Hybrid drive at forefront of Case environmental initiatives
A prototype hybrid materials handling excavator from Case Construction Equipment has the potential to reduce fuel consumption for customers by up to 40%, with a substantial cut in exhaust gas emissions.
Case already meets future emissions legislation both in Europe and the USA but continues to explore alternative fuel and driveline solutions, it says. It is also exploring way of reducing the environmental impact of its manufacturing plants around the world.
Key elements of the prototype Case hybrid materials handling machine - displayed at the Intermat 2009 exhibition in Paris - include an electric generator, an electric swing motor and a magnet. The machine retains a diesel engine to power the hydraulic system for the boom and track drive, but this motor also drives the electric generator, which in turn is used to power the lifting magnet and the electric slew motor.
When the engine is under low load conditions, surplus energy is converted to electricity and stored in high efficiency capacitors. As the engine comes under higher load, the electrical system provides power support, allowing for constant engine speed hence reducing fuel consumption and noise level.
Working in a repetitive operation such as scrap handling, the machine is continually turning from one side to the other. An electric swing motor uses less energy than a hydraulic motor, reducing energy consumption. When slowing down swing, the energy generated is again stored for later use by the capacitors.
A third energy saving is achieved by having the magnet generator integrated into the hybrid drive, rather than powered by the machine's hydraulic pumps. In this way the magnet makes use of the additional electrical energy stored in the system.
By reducing fuel consumption there is an immediate reduction in gaseous exhaust emissions, resulting in a lower environmental impact and a significant cut in operating costs for the customer.
Biofuels and emissions legislation
In the search for a sustainable, renewable energy source, there are a number of options that will be used by manufacturers over the coming years. In some territories this will include biodiesels, Case believes.
At present all Tier 2 and Tier 3 engines produced and used by Case Construction Equipment are approved for use with quality biodiesel. Today, most Case construction machines can be used with a B20 blend of quality biodiesel.
However, for the foreseeable future, low sulphur diesel will remain the major fuel used by construction equipment suppliers worldwide. Case is therefore well equipped to meet the increasingly stringent regulations that control exhaust emissions, in North America, Europe and Asia.
Engines producing more than 130kW will have to meet Tier 4 regulations in January 2011. Case is working with its sister company Fiat Powertrain Technologies (FPT) to provide solutions to meet these new requirements.
The latest F32 engine from FPT is specifically designed for off-highway and static applications. It is a 3.2 litre four cylinder motor capable of delivering 65kW (88hp) at 2,500rpm and a maximum torque of 320Nm at 1,400rpm.
Environmentally responsible manufacturing
Case says that its plants in North America and Europe are working hard to reduce their carbon footprint, from reducing packaging waste to cutting electricity and natural gas consumption,
At the Burlington plant in the USA, home to the Case backhoe loader for the North American market, the company has reduced hazardous and non-hazardous waste as well as significantly reducing emissions from the painting process and cutting water consumption by more than 8m gallons (36m litres) a year.
The installation of an energy recovery system on the paint oven exhaust stack has resulted in a US $54,000 (€42,000) energy saving each year. But more than that, Burlington aims to be using at least 5% renewable energy by 2010 and the plant has plans to send no waste whatsoever to landfill by 2013.
At the Wichita plant, where the Case skid steer range is produced, the company has replaced any hazardous air pollutant solvents in the paint process with non-hazardous materials. In total the plant has reduced air pollution by more than 32 per cent in the last two years, and additional work will further reduce the facility's impact on the environment.
The installation of modern, low energy, electrical fixtures has contributed to savings, while shipping packaging has been targeted as a major area of waste. In the last year Wichita has cut timber packaging by 775 tonnes per year, while installing a wood crusher that has contributed to further savings. At the plant more than 75% of all waste is now recycled, with just 12% now going to landfill.
In Europe too, Case is working hard to reduce the impact of its manufacturing operations. At the Imola plant in Italy, Case is planning to reduce energy consumption by 14% by 2010. It also intends to reduce water use and cut the generation of waste materials.
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