Cummins X-series engine

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The Cummins X-series engine is an Inline (Straight)-6 diesel engine produced by Cummins for heavy duty trucks and motorcoaches, replacing the N14 in 2001 when emissions regulations passed by the EPA made the engine obsolete. Originally called the "Signature" series engine, the ISX uses the "Intellect System" (hence the "IS" which is the moniker for the full authority, on highway fuel system Cummins pioneered) to further improve the engine. This engine is widely used in on highway and vocational trucks and is available in power ranging from 430 hp all the way to 620 hp 2050 lb-ft. The QSX is the off-highway version of the ISX with the Q standing for Quantum. The QSX is used for industrial, marine, oil & gas and other off-highway applications. Cummins also produced a 650 hp and 1950 lb-ft version for the RV market.

Contents

History

Until 2010 this engine was a dual overhead cam design with one cam actuating the injectors and the other the valve train. This injection system is known as HPI (high pressure injection) where the injectors are cam-actuated to create injection pressure. The fuel system uses an Integrated Fuel System Module (IFSM) with a lift pump, gear pump, pressure regulators, shutoff valve, metering and timing actuators to deliver fuel to the injectors. It has a one piece valve cover that is either plastic or on older models a chrome plated steel cover otherwise known as the Signature 600 or ISX CM570.

In 2002, the ISX CM870 brought cooled exhaust gas recirculation (EGR) which takes exhaust gas and recirculates it back into the intake of the engine lowering the combustion chamber temperatures limiting the formation of NOx.

In 2008, Cummins unveiled the ISX CM871, this engine featured a Diesel Particulate Filter (DPF) which trapped the particulate matter or "soot" produced in the engine. With the help of the Diesel Oxidation Catalyst (DOC) the soot trapped in the DPF is oxidized and turned to ash during a process called regeneration. In motorhomes this was available as a 600 or 650 HP version.

The current EPA 2010 version known as ISX15 CM2250 features enhanced exhaust gas recirculation, diesel particulate filter and selective catalytic reduction (SCR), also known as urea injection. SCR consists of a diesel exhaust fluid (DEF - composed of urea and water) injection system: holding tank, pump, controller, and injector and an SCR catalyst brick. DEF is heated, pumped and injected into a decomposition tube which then reacts with the exhaust reducing NOX. The ISX15 CM2250 and CM2350 has eliminated the injector camshaft due to the advent of the common rail fuel system in which the fuel is pressurized from a high pressure, multiple piston pump, transferred through tubing to a rail where fuel is stored under extremely high pressures up to 35,000 psi.

In 2023, Cummins unveiled the X10 and X15N engines. The X10 is slated to replace the X12 and L9 in the truck market as it was made to serve both heavy duty and medium duty truck applications. [1] The X15N is a CNG version of the X15, and is expected to release in 2025 with the same performance as the X15. [2]

Models

ModelFuelBore x strokeDisplacementYears of ProductionNotes
X10Diesel10 LPlanned for 2026 onwardLaunching before EPA 2027 takes effect

Slated to replace X12 in Vocational & Regional Haul

Slated to replace L9 [3]

ISX12Diesel130 mm × 150 mm11.9 L2010–2020Phasing out started in 2018
X12132 mm × 144 mm11.8 L2018–2026
ISX12 GNatural Gas130 mm × 150 mm11.9 L2013–2018Phasing out started in 2017
ISX12N2018–presentReplaced ISX12 G

Built off the X12 block

X15NNatural Gas137 mm × 169 mm14.9 LPlanned for 2024 onward
X15H [4] [5] Hydrogen14.9 LPlanned for 2027 onwardTesting in progress
ISX15Diesel14.9 L2010–2020Phasing out started in 2016
X1514.9 L2016–presentReplaced ISX15

Emissions Control

The Cummins ISX diesel engine can be run in a dual fuel configuration, meaning it can properly operate on diesel fuel and natural gas. The burning of a natural gas alternative preserves diesel thermal efficiencies. The more efficient engine can produce less emissions in turn. The ISX can achieve this by altering ignition delay and injection timing. By examining the start of combustion (SOC), the engine's computer is able to employ a predictive ignition delay correlation. The predictive characteristics of the engine maximize both efficiency and useful power for the given fuel source. Compensations are made for the natural gas so that the power band and operating range are still functional for customers, while reducing emissions. [6] Testing has also been done with the Cummins ISX by the EPA for natural gas usage that yielded results of major NOx emissions reduction. The configuration boasts ninety percent lower NOx emissions than the current EPA standard. This makes the Cummins ISX that burns natural gas one of the cleanest running diesel engines in the world. [7]

The ISX also utilizes a DPF, or diesel particulate filter, required by the EPA. The DPF filters out the solid particles in the engine's exhaust, reducing tailpipe emissions. The DPF does have to be regularly maintained, however, because of its intricate design. The emissions control system will institute a filter regeneration which burns off the particulates. Any non-combustible materials found in lubrication additives will remain in the DPF, which can cause problems with back pressure and efficiency. This means the DPF needs to be regularly removed and cleaned for the Cummins ISX. An ash-less oil could mean that cleaning would be unnecessary, but can inhibit lubrication properties. A zero-phosphorus oil has been studied and found to be ideal for DPF systems and lubrication. The oil displays passing results for both piston deposits and oil consumption, which means the DPF system would be optimized with use of zero-phosphorus, ultra low sulfur oil. [8]

The Cummins ISX also utilized DEF, or diesel exhaust fluid, in later models when EPA requirements changed. DEF is system of injected urea that reduces the emissions of a diesel engine. The Cummins ISX is required to have inhibitors in place for certain failures of the DEF system. When the DEF tank is low or empty, the ISX cuts power by twenty five percent. Power cuts and driver warnings are also used when the DEF system has been tampered with or is not functioning properly. Cummins has corrected several malfunctions and conducted customer based research of several million miles of on road use of the Cummins ISX to make the DEF system as functional as possible. The system is also required to de-rate power given any problems in order to reduce emissions to an absolute minimum. [9]

Technology

In early ISX engines an anti backlash gear train is used. The anti backlash gears allow the engine to operate with minimal gear rattle. Cummins uses a gear train in the front of the engine which is inherently noisy. The anti backlash gearing makes the engine less noisy due to the reduced rattle while in operation. The anti backlash gear train comes at a cost of efficiency. The Cummins ISX 15 model equipped with anti backlash gearing suffers a friction loss. The gears must overcome more friction throughout their moving range than a standard gear. A standard gear in a Cummins ISX 15 needs to overcome 0.75 Newton meters of torque, while the anti backlash gearing needs to overcome approximately 5 Newton meters of torque. [10]

Cummins Signature Series

Starting in 1998 the Cummins Signature was released to the Australian market to replace the out going N14. The Signature was produced up until 2003, In 2003 the highly popular Oceania exclusive was released this being the Gen 2 Cummins Signature. [11] It built upon and improved on the original Cummins Signature. 2008 saw the third Signature revision this was the Signature EGR which utilized the same technology as the ISX EGR range. 2012 brought along the Gen 2 EGR line. [12]

Related Research Articles

<span class="mw-page-title-main">Exhaust gas recirculation</span> NOx reduction technique used in gasoline and diesel engines

In internal combustion engines, exhaust gas recirculation (EGR) is a nitrogen oxide (NOx) emissions reduction technique used in petrol/gasoline, diesel engines and some hydrogen engines. EGR works by recirculating a portion of an engine's exhaust gas back to the engine cylinders. The exhaust gas displaces atmospheric air and reduces O2 in the combustion chamber. Reducing the amount of oxygen reduces the amount of fuel that can burn in the cylinder thereby reducing peak in-cylinder temperatures. The actual amount of recirculated exhaust gas varies with the engine operating parameters.

<span class="mw-page-title-main">Catalytic converter</span> Exhaust emission control device

A catalytic converter is an exhaust emission control device which converts toxic gases and pollutants in exhaust gas from an internal combustion engine into less-toxic pollutants by catalyzing a redox reaction. Catalytic converters are usually used with internal combustion engines fueled by gasoline or diesel, including lean-burn engines, and sometimes on kerosene heaters and stoves.

Vehicle emissions control is the study of reducing the emissions produced by motor vehicles, especially internal combustion engines.

<span class="mw-page-title-main">Exhaust gas</span> Gases emitted as a result of fuel reactions in combustion engines

Exhaust gas or flue gas is emitted as a result of the combustion of fuels such as natural gas, gasoline (petrol), diesel fuel, fuel oil, biodiesel blends, or coal. According to the type of engine, it is discharged into the atmosphere through an exhaust pipe, flue gas stack, or propelling nozzle. It often disperses downwind in a pattern called an exhaust plume.

<span class="mw-page-title-main">Duramax V8 engine</span> Reciprocating internal combustion engine

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<span class="mw-page-title-main">Mazda diesel engines</span> Reciprocating internal combustion engine

Mazda has a long history of building its own diesel engines, with the exception of a few units that were built under license.

<span class="mw-page-title-main">Ford Power Stroke engine</span> Reciprocating internal combustion engine

Power Stroke, also known as Powerstroke or PowerStroke, is the name used by a family of diesel engines for trucks produced by Ford Motor Company and Navistar International for Ford products since 1994. Along with its use in the Ford F-Series, applications include the Ford E-Series, Ford Excursion, and Ford LCF commercial truck. The name was also used for a diesel engine used in South American production of the Ford Ranger.

<span class="mw-page-title-main">Engine braking</span> Retarding forces within an engine used to slow a vehicle

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The Detroit Diesel Series 50 is an inline four-cylinder diesel engine, that was introduced in 1993 by Detroit Diesel. The Series 50 was developed from the existing block of its sister engine, the Series 60, which itself was initially designed by Detroit Diesel. The cylinder heads were cast by John Deere at one time.

<span class="mw-page-title-main">Diesel exhaust</span> Gaseous exhaust produced by a diesel engine

Diesel exhaust is the gaseous exhaust produced by a diesel type of internal combustion engine, plus any contained particulates. Its composition may vary with the fuel type or rate of consumption, or speed of engine operation, and whether the engine is in an on-road vehicle, farm vehicle, locomotive, marine vessel, or stationary generator or other application.

Selective catalytic reduction (SCR) means of converting nitrogen oxides, also referred to as NO
x with the aid of a catalyst into diatomic nitrogen, and water. A reductant, typically anhydrous ammonia, aqueous ammonia, or a urea solution, is added to a stream of flue or exhaust gas and is reacted onto a catalyst. As the reaction drives toward completion, nitrogen, and carbon dioxide, in the case of urea use, are produced.

<span class="mw-page-title-main">Diesel exhaust fluid</span> Standardized aqueous urea solution for exhaust aftertreatment

Diesel exhaust fluid is a liquid used to reduce the amount of air pollution created by a diesel engine. Specifically, DEF is an aqueous urea solution made with 32.5% urea and 67.5% deionized water. DEF is consumed in a selective catalytic reduction (SCR) that lowers the concentration of nitrogen oxides in the diesel exhaust emissions from a diesel engine.

<span class="mw-page-title-main">Diesel particulate filter</span> Removes diesel particulate matter or soot from the exhaust gas of a diesel engine

A diesel particulate filter (DPF) is a device designed to remove diesel particulate matter or soot from the exhaust gas of a diesel engine.

BlueTEC is Mercedes-Benz Group's marketing name for engines equipped with advanced NOx reducing technology for vehicle emissions control in diesel-powered vehicles. The technology in BlueTec vehicles includes a selective catalytic reduction (SCR) system that uses diesel exhaust fluid, and a system of NOx adsorbers the automaker calls DeNOx, which uses an oxidizing catalytic converter and diesel particulate filter combined with other NOx reducing systems.

A NOx adsorber or NOx trap (also called Lean NOx trap, abbr. LNT) is a device that is used to reduce oxides of nitrogen (NO and NO2) emissions from a lean burn internal combustion engine by means of adsorption.

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The Toyota AD engine family is a series of 16 valve DOHC inline-4 turbo diesel engines with electronic common rail direct injection using an aluminium cylinder head and an aluminium cylinder block with cast iron liners derived from the petrol Toyota AZ engine. The AD engine is offered in 2.0 and 2.2 liter versions. These engines are produced mainly for Europe, but few are exported to other areas such as India or New Zealand.

Westport Innovations is a company that develops alternative fuel, low-emissions technologies to allow engines to operate on clean-burning fuels such as compressed natural gas (CNG), liquefied natural gas (LNG), hydrogen and biofuels such as landfill gas. Headquartered in Vancouver, British Columbia, Canada, where the company was founded, Westport also has facilities in France, Sweden, Italy, China, Australia and the United States.

References

  1. ↑ Inc, Cummins. "CUMMINS ANNOUNCES NEW X10 ENGINE, NEXT IN THE FUEL-AGNOSTIC SERIES, LAUNCHING IN NORTH AMERICA IN 2026". Cummins Newsroom. p. 1. Retrieved 26 March 2023.{{cite news}}: |last= has generic name (help)
  2. ↑ Inc, Cummins. "CUMMINS NEXT-GENERATION 2026 X10 ENGINE AND 2024 X15N NATURAL GAS COMPLETE POWERTRAIN EQUIPPED WITH THE LATEST DIGITAL TECHNOLOGIES ON DISPLAY FOR FIRST TIME AT TMC ANNUAL MEETING". Cummins Newsroom. p. 1. Retrieved 26 March 2023.{{cite news}}: |last= has generic name (help)
  3. ↑ McGlothlin, Mike (2023-02-21). "Cummins Launches New 10 Liter Diesel Engine". Diesel World. Retrieved 2023-07-02.
  4. ↑ "Cummins and Accelera showcase broadest portfolio of decarbonizing technologies with an emphasis on hydrogen". Cummins. 2023-05-03.
  5. ↑ "Cummins Inc. Debuts 15-Liter Hydrogen Engine at ACT Expo". Cummins. 2022-05-09.
  6. ↑ Xu, Shuonan (October 13, 2014). "Development of a Phenomenological Dual-Fuel Natural Gas Diesel Engine Simulation and Its Use for Analysis of Transient Operations". SAE International Journal of Engines. 7 (4): 1665–1673. doi:10.4271/2014-01-2546.
  7. ↑ Gerber, Raleigh (July 18, 2018). "Clean Energy Launches Zero Now Financing to Put Fleets in Clean New Natural Gas Trucks for the Price of a Diesel Truck". Business Wire. Retrieved February 20, 2019.
  8. ↑ McGeehan, A, J. (2012). "Extending the Boundaries of Diesel Particulate Filter Maintenance With Ultra-Low Ash". TRID. 5.{{cite journal}}: CS1 maint: multiple names: authors list (link)
  9. ↑ "Control of Emissions From New Highway Vehicles and Engines". EPA. June 7, 2011.
  10. ↑ Joshi, Y. V (2014). "Gear Train Mesh Efficiency Study: The Effects of an Anti-Backlash Gear". SAE International Journal of Commercial Vehicles. 7: 271–277. doi:10.4271/2014-01-1769.
  11. ↑ "History: Cummins engines Down Under". trucksales. May 28, 2019.
  12. ↑ "Cummins announces Gen II EGR engines". Cummins Commentary. March 28, 2012.
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