News

Caterpillar Unveils First Hybrid Excavator
Caterpillar Inc. unveiled the first model in its new line of hybrid excavators, the Cat® 336E H, at its Mossville Industrial Design Center on Oct. 16 at a special trade press event, “The Next Generation is Here.” The new 336E H will be sold and serviced exclusively through the global Cat dealer network following the machine’s official launch at bauma 2013 in Munich, Germany. The order board for the Cat 336E H opens in Feb. 2013, with factory shipments beginning in March 2013.

The Cat 336E H uses a new hydraulic hybrid technology developed by Caterpillar. “A hybrid is independent of any particular technology—it doesn’t have to be electric,” said Ken Gray, global product manager for large hydraulic excavators for Caterpillar’s Excavation Division. “There are many ways to store and reuse energy, including our patented hydraulic hybrid system featured on the Cat 336E H.”

“Caterpillar has developed, built, and tested electric hybrid excavators, but—until now—we had not found a hybrid approach that would actually lower our customers’ owning and operating costs,” Gray said. “Large excavators operate in high-production applications in which fuel is a very significant operating cost for our customers. So, the 336E H, the hybrid version of our workhorse 336E, is ideal for introducing our new hydraulic hybrid technology, with its more than 300 filed patents.”

“We can’t wait to see the reaction of our customers to the 336E H,” said Gray. “We’re confident they will be delighted. No other commercially available technology has higher power density than hydraulics, and that’s why we selected a hydraulic solution to help our customers achieve substantial fuel savings. The 336E H also meets stringent Tier 4 Interim/Stage IIIB emission standards. It is extraordinarily quiet, too. So it’s a socially responsible machine for our customers to own, and they will sacrifice nothing in terms of performance, power, force, speed or production. Once more, the owning and operating costs for the 336E H are actually lower than the standard machine. That’s the value customers expect from Cat excavators.”

“The 336E H is a game-changer—the most revolutionary excavator to come to market in decades,” said Gary Stampanato, vice president of Caterpillar’s Excavation Division. “Customers aren’t going to choose the 336E H simply because it is sustainable. They will select it because it actually lowers their owning and operating costs, and maintains the performance of our industry leader, the 336E. Caterpillar has the most productive and fuel-efficient excavator product line in the industry, and our customers are supported by the best dealers in the world. The 336E H extends our leadership, is the right thing to do for our customers and is a sign of great things to come.”

Technology
“Caterpillar’s corporate technology strategy centers on research and development in advancing technology to meet customers’ needs today, which is what the 336E H does,” said Tana Utley, Caterpillar’s chief technology officer and vice president of the Product Development and Global Technology Division. “We’re also continuously working on innovations that we anticipate will meet their future needs. That’s why we’re continuing our research and development in electric hybrid technology too, which actually began our hybrid development path several years ago.”

“Caterpillar has an extraordinary team of people working on hybrid technology solutions for the next generation of Cat hydraulic excavators,” added Gray. “They are from every corner of the world, are among the very best and brightest minds, and they are listening very closely to our customers. It’s exciting for me to see their enthusiasm for this project and the quality product they have developed in the 336E H, and we’re just getting started.”

“I am absolutely confident our engineers will continue to discover and develop the best hybrid approaches for Caterpillar’s extensive line of equipment and applications, whether that’s some form of hydraulic or electric hybrid system or something as of yet unknown,” Utley added. “At Caterpillar, we don’t simply engage in creating new technologies like the hydraulic hybrid system just for technology’s sake, or simply to prove that we can. Our technology strategy’s focus never loses sight of what our research and development efforts can mean to our customers’ success—today and in the future.”

Since the introduction of the 300 Series in 1994, the family of excavators has become the industry standard in a large variety of general, quarry and heavy construction applications. Caterpillar introduced the standard 336E in 2010 as a direct replacement for the 336D. The 336E was introduced primarily to meet Tier 4 Interim/Stage IIIB emissions standards, and like any new Cat machine, the 336E includes several enhancements over its predecessor, including more horsepower with greater fuel efficiency, more lift capability, higher digging force and automatic aftertreatment regeneration.

The 336E H has all of the same powerful advantages of the 336E with the biggest difference between the two models being even greater fuel efficiency. To achieve added fuel savings, the design of the 336E H uses three building block technologies that:

Conserve fuel with engine power management via the Cat Electronic Standardized Programmable (ESP) pump, which smoothly transitions between the hydraulic hybrid power sources, engine and accumulator.
Optimize performance using restriction management via the patented Cat Adaptive Control System (ACS) valve, which intelligently manages restrictions and flows to seamlessly control machine motion with no loss of power, and to ensure operators experience no difference in control, hydraulic power or lift capability.
Reuse energy via the hydraulic hybrid swing system, which captures the excavator’s upper structure swing brake energy in accumulators, and then releases the energy during swing acceleration.

Fuel Savings
The 336E H delivers industry-leading productivity with up to 50 percent greater fuel efficiency, which is measured in tons per liter, over the 336D. Customers can expect the 336E H to use up to 25 percent less fuel compared to a standard 336E, and up to 33 percent less fuel than the 330/336D. All three of the technology building blocks, Conserve, Optimize and Reuse, are integrated together to maximize fuel savings in a variety of applications. Even in low-intensity swing applications, customers will still experience significant fuel savings because of the Conserve and Optimize technologies. (Additional factors, such as operator skill and jobsite conditions, also affect fuel savings.)

Return on Hybrid Investment
Because the 336E H burns less fuel and reduces regulated engine emissions, owning and operating costs will be dramatically lower compared to the standard machine, and its carbon footprint will be smaller, as well. Precisely when customers will recoup their initial investment in a 336E H depends on fuel prices and their applications. Assuming today’s fuel prices and a high-production application for a 336E H, Caterpillar estimates customers can realistically expect to see a return on their investment for the hybrid excavator model in as little as one year.

Durable and Reliable
Caterpillar designed the 336E H to deliver the same durability and reliability customers expect of all Cat machines, including large excavators like the standard 336E. The design of the 336E H uses Cat hydraulic components with a long track record of proven durability and reliability for maximum uptime and productivity. Also like a standard machine, 336E H components can be replaced or rebuilt to maximize the hybrid’s service life.

Validation
Customers have been using field follow machines, which are first production machines built for customer acceptance testing, to validate fuel burn, controllability, reliability and performance of the 336E H. In a formal production study completed in August 2012, results were impressive, including greater fuel efficiency, and lower cab and spectator noise levels than the 336E and 336D. Additionally, the ACS valve, which intelligently manages restrictions and flows to seamlessly control machine motion, has been in the field since 2008 with superior performance and reliability. The ACS and hybrid system have also proven to work well together to maximize performance and controllability of work tools, including hammers, shears and grapples.

Product Support and Dealer Readiness
Customer support for the 336E H is provided exclusively by the on-the-ground support of Caterpillar’s worldwide dealer network. For decades, Cat dealers have made significant and substantial investments in facilities, people and expertise to support Cat excavators, including the new 336E H. Cat dealers know and understand hydraulics, and are prepared to consult with customers to help determine which Cat excavator model, whether hybrid or standard, is the best match for a customer. Dealers are also equipped with tools developed by Caterpillar that help them weigh factors into their recommendations, including a customer’s projected equipment use, budget and anticipated years of ownership to help ensure the proper decision. The 336E H can also be bundled with extended warranties and service contracts.

Caterpillar Position on Technology
According to Utley, it is the company’s vertical integration and broad technology portfolio, coupled with its wide range of application experience that enable Caterpillar to select and develop the optimal technologies for each Cat machine and varied customer applications. “Our commitment is to match technologies to customer value,” she said. “That means Caterpillar will include hybrid elements in machines where it is evident those elements are the most efficient and effective means of improving value to our customers, which is definitely what we’ve done with the 336E H.”

“Hybrid technology is a key element of our customer-focused technology portfolio, and so are our next generation powertrains, autonomy, alternative fuels, and engine emissions and efficiency,” Utley added. “The new hydraulic hybrid technology Caterpillar developed for the 336E H is an outstanding example of the results we’re achieving from our technology strategy. It provides a critical bridge as we continue to research, develop and build the technologies of the future—technologies that will help ensure our customers’ business success.”

Introducing generation G: a new era in Kalmar counterbalance equipment
At CeMAT 2011, Cargotec unveils its new DCG90-180 range of Kalmar lift trucks - ushering in the new 'G' generation of counterbalance equipment.

This new range of forklift trucks - with capacities ranging from 9-18 tonnes - is the first of Cargotec's G generation material handling equipment. They promise to deliver improvements in fuel efficiency, safety, serviceability and ergonomics while reducing environmental impact.

Starting with the new DCG90-180 range, the extensive benefits will be gradually phased across Kalmar's entire counterbalance fleet. G generation features - which include a revolutionary cabin design - will eventually be incorporated on all forklifts, empty and loaded container handlers, reachstackers, and logstackers, as Cargotec aims to extend its market leadership in these sectors.

The new generation has been under development for three years - including a trial phase with rigorous testing.

Thomas Malmborg, Vice President, Forklift Trucks, says: ""We are continuously working to improve the efficiency and economy of our customers' operations. The new Kalmar G generation counterbalance equipment is the next step in this process, with benefits for all - from drivers to service engineers and senior management. We have enhanced the cost-efficiency, quality and productivity of our counterbalance machines, resulting in better performance and greater total lifetime savings.

""The existing product is obviously the starting point for our development work. We have conducted extensive market research, including discussions with our customers, to make sure we clearly understand the needs of the marketplace.""

Gives savings a lift

Like all Cargotec solutions, the new Kalmar DCG90-180 forklifts offer greater total lifetime savings by improving the synchronicity between truck and driver. Each model in the range is designed to keep truck uptime and driver productivity levels high while keeping lifetime operational costs low.

EGO enhances performance

One of the most notable changes ushered in by the G generation is the new EGO cabin. Further improving what was already one of the best on the market, the EGO cabin is markedly different to its predecessor, with major upgrades to ergonomics and visibility inspiring greater driver productivity, efficiency and safety.

""We have focused on the ergonomics to enhance the operating environment and experience for drivers. We have made sure that the people driving our forklifts can sit genuinely relaxed and comfortable when working - improving their alertness and subsequently enhancing their driving performance,"" adds Malmborg.

The cabin benefits from a spacious new open design and curved front and rear windows that provide the operator with exceptionally good views diagonally, forwards and backwards. High capacity wipers provide over 90 percent surface coverage of the front window, and roof wipers have been intelligently integrated - maintaining good visibility and safety, even under extreme weather conditions.

The combination of a side-tilting steering wheel, comfort pedals, a rotatable and fully integrated Kalmar seat and complete climate control all combine to further enhance operator comfort and posture. This makes the new EGO cabin a luxurious and flexible working environment which can be tailored exactly to the driver's needs.

For improved health and safety, the EGO cabin uses a solid safety cage construction with profiled beams that eliminate blind spots. Additionally, in the DCG90-180 lift trucks, noise levels are reduced through the use of variable pumps and a temperature-controlled cooling fan that only runs when needed.

The most innovative generation yet

Other features associated with the G generation of counterbalance equipment are the new electronic steering system and human-machine interface (HMI) which ensures the same set-up, regardless of which Kalmar vehicle you operate. Operators gain greater operating control and precision thanks to the well-placed, ergonomically improved instruments, levers, pedals, panels, switches and display.

Simple and intuitive, the intelligent system will feed the driver exactly the information needed at each moment. The result is a machine that is simple to operate for new drivers, yet allows experienced ones to excel and maximise their skills.

Equally important - and fundamental to all Kalmar equipment - is lifting performance. The DCG90-180 range helps optimise lifting efficiency and lower fuel consumption at the same time, on every lift. New electric and hydraulic systems mean quicker response, higher lifting speed and increased control. Meanwhile, new load sensing hydraulic pumps improve fuel efficiency. This combination helps drivers to be more productive while using less fuel.

Furthermore, uptime and serviceability are significantly increased on these reliable and easy to maintain lift trucks. The improved electronic system of the DCG90-180 is a fast, intelligent and stable system that makes the truck user friendly and reliable. The electronics also incorporate a modern, distributed and redundant CAN-bus that monitors the condition and performance of the engine, gearbox, valves and more.

The drive train is also built with performance, efficiency and reliability in mind. It features a well-proven drive axel shaft and transmission system, with an electronically controlled gearbox. This allows comfortable, efficient and safe driving at all speeds as well as operating the lifting equipment with high precision.

Sustainable, compliant engine options

At the core is a choice of two new EU Stage IIIB / EPA Tier 4i emissions compliant diesel engines. From Volvo and Cummins, both cut particulate emissions by 90 percent as well as reducing nitrogen oxide emissions by half, helping to keep Cargotec at the forefront of environmental sustainability. Both also improve fuel efficiency whilst maintaining operational reliability, durability and performance by delivering maximum power and torque at low rpm.

A new cooling system further improves uptime by keeping the engine room cooler, promoting a longer lifetime of engine, hydraulic and electrical components. An optional reversible cooling fan helps keep the radiator clean from potentially harmful dirt, dust or particles depending on the intended application of the Kalmar product.

Ease of serviceability

Service accessibility has been dramatically improved for the DCG90-180 range with smart placement of the electric cabinet offering fast and easy access. All hydraulic oil filters can be reached from above at one location. There is also a special drain for drive axle oil which makes it possible to fill oil while standing up. As with previous generations of Kalmar trucks, all check points for daily inspection are directly accessible at ground level on the side of the truck and service intervals for the 9-18 tonne range are after 500 hours of operation.