CH RGINGahead

2013 ISSUE SPRING

DAF Trucks N.V. Eindhoven

The latest Holset Turbochargers news from Cummins Turbo Technologies

Next Generation
Technologies

Revealed

DAF EURO 6 XF

P U T T O T H E T E S T:

WITH HOLSET

Holset HX50

TURBOCHARGER

Will Fit Brand

Welcome...
Welcome to Cummins Turbo Technologies aftermarket magazine, providing you
with the latest news on our world-leading Holset Turbochargers.
Specifically with the Aftermarket in mind, this magazine aims to provide our customers
and potential customers with information about Holset Turbochargers, relevant
applications and the global markets that Cummins Turbo Technologies operates in.

In this issue...

I DAF Launches Euro 6 XF Model with Holset Turbocharger

PAGE 4

I Forward Thinking; Next Generation Technologies from Cummins Turbo Technologies

PAGE 6

I Comparison Test: Holset HX50 vs. Will Fit Brand

PAGE 8

I 2013 Events Schedule

PAGE 12

CHARGING AHEAD

SPRING 2013

Launch of Cummins Turbo Technologies

New Website
We are very excited to be launching our new and improved website in the next few months
where you will be able to read all about the company; from our 60 year heritage and history all
the way to our latest products and future technologies.
Visitors will find a wealth of information about our global locations, products and technologies, career opportunities, contact details
and Parts and Service information for Holset Turbochargers. Visit our Newsroom for our latest press releases and events news,
and download our company and product literature including HTi magazine and Charging Ahead. Or if you are an Authorised
Holset Distributor, log into Partner Zone for all the latest information and access to promotional and marketing support.

Watch this space for

information on the launch date!

Subscribe to CHARGINGahead magazine

Charging Ahead is published twice a year. To make sure you receive each and every copy subscribe by emailing your
full postal address to turbomarketing@cummins.com with the subject header Subscribe Charging Ahead.

About Cummins Turbo Technologies and Holset Turbochargers

Holset Turbochargers are synonymous with turbomachinery and air handling excellence across
the globe. Engineered and manufactured by Cummins Turbo Technologies, Holset
Turbochargers have set the standard for turbocharger technology and design in the mid-range
and heavy-duty diesel engine market for over 60 years. With the introduction of the Holset 200
series, our range now includes light-duty turbochargers and extends our range from high
horsepower and heavy-duty all the way down to serving the light-duty diesel engine market.

What makes a Holset turbocharger?

Cummins Turbo Technologies takes a collaborative approach with key OEMs worldwide to
develop optimum solutions for a wide range of vehicles and applications. Through our
longstanding OEM relationships, and as an autonomous unit of the Cummins organisation, we
have developed an unrivalled knowledge of engines and their interaction with the turbocharger.
We will only use your details to
fulfil your request. You can
update your details or unsubscribe
at any time by emailing
turbomarketing@cummins.com
with the subject header
Unsubscribe Charging Ahead.

This invaluable commercial experience means that our turbochargers are developed as a
critical component for each application. Our specialist engineering teams lead a comprehensive
design process and undertake rigorous testing and analysis to ensure the highest standard of
product quality, safety and superior performance.

Its got to be Holset

SPRING 2013

CHARGING AHEAD

DAF Launches Euro 6 XF Model

with Holset Turbocharger

With the introduction of Euro 6 legislation aimed to reduce emissions
from trucks and buses, OEMs in the heavy-duty engine market have
had to respond with the development of applications that meet the
new emission regulations. DAF, a PACCAR company, responded
last year with the launch of their Euro 6 XF model at the IAA
Hannover show in September 2012.
The flagship model, due to enter

The engine can utilise the best turbo

production in Spring 2013 boasts a

settings at all times and across its

number of features that will benefit

entire speed range, allowing it to

both the operator; low operating

deliver maximum performance.

costs, and the driver; optimised

The variable geometry turbo is also

vehicle performance. The design of

required to optimise the effectiveness

the engine, a PACCAR MX-13, has

of exhaust gas recirculation,

been crucial to the delivery of these

especially at low speeds.

benefits as well as ensuring the

application meets the Euro 6

This technology allows DAF to

emission legislation.

carefully set the proportion of

exhaust gases diverted back into

The PACCAR MX-13, described by

the engine, which again helps with

DAF as the new generation of Euro 6

fuel efficiency.

engines, features innovative

(www.daf.com/newxf/en/index.html)

technologies including a Holset 500

series variable geometry (VG)

Specific features of the HE500VG,

turbocharger from Cummins Turbo

which add to the overall efficiency

Technologies. DAF explains the

of the turbocharger and improved

selection of a Holset VGT for this

fuel economy, are the Super Map

12.9 litre engine by describing the

Width Enhancement (SMWE) and

main advantages:

Inverse Impeller design.

Holset turbocharger information:

I OEM supplied turbocharger:
3781187
I DAF part no: 1907280

CHARGING AHEAD

I Independent Customer part no:

3781185D
I Turbo model: HE500VG

SPRING 2013

 DAF Trucks N.V. Eindhoven

Super Map Width

Enhancement (SMWE)
By using SMWE the compressor inlet
pipe is optimised to provide additional
flow range at surge. This improves
map width by up to 15% which
increases the optimum range the
turbocharger can operate in to provide
performance benefits.

Inverse Impeller
The blade geometry on traditional
impellers has been designed to give
required flow conditions. For the inverse
impeller the aerodynamic design process
has been reversed. The designer
specifies the desired flow conditions and
the software then develops the blade
shape using an optimisation process to
deliver the required flow conditions.
Inverse impellers provide higher pressure
ratio, improve compressor stage
efficiency by 1% and provide a wider flow
range. This can translate to a $160 saving
for an on-highway application per year.

Conventional design

SPRING 2013

Inverse design

CHARGING AHEAD

Forward Thinking:
Next Generation Products from
Cummins Turbo Technologies
The recent shift in focus from emissions-driven innovation towards solutions that prioritise fuel
economy shows how the commercial vehicle industry is evolving. Cummins Turbo Technologies
believes this will drive global engine and vehicle manufacturers to focus on the development of
products designed to help insulate their customers from rising fuel prices.

Inside Cummins Turbo Technologies' award winning waste

heat turbine expander test cell.

In addition to this, the trend towards

downsizing which sees engine and
vehicle manufacturers aiming to maintain
or increase the power outputs from their
products, whilst making them smaller
and lighter represents a significant

Cummins Turbo Technologies receive the Engine Test

Facility of the year award.

Holset Turbochargers
are the component
of choice for
many international
automotive customers...

Holset Turbochargers are the

component of choice for many
international automotive customers
because we dont simply provide them
with off-the-shelf products. We develop
advanced technological solutions that
are fit for market in other words they

engineering challenge. One that

Cummins Turbo Technologies is

advanced technologies for a next

are developed in partnership to meet

meeting head-on.

generation of products. Executive

customers specific requirements.

Director for Product Line Management

With over 60 years of engineering

and Marketing, Mark Firth commented:

These competitive, market-proven

experience and a network of world-class

Our close working relationship with

products and technologies draw on our

technical centres in India, China, the UK

customers has informed the research

60 year history of innovation and

and the USA, Cummins Turbo

and development that is shaping our

engineering excellence to deliver savings

Technologies is well placed to develop

future product range.

without compromising on performance.

CHARGING AHEAD

SPRING 2013

Cummins Turbo Technologies next generation of products include:

I Waste Heat Turbine Expander
prototype captures what would
otherwise be lost energy, in the form
of heat, from a number of sources on
board the vehicle and turns it into
useful mechanical (25kW) or electrical
(5kWe) power that is capable of
reducing vehicle fuel consumption by
5% and delivering estimated fuel
savings of up to $5,600 a year.

I Inverse Impeller replaces

conventional designs and, through the
use of flow optimisation software, has
the capability to improve compressor
stage efficiency by 1% on its own
delivering on average a $160 per year
fuel saving for on-highway
applications.

I Rolling Element Bearings

Cummins Turbo Technologies has
developed its own, high durability, low
friction ball-bearing solution which
improves both transient response and
lowers fuel consumption delivering a
1% improvement in overall
turbocharger efficiency.

I Super Map Width Enhancement

enhances map width by 15% and
facilitates engine downsizing,
improves driveability, widens the
operating range, aids efficiency
mapping and delivers fuel savings.

I Holset Rotary Turbine Control

(RTC) patented flow channelling
technology that directs exhaust gas to
selected ports for limited exhaust
control capability. RTC is integrated
into the turbine housing within
Cummins Turbo Technologies next
generation two-stage systems.

The Companys advantageous research

expander. As part of the technology

of our ongoing commitment to offer

and development capability has recently

development, the company invested

OEMs a choice of solutions for delivering

been recognised in the Automotive

$1 million in a unique test cell facility at its

engine efficiency improvements.

Testing Technology awards by being

UK Research and Development Centre in

named Company of the Year and

Huddersfield. Jonathan Wood, Executive

Cummins Turbo Technologies

receiving the Engine Test Facility of the

Director Research and Engineering,

showcased their next generation

Year award.

said: Innovative and highly capable

products at the Mid-America Trucking

testing technology is a key requirement to

Show, Louisville USA in March and will

The awards specifically recognised

drive our advanced product

be exhibiting their waste heat turbine

Cummins Turbo Technologies

development. This test facility is a major

expander at Busworld, Kortrijk

development of the waste heat turbine

part of the development and confirmation

Belgium in October.

I Next Generation Holset VGT

based on a validated platform that
can be tailored to meet the needs of
individual customers without reengineering, the product is 2kg lighter
and substantially lowers initial cost
compared to the model it replaces
whilst featuring a high efficiency
compressor stage to deliver improved
fuel economy.

SPRING 2013

CHARGING AHEAD

Comparison Test Reveals

Holset HX50 8%
More Efficient
Will fit is an expression becoming increasingly common in the industry to describe turbochargers
and parts that are an alternative option to the original fit for an application. Often marketed and
sold under a brand name, they are classed as legitimate competition for suppliers to Original
Equipment Manufacturers (OEMs), like Cummins Turbo Technologies.
However, branded will fit products are not selected or used by OEMs for use in their engines.
Engineering companies like Cummins Turbo Technologies, manufacturer of Holset Turbochargers,
takes a collaborative approach with OEMs to develop optimum solutions for their applications. It is
this partnership approach that is a key contributor to the companys invaluable commercial
experience and engineering expertise; best placing them to develop superior quality products and
lead on future technologies for the industry.

VS.
To prove this view point, Cummins Turbo Technologies ran a number of comparison tests to
evaluate the differences between a Holset turbocharger and will fit brand of turbocharger.

CHARGING AHEAD

SPRING 2013

The Turbochargers

The Application

Holset HX50 vs. will fit brand HX50

MAN D2866LF14 (Inline 6 Cylinder 11.9 Litre)

The Tests
I Compressor Mapping used to determine the
aerodynamic capability of the compressor stage to
show a direct comparison of compressor performance
and efficiency.
I Engine Performance Testing the turbocharger is
connected to the MAN engine on a test bed fitted with a
dynamometer to show a direct comparison of its overall
performance and efficiency.
I Containment Test the compressor side and the
turbine side are tested beyond their maximum speed
limit until the compressor wheel fails or bursts. This is to
ensure that fragments do not escape through the walls
of the housing if an impeller fails at high speed.

The results...
Compressor Mapping
I The running line is located in the heart of the Holset
HX50s graph, which is where the turbochargers
compressor stage is most efficient and gives the
Holset HX50 a large choke and surge margin.
I The Holset HX50 achieves a higher pressure ratio at
Pressure Ratio (T-T)

a given speed, which leads to a higher maximum

boost limit.
I The Holset HX50 compressor map shows that the unit
doesnt need to run at a higher speed in comparison
to the will fit HX50 to achieve the boost requirement;
this can be seen from the speed lines.

Holset

Will fit brand

m.sqrt(T)/p Corp. (kg/sec.sqrt(K)/MPa)

SPRING 2013

CHARGING AHEAD

The results (continued...)

Turbocharger and Engine Performa

Compressor Efficiency

Turbocharger Efficiency

Compressor Efficiency (%)

77

54

Turbo Efficiency (%)

76
75
74
73
72
71
70
69
900

53
52
51
50
49
48
47
46
45

1100

1300

1500

1700

1900

900

1100

Engine Speed (RPM)

1500

1700

1900

Engine Speed (RPM)

Will fit brand

Holset

1300

Holset

Will fit brand

The Holset HX50 has greater overall turbocharger efficiency

(up to 3.75 points higher) over the whole operating range

(up to 4.04 points higher) over the whole engine operating

in comparison to the will fit HX50.

range compared to the will fit HX50.

This shows that the Holset HX50 compressor stage

In general the Holset turbocharger is producing more boost

requires less effort to produce the same boost output

per effort; reducing the fuel consumption for the application

compared to the will fit HX50.

and ensuring a prolonged life span of the turbocharger.

Compressor Mass Flow

Turbine Inlet Temperature

80

670

70

660

Temperature (C)

Compressor Mass Flow

(Kg/s root K)/Mpa)

The Holset HX50 has greater compressor efficiency

60
50
40
30
20
900

650
640
630
620
610

1100

1300

1500

1700

1900

600
900

1100

Engine Speed (RPM)

Holset

Will fit brand

1300

1500

1700

1900

Engine Speed (RPM)

Holset

Will fit brand

The Holset HX50 delivers a greater mass flow at all

The graph shows that the will fit HX50 brand runs at a

engine speeds (up to 3.84 points higher) in comparison

higher turbine inlet temperature over the whole

to the will fit HX50.

operating range.

This shows that the Holset HX50 compressor stage will

The lower running temperatures on the Holset HX50 will

deliver more mass flow at any given engine speed

prolong the life of the components and prevent damage

(more efficiently) compared to the will fit HX50.

to other sub-components within the application.

10

CHARGING AHEAD

SPRING 2013

ance Testing

The Outcome
The will fit HX50 has to run at a higher speed to
deliver the same boost pressure/mass flow as the
Holset turbocharger, which will cause the

Containment
Test

application to consume a higher amount of

fuel in the general operating range.

In addition, the will fit HX50 runs at hotter temperatures, with a higher Brake Specific
Fuel Consumption (BSFC) value and provides a less cool and dense inlet charge;
achieving a less efficient charge overall. This means an overall decrease in
turbocharger efficiency, a shorter service life and increased running costs. In fact, the
Holset HX50 proved to have an 8% better turbocharger efficiency which
translates to over 5% improved vehicle economy.
Also of note, the will fit HX50 failed Cummins Turbo Technologies containment test
and therefore, in the event of an impeller failure at high speed, could result in serious
damage to the application.

The will fit HX50 brand failed

Cummins Turbo Technologies
containment test:
I Clamp plates buckled
I Threads stripped

I Compressor cover completely

detached from bearing housing
held in place by boost pipe and

Cummins Turbo Technologies takes competition from will

fit brands in the Aftermarket seriously and is using this
information to insist that the original fit turbochargers offer
the best long-term value in terms of:
I Fuel and vehicle economy
I Reducing downtime for repair or replacements
I Providing full confidence that you are achieving the OEMs
intended drivability, response and performance from
an application.

shaft/impeller fragments only.

If an impeller fails at high speed and
the components are not contained
within the housings this could result
in serious damage to the
application.
All Holset Turbochargers pass the
Cummins Turbo Technologies
containment test.

SPRING 2013

CHARGING AHEAD

11

2013 Events Schedule

This year Cummins Turbo Technologies will be at the following events:
Big Bang

Bauma

London Excel Center, UK

(14 17 March)
Celebration of science, technology,
engineering and mathematics for
young people in the UK.

Munich, Germany (15 21 April)

Largest international tradeshow for
construction and mining machinery,
vehicles and equipment.

18th Supercharging
Conference
Dresden, Germany
(12 13 September)
An engaging forum to present papers
and products to technically minded
audiences interested in all aspects of
turbocharging.

Festival of Speed
Mid-America Trucking
Show (MATS)
Louisville, USA
(21 23 March)
Largest heavy-duty trucking event
in the world.

Goodwood, UK (11 14 July)

Largest car culture event in the world.

Busworld
ADS Convention
& Tradeshow
San Diego, USA
(30 July 2 August)
ADS, the diesel industry's leading
trade associations annual show,
displays the latest in diesel technology.

Kortrijk, Belgium
(18 23 October)
The biggest and most established
specialised exhibition for the coach
and bus sector in the world.

Find your Nearest Authorised Holset Distributor

To make sure you get the intended functionality and performance from a Holset turbocharger, Cummins Turbo
Technologies works alongside carefully selected Authorised Holset Distributors. Visit your authorised distributor to ensure
you receive genuine Holset parts and the intended value and performance your Holset turbocharger can deliver.

To find your nearest Authorised Holset Distributor visit:

www.holsetaftermarket.com

Copyright 2013 Cummins Ltd. All rights reserved.

VGT is a trade mark of Cummins Ltd.
Holset and the Holset logo are registered trade marks of Cummins Ltd.
Cummins and the Cummins logo are registered trade marks of
Cummins Inc.

www.holsetaftermarket.com

SKU 5008