Components: The sum of its parts

18 January 2017

John Deere Power Systems has designed and implemented a fully integrated electric hybrid drivetrain

John Deere Power Systems has designed and implemented a fully integrated electric hybrid drivetrain system for demanding off-highway applications

Components really do represent the nuts and bolts on construction machinery, and play an essential part in ensuring a machine operates effectively and efficiently. As well as specialised component companies, large equipment manufacturers are now producing their own components to ensure they’re keeping up-to-date with the many advances in construction technology.

One such company is Liebherr, which has been busy innovating components, including a new installation version of its common rail injection system 11.2, as well as a new engine control unit, which it announced at Bauma China in November.

Both products were developed in-house by Liebherr in the second half of 2016, with a view to meeting off-highway emissions standards, in the shape of EU Stage V.

The second generation of the common rail system 11.2 is an update of its original product, which offered a side feed injector, through high-pressure connectors. Its latest generation, however, offers a top feed injector. In the top feed version, the connections for the pressure lines are located at the top of the injectors, which makes other rail and pressure line positioning options possible, says Liebherr. At the same time, the company has developed an enlarged nozzle variant with a maximum nozzle flow rate of 2,200 ml/30 seconds.

Liebherr says its new version of the 11.2 system offers its customers further flexibility, with the option to adapt more specifically to its requirements.

The new generation also covers a performance range of 120
to 800 kW. Liebherr even claims that, in “exceptional cases”, it can deliver up to 1,000 kW. The 2-cylinder inline pump with oil-lubricated crankshaft delivers up to 300 litres of fuel per hour at 2,200 bar working pressure. The injectors supply a maximum full load injection volume of 300 mg with steady multi-point injection.

Meanwhile, the company’s new ECU3 engine control unit claims to have been completely revised for the new generation of 11.2 common rail systems. As an all-in-one system, Liebherr says it comprises all control functions – not only for the engine and the common rail system, but also for exhaust gas aftertreatment.

The company says it ensures compliance with the common off-highway emissions guideline EU Stage IV and Tier 4 final.

The ECU3 control unit features freely programmable I/O (input/output) customer interfaces and supports internationally common communication protocols like J1939, XCP and UDS, claims Liebherr. The company also says its air-cooling feature makes the product suitable for all applications.

Inside the cab

Moving inside the cab, Danish company Danfoss has launched its new JS1 joystick, beginning its new “JS1-H family”.

Danfoss says its joystick constituted a customisable and ergonomically optimised design, which is easily integrated into the existing workflow of OEMs (original equipment manufacturers).

The company says the JS1-H family combines a professional look, touch and feel with superior quality, making it operationally and technically impressive, as well as safe.

Rüdiger Hüttmann, product manager at Danfoss Power Solutions, said, “Danfoss has drawn on its years of experience both engineering components and working with OEMs to engineer systems to develop the JS1-H family and the entire JS1 joystick platform.

“We are excited to offer our customers – small, medium and large-size OEMs alike – a new level of machine control.”

The JS1-H family of joysticks offers a versatile solution designed for use in heavy-duty mobile machinery such as wheeled loaders, dozers, dumpers, trenchers and haulers in the construction market, as well as pavers, graders, rollers and milling machines in roadbuilding.

The grip options on the joystick are compatible with all base options, and feature six standard electrical interfaces, making it easy to select the suitable choice. The joystick is also PLUS+1-compliant, which Danfoss says gives better control for data and programing.

Meanwhile, Danfoss has launched its new DP730 and DP570 mobile machine displays, featuring a larger-size touchscreen-only display. The DP570 is best used for smaller-scale applications where buttons are needed, it said.

The DP730, which is a new addition to the DP7xx Series, offers three different LCD display options for both in-cab and open use to meet a variety of needs in applications such as drilling, roadbuilding, construction, and specialty vehicles. It is equipped with a 178 mm projective capacitive touchscreen-only display that works through mud and water, and with gloves. In addition, IP69K level protection and a wide operating temperature range of -30° to 60° aim to keep the display working even in extreme outdoor conditions.

The DP570 is described as a similarly robust product, but is specifically suited to in-cab and mid-size control panel machine applications, including material handling, agriculture and speciality vehicles. The DP570 has a 145mm-inch high resolution TFT colour display, an IP67 rating, and a temperature range of -20° to 60°.

Darren Magner, product manager, displays, for Danfoss Power Solutions, said, “Danfoss is committed to providing distributors and OEMs with robust and rugged display options to meet their unique business needs.

“Our PLUS+1 mobile machine displays are specifically designed to perform reliably in extreme conditions, therefore preventing downtime.”

Fully integrated

John Deere Power Systems (JDPS) says OEMs looking for low emissions footprint solutions are starting to turn to its products in off-highway powertrain technology for electric drive components. The company has designed and implemented a fully integrated electric hybrid drivetrain system for demanding off-highway applications.

The portfolio of John Deere electric drive systems was created through a co-ordinated effort between JDPS and John Deere Electronic Solutions (JDES). JDES developed a series of rugged inverters using a simple, modular design for flexibility that can be integrated in a variety of applications. The inverter continuous power goes up to 300 kVA and nominal voltage to 750 V. They also combine multiple functions into a single or dual configuration, which JDPS claims saves costs by reducing the number of interfaces, cables and connections.

The generator pump drives from JDPS – that come in two power ranges, 200 kW and 400kW, as well as the Series Three Speed Electric (STSE) transmission – have accumulated over 250,000 hours in John Deere construction equipment applications. JDPS says that, once combined, the product offerings from its two companies work in conjunction to deliver a “complete electric drive system” for OEMs exploring new ways to utilise electric power.

Darren Almond, global drivetrain business manager, JDPS, said, “The modular nature of the components in our electric drive product portfolio allows them to be considered for a variety of vehicle forms, including construction, mining and even marine applications

“This technology opens the door and creates the possibility for many innovative solutions.”

Since 2013, John Deere has applied diesel-electric hybrid systems on two of its wheeled loaders – the 644K Hybrid and 944K. While the two machines use electric power in different ways, they were both designed to improve machine performance, says JDPS.

The conventional drivelines and axles in the 644K Hybrid are powered by an electrically-driven three-speed transmission. An alternate series electric architecture was used with the 944K, which uses individual wheel motors and gear boxes at each wheel.

JDPS says that this example illustrates how similar applications with comparable functions can use a John Deere electric drivetrain system in varying capacities.

New launches

Components company CrossControl – which recently changed its name from Maximatecc – says its launching a new platform of controller products, which feature highly configurable I/O interfaces.

All its configuration is software-based and the platform uses CODESYS for configuration and application programming. CrossControl says the platform enables OEMs and system designers to design modular control systems, where it is easy to handle optional features and variations across a wide equipment product range. It says the modular approach takes down system cost and that software recycling means reduced time and money.

One of its products – the CrossFire SX – is said to be a versatile I/O controller that is freely configurable as Master, Slave or Smart Slave. With the Smart Slave configuration a slave can be programmed to perform closed loop control tasks. It has 40 I/O channels that can be set up for virtually any sensor or actuation device, meaning it can be applied for different controller jobs in a system.


Dana Holding Corporation is another company which has improved its products, enhancing its Spicer PowerBoost hydraulic-hybrid powertrain technology. It claims an increase in performance, productivity, and fuel economy of telehandlers and other off-highway vehicles.

These enhancements are said to enable vehicles to supply up to 20% more hydraulic power to the work circuits and perform work functions up to three times faster than vehicles that are not equipped with this advanced hydraulic-hybrid technology. Such improvements, says Dana, can further enhance overall productivity by up to 10% and generate additional fuel savings of up to 5% over and above the efficiency gains previously demonstrated by Spicer PowerBoost technology.

Aziz Aghili, president of Dana Off-Highway Driveline Technologies, said, “For off-highway machine owners and operators, increased productivity is key to the success of their businesses, and vehicles that can perform faster in a reliable and safe way will significantly improve their profitability.

“This latest enhancement to Spicer PowerBoost technology enables a much higher level of vehicle performance without increasing the size of the engine or the capacity of hydraulic pumps.”

Interestingly, Dana put this new technology to the test, working with Manitou in its MLT960 Eco-Booster 6 tonne telehandler machine.

Extensive performance analyses indicated a reduced fuel consumption averaging 15% across a range of duty cycles when compared with the standard MLT960 configuration, said Dana.

Quick, easy and convenient

Fireproofing specialist Graco has launched its new ToughTek F340e portable fireproofing pump, which it claims provides a quick, easy and convenient solution.

Stephan Rindfleisch, Graco product marketing manager, said the pump was designed for small touch-up jobs in difficult-to-access locations, and is small enough to be transported in the back of a pick-up truck.

The small, highly mobile unit runs on a single-phase 230 V power supply, and is based on piston pump technology, while handling all kinds of fireproofing materials.

Graco says that, due to new unit’s size and mobility, the ToughTek F340e can get closer to the application point.

The unit is classed as a plug-and-play unit, which is operated by dialing in the speed preferred.

The company says the pump can spray all kinds of low, medium and high density fireproofing materials.

“Graco also offers a bigger brother to the F340e,” says Rindfleisch. “The ToughTek F680e has a hopper capacity of 114 litres and a maximum output of 41 litres
per minute.

It can take a hose length of 90 m and can spray vertically up to 60 m.

The unit is still portable, although obviously with its larger footprint won’t fit into such tight spots as the F340e.”

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