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Dealing with EU stage-V

Dealing with EU stage-V emission norms intelligently EU Stage-V standard: Commercial end for many machines? Hatz 3H50T engine, an intelligent solution to deal with stage-V norms The new emissions norm is a challenge for many machine manufacturers. As of January 2019, it will no longer be possible to sell a large number of existing compact machines of more than 19 kW with hydraulic drive under the new directive. This results in disruption of the existing entire value chain. The reason for this is that the design of stage-V engines is complex and also includes the necessary components for exhaust gas purification, which make the engines considerably bigger. In many compact machines, however, there is no space for a larger engine as well as the additional diesel particulate filter. With additional costs arising due to the exhaust gas cleaning, companies are set to face the decreasing sales margins. Apart from the challenges at the business end, the new norms have presented machines manufacturers with an additional challenge. A diesel particulate filter that is technically required for stage-V engines above 19 kW only regenerates from a permanent exhaust gas temperature of 250 °C . These temperatures are seldom reached in short operating cycles, such as those of a lifting platform or forklift truck, for example. The consequence: besides the relatively high costs of the diesel particulate filter, its lifetime is low due to low working temperatures and it wears off quickly. Downsizing, but more aptly ‘rightsizing’ CEMAT ASIA By intelligently downsizing the engines, machines with a performance class of 19-37 kW, can be driven satisfactorily even with engines smaller than 19 kW. This results in significant savings for machine manufacturers in terms of time and costs in implementing the EU stage-V standard. As always, there are two sides of the coin, even in case of the new EU stage-V emissions standard. This standard is in coherence with the global climate change agreements and is definitely good for the environment. But it poses challenges for machine manufacturers in its implementation. The stage-V emissions standard compliant engines having more than 19 kW power are now significantly more expensive and require considerably more space. The reason for this is the diesel particulate filter (DPF) without which the emission values in this power class cannot be met. A practical alternative to this is provided by the cutting-edge and powerful engines without the diesel particulate filter, but with a power output of just less than 19 kW, that also fulfill the dimensions criterion as well as the performance ranges with stage-V. Author: Martin Hain, Product Manager and Team leader technical sales, Hatz In the past many compact machines with hydraulic drives were equipped with the now obsolete, over-dimensioned engines with a power between 19 and 37 kW (former EU stage-IIIA emissions standard) in order to achieve the required torque. However, from 2019 due to stage-V standard, engines above 19 kW in many cases will be practically no longer usable. In order to make sure that machine manufacturers can continue to produce and sell the products at reasonable costs despite the stage-V standard, there is a alternative. The solution is based on modern diesel engines of less than 19 kW with sufficiently high torque in low revolutions with common rail fuel injection and turbocharger. With the aid of the latest technology and the rightsizing principle, the power of the engines is matched to the requirements of the machine without the bothersome diesel particulate filter. To utilise smaller engines of less than 19 kW, only minor adaptations are required in the specifications of the machines. For example: A fork lift truck has a weight of 2,600 kg and was previously equipped with a diesel engine of 23.6 kW. This means that, from 2019, this fork lift truck falls under the new emissions standard and may no longer be offered without emission optimization with diesel particulate filter. The specifications in drive mode are for a maximum speed of 5.5 kilometers per hour with a 25 % gradient. This results in a required power of 23.6 kW. If the speed in the specifications is reduced to 4.2 kilometers per hour with the same gradient, this results in a required power of 18 kW, which makes it an engine of less than 19 kW. In practice, this speed reduction means an almost slowing by just 30 centimeters per second. Along with speed, the gradient can be used as a variable just as well. The same fork lift truck reaches a maximum speed of 20 kilometers per hour at a gradient of 6.5 %. The calculated power is 23 kW. WORLD OF INDUSTRIES – INTRALOGISTICS & DISTRIBUTION 5/2017

01 Stage V without DPF due to rightsizing 02 Practical example: Forklift truck 2600 kg If the gradient is reduced to 5.2 % this results in a required power of 18.4 kW. Because fork lift trucks are mainly used on relatively level ground, the marginal reduction of the gradient would hardly be noticeable in practical operation. These calculation examples are not isolated cases and can be applied to other compact machines with reasonable costs for compliance with the stage-V standard. The basis for this are modern engines of less than 19 kW, such as the Hatz 3H50T. This engine has been specially constructed for low emissions at a very high torque. This is achieved by state-of-the-art technology on an already existing engine and the expertise of the company. Hatz is taking a renewed approach and has newly constructed its H-series engines from scratch. As a result, the engine can fully exploit the benefits of common rail injection technology, for example, which would not be possible with an older engine technology. Highly efficient modern engines with EU stage-V compliance New production processes and materials in Hatz engines below 19 kW ensure resilience, even at higher loads. A smaller displacement engine with turbocharger technology and the common rail injection system from Bosch in the off-highway version, delivers a high operational effficiency even at low engine speeds. The Hatz H-series engines without exhaust gas after-treatment reach an extremely low particulate mass that actually undercuts the permissible value by a factor of ten. In stage-V, this value is 0.4 grams per kWh. The full power of 18.4 kW of the new Hatz 3-cylinder engines is reached at only 1350 revolutions. Also, the fact that more than enough force is available is proven by the supercharged Hatz engines with 1.5 litres displacement. A torque of 130 Nm is already About Motorenfabrik Hatz Motorenfabrik Hatz GmbH & Co. KG, with its head office in Ruhstorf an der Rott, Germany, is a globally active diesel engine manufacturer. It develops and manufactures diesel engines in a power range from 1.5 to 62 kW, and are used in the fields of construction machinery, compressors, commercial vehicles, agricultural machinery, handling equipment as well as in ships. The family owned company employs more than 900 employees worldwide, out of which, more than 5 % of them are involved in R&D. The company’s global network comprises of more than 500 service centers, 13 with their own subsidiaries and more than 110 Hatz agents in 120 countries. reached at 1300 revolutions, which in many cases exceeds even the torque of older engines of the 19-37 kW class. This ensures, for instance, that torque intensive capacities can be mastered without any problem. In comparison to an engine solution without turbocharger, the low speed of the Hatz engine means that noise emission is reduced by around two thirds. The Hatz 3H50T puts the manufacturers of compact machines in a position of intelligently implementing stage-V, and safeguards investments already made in the construction of their machines. Photographs: Motorenfabrik Hatz Vis sit us at CeMAT ASIA Hall W1 Booth D5-1 EXCELLENCE IN MOTION ■Stacker Cranes −AS/RS ■Telescopic Forks ■Retrofit & Service WORLD OF INDUSTRIES – INTRALOGISTICS & DISTRIBUTION 5/2017 MIAS_Fuh_CeMAT_Asia.indd 2 06.09.2017 08:36:57 MIAS-Englisch.indd 1 06.09.2017 10:27:10