tier 4 interim off-highway product development and systems

| CATERPILLAR CONFIDENTIAL: YELLOW

SCALING NEW HEIGHTS IN EXECUTION

Page 1 | CATERPILLAR CONFIDENTIAL: GREEN

Tier 4 Interim Off-highway Product Development and Systems Integration

Kevin P. Duffy, Ph.D.

Manager, Energy and Power Systems

Caterpillar Inc.

IMechE

Conference on Internal Combustion Engines:

Improving Performance, Fuel Economy and Emissions

CAT, CATERPILLAR, their respective logos, "Caterpillar Yellow," the "Power Edge" trade dress as well as corporate

and product identity used herein, are trademarks of Caterpillar and may not be used without permission.




Customer

competitive

advantage

We develop technologies providing

building roads developing

infrastructuregenerating power

providing mobility

extracting natural

resources

Customer

Value and

Caterpillar

Inc.




2010 Revenue ‐

$42.6B

North America ‐

$16.1B

Asia / Pacific ‐

$10.3B

Europe / Africa / Middle East ‐

$10.0B

Latin America ‐

$6.2B

104, 490 Caterpillar Employees

188 Dealers w/ 126,700 Employees

$1.905B in Research and Development

Construction

Industries

Financial

Products

Power systems

Resource

Industries

Caterpillar

Inc. by the numbers




What Does it Takes to Develop Efficient Off‐road and Industrial Engines for the 21st

Century?

• Answer: A lot of money (but it must be more than that or Microsoft would be the #1 engine manufacturer in

the world!)

• Real Answer:– Understanding your customers and the markets they serve

– Understanding of complex worldwide regulations

– World class facilities

– World class people

– Offer an engine system solution that meets those needs




What it Takes to Develop Efficient Off‐road and Industrial Engines for the 21st

Century

Understanding your customers and the markets they serve




http://www.manitou-na.com/press/MHT10210.jpg




Agriculture Construction Industrial Electric Power

Allam Marine Ltd

Diverse Customer Base –Sector Needs

Perkins Engines Applications

http://www.atlascopco.com/





Century

Understanding of complex worldwide regulations




Multiple Emissions Tiers –

2013Global markets demand

multiple platforms

• Tier 4• Tier 3• Tier 2• Tier 1• Tier 0

EU, EPA, MLIT, CARB, etc.




Extended ambient conditions

Emission limits and timing

Crankcase emissions

37-56 kW compliance options

Test cycles

Not-to-exceed

In-use testing

Flexibility

Averaging, Banking &Trading

Fuels and biofuels

Allowable maintenance

Useful life and emission warranty

Application for certification

Engine families

Labeling

Rebuilding provisionsDelegated assembly

Selective enforcement audits

Confirmatory testing

Defect reporting

Noise Regulations

Infrequent regeneration

Deterioration factors

Caterpillar employs over 100 people

worldwide to interpret, guide, and ensure

compliance with these complex regulations




In-use testing – application challenges





Century

World‐class facilities




Mossville, USA

HEDC Japan

EDC - India

Global Product Development Operational Model

Customer Support Offices

Wor

ld W

ide

Prod

uct

Man

agem

ent

Regional Test Center(s)

Technical Resource Center(s)

Regional Design Center(s)

Wuxi, China

Peterborough, UK

Stafford, UK

Global Product Development




Test and Development FacilitiesNoise Testing

Performance/Endurance Testing

Tilt Testing

Cold Cycle Testing

Transient test cells, PM weighing room





Century

World class people




• Engineering, Sales/Marketing, Finance, Manufacturing, Human Resources, etc.

• Thousands of employees with advanced degrees

• 100’s of patents awarded annually

# of

employeesNorth

AmericaLatin

AmericaEurope,

Africa,

Middle

East

Asia

PacificTotal

Caterpillar 51k 14k 26k 10k 101k

Cat Dealers 53k 17k 29k 23k 122k

Global Employment Workforce





Century

Offer an engine system solution that meets those needs




3116/3126/C-7(86 - 313 kW)

3200 Family(93 - 336kW)

3300 Family(63 - 300 kW)

C-9/C-11/C-13(227 - 492 kW)

C-15/C18/3400 (186 - 1044 kW)

3500 Family(507 - 2500 kW)

3600 Family(1350 - 7200 kW)

M20(1020 -1710 kW)

M25(1800 -2700 kW)

M32(2880 -8000 kW)

M43 (5400 -16200 kW)

800 Series(39 - 60 kW)

1100 Series(49 - 186 kW)

400 Series(3.7 - 45 kW)

4000 Series(322 - 1886 kW)

Diesel Engines




3300 Family(30 - 165 kW)

3400 Family(93 - 500 kW)

3500 Family(500 - 2000 kW)

3600 Family(1200 - 3850 kW)

2000 Series(114 - 176 kW)

3000 Series(152 - 251 kW)

4000 Series(309 - 1000 kW)

G16CM34 (6100 kW)

Natural Gas Engines




Fuel Impact to increaseAnnual Imported Crude Oil Price

0

10

20

30

40

50

60

70

80

90

100

1968 1972 1976 1980 1984 1988 1992 1996 2000 2004 2008 2012

Dollars per barrel

Nominal Price

Forecast

EIA Short-Term Energy Outlook, February 2011

Real Price (Feb 2011 $)

0%

20%

40%

60%

80%

100%

U.S. Europe China India

Depreciation Labor Fuel Maint

Typical Construction Equipment

Owning and Operating Costs

2000 Hrs/Year

Machine Operation

Fuel Prices

US $3.5/Gal

Europe $6.6/Gal

China $4.4/Gal

India $5.0/Gal




Fuel Savings Opportunity

Mining40%

Earthmoving23%

Excavation23%

Building & Construction

14%

Cat Product Vehicle Fuel Usage / Year / 1 Year’s Production Volume

Estimated $5B of Diesel Fuel Consumed @ 2010 Prices




Energy Audits: 2010 Machines

0.0%

10.0%

20.0%

30.0%

40.0%

50.0%

60.0%

70.0%

80.0%

90.0%

100.0%

% F

uel u

sed

by M

achi

ne

Hydraulic losses

Drivetrain Losses

Fan

Useful Work

WheelLoader

Hydraulic Excavator

MotorGrader

Exhaust Energy

Heat Rejection

Flywheel Work

Machine Efficiency Opportunity




Caterpillar Approach to Efficiency – Attack All Levels




Engine

New Combustion

Bowl Geometry

Cooler

CT

Mixer Aftercooler MEUI-A Plunger PressureMEUI-C Plunger PressureMEUI-A Injection RateMEUI-C Injection Rate

Impact – up to a 5%

fuel consumption

improvement on Tier 4

Interim Machines

System Approach

‐Air

‐Fuel

‐Combustion




Perkins Tier4i Ratings Challenges

• Complexity increasing• 50+ unique calibrations

(customer and application driven)

• Time to develop (months=$$)

• Worldwide Certification

Calibration Complexity

0

500

1000

1500

2000

2500

3000

Tier3 Tier4i Tier4f#

of c

alib

ratio

n va

lues



Page 27 | CATERPILLAR CONFIDENTIAL: GREEN 27Caterpillar Overview

Articulated Trucks

Backhoe Loaders

Compactors

Forest Machines

Material Handlers

Motor Graders

PipelayersPaving Equipment

Off-Highway Trucks

Track-Type Tractors

Track Loaders

Wheel Tractor- Scrapers

Skid Steer Loaders

Wheel Excavators

Wheel Loaders

Wheel Dozers

Underground Mining

Cold Planers Compact Track and Multi Terrain

Loaders

Feller Bunchers

Forwarders Harvesters Industrial Loaders Knuckleboom Loaders

Road Reclaimers

Skidders Telehandlers

Electric Power

Hydraulic Excavators

Transmission/Drivetrain

Caterpillar has broad

technology portfolio,

and application

experience.

Caterpillar chooses

technologies for each

of our machines for

optimal Customer

Value




Multi‐Systems Integration

2.53 (16.3%)3.69 (13.6%)30 kph GSL, w/STC

2.35 (7.9%)3.48 (7.1%)30 kph GSL, Base Control

2.18 (Base)3.25 (Base)Base Control

Long Flat Work Cycle

Medium Flat Work Cycle

Fuel Efficiency (mTon / Liter Fuel)

2.53 (16.3%)3.69 (13.6%)30 kph GSL, w/STC

2.35 (7.9%)3.48 (7.1%)30 kph GSL, Base Control

2.18 (Base)3.25 (Base)Base Control

Long Flat Work Cycle

Medium Flat Work Cycle

Fuel Efficiency (mTon / Liter Fuel)

627H WTS Fuel Efficiency with new Controls

Ground Speed Limiting

– Scraper

cruise control

Smart Throttle Control

– Precise

power balance between Scraper

and Tractor engines




Conclusions•

To deliver the best products our customers deserve requires numerous

elements

–

Understanding your customers

and the markets

they serve

– Understanding of complex worldwide regulations

– World class facilities

– World class people

– Offer an engine system solution

that meets those needs

•

Efficiency, at all levels, is key to Cat Engine and Machine technology and

sustainability

•

Cat Tier4 products provide excellent customer value due to extensive

systems integration efforts




Thank You

tier 4 interim off-highway product development and systems

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