model featuring 2.5<br />
tons of capacity and a max lift height<br />
of 6 metres, JCB is making available a<br />
small forklift with telescopic arm – the<br />
Teletruk 30-19E that’s now joined by<br />
the 35-22E introduced at Agritechnica.<br />
Powered by a 24kWh lithium-ion<br />
battery – enough for a full day’s work<br />
– the 525-60E offers 110 V, 230 V and<br />
415 V charging capability and it’s also<br />
fast-charge ready. Moreover, it can be<br />
equipped with LiveLink telematics<br />
using satellite technology to provide<br />
real-time data on machines’ location,<br />
performance, utilization, security and<br />
need for maintenance; also, it features<br />
adaptive load control to automatically<br />
prevent the machine from tipping<br />
forwards. The Teletruks are powered<br />
by a heavy-duty lead-acid battery and<br />
can reach a max lift height of 4 metres.<br />
Their maximum lift capacity is 3000<br />
32<br />
33
OFF-HIGHWAY<br />
#KRAMER #MANITOU #MERLO<br />
Left to right, Claas, Faresin, Manitou.<br />
Above, Kramer.<br />
ELECTRIC TIMES FOR COMPACT TH<br />
and 3500 kg, respectively. To increase<br />
autonomy, the unit’s acceleration<br />
can be reduced by 10, 20 or even 30%<br />
pressing a specially provided “eco”<br />
button right from the cab.<br />
KRAMER – actually an “arm” of<br />
John Deere – took the opportunity<br />
of being at Agritechnica to add to<br />
their list the KT144e compact model<br />
equipped with a 96 volt 18 or<br />
28kWh lithium-ion battery; based on<br />
the unit’s setup, it allows for up to 4<br />
hours of work with no need to charge<br />
it halfway through the work session.<br />
The onboard 6kW battery charger<br />
allows for fast charging. Less than<br />
2 metres high and slightly less than<br />
1.60 m in width, this is one of the less<br />
bulky machines available, with a stacking<br />
payload of 1450 kg and a lift<br />
height of 4.3 m. Hydraulics feature a<br />
42l/min pump and the unit can move<br />
up to a speed of 25 km/h.<br />
MANITOU chose Agribex – held on 6<br />
to 10 December 2023 in Brussels – for<br />
a premiere of the group’s first electric<br />
telehandler designed for the agricul-<br />
tural market. It’s the MLT 625e, also<br />
included in the compact class, with a<br />
max capacity of 2.5 tons and a max<br />
lift height of 6 metres. The lithiumion<br />
battery is 25 kWh and thanks to<br />
an integrated 9kW charger it can be<br />
charged in as little as 3 hours from a<br />
380 V socket. The machine can adapt<br />
to fit existing electrical infrastructures<br />
BRAND<br />
MODEL<br />
CLAAS<br />
SCORPION 732E<br />
DIECI<br />
MINI AGRI E 26.6<br />
FERESIN<br />
6.26 FULL ELECTRIC<br />
JCB<br />
525-60E<br />
KRAMER<br />
KT 144E<br />
MANITOU<br />
MT 625E<br />
MERLO<br />
EW 25.5-90<br />
Max load kg 3200 2600 2600 2500 1450 2500 2500<br />
Max lifting height mm 6930 5680 5900 6000 4301 5850 4800<br />
Max reach mm 4100 3200 3200 3300 2289 3400 2600<br />
Battery kWh 64 22 - 44 24 - 32 - 43 24 18 - 28 25 74<br />
Lenght on the fork mm 4752 4125 4035 4000 2997 3830 3320<br />
Width mm 2380 1840 1890 1840 1564 1810 1540<br />
Height mm 2465 1915 1935 1890 1995 1920 1975<br />
Wheelbase mm 2750 2350 2525 2.390 1992 2300 2100<br />
Mass kg 7585 5100 4800 5.145 3050 4800 4950<br />
and it can be charged using a standard<br />
domestic socket. In standard mode, it<br />
provides for up to 4 hours of uninterrupted<br />
operation. A regeneration system<br />
gets engaged when the accelerator<br />
pedal is released to recover energy<br />
during deceleration so as to increase<br />
the unit’s autonomy. A boost mode is<br />
available in series that can be enabled<br />
from a dashboard-mounted button,<br />
speeding up the hydraulic movements<br />
and reaching the max transfer speed<br />
(26 km/h) in a very short time.<br />
MERLO, for now, it’s only working<br />
on a concept – a simple exercise in<br />
style, for the time being – created to<br />
explore and develop their future electric<br />
range at best. We’re talking about<br />
model TFe 43.7 – derived from the<br />
Turbofarmer range. As is clear from<br />
the model name, the lifting capacity<br />
is 4300 kg, while 7 metres is the max<br />
height that can be reached. The current<br />
Merlo product list already includes<br />
the e-Worker, two models fitted with a<br />
lead acid battery pack and 2- or 4-wheel<br />
drive. The 4-wheel drive 25.5-90 is<br />
the one made for agricultural applications,<br />
with a 2500 kg max capacity and<br />
a 4.8 m lifting height. The e-Worker<br />
only steers on the rear wheels, like lift<br />
carriers with forks, reaching a steering<br />
angle of 85 degrees, which offers an<br />
outstanding manoeuvrability. The machine<br />
is fitted with a 42l/min helical<br />
gear pump controlled by a capacitive<br />
electronic joystick that controls up to<br />
three simultaneous movements. Max<br />
transfer speed reaches 25 km/h; wheelmounted<br />
electric motors can recover<br />
and store braking energy to increase<br />
the machine’s efficiency.<br />
34<br />
35
OFF-HIGHWAY<br />
#COMERINDUSTRIES #AGRITECHNICA #CARDANSHAFT<br />
COMER INDUSTRIES<br />
ELECTRIFYING<br />
AGRICULTURE<br />
Above. The e-742 transmission is designed to equip hose reel<br />
irrigators with integrated motor pump or water turbine and<br />
it is engineered to optimize all irrigation phases.<br />
At Agritechnica 2023 Comer Industries<br />
presented a selection of<br />
its latest solutions for tractors,<br />
implements and harvesting machines<br />
developed to provide answers<br />
to its customers in the agricultural sector.<br />
We asked some questions to Paolo<br />
Negri, General Manager e-comer, and<br />
Jacopo Spaggiari, Business Development<br />
Manager, Sales & Marketing.<br />
How is the integration with Walterscheid<br />
proceeding, starting from the<br />
PWE480 cardan shaft?<br />
Negri: “The integration is progressing<br />
well, it hasn’t been easy, but now we<br />
have reached a good level of clarity on<br />
all points, also with regard to the cardan<br />
shaft that we present here, which is the<br />
first product created, and represents a<br />
mix of the best of the two brands.” The<br />
PWE480 shaft features an improved<br />
hexalobate profile of the tube, which<br />
guarantees perfect operation and higher<br />
performance for high-speed applications,<br />
satisfying the demanding market<br />
requirements typical of round balers.<br />
The new shaft also incorporates a new<br />
overrunning device embedded directly<br />
in the cut-out clutch: this innovation<br />
guarantees a more compact design.<br />
An overview of the updates relating<br />
to the cardan shafts that you are presenting<br />
at this fair.<br />
Spaggiari: “We decided to give some<br />
space to the world of tractors by presenting<br />
two innovations regarding the<br />
cardan shafts with the two different<br />
brands, Walterscheid and Mechanics<br />
Driveshafts. The first novelty is represented<br />
by the new size of the 7C family<br />
under the Mechanics Driveshafts<br />
brand, dedicated to high-power trac-<br />
tors (above 250 hp). It is a cardan shaft<br />
(the 7C) which has some characteristics<br />
that make it particularly interesting<br />
because we have equipped it with a service-free<br />
cross kit.” The new 7C-FS is a<br />
longitudinal shaft that transfers propulsive<br />
power from the main central transmission<br />
to the front axle, suitable for<br />
the most demanding applications for<br />
heavy tractors: this high-performance<br />
cardan shaft is capable of transmitting<br />
up to 10,500 Nm, is suitable for the size<br />
of category 4 machines, it can accommodate<br />
a maximum intermittent articulation<br />
angle of 25° and is equipped with<br />
the “Next Generation” cross kit.<br />
Spaggiari: “The second product that we<br />
are introducing is the new longitudinal<br />
cardan shafts series for the smaller<br />
tractor categories, below 100-150<br />
horsepower. The 687.18 Cardan Shaft<br />
perfect electric, waterproof and interchangeable<br />
alternative to hydraulically<br />
operated gearboxes.<br />
Regarding this new series, Negri comments:<br />
“Obviously integrating the electric<br />
motor inside the mechanical part<br />
is not always easy but it's beneficial<br />
for reducing overall dimensions and<br />
increasing the efficiency. The impact<br />
of this technology is naturally very<br />
high.” The spotlight in this edition was<br />
focused above all on the synergy and<br />
co-design between Comer Industries<br />
and the e-comer R&D department with<br />
the preview of the e-742 transmission<br />
dedicated to hose reel irrigators with<br />
motor pump or hydraulic turbine.<br />
Which types of pumps is the e-742<br />
transmission associated with exactly?<br />
You are talking about a 10% reduction<br />
in consumption due to greatis<br />
on exhibit, transmitting up to 3,500<br />
Nm, and representing most of the key<br />
features of this new range, like flanged<br />
version, service free length compensation,<br />
modular and flexible design.”<br />
The latest electric innovation from<br />
e-comer exhibited at Agritechnica, the<br />
new WD220 Series, is an “all-in-one”<br />
integrated electric transmission: ideal<br />
for the constantly growing sector<br />
of self-driving agricultural machines<br />
(also called AgBot) or for harvesting<br />
and multipurpose machines. This new<br />
product combines a two-stage planetary<br />
gearbox with an internal permanent<br />
magnet motor from the e-comer<br />
SMAC series, capable of delivering<br />
high torque and meeting the long-life<br />
performance expectations of the machine,<br />
as tested on some machines<br />
already operating in the field; it is the<br />
er efficiency. Technically, how did<br />
you achieve this result?<br />
Spaggiari: “The e-742 transmission is<br />
designed to equip hose reel irrigators<br />
with integrated motor pump or water<br />
turbine and it is engineered to optimize<br />
all irrigation phases, from hose-rewinding<br />
to remote speed management,<br />
as well as automatic decoupling of the<br />
power transmission, therefore it aims<br />
to combine the operator’s safety with<br />
a reduction in the operator’s engagement<br />
times because with the use of the<br />
electric motor we have eliminated the<br />
need of gear shifting, thus significantly<br />
reducing the direct intervention of the<br />
operator, in other words we have been<br />
working on the overall improvement<br />
of the transmission efficiency and consequently<br />
on the efficiency of all field<br />
operations.”<br />
36<br />
37
COMPONENTS<br />
#MTA #STMICROELECTRONICS #NEWHOLLAND #DEUTZFAHR<br />
MTA @AGRITECHNICA<br />
SMART<br />
UNITS<br />
MTA AND STMICROELECTRONICS<br />
MTA and STMicroelectronics are cooperating on the<br />
evolution of the electrical and electronic architecture<br />
of agricultural machinery. The first product of this<br />
collaboration is the Smart Fuse Box, an intelligent control<br />
unit using ST electronic fuses, the STi2Fuse. Developed for<br />
off-highway applications, it can be used to drive, protect,<br />
diagnose and monitor up to 30 electrical or electronic<br />
loads through the STi2Fuse and interface analogue/<br />
digital signals and loads via the vehicle’s CAN network.<br />
The STi2Fuse is ST’s new family of smart electronic fuses.<br />
Compared to conventional fuses, STi2Fuse are resettable<br />
and have 100 times faster intervention times. A feature<br />
of STi2Fuse is that the rated current and the tripping<br />
curve are programmable and the nominal current is<br />
optimised according to the load and not the size of the<br />
fuse. This aspect leads to an optimisation of the wiring<br />
size. The STi2Fuse Smart Fuse Box combines both fuse<br />
and relay function in one unit. The system diagnostics<br />
allow “health monitoring” and “predictive maintenance”<br />
algorithms to be set up. The hardware and software<br />
architecture of the Smart Fuse Box is also designed to<br />
meet the most stringent Functional Safety and Cyber<br />
Security requirements.<br />
In Hannover, MTA focused on<br />
power electronics. The acquisition<br />
of all shares in EDN, specialised<br />
in the development of OBCs<br />
(On-board Battery Chargers) and DC/<br />
DC converters for electric and hybrid<br />
vehicles, enabled MTA to articulate<br />
and detail its strategy for the electrification<br />
of vehicle platforms. The<br />
synergetic work in terms of research<br />
and development, logistics and business<br />
relations between MTA and EDN<br />
made it possible to develop projects<br />
with off-highway machine manufacturers.<br />
The stand we saw at Agritechnica<br />
featured a display area, with dedicated<br />
graphics, of OBCs. The latest<br />
OBCs introduced to the market are<br />
the BHP22, designed for the European<br />
market, and the BHP19, aimed<br />
instead at the North American basin.<br />
MTA has placed<br />
emphasis on power<br />
electronics, also<br />
due to the synergy<br />
with EDN. With New<br />
Holland and with<br />
SAME Deutz-Fahr,<br />
among others, the<br />
Italian company is<br />
involved in the control<br />
panels business. With<br />
STMicroelectronics<br />
for electrical and<br />
electronic technology<br />
for agricultural<br />
machinery<br />
Common features are bi-directionality<br />
and high resistance even in difficult<br />
environmental conditions. Finally,<br />
they are designed with a conversion<br />
technology that improves power density<br />
and specific power. One of MTA’s<br />
winning features are the High Voltage<br />
and 48V architectures, as well as the<br />
availability of products such as fuses<br />
and fuse holders, power distribution<br />
units and connectors. The OBCs and<br />
DC/DC converters offered by the<br />
power electronics division are marketed<br />
under the EDN brand and manufactured<br />
in the production facility in<br />
Cinisello Balsamo (Italy). In the factory<br />
on the outskirts of Milan, production<br />
has been increased and research<br />
and development expanded to meet<br />
the rapidly growing curve of demands<br />
from the global market. In front of<br />
the audience of agricultural mechanisation<br />
professionals, there was also<br />
room for MEC 97, Maxi-MEC and<br />
C-MEC 138, electrical power distribution<br />
and utility protection units<br />
made specifically for agricultural applications,<br />
as well as earth-moving<br />
applications, which can be defined as<br />
“smart” thanks to a new CAN Plugin<br />
module. They are all plug & play<br />
modular control units, made with Pcb<br />
and press-fit technology, in order to<br />
customise the content of fuses and<br />
relays and the wiring diagram to the<br />
customer’s distinct specifications.<br />
MEC 97 and Maxi-MEC are designed<br />
for the engine compartment, while<br />
C-Mec 138 is designed for in-cab installation;<br />
they are compact in size and<br />
allow all functions to be integrated in<br />
a single unit, eliminating the need for<br />
several modules and associated wiring.<br />
The CAN Plug-in module, which<br />
is capable of driving the relays of the<br />
3 MEC ECUs, connects them to the<br />
vehicle’s CANbus network. Through<br />
this network, the module transmits<br />
commands to generate the necessary<br />
actuations, as well as conveying diagnostic<br />
information. Just like the<br />
customisable control panels, displays<br />
and electronic control units offered by<br />
MTA, the Can Plug-in module can be<br />
programmed thanks to MTA Studio, a<br />
proprietary software tool that allows<br />
even the less experienced ones to customise<br />
all products, both off-the-shelf<br />
and custom. There is also a lot at stake<br />
for tractor cabs. The switch control<br />
panel is aimed at New Holland specialists.<br />
It supervises certain functions<br />
via the CAN network. The 10 MTA<br />
buttons are used to manage headland<br />
manoeuvres, suspension or front and<br />
rear hitch control, and status LEDs to<br />
show the actual activation of controls.<br />
It is designed with an IP54 degree of<br />
protection to operate in the hostile environments<br />
typical of the agricultural<br />
sector, and it is characterised by its<br />
small size, which facilitates its placement<br />
in the cab next to the armrest. For<br />
SDF, there is the MLC control panel<br />
for some open field and specialised<br />
tractors. In the same shape and size as<br />
the previous version, also by MTA, it<br />
has been thoroughly revamped. At the<br />
centre of the MLC is the 3.5-inch colour<br />
TFT, the heart of the user interface,<br />
the layout of which can be configured<br />
at the SAME and Deutz-Fahr plants at<br />
the end of the assembly line by sending<br />
specific CAN messages.<br />
38<br />
39
OFF-HIGHWAY<br />
#BOSCHREXROTH #SAFETY<br />
REXROTH @ AGRITECHNICA<br />
WATCHFUL<br />
AND DISCRETE<br />
EYE<br />
Bosch Rexroth continues its<br />
authoritative presidency of<br />
hydraulic and mechanical solutions,<br />
simultaneously penetrating<br />
the electrical, electronic and IT<br />
domains. Let’s start with hydraulics.<br />
The eOC (electronic Open Circuit)<br />
platform is enhanced by the A10VO<br />
60 series medium pressure axial piston<br />
pump, which is equipped with an<br />
integrated pre-pressure volume. This<br />
solution claims a 50% reduction in<br />
pressure pulsations. Power density<br />
has increased by 49%. The increase<br />
in pressure to 280 bar, combined with<br />
an optimised pump design, results<br />
in an installation length that is up to<br />
10% shorter. The rotating assembly<br />
has been reworked to further raise the<br />
bar for efficiency levels, both at part<br />
and full load. The eOC version of<br />
Bosch Rexroth<br />
explores all “sensory”<br />
dimensions<br />
of agricultural<br />
mechanisation, from<br />
mobile hydraulics<br />
to digitisation,<br />
automation and<br />
electrification. From<br />
the eOC platform, to<br />
Bodas Connectivity’s<br />
over-the-air firmware<br />
system for radar-based<br />
collision protection<br />
the A10VO 60 was developed with a<br />
reduced variance. The different controller<br />
types and mechanical settings<br />
are transferred to the software. The<br />
reduced pump variance allows OEMs<br />
to reduce stock levels and simplify the<br />
management of spare parts and aftermarket<br />
components. In addition to the<br />
eOC version, Rexroth now also offers<br />
the Series 60 A10VO in a version with<br />
classical pressure and flow control<br />
(DRS). Function updates are available<br />
for maintenance: software can be<br />
managed via the Bodas Service interface.<br />
With the FOTA system, over-theair<br />
firmware, Rexroth has accelerated<br />
the standardisation of remote update.<br />
The universal flasher is available as<br />
part of the device management for the<br />
Bodas Connectivity telematics package.<br />
Over-the-air flashing is simple<br />
and safe thanks to the Rexroth RCU<br />
telematics unit and a pre-integrated<br />
software stack with related services<br />
based on the Unified Diagnostic Services<br />
(UDS) CAN bus protocol. All<br />
third-party devices connected to the<br />
RCU via the CAN bus, such as engine<br />
control units or displays, are automatically<br />
displayed together with the<br />
Rexroth units in the web-based frontend<br />
of the Bodas Connect Device Portal.<br />
Compliance with the UDS CAN<br />
bus protocol ensures that the sequences<br />
executed correspond to current<br />
safety mechanisms. The RCU acts as<br />
a secure gateway between the cloud<br />
and the vehicle. To ensure the continuous<br />
availability of the machine, the<br />
firmware is first transferred in its entirety<br />
to the robust RCU. After authorization,<br />
the target device is updated in<br />
the vehicle via the CAN bus through<br />
a wired connection. By connecting to<br />
the open telematics ecosystem, Bosch<br />
Rexroth is gradually extending the<br />
benefits of previous OTA services to<br />
third-party devices. The skills of German<br />
engineering do not include only<br />
the material and immaterial architecture<br />
of the vehicle. At Agritechnica,<br />
with the radar-based collision warning<br />
system, Bosch Rexroth revealed<br />
a complete solution for off-highway<br />
vehicle safety, from hardware to control<br />
system. The components include<br />
automotive radar sensors from Bosch<br />
adapted for the operating environment<br />
of industrial mobile applications, with<br />
its different surfaces such as grass,<br />
gravel and asphalt, to detect collision<br />
dangers at an early stage. Other elements<br />
include Bosch’s MM7.10 iner-<br />
tia sensor, a Rexroth controller (e.g.<br />
RC 40 small) and adaptable software<br />
modules. Using the steering angle<br />
and speed of the vehicle, it calculates<br />
the expected travel path and classifies<br />
the detected objects according to the<br />
probability of collision. If a collision<br />
is imminent, the system suppresses<br />
any acceleration by the operator and<br />
reduces vehicle speed via the hydrostatic<br />
travel control. With the Rexroth<br />
drive controller, the drives are already<br />
“radar ready”. The system can be used<br />
in both directions of travel or in one<br />
direction only. The “security package”<br />
is prepared for future integration with<br />
an ultrasound system or video camera.<br />
Environmental interference can be detected<br />
both at close range and at low<br />
speed, and at greater distances and higher<br />
speeds.<br />
40<br />
41
COMPONENTS<br />
#FPTINDUSTRIAL #NEWHOLLAND #SAMEDEUTZFAHR<br />
UFI FILTERS @AGRITECHNICA<br />
ALL<br />
TOGETHER<br />
NOW<br />
UFI Filters Hydraulics turned<br />
up at Agritechnica alongside<br />
the Aftermarket division.<br />
They provided FPT Industrial’s<br />
Cursor 16 TST – driving the Case<br />
IH Quadtrac 715 AFS Connect – with<br />
their blow-by filter, which is a rotary<br />
and self-cleaning filter, developed<br />
with a multi-layer filtering media<br />
made of synthetic fibres – FormulaU-<br />
FI.Micron – and a metallic mesh to<br />
ensure its full operation over time.<br />
As for their partnership with FPT, we’ll<br />
mention the F28 (Diesel of the Year<br />
2020). The filter and diesel pre-filter<br />
are assembled in a single aluminum<br />
die-cast support and combine the<br />
function of the priming pump, heater,<br />
temperature and water presence sensor.<br />
The engine is mainly intended for<br />
agricultural applications, such as the<br />
All time debut in<br />
Hannover for the<br />
Aftermarket division,<br />
hand in hand with UFI<br />
Filters Hydraulics.<br />
There was plenty of<br />
testimonials to UFI’s<br />
penetration into the<br />
agricultural sector,<br />
from New Holland to<br />
SAME Deutz-Fahr<br />
and Carraro Tractors.<br />
Most remarkable,<br />
its presence among<br />
specialized tractor’<br />
filtering systems<br />
Carraro Agricube Pro range of specialised<br />
tractors. These electrical sensors<br />
are therefore essential to guarantee the<br />
four-cylinder engine’s operation, even<br />
during the coldest months. The priming<br />
pump is useful when replacing the<br />
filtering element, to correctly refill the<br />
circuit with fuel.<br />
The pre-filter plays a central role in<br />
filtering the coarsest particles and performs<br />
the primary function of separating<br />
water from fuel. This is why it is<br />
equipped with a liquid presence sensor<br />
that tells when it is time to empty<br />
the separated water with a purge tap<br />
incorporated in the sensor. It also has<br />
a mixed cellulose and synthetic filter<br />
media, developed by UFI according<br />
to its FormulaUFI.H2O material specifications,<br />
with a water separation capacity<br />
of more than 95% according to<br />
ISO 16332 and a filtration capacity that<br />
allows to block more than 98% of particles<br />
larger than 20 microns. Thus, it<br />
provides for a replacement interval of<br />
up to 600 working hours. The filter relies<br />
on the same filtration formula, but<br />
has a fine filtration function, with a separation<br />
capacity of more than 95% for<br />
particles up to 4μm, according to ISO<br />
19438. Now switching to agricultural<br />
machinery manufacturers, UFI makes,<br />
amongst others, filters and pre-filters<br />
for New Holland, made with the<br />
FormulaUFI.H2O filtration material.<br />
There are also layered oil filters, such<br />
as FormulaUFI.Stratiflex, and synthetic<br />
fibre filters such as FormulaUFI.<br />
Micron. Lastly, the self-cleaning and<br />
panel rotary blow-by filter range. At<br />
Agritechnica UFI Filters Hydraulics<br />
also brought its new FRI series, a tank<br />
filtering solution for return lines; the<br />
FPO pressurized spin-on filter series<br />
with Fortimax element; the eco-friendly<br />
version of the UOW mobile filtration<br />
unit, with coreless element; and the differential<br />
clogging indicator with double<br />
calibration. The FRI series features a<br />
tank-integrated layout and is available<br />
in four sizes, with connection options<br />
from 1/2” to 1”1/4, for flow rates up<br />
to 150 l/min. The FPO series belongs<br />
to the big spin-on family that includes<br />
complete filters and screw-on elements<br />
for hydraulic systems on suction, return<br />
and pressure lines with filtration from<br />
90 microns up to 5 absolute microns<br />
and flow rates up to at 300 l/min. The<br />
main feature of spin-on filters is the<br />
easy and quick replacement of the used<br />
cartridge. They are typically mounted<br />
in-line on hydraulic circuits with maxi-<br />
mum working pressure up to 35 bar and<br />
flow rates up to 200 l/min. The UOW<br />
off-line mobile filtration unit is used<br />
for cleaning the fluid offline, as well<br />
as for the transfer, filling and topping<br />
up of the oil tank. The filter element is<br />
available with FormulaUFI. micron,<br />
from 5 to 21 μm(c) (ßx > 1.000) and<br />
FormulaUFI.H2O. The differential indicator<br />
with double setting and built-in<br />
connector allows to adjust the setting.<br />
Version 1 has a lower double setting –<br />
1.5 bar (75%) and 2 bar (100%) – while<br />
Version 2 features higher values, 3.75<br />
bar (75%) and 5 bar (100%). It can be<br />
mounted on all filters from the UFI Filters<br />
Hydraulics range, mainly pressure<br />
and return filters, up to a maximum<br />
operating pressure of 450 bar, with an<br />
IP67 protection class and a differential<br />
measuring range from 2 to 10 bar.<br />
42<br />
43
OFF-HIGHWAY<br />
#ABB #MINING #ELECTRIFICATION<br />
ABB AND ELECTRIFICATION<br />
FOR<br />
MINING<br />
TOO<br />
ENERGY EFFICIENCY MOVEMENT<br />
During his speech, Roberto Diana advocated joining the<br />
Energy efficiency movement, an initiative promoted by<br />
ABB. What is it about? The manifesto reads: In order to<br />
bring about change, all stakeholders must work together<br />
to adopt and promote available solutions and continue<br />
to innovate to achieve more. We need to invest in<br />
sectors that help mitigate climate change and we need<br />
governments to provide supportive regulations and incentives.<br />
To promote greater energy efficiency at scale,<br />
we need certain conditions to occur. Academia must<br />
intensify research and provide scientific data to inform<br />
decision-making. Technology companies must continuously<br />
innovate on new applications and case histories to<br />
accelerate energy efficiency improvements. Public decision<br />
makers and government regulators must incentivise<br />
the rapid adoption of the most energy efficient solutions<br />
and technologies. Companies, cities and countries must<br />
be aware of the environmental savings and benefits and<br />
be willing to make the necessary investments. Investors<br />
must reallocate capital towards companies that are<br />
better prepared to deal with climate risk. Other actors<br />
(NGOs, politicians, media, individuals) must use, support<br />
and amplify energy efficiency measures.<br />
Power density? It is no longer a<br />
“low intensity” input, a function<br />
of the downsizing of combustion<br />
engines and the lack<br />
of space in the engine compartments,<br />
which are vampirized by aftertreatment<br />
systems. It is a necessity arising<br />
from peak load calibration and battery<br />
pack configuration. The power ratings<br />
are also an even more thoughtful matter.<br />
The modularity of cells is then the<br />
constitutive dimension of the architecture.<br />
Far from the redundancy of ICEs<br />
for CHP, for example, with the partitioning<br />
of loads according to demand.<br />
From this one can understand ABB’s<br />
physiological projection to system integrator<br />
status. As pointed out during<br />
the webinar on the electrification of<br />
mobile applications: “We start with<br />
the battery, converter and traction<br />
In its mission and<br />
“sentiment”, ABB has<br />
the skills to assist<br />
off-highway OEMs in<br />
converting to electric<br />
technology. Including<br />
mining players.<br />
A challenging horizon<br />
that ABB is capable<br />
of embracing with<br />
all elements of the<br />
electric fraction. They<br />
told us about it at an<br />
event dedicated to the<br />
electrification of heavyduty<br />
applications<br />
motors. What happens downstream of<br />
the traction motors is the responsibility<br />
of our partners, who are typically<br />
competent in the mechanical part.”<br />
Let’s give the floor to the speakers,<br />
starting with Roberto Diana, ABB<br />
Local Sales Manager, who introduces<br />
us to the electrification of traction systems.<br />
“Electric motors, the number of<br />
which will double by 2040, use around<br />
45% of the world’s electricity. Increased<br />
efficiency allows savings of up to<br />
10%”. Commenting on ABB’s contribution,<br />
Diana emphasises that: “We<br />
are flexible in terms of technical solutions,<br />
adapting to different systems<br />
and applications with limited effort,<br />
because our systems are modular. We<br />
are among the few in this field that can<br />
provide integrated systems, comprising<br />
converter, motor and batteries.<br />
On the traction system, we typically<br />
deal with power conversion. We have<br />
a family of inverters and DC/DC converters,<br />
traction motors, traction batteries,<br />
PLCs”.<br />
With Augusto Fusari, Application<br />
Manager, we dive into power conversion.<br />
“The HES880 is derived from an<br />
industrial inverter, on a chassis specifically<br />
designed for a vehicle application.<br />
IP67 protection, 4 Giga, shock<br />
up to 30 Giga, quadriface connectors.<br />
Liquid cooled (-40°C to +70°), it uses<br />
a CAN-bus and operates in a temperature<br />
range of -40° to +85°. With the<br />
same chassis, acting on software, we<br />
can have several functionalities. A<br />
DC/DC control on batteries or supercapacitors,<br />
motor control and a grid<br />
connection. We can also work offgrid,<br />
creating a grid with the desired<br />
frequency and voltage. This inverter<br />
is available in 3 sizes: 350A, 600A,<br />
900A peak, which are suitable for heavy<br />
vehicles. Here we present a typical<br />
configuration: on-board charger, an<br />
HSE880 with its own filter, which can<br />
be connected to a grid or have a DC/<br />
DC controlling battery charging and<br />
discharging. It is useful for batteries<br />
with a lower voltage than the DCBus.<br />
The inverter controls electric motors<br />
of all types, both permanent magnet,<br />
asynchronous and reluctance motors.<br />
A built-in chopper is available on this<br />
inverter. We are thinking of the new inverter<br />
generation, more compact and<br />
lighter, 300A current and 500A peak,<br />
high VdcBus voltage, 400 to 850 volts.<br />
AMXE motors are available in four sizes,<br />
132, 160, 200, 250, which do not<br />
differ in speed (the standard is 5,000<br />
rpm). They can range from 20 to 250<br />
kW and are segmented at 240, 500,<br />
900 and 1,500 Nm. The shock that is<br />
continuously withstood is 4G of vibration<br />
and for a shock we go up to 50G.<br />
As standard, the motors always have<br />
the resolver fitted, in order to have<br />
feedback and allow the inverter to<br />
work in closed loop, but with the ABB<br />
control we can also control the motor<br />
in open loop without any feedback”.<br />
Lorenzo Gambelli is Project Leader<br />
Engineer. He is in charge of narrating<br />
the energy storage systems. “ABB uses<br />
LTO technology. Inside the cell is an<br />
anode composed of lithium titanate<br />
oxide. It is not susceptible to thermal<br />
runaway, does not generate unstable<br />
phenomena, has a high power density<br />
and a higher number of loaddischarge<br />
cycles than other techno-<br />
44<br />
45
OFF-HIGHWAY<br />
#ENERGY #STORAGE #PROTECTION<br />
ABB CAPITAL MARKETS DAY 2023<br />
Volvo Group recently formed a new business area called Volvo<br />
Energy, which will focus on battery lifecycle and circularity. They<br />
are responsible for taking care of them in each step of their lifecycle<br />
and making sure the batteries are performing and recycled<br />
or remanufactured at the proper stage to recover the very<br />
valuable and rare raw materials. For example, Volvo Energy has<br />
a team involved in the development of charging and infrastructure<br />
solutions to help expand charging locations. They also have<br />
a team dedicated to monitoring and reporting on the state of<br />
charge (SoC) and state of health (SoH) of the batteries to determine<br />
how they’re performing and when they might need to<br />
be replaced — and if they do need to be replaced, where they<br />
go next. These two groups are focused on a battery’s “first life.”<br />
During a battery’s first life, Volvo’s intelligent battery management<br />
system protects the battery from excessive degradation.<br />
These systems ensure an optimal SoC, prevent extreme temperatures<br />
and optimize charging cycles. They continuously collect<br />
data and analyse it to further improve the battery’s performance<br />
throughout its life. This work helps EV owners and operators get<br />
optimal performance.<br />
Björn Rosengren, ABB CEO: “Our strong 2023 delivery was the result of both<br />
our leading market position in electrification and automation, as well as ABB<br />
being a more agile and efficient company in its execution. With our upgraded<br />
financial and sustainability targets we look to the future with confidence.”<br />
logies. It allows less degradation of<br />
the cell over time. Compared to LTO<br />
technology, Nmc has higher energy<br />
density, lower fast-charging and peak<br />
power handling performance, as well<br />
as fewer cycles. LTO batteries allow<br />
more charge and discharge cycles and<br />
less degradation of the cell’s intrinsic<br />
parameters”. Gambelli reiterates the<br />
concept of modularity and flexibility.<br />
“The single cell is our building block<br />
for all storage systems, which see integration<br />
at the sub-system level and<br />
increasingly complex integration at<br />
the high level”. We move on to BESS<br />
(Battery Energy Storage Systems).<br />
“The ABB 55V module integrates 48<br />
base cells and 2.5 kW of energy. These<br />
modules are made with the help of<br />
robots that organise the laser welding,<br />
in order to minimise human error and<br />
contamination from external agents.<br />
Then, there is the standard string,<br />
which integrates a certain number of<br />
variable modules, depending on the<br />
application. Finally, there is the possibility<br />
of integrating five strings, for<br />
customised designs. In the mechanical<br />
layout of a standard string, there are<br />
power interfaces. Power and signal<br />
interfaces interconnect the strings<br />
with other strings and also with external<br />
systems, to simplify high-level<br />
management and supervision of the<br />
entire ESS. Inside this string there are<br />
additional components: voltage sensors,<br />
power contactors, pre-charge<br />
contactors, protection fuses and the<br />
BMS unit, which monitors the status<br />
of the cells. With this type of data<br />
analysis, both in real time and postprocessing,<br />
it is possible to implement<br />
condition base maintenance activities<br />
on the entire fleet. To summarise: the<br />
chemistry used for the ABB cells guarantees<br />
a high level of intrinsic safety;<br />
high performance over an extended<br />
range of temperatures and extreme<br />
environmental conditions; the ability<br />
to charge and discharge the batteries<br />
at high power rates; and high durability”.<br />
With Giovanni Andrea Amodeo, Product<br />
Marketing Specialist, we move<br />
on to the cable protection system. “We<br />
have three families of risk factors: mechanical,<br />
environmental, and factors<br />
such as water, steam and other material<br />
or chemical agents that can enter the<br />
cable protection system. What does a<br />
cable protection system look like? There<br />
are four key elements. Corrugated<br />
conduits; joints or connectors; shells<br />
protecting the wiring interface, corrugated<br />
conduit and actual connector;<br />
modular supports that help us in the<br />
orderly distribution of wiring inside<br />
the machine. ABB’s Harnessflex Evo<br />
system is the only one on the market<br />
specifically dedicated to heavy-duty<br />
electrically-driven vehicles, protecting<br />
the complete system from connector<br />
to connector. The corrugated conduits<br />
are offered by ABB in the orange<br />
colour that distinguishes high-power<br />
connectors. We use two materials, copolyester,<br />
which is flame retardant, and<br />
polyamide 6, which is more resistant<br />
to abrasion and ageing. A proprietary<br />
feature of our corrugated conduits is<br />
the ‘vibration friendly profile’: when<br />
the conduit flexes at the bottom point,<br />
where there is the highest concentration<br />
of stresses, the design redistributes<br />
stresses around the circumference.<br />
Where there is a high fill factor in the<br />
corrugated conduit, there is no damage<br />
to the conductor insulation. The<br />
conduits are severely tested both in<br />
terms of hours and bending cycles, so<br />
that they follow the entire life cycle of<br />
the machinery”. Let’s proceed with fittings<br />
or joints. “Of different types and<br />
sizes, they are all orange. The opening<br />
of the fitting is in the horizontal plane<br />
and, as a result, the intersection of<br />
the conduit facilitates installation. The<br />
low-profile clips are integrated into<br />
the structure. They are made in such a<br />
way as to prevent accidental opening.<br />
They have an internal profile, from the<br />
point of view of the conduit intersection,<br />
which exerts a very strong resistance<br />
to tearing”. Let’s move on to<br />
the back-shells, or protective shells at<br />
the interface between the corrugated<br />
conduit and the connector. «Compared<br />
to heat-shrinkable conduits or other<br />
types of systems, they provide true<br />
protection of the interface and connector.<br />
When we install them, we create<br />
an integral connection between connector<br />
and corrugated conduit, which<br />
reduces the effect of vibrations and<br />
impacts. It protects the connector and<br />
the interface with the cable, the heart<br />
of the electrical system. Only ABB has<br />
dedicated shells for power connectors<br />
for electric traction heavy-duty applications.<br />
We cover single- and doubleposition,<br />
straight or 90° connectors<br />
with just 9 codes. Thanks to their flexible<br />
design, the PMA trust modular<br />
support systems allow us to distribute<br />
wiring and conduits neatly on the vehicle<br />
surface”.<br />
46<br />
47
SUSTAINABLE TECHNO<br />
#BOSCH #YANMAR #CATERPILLAR #BORGWARNER #BYD<br />
BOSCH: NEW INJECTION TECHNOLOGY FOR HYDROGEN ENGINES<br />
I NEED NO MORE<br />
LUBRICATION<br />
Bosch’s focus on hydrogen as a<br />
key element for achieving climate<br />
neutrality goals, particularly<br />
for heavy vehicles and<br />
specific applications in agriculture.<br />
At Agritechnica 2023, Bosch highlighted<br />
an injector for direct hydrogen<br />
injection that doesn’t need additional<br />
lubrication. This innovation could<br />
potentially enhance the efficiency<br />
and reliability of hydrogen-powered<br />
engines in agricultural machinery. In<br />
the course of a vehicle’s service life,<br />
the injector opens and closes roughly<br />
one billion times. To ensure that this<br />
always works reliably, the engineers<br />
developing the hydrogen engine had<br />
to overcome two challenges: one, the<br />
lubrication provided by the fuel in<br />
the diesel engine is absent; and two,<br />
the hydrogen may react with materials<br />
it comes into contact with. The<br />
engineers’ solution is a sophisticated<br />
design that keeps the media separate<br />
inside the injector, and uses various<br />
coating technologies. The systems<br />
for low-pressure direct and port injection<br />
have been developed for engines<br />
that can also be operated with heavy<br />
loads and in difficult environmental<br />
conditions. As a systems supplier,<br />
Bosch also offers electronic control<br />
units, products for storing and supplying<br />
hydrogen, and other powertrain<br />
components. “More than 90% of the<br />
development and manufacturing technologies<br />
needed for the hydrogen engine<br />
already exist,” says Jan-Oliver<br />
Röhrl, the executive vice president<br />
responsible for commercial vehicle<br />
powertrains in the Bosch Powertrain<br />
Solutions division. In addition, the<br />
hydrogen engine consists primarily<br />
of steel and aluminum, which reduces<br />
dependencies on critical raw materials<br />
and their supply chains. At the same<br />
time, Bosch is continuing to improve<br />
its conventional diesel-injection and<br />
exhaust-gas treatment systems for<br />
commercial vehicles and the off-highway<br />
sector. “We want our solutions to<br />
help automakers worldwide further<br />
reduce CO 2<br />
and other emissions,”<br />
Röhrl says.<br />
For example, the modular CRSN common-rail<br />
system for commercial vehicles<br />
and off-highway applications exhibited<br />
at Agritechnica 2023 ensures<br />
efficient fuel supply and injection in<br />
diesel engines. It is scalable for pressure<br />
levels between 1,800 bar and<br />
2,500 bar, and can be configured for<br />
engine sizes of up to eight cylinders.<br />
In addition, Bosch diesel technology<br />
can already run on renewable synthetic<br />
fuels. Such fuels can complement<br />
electromobility or hydrogen-based<br />
powertrains where these solutions face<br />
economic or physical challenges.<br />
YANMAR MODEL E-X1 FOR AGRICULTURE<br />
Following the<br />
prototype electric<br />
machine<br />
presented at<br />
the Construction<br />
DX Challenge 2023,<br />
Yanmar has revealed<br />
its e-X1 concept, an<br />
electric drive compact<br />
electric agricultural<br />
machine. The Yanmar<br />
e-X1 can accommodate<br />
various implements<br />
such as rotary<br />
tillers and grass cutters<br />
at the front and<br />
rear, enabling tasks<br />
like weeding, snow<br />
removal, and cultivating.<br />
Opting for<br />
crawlers instead of wheels ensures<br />
stable operation on slopes and uneven<br />
terrain. With no driver’s seat, the machine<br />
guarantees operator safety during<br />
agricultural tasks through remote<br />
control. The incorporation of autonomous<br />
driving features is also under<br />
consideration. Yanmar Agribusiness<br />
plans to initiate market monitoring<br />
in 2025 and actively progress toward<br />
mass-production through rigorous design<br />
and testing, with the goal of contributing<br />
to the decarbonization of the<br />
agricultural sector.<br />
BorgWarner enters deal with BYD’s FinDreams<br />
BorgWarner will be in charge of manufacturing LFP battery packs for<br />
commercial vehicles utilizing FinDreams Battery blade cells (presented<br />
in 2020) in Europe, the Americas, and select regions of Asia Pacific.<br />
The duration of the agreement is 8 years. At Busworld Europe 2023<br />
BYD presented the B2 electric bus platform, utilizing the Blade<br />
Battery. BorgWarner’s battery capabilities build back on the purchase<br />
of German battery module producer Akasol in 2021. In addition to<br />
receiving state-of-the-art blade cells for manufacturing LFP battery<br />
packs in the covered geographies, BorgWarner will receive a license<br />
from FinDreams Battery to use FinDreams Battery’s intellectual<br />
property related to its battery pack design and manufacturing process.<br />
Cat and CRH for electric off-highway trucks and charging solutions<br />
Cat has signed an electrification strategic agreement with CRH to advance the deployment of Caterpillar’s zero-exhaust<br />
emissions solutions. CRH is the number one aggregates producer in North America and the first company<br />
in that industry to sign such an agreement with Cat. The agreement is focused on accelerating the deployment of<br />
Caterpillar’s 70 to 100-ton-class battery electric off-highway trucks and charging solutions at a CRH site in North<br />
America. Through the agreement, CRH will participate in Caterpillar’s Early Learner program for battery electric<br />
off-highway trucks, testing and validating the units in real-world applications. CRH will also provide voice of customer<br />
feedback to address safety, performance, operational and compliance requirements for the aggregates industry.<br />
48<br />
49
TECHNO<br />
#KOMATSU #GM #FUELCELL #MINING<br />
SUPPLEMENT<br />
DUMPER TRUCK LIKES H2<br />
General Motors and Komatsu are<br />
collaborating to jointly develop<br />
a hydrogen fuel cell power<br />
module tailored for Komatsu’s<br />
930E electric drive mining truck. According<br />
to the OEM from Japan, hydrogen<br />
fuel cells are lightweight, quick<br />
to refuel, and suitable for electrifying<br />
applications traditionally powered by<br />
diesel engines. Hydrogen enables the<br />
storage of large amounts of energy<br />
in the vehicle without compromising<br />
its load capacity. Furthermore, fuel<br />
cells offer a zero-emission solution<br />
for demanding mission vehicles, like<br />
the Komatsu 930E dump truck with<br />
a rated payload of 320 tons. These<br />
vehicles typically operate in a single<br />
mine, which simplifies the challenges<br />
of sizing and implementing an effec-<br />
tive hydrogen refuelling infrastructure<br />
to serve the vehicle fleet. “At GM, we<br />
believe fuel cells can play an integral<br />
role in a zero-emissions future, helping<br />
to electrify heavier-duty applications,<br />
beyond passenger vehicles,” said<br />
Charlie Freese, executive director of<br />
GM’s Global Hydrotec business. “Mining<br />
trucks are among the largest, most<br />
capable vehicles used in any industry,<br />
and we believe hydrogen fuel cells are<br />
best suited to deliver zero emissions<br />
propulsion to these demanding applications.”<br />
In GM and Komatsu’s plans,<br />
the prototype Hydrotec-powered mining<br />
dump truck will be tested at Komatsu’s<br />
Arizona research and development<br />
proving grounds over a couple of years.<br />
This vehicle will be powered by over<br />
2 megawatts of Hydrotec power cubes.<br />
Engines and components for OEM<br />
Culture, technology, purposes<br />
and market of diesel engines<br />
Established in 1986<br />
Editor in chief<br />
Maurizio Cervetto<br />
Managing editor<br />
Fabio Butturi<br />
Editorial staff<br />
Stefano Agnellini, Ornella Cavalli,<br />
Fabrizio Dalle Nogare, Stefano Eliseo,<br />
Fabio Franchini, Riccardo Schiavo,<br />
Cristina Scuteri<br />
Contributors<br />
Carolina Gambino,<br />
Maria Grazia Gargioni,<br />
Erika Pasquini,<br />
Mariagiulia Spettoli<br />
Layout & graphics<br />
Marco Zanusso (manager)<br />
Editorial management<br />
Fabio Zammaretti<br />
Printing<br />
Industrie Grafiche RGM srl,<br />
Rozzano (MI)<br />
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n. 860 – December 18th 1987 National<br />
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Poste Italiane Inc. – Mail subscription<br />
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46) Art. 1, subsection 1, LO/MI<br />
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CM<br />
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50
The real power of<br />
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is how<br />
TODAY.<br />
we power<br />
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It’s not just the power of our engines.<br />
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Together, we power ahead.<br />
perkins.com