The world of Dieselman – MTU

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MTU Powers Deepwater National Security Cutter

·         U.S. Coast Guard’s first of class National Security Cutter successfully completes initial sea trials.

DETROIT, JANUARY 30, 2008 – MTU Detroit Diesel, the Propulsion Plant Single Source Vendor contractor for the U.S. Coast Guard Deepwater National Security Cutter (NSC) Program, working together with prime contractor Northrop Grumman Ship Systems has completed the first in a series of trials for the lead ship Bertholf (WMSL 750). The Bertholf is the first of eight planned cutters to be powered by a Combined Diesel and Gas Turbine (CODAG) propulsion plant that was specially designed and integrated for the vessel by MTU.

The CODAG propulsion plant consists of two MTU 20V 1163 TB93 diesel engines each rated at 7,400 kW (9,925 hp) and a single General Electric LM2500 marine gas turbine engine rated at 22,000 kW (29,500 hp). The engines are connected through the CODAG reduction and combining gear system to the dual shaft-lines with controllable reversible pitch propellers. With all three engines working together the total combined output of the plant is 36,800 kW (49,350 hp). The propulsion plant and its auxiliaries are all controlled and monitored by an MTU provided automation system.

“This will be the largest, most technologically advanced high endurance cutter ever to enter U.S. Coast Guard service” said Phil Wasinger, Managing Director for MTU Detroit Diesel’s Washington Office. “The MTU team are proud to have completed a successful sea trial on this advanced propulsion system.”

The 418-foot cutter’s propulsion system when in full CODAG operation allows the ship to achieve speeds in excess of 28 knots and can easily make 18 knots when operating economically in single diesel engine mode. These speeds meet and exceed all of the Coast Guard operational requirements for this new cutter class, while the operating flexibility of the propulsion system allows for exceptional endurance and affords reduced lifecycle cost.

The Bertholf completed the Machinery Trials in December of 2007. Next up are Builder Trials scheduled for mid-February followed by Acceptance Trials in March. The Bertholf is scheduled to be turned over to the Coast Guard soon after Acceptance Trials and will then transit to it’s homeport in Alameda, California.

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January 30, 2008 Posted by | Cool Stuff, Defense | , , , , , , | Leave a comment

American Axle & Manufacturing Introduces New Exclusive 3.42 PowerDense® Gear Set Designed to Improve Fuel Economy – AAPEX Show Booth #1458

AA&M LogoDetroit, Michigan, October 16, 2007American Axle & Manufacturing (AAM), which is traded as AXL on the NYSE, today announced a new exclusive aftermarket 3.42 PowerDense® gear set for 2003 to 2007 Dodge Ram Heavy Duty 2500/3500 turbo diesel pickups.  2007 Dodge Ram Heavy Duty 2500/3500 Turbo Diesel

The gear set and its technology will be showcased at the Automotive Aftermarket Products Expo (AAPEX), October 31 through November 2.   

AAM Aftermarket now offers Dodge Ram diesel pickup owners the 3.42 ratio gear set as an alternative to the numerically higher ratio gear sets that are currently available.  The lower ratio set reduces engine rpm, which helps improve fuel economy under normal driving conditions which exclude hauling, climbing grades, or pulling a trailer.                

The 3.42 ring and pinion is designed to fit inside the original equipment AAM 9.25-inch front and 11.5-inch rear axles without modifications to the transmission or the truck’s on-board computer.  In pre-2007 pickups the front axle requires a new redesigned differential case along with new side and differential pinion gears.  All 2007 models have the advantage of coming with a factory installed redesigned differential case, side and pinion gears making the installation process easier.  

 AAM PowerDense® Ring and Pinion Gear Sets – AAM utilizes state-of-the-art face hobbing to generate the gear tooth form in a two-cut process.  This represents AAM’s latest effort to enhance NVH, durability, quality and reliability of its ring-and-pinion gear sets.  The key advantage of a two-cut gear set occurs when the components are being hobbed or generated.  Hobbing creates more surface area and equal tooth depth.  This produces lower alternating bending stress levels while creating a more even distribution of loading across all of the teeth.  The results are reduced levels of NVH and increased durability.   Another key advantage of the two-cut process is the use of continuous indexing.  In the manufacturing process the gear teeth are generated simultaneously with uniform tooth spacing and no imperfections.        

Additionally, the two-cut manufacturing process permits tighter backlash specifications between the gear and the pinion.  Backlash is defined as the amount of free play between two gears in their operating positions.  The results are reduced heat, NVH, driveline clunk and increased gear set durability.   Finally, two-cut manufacturing is an environmentally friendly process.  Since the components are dry cut, the presence of a coolant medium at the point of engagement of a tool and a component is eliminated.  Without coolant, no mists or smoke are produced.   

Tough Stuff – AAM PowerDense® gear sets are made from high quality Society of Automotive Engineering (SAE) steel purchased only from approved AAM and OEM steel suppliers.  Special high core hardenability steel is utilized to enhance the design and manufacturing process of the gear sets.   

AAM Ring and Pinion GearMade Even Tougher  – The specified steel also lends itself to precision shot peening which extends the life of AAM PowerDense® gear sets.  In this process spherical shot is targeted at the root of the gear teeth and bombards the surface, resulting in compressive stresses to combat fatigue loading.  The compressive stress increases AAM ring-and-pinion durability and reliability.  AAM parts are also forged, lapped and heat treated to meet OE manufacturers’ stringent standards.  Coordinate Measuring Machines (CMM) are then used to inspect the parts for accuracy.   

AAM – Tough to Beat  AAM engineering teams have advanced the design and manufacturing processes of driveline systems, chassis systems and metal formed products since 1994.  AAM designs, tests and validates its ring and pinion sets to vehicle manufacturers’ exact specifications.  AAM’s on-going programs in NVH, thermal management, vehicle-system efficiency, dynamics and vehicle handling and other disciplines assure customers that the parts they are getting incorporate the latest product, process and systems technology. For more information on AAM gear sets and other products and services, visit the Internet at http://www.aam.com or dial 1-800-299-AXLE.  

About AAM AAM is a world leader in the manufacture, engineering, design and validation of driveline and drivetrain systems and related components and modules, chassis systems and metal-formed products for light trucks, sport utility vehicles and passenger cars. In addition to locations in the United States (in Indiana, Michigan, New York and Ohio), AAM also has offices or facilities in Brazil, China, Germany, India, Japan, Luxembourg, Mexico, Poland, South Korea and the United Kingdom.     

Certain statements contained in this press release which are not historical facts contain forward-looking information with respect to the Company’s plans, projections or future performance, the occurrence of which involves risk and uncertainties that could cause the company’s actual results or plans to differ materially from those expected by the company which include risk factors described in the Company’s filings with the Securities and Exchange Commission. 

For more information…

Renee B. Rogers – Manager, Communications & Media Relations                         

(313) 758-4882                                                                     

Renee.Rogers@aam.com 

Or visit the AAM website at www.aam.com

October 16, 2007 Posted by | Automotive | 1 Comment

MTU holds topping-out ceremony in Überlingen

MTU Friedrichshafen holds topping-out ceremony: The new Logistics Center for spare parts which is currently under construction in Überlingen will provide the future hub for MTU’s entire spares logistics processes, ensuring significant benefits for the whole sequence from order through to dispatch. Precisely coordinated IT systems will be available to control and monitor every stage of work in the new stores which are located on a covered site extending over a total of 20,000 square meters or the equivalent of three football pitches. The Logistics Center will house around 60 workers and provide approximately 14,000 storage locations in a 14-meter high-bay pallet store served by high-lift stackers.

The Center will also accommodate a fully-automatic small parts store with around 35,000 storage locations served by automatic rack storage and re-trieval units. Other storage and order-picking systems will also be in place to handle bulky and heavy items such as crankcases.

Central location simplifies spare parts logistics

The new facility is MTU Friedrichshafen’s response to the increasing de-mands associated with spare parts logistics. 20 years ago, MTU erected a logistics center at its Friedrichshafen-Manzell plant. Over the years, how-ever, demand has outstripped the capacity available there so that the company had to rent several different off-site stores and was no longer able to process spare parts storage centrally. The processes involved be-came ever more complex whilst the market demand for just-in-time supply continued to grow with customers expecting same-day processing of their orders.

Integration of IT systems

MTU’s economically efficient and comprehensive concept for spare parts logistics at a new, central location satisfies these market requirements as well as benefiting its lucrative spare parts business. The concept involves storage systems which are automated and mechanized to a high degree so that the integration of the materials flow and the IT systems is a vital factor in ensuring fast and trouble-free operation.

In future, all orders will be processed online at MTU with computerized control from receipt of order to dispatch. To achieve this, amongst other tools, MTU will be using the “Extended Warehouse Management” program which was specially developed by the SAP company. This warehouse administration software was conceived with large-scale spare parts stores and complex processes in mind and it controls all the processes which run within the stores. When an order is received, the parts required need to be removed from the store and collated. In the case of items from the small parts store, this is accomplished using fully automatic rack storage and retrieval units moving at up to four meters a second. Items from the 14-meter high pallet store are retrieved by high-lift stackers.

With 14,000 storage locations in the pallet store and 35,000 in the fully-automated small parts store, powerful software is needed to ensure a clear overview. The warehouse administration software to be used can depict the entire warehouse in detail on screen. The quantity of any particular spare part available can be determined with a click of the mouse and the system can also identify the parts’ exact location.

The software controls order collation and processes procedures between the placement of an order and dispatch of the goods rapidly and reliably. As a result, even urgent, last-minute orders from foreign customers can be made up on the same day and passed on to the relevant logistics partner ready for dispatch and with the correct transport order. In future, orders received before 16:00h will be guaranteed for same-day dispatch without the need for any special procedures.

Operation to start in mid-2008

MTU placed the first orders for the new storage facility in April 2007 and tendering for various fitting-out contracts is currently in progress with the aim of completing the building by December 2007. Installation of the technical facilities is scheduled to begin in parallel.

Comprehensive systems and facilities tests are planned for the first quarter of 2008 with relocation due for completion by the end of June 2008 when the entire spare parts logistics system will be run from the Überlingen facility.

October 12, 2007 Posted by | Parts | 2 Comments

MTU DETROIT DIESEL SERIES 106 ENGINES FOR TRUCK AND LAV APPLICATIONS

 MTU Detroit Diesel has unveiled its latest offering for the defense market, the Series 106 diesel engine family for trucks and light armored vehicles (LAV). These engines available in four- and six-cylinder in-line versions produce between 100-325 horsepower and are rated the lightest in their power class.

The Series 106 has already been proven in military applications. The engines come equipped with electronic engine management systems, direct injection, turbocharging and air-to-air charge air cooling.  The engines have wet weights of only 917 lbs. for the 4R and 1,248 lbs. for the 6R. Both are compatible with diesel and jet fuel and have passed NATO 400-hour testing.

“These are commercial, off-the-shelf engines currently in high-volume serial production,” said Tedd Grulke, Director of Defense Sales. “MTU Detroit Diesel has a long-term perspective on the defense business, so we will be making this engine for some time to come.”

The Series 106 engine family will be manufactured both in the United States and Germany, and is currently being demonstrated in the Combat Tactical Vehicle Technology Demonstrator (CTVTD) at the Nevada Automotive Test Center. 

October 9, 2007 Posted by | Defense | Leave a comment

MTU Detroit Diesel 5R890 Successfully Tested for US Army FCS

The newest member of the MTU Series 890 family had a successful initial run on a test bench at the company facilities in Friedrichshafen, Germany in September 2006.  The in-line, five-cylinder diesel engine, 5R890 (MT 895), is rated at 590 horsepower (440 kW) at 4,250 rpm. This configuration will be used in the US Army Future Combat Systems Manned Ground Vehicle.

Since the initial run, the company has built, tested and delivered four 5R890 engines with plans to produce eight more by December 2009.  In addition to the many engineering verification tests accomplished, HALT (highly accelerated life testing) and cold testing has been initiated in 2007 and is currently ongoing.

The Series 890 family takes power density to new levels for conventional diesel engines. The demonstrated design targets are one kilowatt of power per kilogram of weight, coupled with the smallest possible external dimensions. The engine uses all of the available packaging space for integrating oil system components within the crankcase, resulting in straight line exterior contours. The crankcase and pistons are made of aluminum to reduce weight, while the cylinder heads are cast iron and the connecting rods and crankshaft are made of steel to increase strength.

The five-cylinder configuration joins the other family members now on test or in the hands of customers, including the V10 in the German Army Puma; the V6 for US Army Tank Automotive R&D Center, and the in-line 4 used in Rheinmetall Landsysteme GeFas vehicle. Through September 2007, the total running hours of the series 890 engines now add up to nearly 7,000 hours with the 5R890 accounting for approximately 1,000 of these.

October 5, 2007 Posted by | Defense, Uncategorized | 2 Comments

MTU DETROIT DIESEL DEBUTS NEW POWER DRIVE UNITS

MTU Detroit Diesel has introduced a new Series 900 PowerDriveUnit for the maintenance of way (MOW) market designed with maximum flexibility in mind. These integrated systems are engineered to provide power when you need it between 101- 275 hp, even under the harshest conditions of temperature, dust and workload. Combined with the company’s other offerings, customers now have access to power units covering the full range from 40-630 hp.

The heart of the new PowerDriveUnit is the proven Series 900 engine. Known for fuel efficient dependable power in other markets, MTU Detroit Diesel is now making this engine available to support maintenance of way operations.

“We are very happy to be able to provide these PowerDriveUnits for use in maintenance of way,” said Deanne Wise, Application Engineer for MTU Detroit Diesel. “We had strong input from this market and a demand for these units. The Series 900 engines have a reputation for reliability and performance, and we feel they will exceed the demands of this marketplace.”

The PowerDriveUnits are skid mounted and available in open or closed configurations depending on model option. The units come complete with radiator, air cleaner, muffler and optional control panels that make the units ready to connect directly to any on-site pump or power take off application.

Regardless of the application, MTU Detroit Diesel’s new PowerDriveUnits will deliver the performance, reliability, economy and durability that the job demands.

September 14, 2007 Posted by | MOW, Rail | 1 Comment

MTU Recieves EPA Approval: Independently Certified Green Tier 2 Rail Engine

MTU 16V4000 Tier 2 Certified Rail Engine  MTU received certification today from EPA for the first independently certified, high-speed rail engine. The low-emission 12V4000 R33 engine is optimized for the rail industry and meets EPA’s Tier 2 emission standard (40 CFR 92). 

“This is the first time EPA has certified to Tier 2 emission limits a stand-alone, high-speed engine for use in locomotive applications,” said Doug Berry, MTU Detroit Diesel Rail Sales Manager. “Certifying the engine itself, instead of the locomotive as a whole, provides OEMs and operators the flexibility to use this engine in any locomotive application, whether for re-powers or new construction.”

With MTU’s experience in the European rail business and leadership in today’s clean diesel technologies, the introduction of its new Series 4000 rail engine allows the company to offer a certified engine that is ideally suited for the new emissions challenges posed by the North American rail market.

The new MTU 12V4000 R33 engine provides 2,250 horsepower at 1,800 rpm and has the latest in common rail fuel injection systems, advanced turbocharging and Advanced Diesel Engine Controls (ADEC) electronics for cleaner, more efficient operations.“MTU has been a leading force in developing clean diesel technology,” said Berry. “The technology in our new rail engines has been used on rails worldwide and in numerous other applications, from mining trucks to tug boats. That proven track record gives us an edge over the competition and provides peace of mind for our customers.”

The Series 4000 engines have been optimized for use in the rail market by:

  • Adding water-cooled exhaust and turbochargers to reduce engine skin operating temperatures and provide unprecedented safety.
  • Employing MTU’s patented, second-generation common rail fuel injection system for better fuel efficiency.
  • Utilizing a self-cleaning oil filtration system to reduce maintenance downtime.
  • Designing the turbocharger and exhaust outlets to be reversible to allow for more installation flexibility for locomotive builders.

August 7, 2007 Posted by | Rail | 3 Comments

Tognum Group acquires Katolight, a manufacturer of gensets in Mankato, Minnesota, USA

Mankato, Minnesota (USA) /Friedrichshafen. Tognum GmbH, headquartered in Friedrichshafen, Germany, today announced the acquisition of Katolight Corp., a U.S. manufacturer of generator sets. Katolight is based in Mankato, Minnesota, USA, and produces diesel and gas-powered engine generator sets for industrial and agricultural applications as well as for emergency power supply, covering a power range of 15 to 3,250 kilowatts. With around 340 employees, Katolight posted sales revenues of approximately $135 million (approx. €100 million) in 2006/07 (fiscal year ending March 31, 2007).

The parties to the transaction have agreed not to disclose any details of the price paid. “With the acquisition of Katolight, we have passed another milestone on our track to become a globally leading provider of decentralized power generators,” stated Volker Heuer, CEO of Tognum. “Katolight is a perfect element in our growth strategy, because it is a well-positioned brand and an excellent supplement to our product range in the important and further growing North American market. Another crucial factor is that Katolight gives us direct access to end-customers.”   Business relations have already existed between Tognum and Katolight for many years. For example, some of Katolight’s generator sets are based on diesel engines from the core Tognum company, MTU Friedrichshafen GmbH. Its subsidiary, MTU Detroit Diesel Inc. (in Detroit, Michigan, USA), supplied more than 170 of its Series 60, Series 2000 and Series 4000 engines to Katolight last year.  “We know the company very well and know that we have acquired a platform with great potential for the distribution of power generators, primarily based on our own engines,” explained Heuer. MTU Detroit Diesel, while now supplying Katolight with engines, will maintain its role as engine supplier to other customers in North America. Katolight, a family owned business founded in 1952, was most recently owned by Kay R. Jacobson and managed for the past 21 years by her husband, Lyle G. Jacobson. “The main reason for the sale to Tognum was the fact that Katolight will be in the hands of a long-standing and reliable business associate”, said Lyle G. Jacobson. “It is also important to us that Tognum is taking over all of our workforce and will continue to operate under the Katolight name inMankato, Minnesota.” The new company in the Tognum Group will play a key role in the Systems and Components division offering standardized power generators. Katolight will be operated as a brand for generator sets based on diesel engines. It complements the well-known Tognum brands MDE and CFC Solutions, which specialize in gas-engine generators and fuel-cell generators, respectively.   “We are excellently positioned in the marketplace with this trio of proven and future-oriented products for the constantly growing demand for local power generation,” stated Tognum Executive Vice President Christof von Branconi, who is responsible for the Systems and Components division. “It is becoming increasingly important to have electrical energy available quickly and reliably wherever it is needed,” pointed out Branconi. “This is particularly apparent in the
United States, where hurricanes or heavy snowfalls often disrupt the regular power supply.” 
 
With immediate effect, Katolight will be managed by Armin Groeber as CEO, who until now has been responsible for the entire assembly of engines and main components at the core Tognum company MTU Friedrichshafen. Groeber already has over two years’ of business experience in theUnited States: he was Head of Operations for the North American region from 2002 until 2004. “I’m looking forward to returning to the United States,” said Groeber. “Taking full entrepreneurial responsibility for Katolight with its highly motivated team is a great opportunity to further develop the company and strengthen its market position.”

April 24, 2007 Posted by | Gen Sets | Leave a comment

MTU Detroit Diesel “Drilling for Solutions” with Series 60

In the hard driving, fast paced drilling industry time is a luxury seldom encountered. When Pollister Drilling Corp. of Elk Rapids, Mich. was looking to assemble a new project near Midland, Mich. they powered their drilling rig with MTU-Detroit Diesel units.

The Saginaw, Mich. branch of W.W. Williams, an MTU-DD distributor, supplied two Power Choice 14L Series 60 500 hp engines and two 350 KW Series 1 Power Gensets for the oil and gas drilling operation. “It was a combination of price and availability,” Ed Pollister, President of Pollister Drilling, said. “The competition was about a year out on delivery and nearly double on price.” W.W. Williams was able to provide the equipment in about three months.

“Ninety days compared to 11-months seems like an eternity,” Ron Taylor of W.W. Williams said.” We were able to provide the units in a timely manner where our competition couldn’t. And we did so at a good price.” “In addition to the price and availability Pollister wanted to try our DDEC electronic controls. The DDEC IV was used with these units. Our controls set the standards for the industry. We set the bar out there.”

A benefit to the combination of the engines and gensets selected is the common use of parts. “We wanted to put a package together with the engine and Genset’s where there was interchangeability among the units,” Taylor said. “There is continuity between the parts and they only have to stock one type of replacement and maintenance parts.”

 

The two Series 60 engines were factory remanufactured by the MTU-DD owned Specialty Tool Corp. of Cambridge, Ohio carrying the same one-year parts and services warranty as a new version. Although the engines are rebuilt, a good portion of the units have new parts. As much as 85-percent of the engine components are new.

“I have been real happy with the MTU’s,” Pollister said. “As far as the remanufactured engines go the availability was important, the warranty is the same and there is no difference in the work.”

April 6, 2007 Posted by | Oi & Gas | Leave a comment

MTU Detroit Diesel Series 906 and TigerCat’s New H850C Harvester Ready for the Woods

After a year in the development process the new TigerCat Harvester has fired up its MTU Detroit Diesel 906 series engine. The six cylinder engine that develops 275 horsepower at 2,200 rpm will begin rigorous testing in March.  

“The smaller displacement, fuel efficiency and our previous experience with the 906 in the TigerCat line of forwarders made this the perfect engine for this application” said TigerCat’s Product Manager Track Machines, Andy Hoshel.

The H850C is designed specifically to replace converted excavators. All TigerCat harvesters offer a number of advantages over excavator conversions including a high capacity cooling system, the highest quality steel construction throughout, a spacious, well finished operator’s station and the TigerCat-built, forest-duty under carriage that can boast a more robust construction and a heavy frame plate that easily handles demanding forest conditions. “Dust, debris and pine needles and the like are always a clogging issue that need to be addressed” says Hoshel. “Making routine maintenance easy is essential.” The design of the H850C allows excellent access to pumps, valves and coolers that is far superior to converted excavators.

When considering a major equipment purchase, costs are always a consideration and while the upfront investment in a harvester may seem significantly more than in a converted excavator there are several things to be considered. If you want to take the excavator into the woods there are all sorts of improvements needed: Additional cab safety for the operator, greater cooling capacity and increased armor to stand up to rigorous challenges of forest operations. By the time all this is accomplished the costs aren’t so different and basically you still have an excavator that was designed with a hydraulic package to dig dirt.  

Hoshel quipped “if you put big tires on a pickup, made a few adjustments and found the right attachments you could probably plow a field. But if you invested in a tractor designed for the job you’d plow better, quicker and more safely which all add up to improved profit.” 

 

April 5, 2007 Posted by | Forestry | Leave a comment