B - Introduccion Motores QST30 A.ppt

Programa Mecanico de Competencias Departamento de Servicio

Curso:“Familiarización Motores QST30”

Introducción


Objetivos del curso

El curso de motores SA12V140Z-1/QST30esta diseñado para cumplir con los siguientesobjetivos:

Objetivos del curso:El estudiante podra describir la estructura y funcionamiento, de los motores 12V140Z-1 / QST30, ademas de evaluar los conocimientos adquiridos


El Komatsu SA12V140Z-1 o

Cummins QST30Engine


Modelo de motor Komatsu

S A 12 V 140 Z - 1

Super charged engine (turbocharger)

Aftercooled

Number of Cylinders

V Type Block

Bore diameter in mm

Cummins Manufacture

Series




Modelo Cummins

Displacement (Liters)

Q S T 30 - (*)

QUANTUM Family

Engine SeriesSystem

Application Codes








Cummins Application Codes

C = Construction

D = Generator Drive

F = Fire Pump

G = Generator Set

L = Locomotive

M = Marine

P = Power Unit

R = Railcar


A New Addition to the Quantum Line

The Cummins QST30

or

Komatsu 12V140Z-1

Engine


QST30 /(12V140Z-1)

CKEC Seymore INQST30 /

12V140Z-1Application

Platforms (a) 330M (b)WA800 (c) WA900

KCEC Osaka Japan12V140-1Application Platforms (a) D475A-3

3rd Qtr 98 QST30

(b) HD785 Z engine Units built in

Peoria


Historia del SA12V140

1981 El desarrollo comenzo en 1981 con el SA6D140 1984 Se desarrolla la versión del SA6D140 “V” 1986 Primer prototipo

1987 Pre -Production

1988 HD785 (dump Truck)

WA800 (wheel Loader)

1989 D475 (bulldozer)


Komatsu SA12V140Z-1 Komatsu comenzo la produccion en Japon

en 1988 Los niveles de produccion han sido 200

unidades por año (270 en 1996) Los motores Komatsu han sido usado en

el camion HD785, en el cargador WA800/WA900, y en D475A-2 crawler dozer applications

Menos del 5% de estos motores se vendio para aplicación marina y generacion.


Komatsu SA12V140Z-1

Entre los años 1988 y 1992 Komatsu produce 400 motores SA12V140-1

Los estudios y evaluaciones completadas a los motores en Japon el año ‘93 comparan al SA12V140-1 v.s. K38

La compañía Cummins Komatsu Engine se forma en Oct. 1993.


Cummins Komatsu Engine Co.Se forma una sociedad 50/50Komatsu retiene el control del diseño

base de las opciones del motor controlEl control del diseño y las opciones del

cliente es retenido por CumminsCummins paga Komatsu una licencia por

cada motor Komatsu vendido.La sociedad emplea mas de 100

personas trabajando en el Centro Industrial Cummins


Desarrollo del programa QST30

El desarrollo del programa comienza en noviembre del año 93

Focus of efforts was to resource components through the Cummins supply base

Some engineering effort on re-design of fuel pump drive and mounting to accommodate Bosch fuel pump

Power Gen. and Industrial Electronic controls designed entirely by CECo.


QST30 Recursos puestos

-75% del total del costo del motor es suministrado a travez de Cummins. Examples include : Golden: Fundicion del block CKEC: Mecanizado del block Bosch: fuel pumps and

injectors


QST30 Recursos puestos

Holset: turbochargers, air compressors, & dampers Cifunsa: Fundición de la culata Cummsa: Mecanizado de la culata Concentric: Boma de aceite y

bomba de agua Delco: Motores de arranque


QST30 Resourcing Effort

Varios componentes siguen siendo suministrado

por Komatsu:

Pistones

Rough block castings

Camisas

Metales

Maquinado del Cigueñal

La mayoria de las empaquetaduras


Producción lanzada

– Power Generation• Full production began in 4/96 or Onan only• G-drive production began in 4Q96• -250 engines built in ‘96• -600 planned for 1997

– Industrial • Limited production launch 7/97• -60 engines planned for 1997

12V140-Z1/QST30Komatsu America International Company – Service Training

12V140Z-1 / QST 30

Base Engine Introduction


Discussion of Selected Engine Components

General Engine OverviewValve Settings:

Intake Valve Adjustment 0.43 mm [0.017 in] Exhaust Valve Adjustment 0.80 mm [0.032 in]

QST3O Aspiration

-Turbocharged and Aftercooled


Discussion of Selected Engine Components

General Engine OverviewBore and Stroke140 mm x 165 mm [5.51 in x 6.5 in]

Compression Ratio: 14.0:1

Displacement 30.5 Liters [1860 Cu ml

Crankshaft Rotation

(Viewed from the front of the engine

Clockwise


CompactHigh OutputHigh Reliability and DurabilityFuel EconomyEasy Maintenance

Development Target


SA12V140Z-1 / QST30

Bore & Stroke 140 mm X 165 mm

Cylinder Arrangement 12 Cylinder

50 Degree Vee

Volume 30 Liters

Industrial Power Output 750 - 1050 Hp


1. Angulo Block 50 Degree VeeFiring Order:1R-1L-5R-5L-3R-3L-6R-6L-2R-

2L-4R-4L

2. Piston Ductile iron piston, High Top Ring

3. Culata Dry sleeve injector bore

4. Cylinder block FEM Design, STORM threads two bolt main with future four bolt main.

5. Crankshaft Induction hardened Journal Fillets

Diseño y caracteristicas


Caracteristicas Standard6. Diseño de bomba Inyectora Two Bosch RP39 or Two

Zexel KP21E with electro -hydraulic

governor7. Intake/Exhaust Layout offset 15’ Intake - Outside

Exhaust - Inside8. Bomba de aceite Alto flujo, diseño 3

engranajes 9. Aspiration Turbocharger & Aftercooled

10. Turbochargers Twin Holset HX60

11. Filtración de aceite Full flow and bypass filtration

12. Sistema de refrigeracion Conventional radiator


Sistema de combustible

4 sistemas son permitidos» Zexel PS7S with Mechanical governor» Komatsu High Pressure KP22 with

electro-hydraulic control» Bosch RP39/RE36 full authority

electronic control» Bosch P8500/RE30


Componentes Comunes(SA6D140 & SA12V140)

Culatas, Rocker Housing, Head Cover Piston, Piston Pin and Piston Ring Rocker Arm, Push-rod, Cam Follower Oil Cooler Element (2 elements for

SA12V140Z-1) After-cooler Element (2 elements for

SA12V140Z-1) Note: Valve components are improved

can be used to uprate SA6D140


Controls for Industrial Ratings

Dual Cummins CM552 ECMOn Engine Mounting


Ventajas del sistema electronico de combustible Bosch

Alta presion de inyeccion, principalmente para reducir las emisiones.

Eliminacion de uniones mecanicas entre las bombas de combustibles

Capacidad de relacionarse con otros dispocitivos electronicos del equipo

Un mejor costo


Engine Model KomatsuSA12V140

CumminsV28

Cat3412

Cat3508

DDC12V92

Type

Nuber of Cylinders 12 12 12 8 12

Bore x Stroke 140x165 139.7 x152.4

137 x 153 170 x 190 123 x 127

Displacement 30.5 28 27 34.5 18.01

Rated Output (hp/rpm) 1050/2100 900/2100 750/2100 1000/1800 825/2300

Peak Torque (kgm/rpm) 425/1500 343/1500 297/1500 462/1200 307/1200

Dry Weight (kg) 2930 2633 2157 3680 1940

Length (mm) 1670 1833 1650 1905 1730

Width (mm) 1252 1273 1136 1422 1190

Height ( mm) 1524 1608 1318 1702 1370

Output/Displacement (hp/l) 34.4 32.1 27.8 29 45.8

Weight Displacement (kg/l) 96.1 94 79.9 106.7 107.7

Output/Bulk Volume(hp/mm2)

329 240 304 217 293

Specifications


Engine Ratings

Power Generation Ratings: -60Hz Standby 750, 800, 900 Kw

(1135,1200,1490 bhp)-50Hz standby : 620, 705, 800 kWh.(940, 1030, 1200, bhp)

50hz standby: 675 & 725 kWh. (1010 & 1080 bhp 60Hz prime 675 & 725 kWh. (1010 & 1080 bhp 50hz prime 560 & 640 kWh. (840 & 960 bhp)

Industrial Ratings: Carga intermitente: 1050 @21200 rpm C torque

rise Carga continua : 850 hp @ 2100 rpm 50hz prime

675 & 725 kWh. (1010 & 1080 bhp


How to Achieve High Performance

1. Good Intake / Exhaust System2. Good Combustion3. Reduced Friction


1. Good Intake / Exhaust System

Backward Rake Turbo Charger Holset HX60 Komatsu KTR110-2

Pulse Reserving Exhaust ManifoldDuctile Cast Iron Piston


Ductile Cast Iron Piston


Sistema de alta presion de combustible

SA12V140 dos Komatsu KP21sSA12V140Z-1 dos Bosch RP39QST30G & D dos Bosch P8500

Combustion mejorada en la camaraDuctile Cast Iron Piston

2. Buena Combustion


Intake Port Development For Good Combustion


Optimized Combustion Chamber Shape


Minimum Dead Volume Combustion Chamber(MDVCC)


3. Reduced Friction

Four Valves / Cylinder Set de valvulas de admisión de Tribaloy

Reduced valve and valve seat wear Stem Seals Chrome stems Nitride intake valve face material Eatonite 6 exhaust Valve face material

Extended service intervals

Three Ring Piston High Efficiency Oil & Water Pumps


Como alcanza alta durabilidad y confiabilidad

1. Componentes de la camara de combustión (Reduce cargas termicas)

2. Componentes principales fuertes y rigidos (FEM Design & Stress Tested Components)

3. Diseño de Bajo desgaste y alta resistencia al arrastre


Componentes de la camara de combustión(Reduced Thermal Load)

Piston Oil Jet Cooling Cooling Gallery Around Combustion

Chamber & Ring PackCulata

Forced Cooling Through Drilled Holes in Valve Bridge


Piston Oil Jet Cooling


Pasaje interno de refrigeración del piston


Strong and Rigid Main Components

FEM Design & Stress Tested as Components

Cylinder Block, Connecting Rod Mechanical Stress

Cylinder Head & Piston Mechanical & Thermal Stresses

Crankshaft Bearing Oil Film Calculation


Low Wear & High Scuffing Resistance Design

Roller Cam FollowerSpecial Surface Control for Cylinder

LinerLa base de los anillos del pistonCutback Top Land Piston


Key Changes in the Cummins QST-30

Komatsu Sa12V140-Z1

Fuel System/ Controls Zexel to Bosch Cummins Electronic

Turbochargers Komatsu to Holset

Upgraded Components: Improved Rating Capability and Problem

Counter Measures Resourced Components with Cummins

Suppliers Reduced Engine Cost


Fuel System /Controls

1. Fuel Pumps2. Controls3. Advantages of Bosch

Electronic Fuel System


Fuel Pumps for Industrial Ratings:

Bosch RP39/RE30Bosch P8500/RE36


Controls for Industrial Ratings:

Dual Cummins CM520 ECMsOn Engine Mounting


Advantages of Bosch Electronic Fuel System

Higher Injection Pressure Capability for Emissions

Elimination of mechanical Linkage Between Fuel Pumps

Capability to link with Other Vehicle/Power Train Electronics

Improved Cost


Turbochargers

“Cumminization”Improved EfficienciesImproved CostWastegates Available for Quick

Response Applications


THE END

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B - Introduccion Motores QST30 A.ppt

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