maximum power

forum
the man group magazine 04/2013
Sparking idea
maximum
power
why Diesel engines are still breaking records
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content
04/2013
section 1
forum
man at work
the man group magazine 04/2013
the man group MAGAZINe
04 gentlemen, start your engines
Where a roaring 1,150 hp meet sensitive metrology: a look
inside the driver’s cab of an MAN racing truck.
moving ahead
Revolution of a sparking idea
06 where we are now
In Spain’s Les Borges Blanques, the world’s first solar-bio-
In our time, diesel engines have become an essential ele-
mass hybrid power plant generates environmentally
ment as energy providers and drive sources around the
friendly electrical power for 27,000 households.
globe—be it in airplanes or ships, rail transport or in power
12 news
plants. Developed by Rudolf Diesel in the late 19th century,
the basic principle of a self-igniting engine has propelled
News from the world of MAN
high-tech diesels until this very day. Due to state-of-the-art
technology, however, the stationary giant machines of yes-
section 2
extensive dossier, the current issue of MAN Forum focuses
16
on Rudolf Diesel’s revolutionary invention. This dossier is
also available as an app for the iPad and offers an additional and wide range of dynamic illustrations, multimedia
choices and interaction with you, our readership. Available
now in your app store.
dossier
man think tank
teryear have become compact, efficient and mobile. In an
one Engine for All
22 a world of Diesel The diesel engine evolved from stationary machine to a
mobile energy supplier and vehicle drive. 27 A life of triumph and tragedy How
Rudolf Diesel garnered international fame with his heavily critiqued idea.
28 The trailblazers Three mayors on the impact of Rudolf Diesel on their cities
29 Efficient drives for Stars and Stripes The United States is converting into
a market for diesel vehicles. 30 perfect Principle From the first series-ready
machine to modern high-tech diesel 34 Otto engines are taking after DIesel
drives Interview with Professor Stefan Pischinger, expert for combustion
engines at the Technical University Aachen 35 the richest range of movement
From auto rickshaw to Zeppelin: the application choices for diesel engines seem
fairly indefinite. 38 adaptable omnivore Diesel engines can run on fuels generated from a very diverse range of sources. 39 around the world on diesel
power Columnist Jan Weiler on his love for trucks
Sparking idea
maximum
power
why Diesel engines are still breaking recorDs
how to access
your dossier:
Scan the QR Code and
download the app.
section 3
man projects
40 Safety on the Radar screen
Electronic assistance supports the drivers of MAN trucks.
44 Energy for dry spells
In Costa Rica, engines built by MAN Diesel & Turbo are deployed in the most modern diesel power plant worldwide.
02
MANFORUM 04/2013
publisher Burda Creative Group GmbH,
Arabellastraße 23, 81925 Munich, Germany
Tel.: +49. 89. 9250-1320, Fax: +49. 89. 9250-1680
www.burdacreativegroup.com
editors & Authors Klaus-Peter Hilger (resp.),
Vanessa Plodeck (dep.), Miriam Blum, Dr. Wolfgang
Hörner, Christoph Hus, Christine Mattauch, Barbara
Rott, Christoph Sackmann, David Selbach, Sarah
Sommer, Marcus Schick, Jan Weiler
international editors Patricia Preston (resp.),
Asa C. Tomash
MANAgiNg editor Bojana Milankovic
concept Stefan Lemle, A new kind
Art direCtor Michael Weies, A new kind
Creative Director Michelle Otto
Graphics Micheline Pollach
Graphics editors Elke Latinovic
cover Ferdi Kräling
Audi Motorsport-Bild GmbH
productioN Wolfram Götz (resp.),
Simone Bindernagel, Cornelia Sauer
printing Pinsker Druck und Medien GmbH,
84048 Mainburg, Germany
Printed on Galaxi Supermat
reproduction permitted with reference.
Any changes must be coordinated with the
editors.
Copyright ©2013 by MAN SE
and Burda Creative Group GmbH
50 fast track to growth
Engines made by MAN Truck & Bus are in demand around
Photo: APPLE INC. Pr
masthead
MAN Forum – the MAN Group magazine is
published four times a year in German and English.
published by MAN SE
Andreas Lampersbach, Corporate Communications,
Ungererstraße 69, 80805 Munich, Germany
www.man.eu
editors in chief Florian Wöst (resp.),
Ute Hofmann, Claudia Weber
Tel.: +49. 89. 36098-384, Fax: +49. 89. 36098-382,
E-Mail: [email protected]
the globe as efficient and compact drive solutions for rail.
54 Size Matters
Gigantic planetary gears
standards
02 Masthead
03 Content
04/2013 MANFORUM
03
1
man
at work
gentlemen, start
your engines
More than 1,150 hp is the performance of
European champion Jochen Hahn in his MAN
racing truck. Equipped with a six-cylinder racing
engine by MAN, last year’s victor will compete in
the 2013 FIA Truck Racing Championship.
01 rev counters
04 Braking
Temperature
The racing engine already develops its
In curves, the pneu-
maximum revolu-
matic brakes must
tion moment short-
provide extreme
04
ly beyond idling
braking forces for
speed. At 1 ,200 revo-
the racing truck with
02
lutions per minute,
its 5.5 tons. Thus, the
more than 5,500
braking temperature
Newton meters are
is among the most
generated.
important data.
02 pressure
indicator
05 Braking
cooling
05
01
03
A one-stage racing
The high-perfor-
turbocharger is
pressing combustion air into the cylinders with a load
mance braking discs
08
at the front and rear
07
axles are water-
06
cooled to dissipate
pressure of up to
the huge amount of
four bar. The com-
braking energy.
pressor wheel in the
turbo turns with
06 engine start
more than 100,000
This small switch
revolutions per min-
starts up an MAN
ute, and the com-
six-cylinder racing
bustion air is cooled
engine—and entire-
additionally. This
ly without a key.
allows for converting more fuel into
07 pit radio
performance: more
Drivers and their
than 1, 150 hp.
pits are linked via a
special radio system,
03 GPS display
with headset and
Limited to 160 kilo-
microphone inte-
meters an hour by
grated into the driv-
FIA, top speeds are
er’s helmet.
closely monitored.
Those exceeding the
08 stick shift
The gear box is a
ceive penalty points.
manual one, featur-
Pilots must also pay
ing a total range of
close attention to
16 gears.
their speed while in
the pit lanes.
04
MANFORUM 04/2013
Photo: MAN
speed limit will re-
04/2013 MANFORUM
05
1
man
at work
where
we are
now
Spain
Hybrid power
At Les Borges Blanques in Spain, row
upon row of parabolic mirrors reflect the blazing rays of the sun. They
form an integral part of the world’s
first combined solar-biomass hybrid
power station. Extending over an
area of 70 hectares, equivalent to the
size of 100 soccer fields, the system
produces environmentally friendly
electricity for about 27,000 households in the vicinity. And it does so
ceaselessly, even on cloudy days. In
the absence of sunshine, the power
station’s biomass block generates
steam from energy plants, wood
chippings and agricultural waste.
This drives the centerpiece of the
system: the new MARC-R reheat turbine made by MAN Diesel & Turbo.
In comparison with power production derived from fossil energy
sources, this saves 24,500 tons of CO2
emissions per year—a significant
step in the direction of environmen-
Photo: abantia.com/pr
tally friendly power supply.
06
MANFORUM 04/2013
04/2013 MANFORUM
07
1
man
at work
Where
we are
now
Germany
Smart and efficient
It is a bustling scene inside the large
warehouse structure: Pierre Scholler
(shown here) and his colleagues
from plant logistics are navigating
among shelves the size of houses,
maneuvering heavily loaded pallets
into position. There is more to this
activity than meets the eye. With its
smart route planning and energysaving lighting, the NEOPLAN logistics center in Plauen, Germany, is a
showcase example for the economical use of power. In addition, an “energy house” is slated for construction in 2014 to supply the site with
heat and electricity generated directly by MAN engines. “The independent energy supply is a big bonus,” emphasized Plauen’s Plant
Manager Achim Knabe, “as rising energy costs are evolving into an ever
expanding factor in overall production expenditures.” Increasingly,
customers focus not only on low
fuel consumption rates of buses, but
also on a resource-efficient manu-
Photo: : Jörg Gläscher
facturing process of these vehicles.
08
MANFORUM 04/2013
04/2013 MANFORUM
09
1
man
at work
where
we are
now
south korea
Emerging behemoth
Commissioned by the Switzerlandbased offshore ser vice provider
Allseas, a veritable giant of the seas is
currently under construction at the
Daewoo shipyard in Okpo, South
Korea. Upon its completion in 2014,
the Pieter Schelte will be the world’s
largest working vessel for the setup
and dismantling of gas and oil rigs as
well as the installation of pipelines.
With a length of 382 meters, a width
of 124 meters and equipped with special cranes, Pieter Schelte will be capable of installing or removing drill
tower platforms of up to 48,000 tons
and steel piers of up to 25,000 tons in
a single operation. Rig tower platforms can be lifted through an opening at the bow, which is 122 meters
long and 59 meters wide. Nine MAN
Diesel 32/44CR engines with a total
output of 94.6 megawatts will supply
the extraordinary ship with propulsion power and cover the daily elec-
Photo: allseas.com/pr
tricity needs on board.
10
MANFORUM 04/2013
04/2013 MANFORUM
11
1
news
04/2013
man
at work
Passenger transport
MAN supplies 173 bus chassis
Clean streets in Malaysia
MAN service in South Africa is provided by a dense network of dealerships and emergency service through
Mobile24 roadside assistance.
The Israeli bus companies Metropoline and Egged have ordered a
Now in service in Malaysia are 158 MAN CLA trucks
with customized bodywork. Alam Flora Sdn Bhd, one
of Malaysia’s leading waste disposal companies, uses
the vehicles both for garbage disposal as well as street
sweeping machines. As they are built at MAN’s plant
in India, the features and functionality of the vehicles
total of 173 bus chassis for national passenger transport from the
Silvio
Sangalli has
been a crew
coordinator
at Ducati for
10 years.
MAN importer AET (Automotive Equipment and Trucks L.P.). The
chassis will be delivered by the fall of 2013, after the buses are assembled locally. The market share of MAN buses in Israel currently
amounts to a solid 30 percent.
that is easy to maintain (including the wear-free
on the way
from race to race
Exhaust Valve Brake engine braking system and a
Silvio Sangalli is always on the road. The Italian crew coor-
nine-gear overdrive transmission), the vehicles also
dinator has just delivered seven MAN trucks for the Ducati
are notable for the comfort and user-friendly func-
plant team to the MotoGP Grand Prix in Assen, Holland.
The Reinhardt Transport Group (RTG), one of the leading truck trans-
tionality of the driver cab.
Next week, it will be the Sachsen Ring in Leipzig, and Cali-
port companies of South Africa, has put another 140 TGS tractor
fornia after that. Meanwhile, two trucks are under way to
trailer vehicles from MAN into service this year. The company had
are ideally adapted to the requirements of the Asian
target market. Besides featuring robust technology
Freight transport
South Africa turns to MAN once more
Ducati’s Italian headquarters in Bologna for testing rounds.
More than 1,400 MAN vehicles
service the vehicle fleet of
Israel’s largest bus company, Egged.
“It’s actually less complicated than it sounds,” comments
Silvio. As the crew coordinator, he is responsible for organi-
already acquired MAN tractor machines in 2012. The decision to purthe high standard of driver comfort.
zation and also drives one of the trucks himself. Each of the
480 hp MAN TGX 18.480 tractor trailers is a specialized
model: One accommodates motorbikes, another carries a
Robust and reliable
CLA trucks by MAN are suitable for specialized areas of service.
galley, the third contains tools and replacement parts.
Question & answer
How does a container
giant berth at port?
“Once things fall into place, the transport process practically manages itself,” says Silvio. The 48-year-old spends up
to 10 hours a day at the wheel. The longest stretch in the
MotoGP calendar extends over 2,360 kilometers, from Jerez,
Spain, to Bologna. There are 18 races every year. Silvio joined
silver and gold
MANforum awarded
The cross-media approach taken
Ducati in 2003 and is now responsible for transport and all
Putting in a container ship at harbor requires more than an auto-
logistics operations, together with 35 employees on site. He,
mated parking assistance system, as maneuvering a 100,000-ton
at least, gets a comfortable hotel bed. Others sleep in the
ship in the frequently shallow and closely confined waters of a
truck—as one of the vehicles is also equipped for that.
port is a very challenging task. Several port pilots are therefore on
by MANforum comprises a
standby to guide larger ships into the right position during a
printed magazine as well as an
berthing operation of about two hours. The pilots will check the
app. It won gold in the category
availability of a berthing space, note the wind direction and the
“Best Cross-Media Solution –
water level of tides. Per their instruction, tugboats then tow the
Industries” of the BCP Award
container colossus—which may be more than 10 times as large as
2013. Out of more than 670 en-
they are— into the right position. In addition, the tugs also slowly
tries, the jury of Europe’s largest
and evenly press the ship against the pier from the other side to
ensure that it remains in parallel position to the dock and won’t
Europe’s largest Corporate
publishing competition 2013:
MANforum received four awards.
12
MANFORUM 04/2013
tion selected the MAN magazine to win silver medals in
three additional categories.
Both in the truck workshop
and on the racetrack, Silvio Sangalli
always has his eye on the motorbikes.
Photos: MAN
corporate publishing competi-
suffer any damaging collisions. Workers then stand ready on the
pier to securely moor the container ship with several lines.
???
chase was due to the vehicles’ low fuel consumption rates as well as
04/2013 MANFORUM
13
1
news
04/2013
man
at work
MAN News
New app offers mobile information
Ship engines from MAN impress with economic
fuel consumption and low emissions properties.
New gas turbines
will boost efficiency
With the “MAN news” app for iOS and Android devices, the most
important news items relating to MAN can now be accessed at
Cruise ships
Powerful engines for luxury liners
A recently developed gas turbine from
any time and anywhere. The app offers recent press releases and
MAN Diesel & Turbo is making the
various corporate publications, including the Annual Report
chemical company SolVin GmbH &
and the MANforum magazine. It also offers current figures and
Co. KG in Rheinberg less dependent
all relevant facts about the company. Numerous pictures and an
on the public energy grid. The manu-
overview of MAN’s social media activities complete the range
facturer of industrial chemicals uses
of choices. The new app is aimed primarily at media outlets, but
heat and power cogeneration to save
can be downloaded by all interested users for free at the App
energy. With the new turbine, the sys-
Store and on Google Play.
MAN Diesel & Turbo is supplying Fincantieri Cantieri Navali Italiani S.p.A, the
tem delivers six megawatts of electri-
world’s leading shipyard for cruise liners, with eight diesel engines for the drive of
cal energy and 11 megawatts of ther-
two new ships. Each of the luxury liners will receive four MAN engines, as part of a
mal energy, achieving an efficiency
diesel electric drive providing an overall output of 23,520 kW per ship. MAN is coop-
rating of more than 80 percent. For
erating with Alfa Laval, which delivers the exhaust gas recirculation system. The
the Rheinberg plant, this amounts to
technology company’s PureSOx system removes more than 98 percent of sulphur
annual savings of around 7,000 tons
oxide from exhaust fumes. The ships are due for delivery to the Viking Ocean
of CO2 emissions.­
Swift, easy and streamlined: The new MAN news app now offers all
important information and news items relating to MAN.
Cruises shipping company in early 2015 and 2016.
MAN pioneers
Anton von Rieppel
At the Telekom Cup in July
2013 the soccer teams presented
their MAN team buses.
From crisis to success
After a crisis that lasted 20 years, the appointment in 1889 of
Anton von Rieppel to the top executive management position of
the Maschinenbau-Actien-Gesellschaft Nürnberg proved the
turning point for the company’s fortunes. The 37-year-old had
set himself the ambitious goal of making the plant competitive
once again and he worked to meet this challenge on the basis of a
new strategy and new investments. His strategy was supported
by an economic upswing and his approach to the workforce with
a rather unconventional habit of appearing as construction site
supervisor in a slouch hat won him sympathy points. A decade
after Rieppel took over, the dilapidated plant had evolved into
one of the leading German bridge-building companies. One pio-
years effectively presented its buses in the at-
games in MAN buses. MAN also provides par-
tractive and dynamic field of professional
ticular vehicles for special occasions: The
soccer. The partnering clubs—namely
victory tour through Munich by triple win-
MAN’s successful commitment to Germany’s
FC Bayern München, Borussia Dortmund,
ner FC Bayern in a customized convertible
Bundesliga soccer teams will continue. As a
Hamburg SV, VfL Wolfsburg and Borussia
truck from MAN, made it to the evening TV
long-term sponsoring partner, MAN has for
Mönchengladbach—travel to their away
news. More at www.manschaftsbus.de.
MAN goes into overtime
14
MANFORUM 04/2013
Photos: MAN, f1-online
Sponsoring
neering move was the conclusion of a licensing agreement for
the production of diesel engines with the company’s competitors in Augsburg. This cooperation resulted in the merging of
the Nuremberg-based machine works with the Maschinenfabrik
Augsburg in 1898, resulting in the MAN that is known today.
Engineer and entrepreneur
Whether wearing a respectable suit or sporting a slouch hat on construction
sites: Anton von Rieppel persuaded shareholders and customers with his ideas.
04/2013 MANFORUM
15
2
man
think tank
dossier
04/2013
one e ngine
for all
Rudolf Diesel passed a century ago –
yet his invention still shapes our world
22
triumphant
A century after Rudolf Diesel’s death,
his engine enjoys unprecedented popularity. The success story of the diesel
engine and its potential for the future.
16
MANFORUM 04/2013
27
Revolutionary
Against all odds and opposition,
Diesel prevailed with his pioneering
idea of an engine. The life of an ingenious inventor in a short portrait.
30
sparking
One very successful concept:
Why the functional principle of the
diesel engine has not fundamentally
changed in the last 100 years.
39
exemplary
When still a young boy, columnist
Jan Weiler admired the “lords
of the highway”—for long-haul
truckers could travel the world.
04/2013 MANFORUM
17
MAN Archive, Augsburg
One ingenious idea...
Photo: Vuk Latinovic
Propelled by his vision of an “ideal heat-driven machine,” the young engineer Rudolf Diesel
spent day and night at his drawing board back in the late 19th century. pushing himself to
the brink of exhaustion, he tirelessly sketched his drawings, pondered calculations and
optimized an entirely new engine design until he finally found the perfect solution: his
own engine, with an efficiency factor of 26 percent – an extraordinary accomplishment at
that time. Sponsoring the inventor was the Maschinenfabrik Augsburg-Nürnberg, the predecessor to today’s MAN, which had recognized the potential of Diesel’s idea early on.
18
MANFORUM 04/2013
04/2013 MANFORUM
19
Colombo Express, Pacific
… Can move goods
around the world
Photo: MAN
Nowadays, 85 percent of global trade is transacted by sea, driven by
diesel engines the size of multi-story buildings and featuring the unbelievable power of more than 100,000 hp. Every other ship navigating
the world’s oceans is equipped with an MAN diesel engine.
20
MANFORUM 04/2013
04/2013 MANFORUM
21
2
dossier
04/2013
Animations
More information in
your MANforum app.
man
think tank
Low
emission
ZONE
Europe
Umwelt
a world
of diesel
EURO 6
Efficient fuel injection systems like
common rail and technologies such
as exhaust gas recirculation, selective catalytic reduction and soot
particle filters bring European diesel
trucks up to par with the
Euro VI exhaust emission standards.
ZONE
EURO 6
frei
Low
emission
ZONE
Russia
Low
ZONE
EURO 6
From its early career as a stationary engine,
it became progressively smaller and more
efficient, before going mobile and conquering
the world: Diesel engines now are omnipresent to generate energy and power vehicles.
R
asia
Nowadays, nine of the 10
largest ports in the world
are located on the Asian
continent. The drive required for huge container
ships is supplied by gigantic
two-stroke diesel engines.
United States
For a long time, the market for diesel
cars in the USA was negligible. Just in
the last two years, however, sales figures for the self-igniting engines have
gone up (also see story on page 29).
Low
emission
Low
emission
australia
ZONE
ZONE
EURO 6
oughly
3,500 kilometers east of Moscow,
Low
emission
ZONE
a truck slowly makes its way across the
main trading center, Novosibirsk. At
the same time, a gigantic container
ship glides evenly across the South
China Sea, while a convertible gleams
in the sun while cruising down Sunset
Drive in Miami. Be it in trucks or in
ships, buses, passenger cars or rail cars:
Nowadays, diesel engines move more
than 90 percent of all transported
22
MANFORUM 04/2013
AfricaEURO 6
South America
Due to subsidy policies in many
South American countries, biodiesel
engines are very much in demand.
They are used to drive vehicles, as
well as in power stations.
Illustration: Helen Gruber
Russian taiga. It is headed for Siberia’s
EURO 6
The market for diesel trucks in Russia continues to grow: Currently, 80,000 trucks with a
load capacity of 16 tons or more are sold every year. This figure is expected to grow to as
many as 180,000 vehicles by the year 2020.
emission
African nations are currently
investing heavily in renewable
energy. In many areas, diesel
power stations are used as a
backup in order to bridge
power shortages.
Australia is one of the world’s
EURO 6
largest mining countries. Traditionally, Germany has been
strongly involved in the construction sector—powerful
machines with diesel drive are
therefore in great demand in
“The Lucky Country.”
04/2013 MANFORUM
23
2
dossier
04/2013
man
think tank
Power generation
frei
Working ships and container ships
High-speed MAN engines with up to 6,800 hp deliver powerful drives for
operational boats and working ships. Power on board is provided by maritime
generator sets with an output of more than 15,000 hp. In large container
ships, two-stroke engines by MAN deliver an output of more than 100,000 hp.
In the stationary sector, MAN diesel engines
are primarily used in power plants. For power
generation, MAN offers two- and four-stroke
engines with a performance ranging from
450 kilowatts to 80 megawatts.
powerful and efficient diesel engines.
Robust MAN diesel
engines with up to
1,200 hp and 24 liters
cubic capacity provide
the necessary power
for forestry vehicles
and harvesters.
Trucks
Whether for long-distance or urban transport, delivery operations or
heavy traction, MAN’s trucks are equipped with diesel engines with a
performance ranging from 160 to 680 hp.
Umwelt
ZONE
EURO 6
frei
Yachts
In the performance range up to 1,800 hp, the six-cylinder serial engine
as well as the eight- and 12-cylinder V-engines are market leaders in
Europe. The powerful MAN drives meet all crucial emission standards.
Special vehicles
Snow-slope caterpillars, fire-fighting vehicles or garbage
collection trucks: MAN supplies diesel engines with four,
six, eight or 12 cylinders for such special purpose vehicles.
The success of the diesel principle
power stations around the globe. While
is omnipresent on roads all over the
these high-tech systems are still based
world. Almost all commercial vehicles,
on Rudolf Diesel’s idea of a self-igniting
ranging from trucks to agricultural
engine, modern drives have nothing in
machines, have a diesel drive. Detlef
common with the stationary engine of
Hug, Head of Product Information
former times other than the funda-
Management at MAN Truck & Bus, ex-
mental principle of self-ignition.
plains that “Commercial vehicles are
houses, weigh several thousands of
supposed to earn money for our cus-
tons and move container ships hun-
24
MANFORUM 04/2013
Buses
For buses, MAN offers powerful fourand six-cylinder diesel engines and
six-cylinder natural-gas engines.
Backup generators
In cogeneration units and emergency
backup power systems, MAN engines are reliable even at peak loads.
Illustration: Helen Gruber
Flexibly upgraded six-cylinder serial engines
and 12-cylinder diesel engines from MAN offer
rail manufacturers many choices in the design
of railcars, locomotives and service vehicles.
tomers. Thus, engines must be efficient
While supporting the inventor during
and reliable. On those counts, the die-
his development efforts, the machine
sel engine remains unbeatable today.”
but also have a huge presence on the
world’s oceans: Gigantic two-stroke
engines from MAN drive practically all
large freighters and tankers on the
high seas. These slow-running engines
are impressive power packs: The largest models tower over several-story
dreds of meters long over the oceans
with an output of 100,000 hp or more.
These colossi must deliver not only
works then known as Maschinenfabrik
MAN engineers are continuously
Augsburg-Nürnberg could hardly have
developing the diesel principle step by
anticipated that the diesel engine
step: Over time, the engines have be-
ning up to 8,000 hours per year, or
would be conquering the world with
come increasingly compact, light,
practically without a break.
such a wide range of applications. The
flexible and efficient. “A significant
first experimental engines were in-
milestone in the recent past undoubt-
Important license business
tended for stationary use—and with
edly was the development of the ultra-
As a rule, the largest two-stroke ship
good reason. At the time, one hp of
efficient common rail fuel injection
engines are built right on site at the
diesel power exceeded 250 kilos. In
technique,” says Hug. Since the early
important shipyards of the world, pri-
1898, such a heavyweight MAN engine
1990s, the engineers at MAN Truck &
marily in China, South Korea and
was set up for the first time in a saw-
Bus have primarily focused their ef-
Japan. However, the real home of
mill. The two-cylinder engine man-
forts on reducing the engines’ emis-
MAN’s gigantic two-stroke engines is
aged an output of up to 70 hp. The first
sions of toxins and CO2 even further.
the MAN Diesel & Turbo development
lightweight four-stroke engines al-
“Modern MAN diesel engines can op-
center based in Copenhagen, says
ready reached a performance 140 hp in
erate with less fuel, are more environ-
Klaus Engberg, Head of License Busi-
1903 and laid the foundation for the
mentally friendly and at the same
ness in the Danish capital. “Our re-
triumphant progress of MAN’s diesel
time more efficient than ever before,”
search and development department
engines in automotive engineering
explains Hug.
is working intensively on further re-
and shipbuilding in the decades to
Rail transport
Yet diesel engines are not just
ubiquitous on the roads these days,
same time, they generate energy in
Versatile applications
Agriculture
technology
Truck emissions
in Germany
have been declining
for years. The most
significant reduction
was achieved for
sulfur dioxide. Compared with 1995,
sulfur dioxide pollution had been reduced by 99.6 percent by 2010.
Carbon dioxide
ZONE
EURO 6
through the development of ever more
mobile on every continent. At the
Fine dust
Umwelt
goods worldwide, and make people
Sulfur dioxide
Efficient, robust
and reliable
Whether in luxury
yachts or as a powerful drive for working machinery, used
for power generation
or for the transport
of freight and passengers: With their
long servicing intervals, powerful output
and extended
service life, diesel
engines by MAN enjoy an excellent reputation worldwide.
99.6 84.8 28.3
performance, but also an outstanding
level of reliability—for they are run-
finement of the diesel concept,” says
come. The world’s first large diesel
For roads and oceans
power station was built in Kiev in 1904
The four-stroke engines for commer-
engines that we develop for our world-
and caught global attention. When
cial vehicles are built at MAN’s plant in
wide family of licensed partners. Our
Rudolf Diesel died in 1913, diesel en-
Nuremberg, with 90 percent of these
portfolio of modern two-stroke en-
gines with an overall output of around
engines destined for installation in
gines is unsurpassed anywhere in the
1.7 million hp were already in operation
MAN vehicles. In the MAN Group, en-
world.” Building these engines at a cen-
or under construction—with the lion’s
gine development and vehicle devel-
share of these projects being handled
opment therefore work hand in hand.
by MAN. Commercial vehicles, ships,
“We are currently testing modern hy-
power stations: These would be the fu-
brid vehicles, for example, where the
ture fields of application, to be con-
diesel drive is supplemented by an
quered and revolutionized by MAN
electric one,” says Hug.
Engberg. “It provides the basis for the
tral production site would not make
Emission reductions from
1995 to 2010
(in percent)
much sense, points out Engberg, as
shipping an engine of 2,000 tons from
Europe to China is no easy feat. Work-
Source: Federal Environmental Agency, TREMOD,
Version 5.23, 2011
ing with licensees offers MAN access
to local markets and on-site manufac-
04/2013 MANFORUM
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2
dOSSieR
04/2013
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man
think tank
12
10
turing capacities—a business model
operate in drilling ships, ferries, frig-
great demand for flexible diesel power
managing director of Maschinenfabrik Augsburg, the pre-
that benefits both sides. “Our license
ates, coast guard vessels, and luxury
plants at the moment,” says Christian
decessor to MAN, had confidence in Diesel and his idea. Still,
holders are crucial partners for us,
yachts. In addition, four-stroke engines
Poensgen, Head of Four-Stroke Engine
this enterprise demanded much patience of the director, his
with whom we foster close and long-
also supplement the two-stroke main
Development at MAN in Augsburg.
term relationships,” says Engberg, ex-
drive on large ships as auxiliary en-
plaining the principle. “It is our goal to
gines that generate electricity. Modern
always offer the right product at the
and efficient engines are absolutely in-
right time.” He points to the new dual-
dispensable for worldwide transport
fuel engine as an example. In late 2012,
flow. “Fuel consumption makes up
the ME-GI models from Copenhagen
more than 80 percent of a ship’s oper-
entered the market. They run either on
ating costs,” explains Ulrich Vögtle,
heavy oil or on liquid natural gas. “Evi-
Head of Four-Stroke License Business
dently we hit a nerve. Our customers
in Augsburg. “For that reason, we are
all over the world have shown enor-
not just working on the development
mous interest,” reports Engberg.
of new and ever more efficient engines,
FOUR-StROke pOweR pAckS
5
2
3
gines, MAN Diesel & Turbo is also de-
sions.” This effort is well worth it: Every
veloping medium-speed four-stroke
other ship underway on the world’s
engines. The oversized brothers of the
oceans is driven by an MAN engine.
Nuremberg Truck & Bus vehicle en-
Aside from ships, the four-stroke
gines are developed and produced at
powerhouses also drive power sta-
MAN production sites in Augsburg,
tions. The Power Plants sector of MAN
France and India, as well as at many
Diesel & Turbo relies on modern diesel
facilities operated by license holders
engines for the efficient generation of
around the world. They are installed
electricity. “Especially countries on
in cruise ships, for example, and also
the verge of industrialization show a
2
1
1
1
1
1
1
1
two-stroke
Four-stroke
China
Japan
Croatia
South korea
poland
india
russia
Spain
Vietnam
uS
namely upgrading existing engines to
reduce both consumption and emis-
2
number of license holders
stations: They are set up and opera-
but are also counting on retrofits—
Besides its large two-stroke diesel en-
A liFe OF
tRiUMph ANd
tRAgedy
The great advantage of diesel power
5
liceNSe pARtNeRS
the maschinenfabrik
augsburg-nürnberg
set up its first licensed partnerships
in 1911. Currently,
man cooperates
with 48 licensees.
Source: man Diesel &
turbo, July 2013
tional after just a few months. Both the
two-stroke and four-stroke diesel engines can run on different fuels: heavy
oil and distillate oil are possible options for the engines, as are renewable
RuDolF Diesel wanTeD To RevoluTionize The
heaT engine. aFTeR muCh eaRly CRiTique, his
invenTion wenT on To ConqueR The woRlD.
bio-fuels as alternatives—including
plant oils, recycled cooking oil and animal fats. Natural gas and dual-fuel engines by MAN Diesel & Turbo cover the
R
demand for natural-gas engines.
MAN’s dual-fuel engines, for example,
can initially be powered by heavy oil, a
cheap and readily available fuel, and
can later be easily switched to natural
gas. “We are continuously working towards developing even better and
MechANicAl
RevOlUtiON
The invention of the
diesel engine rendered the services
of steam engines
obsolete.
quantity of fuel would be required to generate an explosion—yet the needed pressure was not easily achieved. New
challenges kept emerging on a continuous basis, necessitating a total number of six test series.
iNteRNAtiONAl tRiUMph
At last, the breakthrough came in 1897: The engine ignited,
and soon thereafter, the first functional four-stroke diesel
Paris World Exhibition of 1900, the diesel engine began its
triumphal procession around the world. In 1905, the first
versial, inventor of the diesel engine, was on his
diesel power station was commissioned in Kiev, while in
way to a meeting of the Consolidated Diesel Man-
1912, the first ocean steamer with a diesel drive was
ufacturing company in London on the night of
launched in Copenhagen. This rapid process proved a super-
September 29, 1913. When other members of his
they found his bed untouched. Diesel had vanished without
a trace from aboard the German post steamer Dresden. Days
“Piston engines will maintain a pres-
later, his body was found floating in the North Sea. The life of
ence in market for decades to come, as
this ingenious inventor had come to a tragic end.
ROcky ROAd tO sUccess
version systems.”
thus heat, air in a cylinder to such a degree that just a small
UdOlF diesel, the celebRAted, if contro-
tions for our engines,” says Poensgen.
a key component of smart energy con-
fered from a critical flaw: Diesel strove to compress, and
engine was presented to the trade experts. Following the
party went to wake him the next morning, on September 30,
more energy efficient application op-
engineers and the inventor himself, as the design still suf-
WORld FAMOUs
iNveNtOR
From an ambitious
scholarship student
at the Royal Bavarian
Technical College,
Rudolf Diesel
advanced to become
an internationally
celebrated engineer.
human effort for the inventor, however. Diesel’s workload
rose, just as did the pressure to succeed, with negative consequences for his health: He suffered from migraines, gout,
insomnia and a stubborn nervous condition. Diesel did not
live to see the serial production of MAN trucks with diesel
engines, which got under way in 1923. The ingenious inventor died at the age of 55. His self-igniting idea, however, is
still powering our world today.
In 1893, precisely two decades earlier, Diesel had published
a study titled “The Theory and Construction of a Rational
pROFile iN ShORt
Heat Engine to Replace the Steam Engine and other Combustion Engines Known Today.” In this paper, he set forth
SchwäbiSch hAll geRMANy
dOMiNik ZöRleiN, 23
his idea of a “new and rational thermal engine,” which he
patented that same year. While attending lectures in
As an electronics technician for operating technology at the municipal works of
mechanical engineering at the Royal Bavarian Technical
Schwäbisch Hall, he services a mobile diesel emergency power generator from MAN.
In what kind of situation is the emergency backup used?
College, where he was a scholarship student, he had learned
Most commonly
that the steam engine converted merely six to 10 percent of
when we are overhauling transformer stations. Or when a tree falls on the line,
its fuel energy into mechanical performance. Since that
How long does it take until the power supply is up and running again?
Once
we are on site, we need about an hour to find the best position for the unit and
get it connected.
How do you transport the generator?
The engine is firmly installed on a truck
trailer and transported this way to our operations.
26
MANFORUM 04/2013
Photos: Susanne Wegner, MAN
for example, and cuts supply.
time, he had pondered the concept of heat engines with improved degrees of efficiency.
Initially, however, the patent protection for his engine
did not generate much initial recognition for Diesel: He became a target of critique from university professors, industrialists as well as the general public. Several trial runs failed
to deliver satisfying results. Only Heinrich von Buz, the
04/2013 MANFORUM
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04/2013
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your MaNforum app
28
MANForUM 04/2013
bertrANd delANoë
Born in tunisia in
1950, delanoë has
served as mayor of the
french capital for
the last 12 years.
he is a member of
the socialist party.
KUrt Gribl
the 49-year-old politician, a member of the
conservative csu party,
has been chief mayor of
augsburg for five years.
Gribl trained as a lawyer, specializing in the
field of construction
and architecture law.
tAtsUo YAdA
yada (73) was elected mayor of kobe,
Japan, in 2001.
previously, he had
already been active
in politics in various
capacities and roles.
Americans, however, are gradually getting used to the foreign engine. The year 2011 already registered a 27 percent
increase in diesel sales compared with the previous year,
and 2012 saw a growth rate of 24 percent. By 2016, the diesel
ratio in new car sales could be tripled or more, estimates the
research firm ALG, based in Santa Barbara, California. The
problem of filling stations is also close to being solved:
While diesel fuel was available only at one of three gas sta-
pAris
AUGsbUrG
tions 15 years ago, every other filling station offers it today.
Kobe
For one, the comparative unpopularity of diesel in the US
is due to the fact that diesel fuel costs 20 to 30 cents more per
WhAt liNKs YoUr citY to rUdolF diesel?
actually, paris happens to be rudolf diesel’s
birthplace. he was born here in 1858 in a house
on the rue notre-dame-de-nazareth, which features a plaque commemorating the inventor. and
42 years later, the diesel engine won the Grand
prix at the paris world exhibition in 1900—the
highest technological prize the jury could bestow.
maschinenfabrik augsburg supported and
encouraged rudolf diesel throughout the four
development years for the diesel engine. after
1898, the engine went into series production.
the maschinenfabrik augsburg—later renamed man—has been marketing diesel’s
invention all over the world ever since.
gallon than gasoline. Unlike in Europe, where diesel is taxed
at a lower rate, it is actually subject to higher taxes than stan-
more than 100 years ago, a local kobe company, kawasaki heavy industries, acquired
licenses to manufacture diesel engines. while
kawasaki is mostly known for its motorbikes outside of Japan, in fact the company’s main business is shipbuilding. and these ships are still
driven by diesel engines.
dard gasoline in the US. In addition, diesel suffers from its
past reputation. Ever since the 1970s, when General Motors
and other automotive companies put dirty, noisy and unreliable diesel cars on the market, the image of diesel has been
skewed in a negative angle. However, the new and stringent
“Corporate Average Fuel Economy” standards, introduced in
hoW hAs rUdolF diesel’s iNveNtioN chANGed YoUr UrbAN lANdscApe?
the diesel engine plays a very important
role and especially so on the streets of paris.
many of the municipal buses serving the capital are man models equipped with a diesel engine, or a hybrid version combining diesel and
electrical engines.
our man museum exhibits some of the
world’s oldest diesel engines and also displays
documents and personal objects once owned
by rudolf diesel. these historic artefacts range
from technical design sketches to original patent papers and even love letters addressed to
his wife, martha.
August 2012, have worked in favor of the diesel engine. These
diesel is not just a presence in kobe itself—
but quite visible all over the country. Japan’s
shipbuilding industry has benefited from the
acquisition of diesel engine licenses: after the
deal between kawasaki and man in 1912,
Japan evolved into one of the most successful
nations for ship export.
eFFiCieNt dRives FOR
stARs ANd stRipes
WhAt is the relevANce oF rUdolF diesel For YoUr citY todAY?
due to the many diesel-powered buses on
the streets, rudolf diesel’s invention is omnipresent all over the city. Just in march 2013,
the capital’s municipal transport authority
ordered another 15 new buses. overall, 760
of its vehicles are currently supplied by man.
2.5 mn
residents
at its augsburg facilities, man still produces
massive diesel engines to special order for ships
and power stations and employs more than
3,800 people there. diesel engine production
continues to be an important economic factor
for the city of augsburg to the present day.
0.3 mn
residents
the kawasaki company has been in existence for over a century. undoubtedly, it has
benefited from the licenses it first acquired in
1912—and therefore can continue to keep
more than 30,000 employees on its payroll at
this time.
1.5 mn residents
Illustrationes: Bernd Schifferdecker, Photos: MAN(2), corbis, gettyimages
an invention that moved the world:
three mayors explain how
rudolf diesel has shaped their cities.
the trAilblAzers
man
think tank
While the US WaS loNg CoNSidered a diffiCUlt Market for
dieSel vehiCleS, SaleS figUreS have BeeN riSiNg reCeNtlY.
US CorreSpoNdeNt ChriStiNe MattaUCh Met a dieSel CoNvert.
standards demand that US automotive makers raise average
fuel efficiency to 54.5 miles per gallon by 2025. In February
2013, new cars sold on the US market could manage an average of just 24.5 miles per gallon. As diesel-powered automobiles are 30 to 35 percent more efficient in consumption than
comparable cars running on gasoline, and very long distances are covered in this country, such drives actually seem a
perfect fit for the US. With 16,000 kilometers per year, the
average mileage per car is a third higher than in Germany.
Industry experts consider it a good sign that US competitors, which had steered clear of diesel for years, have re-
t
he RetURN tRip
entered the market. This summer, General Motors launched
a diesel version of the Chevy Cruze, and Chrysler is following
from visiting a customer in
suit with a diesel Jeep Grand Cherokee. That development is
northern Michigan back to Jackson, a small town
not likely to pose an immediate threat to the pole position
west of Detroit, was a lengthy one. Still, driver
of German manufacturers in the USA, however. In June 2013,
Tim Jennings enjoys the 360 kilometers in his
Volkswagen was in uncontested first place, with a market
new black VW Jetta TDI, which he describes as “ef-
share of more than 80 percent.
ficient and a smooth ride.” And the 59-year-old marketing
Tim Jennings, who finally converted to his diesel last
manager has another reason to rejoice: “I saw two other die-
winter, has since become a fan of its technology. A full tank,
sel cars on the road,” he says. From his point of view, that is
quite a lot. Diesel owners like Tim Jennings are still a minority in the United States: In 2012, a meager 125,000 out of 14.4
million cars sold, or less than one percent, had diesel engines—while in Europe, their share is more than 50 percent.
ChRistiNe
MAttAUCh
Business journalist
Christine Mattauch
has lived and worked
in New York for the
last six years.
he reports with enthusiasm, can take him 960 kilometers.
When he acquired his new car, he hung on to his old gasoline-powered Chevy Suburban, just to be on the safe side. Yet
the old car uses at least twice as much fuel. “These days,” admits Jennings, “I hardly ever take it out of the garage.”
04/2013 MANFORUM
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man
think tank
perfect
principle
ever since the first spark ignition engine suitable for serial
production was completed in 1897, the basic principle of
Diesels has not changed. yet a closer look shows that current
high-tech diesel systems barely resemble their ancestor.
D
MANFORUM 04/2013
efficiency was an astonishing record
performance back in 1897. During those
days, steam-driven machines reached
an efficiency factor 12 percent.
total weight
was the result of a
particularly massive
design necessitated
by the high pressures caused by
compression. Due
to its weight, the
engine was merely
stationary in the
early years.
Rudolf Diesel still needed compressed
air to inject his fuel, modern injection
systems are standard nowadays. While
the first diesel reached peak pressures
of 35 bar within the cylinder, 250 bar
are series-tested today. Even Diesel believed that 150 bar would be the utmost limit achievable.
four-stroke to two-stroke
14.7 kW
Unlike the original diesel, the engines
of large trading ships—including oil
of power was the output of the first
spark ignition engine. Today, the strongest
two-stroke ship diesels can reach up to
85,000 kilowatts and are deployed in container ships, for instance.
tankers, mass cargo freighters and also
container vessels—work on the basis
of the two-stroke principle. Coastal
boats, military marine, ferries and
cruise ships, on the other hand, are
driven by four-stroke machines. The
strokes represent the working operations of the engine. Four-strokers like
the first diesel have a four-part sequence. Stroke one: The piston plunges
iesels are a
perennial phenomenon when it
Even if modern natural-gas engines
down into the cylinder and sucks in air
have caught on—often Diesel’s com-
—or the fuel mixture in the case of
comes to innovation. Since inventor
pression ignition engine still is consid-
Otto engines. Stroke two: The piston
Rudolf Diesel developed the idea 120
erably more efficient than its techni-
compresses the air and the mixture ig-
years ago and the Maschinenfabrik
cal predecessor, the Otto engine
nites. Stroke three: The piston is
Augsburg-Nürnberg—which was later
running on gasoline. Nicolaus August
pressed down again and passes on mo-
to become MAN—brought it to serial
Otto had decided to first mix gasoline
mentum to the crankshaft for motion.
production, these machines have
and air before funneling the mixture
Stroke four: The piston returns into the
managed to surprise time and again.
into the combustion chamber. There a
cylinder, forcing out the exhaust gas in
The sparky concept behind it has re-
spark plug will ignite fuel and air. The
the process. This procedure requires
mained as modern as on its very first
advantage of the diesel engine: As
more components than the two-stroke
day: The piston compresses the air in
the air in the combustion chamber can
approach, but the engines are lighter
the combustion chamber so much
be more compressed, it raises the effi-
and more compact.
that it heats up to between 700 and
ciency of combustion. This makes
900 degrees Celsius. Only then comes
diesels more economical.
the addition of diesel fuel—or heavy
30
26%
4.5 t
of a combustion piston engine. While
oil in case of ships. The heat is so ex-
unimagined top pressures
treme that the fuel vaporizes by itself
When comparing the design of the
and then catches fire. This combustion
first compression ignition engine with
causes rising pressure in the cylinder,
the diesel engines of today, they do not
which forces the piston down again
share many common features other
and thus gets the crankshaft moving.
than the utilized fuel and the principle
Two-stroke engines, such as mod-
19 l
cylinder capacity at a rotational speed of 172 revolutions
per minute offer a high torsional moment, which makes
the first diesel engine especially robust and persevering.
ern marine diesel engines made by
MAN, do everything in just two movements: In the first stroke, the piston
moves into the cylinder. A fan blows in
fresh air through an inlet grill above
Photos: MAN
Diesel received
his Patent in 1893
for his innovative
engine. As of 1897,
series production
began at the
Maschinen­fabrik
Augsburg-Nürnberg.
The first sold diesel
engine was set up in
1898 in a matchstick
factory in Kempten.
the first operational Diesel engine
was presented to the public on
February 17, 1897, in Augsburg.
Today, the original engine is displayed
at the Deutsches Museum in Munich.
the piston’s return point. At the same
time, an outlet valve is opened at the
cylinder head to allow for the emission
04/2013 MANFORUM
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man
think tank
of exhaust fumes. As soon as the pis-
engine, a two-stroke rotary engine, was
precise amounts of air and exhaust gas
continuous optimization of utilized
reach ignition pressures of 180 atmo-
ton has reached the upper return
built in 1910. The simple, yet ingenious
entering and leaving the system. Like-
materials. Four-stroke diesel engines
spheres—six times the pressure that
point, the outlet valve is closed and
idea of a turbo: Effusing exhaust gas
wise, computer-controlled injection
work with common rail systems, which
Rudolf Diesel achieved with his first
the diesel fuel injected. During injec-
drives a turbine, which transports ad-
nozzles for the fuel in order to adjust
inject fuel into the cylinder several
engine. “Series production four-stroke
tion, the fuel ignites, the pressure in
ditional air into the cylinder, thus en-
the quantity exactly to individual op-
times during one working cycle. This
engines reach 250 bar, even though we
the piston chamber rises, pushing
hancing performance.
erating conditions. In two-strokers for
allows engineers very precise manage-
have already demonstrated 400 bar in
test trials,” says R&D expert Poensgen.
down the piston. During this process,
Additional innovations were to fol-
marine applications, the cylinders
ment of the combustion process. MAN
the piston renders its momentum to
low in the ensuing decades, which
have become taller, while cylinder ca-
has even been the only manufacturer
the crankshaft. At the lower return
nowadays have become standard
pacity grew. Today, MAN’s ship diesel
to introduce a common rail system
new technologies
point, the procedure repeats itself.
features in MAN’s engine repertoire:
engines can reach an output of up
for heavy-oil engines. Modern two-
Meanwhile, engineers are continuous-
Large ship engines are very slow and
electronically controlled valves, for
to 120,000 hp—which also is due to
stroke engines make it possible to
ly working on new technologies to in-
gear units and directly to the propeller
with rotary speeds of between 70 and
130 revolutions per minute. By comparison: In the four-stroke engines of
modern diesel automobiles, rotary
speeds of 4,000 to 5,000 have become
commonplace.
more efficient through turbo
While the first diesel engines still had a
crosshead transmission, the joint was
moved into the piston as of 1901, turning it into a so-called plunger. “The final breakthrough for the diesel engine
came in 1909 with the concept of pre
chamber injection,” explains Christian
Poensgen, Head of R&D Engineering
Efficiency
champion
The 32/44CR B2
is a state-of-the-art
four-stroke engine
with common rail
technology that is
also deployed in
ferries. The electronically controlled
fuel injection
process optimizes
fuel consumption.
Currently, this
engine is the most
efficient machine
in its weight class.
crease efficiency while reducing fuel
3 600 kW
consumption. Until 2017, for example,
six liquid natural gas (LNG) tankers
with MAN’s dual-fuel engines will be
launched in China and Japan. Built at
of power are distributed among six cylinders. With 600 kilowatts per cylinder, MAN’s
four-stroke common rail engine is market
leader in terms of performance.
the Hudong-Zhongua shipyard near
Shanghai, these ships are the first large
LNG tankers with an electric drive on
the basis of dual-fuel engines, which
are built in China. These engines can
sel mode, but can also utilize a mixture
New York United states
Evans Hoyt, 52
of liquid fuel and natural gas. When in
Hoyt was appointed Captain of
natural gas mode, they already meet
the Norwegian Breakaway, the
the requirements of the future Tier III
largest cruise ship ever built in
emissions standard issued by the Inter-
Germany to date, in April 2013.
national Maritime Organization.
How long does it take to start
not only operate in natural gas or die-
48.5%
effectiveness delivers an outstandingly high degree of efficiency.
Since Diesel’s first engine, the efficiency factor has nearly doubled.
In the near future, MAN will equip
up the engine?
We have a
diesel drive with four MAN
in Augsburg. “That was the technical
mostly on natural gas. And even if gas
engines. Getting it up and run-
basis of the secure, adjustable and ef-
turbines with downstream steam pro-
ning takes about two minutes.
cesses or fuel cells offer higher degrees
What is the power output of
of efficiency, it looks as if the diesel en-
your ship in hp and the rate of
gine will continue its triumphant jour-
her fuel consumption?
ney around the world. For while gas
Norwegian Breakaway has
turbines can surpass the diesel engine
83,500 hp. Consumption lies at
only in full load conditions, fuel cells
49 liters per minute and engine.
are still too energy-intensive for series
Which are your favorite
production. At any rate, MAN’s Head of
destinations or routes?
Development Poensgen remains a fan
sonally, I enjoy our excursions
of the self-igniting combustion en-
up and down the Canadian and
ficient injection systems of today.” The
success story continued with the development of in-line engines, V-engines.
As for aviation, World War I gave rise to
the first radial engines, which were
built until the 1950s. “In the following
decades, diesel engines underwent
continuous improvements,” emphasizes Gerlinde Simon, Director of the
MAN Museum in Augsburg. The patent
for the first exhaust turbocharger went
to the Swiss engineer Alfred Büchi as
early as 1905, and the first charged
32
MANFORUM 04/2013
210 l
cubic capacity at a rotational speed of 750 revolutions per minute ensure low fuel consumption. The
larger the ratio of cubic capacity to rotational speed is,
the lower consumption levels are.
39 t
of total weight make
the 32/44 CR almost a
­lightweight in relation to its
performance. The common
rail engine reaches an output
of 125 hp per ton. The
first diesel engine delivered
a meager 3 hp per ton.
gine: “Diesel engines are not only very
robust,” he says. “But altogether just
more economical.”
Photos: MAN
the first container vessels to operate
Medium Speed at MAN Diesel & Turbo
The
Per-
Profile in short
transmit their momentum without
US-American East Coast.
04/2013 MANFORUM
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04/2013
man
think tank
‘OttO eNgiNes ARe tAkiNg
AFteR diesel dRives’
That is correct, in absolute terms
hybridization can achieve greater savings with the Otto engine. Here the
ratio of expense versus output is less
AirplAne
favorable for diesel engines. Diesel
Diesel diamond
hybrids, however, are the ideal solution
PRoFEssoR stEFan PisChingER is an ExPERt FoR CombUstion EnginEs at thE
RhinE-WEstPhalia tEChniCal UnivERsity in aaChEn. hE ExPlains Why EvEn aFtER
120 yEaRs, thE DiEsEl invEntion is still RElEvant anD moDERn.
is now 120 years old. Has its technology become an obsolete concept?
Not at all. Indeed, there are new developments all the time. Just think of
multistage charging or injection systems with higher pressure levels:
PROFessOR
steFAN PischiNgeR
is Director of the
thermodynamics
institute and head of
the internal Combustion Engines Faculty
at the Rhine-Westphalia technical
University in aachen.
cles. Increasingly, hybrids with diesel
In 2002, with the DA40 TDI Dia-
engines are also being designed for
mond Star, the Austrian airplane
passenger cars and are already avail-
manufacturer Diamond Aircraft
while reducing soot particles to the
able on the market. Based on the appli-
obtained certification for the
lowest limit of detection. The diesel
cation in question, pure diesel solu-
world’s first serial plane using a
engine is not a zero-emissions design,
tions also make sense, especially when
diesel engine. Two years later, the
yet when comparing the achieved re-
low fuel consumption and high reli-
same company’s DA42 Twin Star
sults of today with those of the past,
ability are essential, and where electri-
became the first diesel airplane
we have just about come down to
fication makes no sense due to range,
in the world to make a non-stop
zero—and such particle filters are
cost, available space or durability.
trans-Atlantic crossing.
well-established in the market.
There will be an increasing number of
In concrete technical terms, how
applications capable of switching from
will diesel engines change in com-
a diesel to a natural gas drive. Or diesel
ing years?
with a gas admixture, or gas-based
The trend toward downsizing—
Otto engines, or some concept in be-
such as reducing weight or cubic capac-
tween. At any rate, these engines are
ity while maintaining performance—
closely related to the corresponding
will continue. Further standardization
diesel engine in terms of design.
of engine platforms is also likely to oc-
So will Otto engines increasingly
cur. Even today, it is already foresee-
adapt diesel technology?
able that many commercial vehicle
We already see self-igniting Otto
and industrial applications will have
engines that reach the same degree of
smaller engines with fewer cylinders
efficiency as diesel engines. Strictly
that are just as powerful in terms of
speaking, they should actually be called
torque and performance, while using
diesel engines because of the self-igni-
less fuel. With its thermodynamic
tion, even though they use Otto fuel
properties, the diesel engine is still
rather than diesel, as well as natural gas
ahead of other drive concepts when it
in the power plant sector. Today’s diesel
levels and continuously decreasing
comes to performance range. Its tech-
engines are ideally suited for a mix of
fuel consumption. In addition, friction
nology harbors additional potential,
diesel fuel with gasoline or natural gas
levels are steadily reduced, there are
and remains solid throughout the en-
without needing major adjustments. It
the improvements in coolant and wa-
tire service life. When evaluating total
should not be overlooked that with the
ter circulation and the utilization of
cost of ownership, diesel is still a very
introduction of new technologies like
thermal energy from exhaust gas. All
attractive solution.
direct fuel injection, supercharging and
these approaches carry considerable
Yet hybrid systems and additional
exhaust gas recirculation, the modern
potential for increasing efficiency. As
units in electric vehicles appear more
Otto engine is becoming more complex
for exhaust treatment, we have now
focused on the Otto engine. And they
and thus more expensive—and increas-
reached the level enacted by Euro VI,
are the technology of the future.
ingly resembling the diesel engine.
These offer constantly lower emission
34
MANFORUM 04/2013
Photos: Albrecht Fuchs, Diamond Aircraft Industries GmbH
Professor Pischinger, the diesel idea
for municipal buses or delivery vehi-
the Richest
RANge OF
MOveMeNt
There is hArdly noThing ThAT A diesel cAn’T
geT moving: The ApplicATion choices of This
engine Are As diverse As wAs The brilliAnce
of iTs drive invenTion. A look AT iTs diversiTy,
from AuTo rickshAw To zeppelin.
04/2013 MANFORUM
35
2
dossier
04/2013
Auto rickshaw
Three wheels, eight hp
In the tight tangle of metro areas in Asia,
there is no easier way to get around than with
an auto rickshaw, which is generally equipped
with a two-stroke diesel engine. In Europe, the
three-wheeled taxi is known as a Vespacar
from Italy. The Ape Calessino by Piaggio built
in the 1960s was reproduced in 2007 as collector’s item. The “Bee” is powered by a fourstroke diesel engine with eight hp. A special
model with the papal coat of arms was delivered to Pope Benedict in 2008.
Zeppelin
Solar airship with diesel power
The US company Millennium Airship Inc. has gotten diesel into
shape for the next 1,000 years: Its visionary Sky Freighter airship
has a drive powered by photovoltaic cells on the outer shell, with
a diesel engine serving as backup.
Racing car
Premiere at Le Mans
For the first time in the history of the 24-hour rally at Le Mans, a diesel
vehicle—an Audi R10—won the famous long-distance race in the northwest of France back in 2006. With an output of 646 hp, the Le Mans prototype is more powerful than most previous Audi racing vehicles. Since
then, vehicles with diesel engines have always won the Le Mans race. The
racing diesel can manage top speeds of up to 335 kilometers per hour.
VW beetle
Boxer for Beetle
36
MANFORUM 04/2013
Photos: Stefano Dal Pozolo/laif, Millenium Air Ship Inc,, Christian Bittmann/AUTO BILD, Audi Ag, MAN(2), Royal Endfield Pr, Uli Sonntag/VW Presse, hgm-press, shutterstock
man
think tank
Diesel for steam
The first ship built for the
high seas and propelled by a
diesel engine was launched in
Copenhagen in 1911. The drive
of the “MS Selandia” was supplied by Burmeister & Wain,
its engine division later becoming a part of MAN. Funnels
were no longer needed, as the
exhaust gas could simply be
expelled through an exhaust
pipe in the mizzen.
Motorbike
Regal two-wheeler
Royal Enfield was the only motorcycle
manufacturer to offer a diesel twowheeler in serial production for a longer period of time. Still, the “Enfield
Taurus” is not suitable for Western
emissions standards. The diesel-powered motorbike was built in India and
ideally adapted to local conditions and
regulations with only 7 hp. Today, diesel engines are still fitted into Enfield
Direct and efficient
At the Berlin Automotive Exhibition in December 1924, MAN
presented the world’s first diesel vehicle with direct fuel injection. This innovation created
the basis for the production of
diesel-driven commercial vehicles, as complicated auxiliary
units were no longer needed.
chassis in small numbers in Germany,
One-liter car
Thrifty hybrid
requiring an EU operating permit.
The first one-liter car celebrated its premiere earlier this year
at the Geneva Auto Show. Weighing in at just 795 kilos, the
VW XL1 features a two-cylinder diesel engine, 48 hp and a
20-kilowatt electrical engine and can manage speeds of up to
160 kilometers per hour—while utilizing merely 0.9 liters of
gas for the distance of 100 kilometers.
Tractor
Prestigious red noses
Cable car
Line to civilization
Porsche built diesel tractors in
series from 1950 to 1963. The
Reaching the picturesque Chinese
red paint was a distinctive fea-
village of Yushan first requires the
An air-cooled diesel boxer engine was installed in this
ture of the vehicles. Affection-
crossing of a 400-meter-deep gorge.
VW Beetle for the 50-year anniversary celebration of
ately dubbed “Red Noses” by
The only access to this remote hamlet
Porsche—an unusual combination. As long ago as the early
connoisseurs, the tractors are
in Hubei Province is a spectacular
1950s, VW experimented with diesel boxers, yet they never
traded as prestigious collector’s
cable railroad that extends over more
went into serial production. The reason: Too noisy, too messy
items these days and have
than a kilometer in length and is pow-
and inefficient. Today, this gem is in the Porsche Museum.
fetched five-figure prices.
ered by a diesel engine.
04/2013 MANFORUM
37
2
dOssieR
04/2013
MORe iMAges in
your manforum app
man
think tank
jAN weileR ReAds
Audio in your mAnforum app
AdAptAble
OMNivORe
AROUNd
the wORld
ON diesel
pOweR
algae, bacteria, old cooking oil:
diesel engines can utilize a wide
range of raw material as fuel.
e
A column by JAn Weiler
veN As eARly as the year 1900, the World Expo-
O
sition held in Paris displayed a diesel engine running on peanut oil. Rudolf Diesel himself experimented with plant-based oils. Today, biodiesel
made from comestible plants is a controversial
matter, considering the impact on food prices. Whenever
balance looks much better: Special biodiesel power plants can
produce energy from old cooking oil generated by restaurants—or even private households. Fuel oil generated from
algae is another option: This oil has similar properties as does
kerosene used in airplanes, and is an even richer source of
energy. In addition, diesel engines do not require a special
conversion to utilize seaweed fuel. The human digestive tract
is probably the last imaginable place to look for raw materials.
FUel FROM
bActeRiA
the bacterium
escherichia coli can
transform fatty acids
into the hydrocarbons that form the
basis of diesel fuel.
to this end, however,
the bacteria must
be genetically
modified first.
A method developed in Germany appears like a modern version of alchemy. Through a process known as catalytic pressureless depolymerization, refuse can be turned into diesel.
The method imitates the way in which mineral oil is created
naturally, using a chemical catalyst. While there are seven
plants of this kind operating worldwide, only one exists in
Germany for experimental purposes. Cellulose can also be
nology has developed a special thermal decomposition
Yet the intestinal bacterium Escherichia coli can be geneti-
method whereby straw can be transformed into an interme-
cally modified in such a way that the resulting chemical com-
diate product resembling mineral oil, which in turn can be
pounds resemble those of petroleum-based diesel.
used to operate a diesel engine.
pROFile iN shORt
ReykjAvik icelANd
steFAN thORvAldssON, 44
Stefan Thorvaldsson drives an MAN truck—like most of his colleagues in Iceland.
What is it like as a truck driver in Iceland?
It’s nice to experience the natu-
ral landscape of my home country first hand. Weather conditions can be a little
challenging at times, particularly the blizzards.
How have your MAN truck experiences been so far?
MAN trucks are robust
and therefore do very well in tough road conditions.
Where would you drive if you were free to pick your route?
I would like
to drive the “Road of Bones,” a route of almost 2,000 kilometers connecting
Yakutsk in Siberia to the Pacific Ocean.
38
MANFORUM 04/2013
Ne liteR OF
diesel cOsts ABOUt the same as a
used to produce biodiesel. The Karlsruhe Institute of Tech-
liter of milk in Germany. Nevertheless,
Photos: all mauritus images, Richard Kienberger, Enno Kapitza/pr
food waste is processed for fuel, however, the sustainability
up to its reputation as a true power
source, even though diesel was once
vilified. It belched soot, emitted stinky
smoke and stuttered like a woodpecker
on speed. When I was a boy, diesel was
still regarded as the juice for farmers
and construction workers. I thought it
fascinating that their machines and
engines were much bigger and more
impressive-looking than our simple
family car, which ran on ordinary gasoline. How pathetic was that! Diesel, on
the other hand, was anything but ordinary. It was diesel that powered the really large engines.
Therefore, it seemed perfectly natural that I should adore the German
TV series “On the Road,” featuring the
cult actor Manfred Krug. He played the
role of a long-distance truck driver
with sideburns as big as washcloths.
When the series was first broadcast in
1978, Krug had only recently emigrated from East Germany and allegedly
took the part because impersonating
an international trucker was his first
opportunity to explore the world.
As A BOY,
columnist Jan Weiler
worshipped the
“lords of the highway,” because longdistance truckers
could travel to the
far ends of the earth
with their diesel engines. Today, Weiler
is a prominent writer
and journalist.
Whenever we stopped at service
stations on holiday trips, I’d creep
around the supertrucks with their gi-
diesel really doesn’t taste very good,
Krug’s character Franz Meersdonk
even after adding generous amounts
traveled to the Near East, through
of cocoa. On the other hand, a truck
South America and many other places,
will hardly move an inch if filled up
always concerned that the goods be
with fresh milk. Even pasteurized or-
delivered safely and his diesel rations
ganic milk will leave the performance
not be depleted. While his rather silly-
of a combustion engine decidedly
looking cap did not exactly render him
something in common with those
wanting. Here, however, is where the
a model of nonchalance, he still em-
lords of the highway.
essential differences between these
bodied reliability and robust truth.
Even today I still nurture a secret
two liquids end—because they actu-
Even though he didn’t understand a
love of trucks—even though I’ve never
ally have a lot in common. Both are re-
word of what people said to him dur-
actually had the experience of riding
garded as staples, both get bodies
ing his exotic travels, he still managed
in one. So far, I have at least managed
moving, even if one system is made up
to muddle through and always tracked
to own a car with a diesel engine. No
of heavy machinery innards and the
down enough diesel fuel to deliver his
stutters, no soot, no vibrations. And
other of flesh and blood.
load more or less on time. I was much
when I apply the hand brake, no
gantic tanks. I watched while these
monoliths guzzled diesel by the hectoliter, and I always begged for a strapping trucker sandwich or some other
hefty snack favored by long-distance
veterans because I longed to have
Indeed, diesel is the milk among
impressed. And I also loved that
“whoosh” sound either. Alas, I must
fuels: Rich, creamy and supple, it sus-
“whoosh” sound when Franz pulled
admit, I have not yet come a long way
tains the strongest machines and lives
the hand brake of his truck.
in the world of diesel.
04/2013 MANFORUM
39
3
man
projects
Assistance systems
Safety on the
radar screen
As of 2015, all trucks in the eu zone must be equipped with automatic
braking assistance systems. They are just one of numerous electronic
accessories to enhance the safety standards of MAN trucks.
attention, obstacle ahead
Whether in stationary or moving
mode: Radar sensor and camera
systems detect potential hazards,
bring them to the attention of the
driver and apply the brakes automatically if necessary.
A
Photos: MAN, Audi AG, [M]
it is improbable
40
MANFORUM 04/2013
dmittedly,
that Eberhard
Hipp, Head of Vehicle Research at MAN
Truck & Bus, would drive like this on
any public road. Yet here on the testing
ground, he is aware of how effective his
demonstration can be: After starting
up the test truck and accelerating the
3
man
projects
E l e ct r o ni c St a bility Pr og r a m
vehicle to 80 kilometers per hour, he
traffic jam, or a car involved in an ac-
truck itself a safety hazard. Therefore,
leans back comfortably in his seat—
cident. In technical terms, it is much
the EBA system has a radar sensor to
and without seeming to notice the un-
more complex to detect stationary ob-
monitor the area ahead. The system’s
Lan e G uar d S y st e m
moving car that appears in front of
jects than objects moving in front, as
future development should make it
Tire Pressure Control
him. Unfazed, the truck keeps hurtling
performed by MAN’s Adaptive Cruise
possible to also trigger automatic
toward the obstacle and a collision
Control for instance. It works with ra-
braking in response to stationary ob-
seems unavoidable. All of a sudden,
dar, which monitors the distance from
stacles when traveling at low speed. To
many things happen at once: A loud
the vehicle ahead, to adjust the speed
this end, the radar sensor will be com-
warning signal, alarm lights flashing
selected by the driver when required.
bined with a camera system for safe-
on the dashboard and a slight reduc-
The Automatic Emergency Brake As-
guarded obstacle detection. Only
Night Vision Support
tion in speed—but not nearly enough
sist, however, must be able to recog-
when supplied with this data can the
to avoid the crash. While Hipp gives a
nize every kind of object—as an EBA
control electronics generate an accu-
meaningful nod, the truck goes into a
system, and, even more significantly,
rate image of the surrounding area
Ultrasonic Guard System
Continu
e
ous Lateral / Longitudinal Guidanc
in the version currently under devel-
and detect potential hazards on the
opment that brings the truck to a com-
basis of appropriate algorithms—be
plete stop. Technically speaking, this
they moving or stationary.
car lengths from the obstacle. “It all
happens automatically!” calls out the
Head of Development in the last few
seconds before the vehicle comes to a
final stop. At no time was the braking
pedal even touched.
Detecting obstacles
Automatic Convoy Mode
Automatic Emergency
Brake Assit
Adaptive Cruise
Control
Road Sign
Recognition
Emergency
Brake Assist
available
future development
360-degree safety package
The developers at MAN have been
focusing for a long time on assistance systems to make driving
safer. Numerous systems of this
kind have been developed up to
the present.
raises a simple question: What exactly
The EBA is an important step to-
is an obstacle? Criteria may not be de-
ward even more traffic safety, even if
fined too loosely, otherwise some haz-
the Head of MAN Development points
tems today that meet the standards
even more elaborate. These include
complex environment in cities makes
ards could be overlooked. By the same
out: “It is the combination of a wide
called for by transport policy-makers
the Automatic Emergency Brake As-
entirely different demands than driv-
token, the system should not trigger
range of different assistance systems
in their commercial-vehicle directives
sist, the Adaptive Cruise Control men-
ing on the freeway, for example,” ex-
emergency braking due to an insignif-
that makes driving safer.” Indeed, once
for late 2013 and 2015. After all, easing
tioned above or the Lane Guard Sys-
plains Eberhard Hipp. He also serves as
icant detail, as this could make the
again, MAN is already offering sys-
the strain on drivers and safety stan-
tem (LGS). The latter alerts drivers via
coordinator for the UR:BAN project
The system is called Automatic Emer-
dards have always been definitive fea-
a warning signal whenever they leave
consortium for user-friendly driver-
gency Brake Assist. MAN is currently
tures of the brand.
the lane without using the indicator
assistance systems and network man-
lights. The Continuous Lateral and
agement. Although traffic flowing in
conducting further research and will
No braking 39%
soon develop it up to serial production.
Other 8%
Meanwhile, one variant of the system
is already available. While the Emergency Brake Assist (EBA) system meets
Accidents involving
pedestrians 2%
Partial braking 20%
All-around assistance
Longitudinal Guidance Systems will
the city center tends to be much slow-
Many safety aspects are already so
go even further, by actively interven-
er than in surrounding areas, drivers
much ingrained at MAN that they
ing in the steering process to remain
are surrounded by many more sources
could easily be overlooked: The Elec-
in the lane. With the Ultrasonic Guard
of distraction, such as pedestrians, cy-
tronic Stability Program, for example,
System, a sensor measures the dis-
clists, stopping automobiles and inter-
all newly registered trucks must be
which has been used by MAN for years
tance to objects up front. Should the
sections, to name just a few. “When
equipped with an AEBS (Advanced
but still won’t become mandatory by
truck come too close, an optical signal
moving in urban traffic,” states Hipp,
law until 2014. If a vehicle threatens to
alerts the driver. The Tire Pressure
“it does not suffice to merely keep an
skid or overturn, the ESP system inter-
Control System and Continuous
eye on the vehicles in front, but actu-
venes in fractions of a second by ap-
Damping Control (CDC) are two fur-
ally demands complete all-round
plying the brakes and throttling the
ther assistance systems to ensure an
vision. In some situations, an emer-
engine. In order to detect such hazard-
optimized connection between truck
gency braking maneuver is not the
with moving or suddenly braking ve-
ous moments—like those occurring
and road. Especially CDC prevents the
best option—for example, if there is
hicles or mitigate the outcome of a
when a bend is taken too fast, in slip-
dangerous escalation of pitching and
enough clearance to veer around the
crash by reducing the speed on impact.
pery road conditions or during a hec-
rolling movements by adapting the
problem.” Hence, taking a look back at
With EBA, a driving assistance
tic evasive maneuver—permanent
damping intensity of the shock ab-
the last decade clearly reflects the rap-
readings are necessary. Assistance
sorbers to any new conditions.
id pace of driver assistance system
the EU requirements stipulating that
Emergency Braking System) as of No-
intersection
accidents 18%
vember 2015, it does not yet succeed in
rear-end
collisions 33%
bringing the vehicle to a complete
standstill after a braking maneuver.
Full braking 38%
EBA can reduce the risk of accidents
system from MAN can also detect stationary obstacles for the first time. In
practice, this might be the tail end of a
42
MANFORUM 04/2013
No data 3%
departure
from the
road 39%
Source: Federal Statistics Office
Period reviewed: 2010/2011
systems that also register other traffic
Making driving in urban areas saf-
participants or the road ahead are
er presents a particular challenge. “The
development: Safe and assisted driving has a great future at MAN.
To make driving safe, several
systems need to interact.
before finally coming to a halt three
Accidents with
heavy trucks
Leaving the roadway
is the most common
cause of accidents
for trucks (39%),
closely followed by
collisions with a vehicle in front (33%).
Collisions with pedestrians come last
in the statistical
rating, with just two
percent.
Maneuvering
Assistant
drastic emergency braking maneuver
C o n t i n u o u s D a m p i n g C o n tr o l
04/2013 MANFORUM
43
3
man
projects
Electricity from oil and diesel
Energy
for dry
spells
Near the city of Puntarenas in
the northwest of Costa Rica, MAN Diesel
& Turbo oversaw the construction of the
world’s most modern and efficient diesel
power station.
hydropower covers 80 percent of Costa
Rica’s energy needs. during its dry season,
the country relies on diesel as an additional
energy source.
W
ith the
air shimmering over asphalt,
the Panamericana highway. Our route
takes us from Puntarenas, the lively
Pacific port on the Gulf of Nicoya in
Costa Rica, into a gently rolling hilly
landscape. Far and wide, there is nothing but luscious green and rampantly
Photos: Hauke Dressler
we are making rapid progress along
04/2013 MANFORUM
45
role in the construction process of one
always humid Caribbean side of the
that here, right in the heart of the jun-
of the world’s most advanced and ef-
country receives regular precipitation,
gle, should be the location of Costa
ficient diesel power stations: “Costa
the wet-dry Pacific side must rely on
Rica’s largest power station. And yet:
Rica is a very ecology-minded country,
additional power sources during its
After about 20 kilometers, a sign by
with strict emission standards for in-
dry season, which lasts from Decem-
the side of the road comes into view:
dustrial facilities, which apply both to
ber to May. Single-source diesel power
“Turn left for Termoeléctrica Garabito.”
noise and exhaust gases,” says Frank.
stations, such as supplied by MAN
Among countries in Central America,
Diesel & Turbo, feature low levels of
Costa Rica presents itself as a stable
consumption, emission and noise, and
“Remaining inconspicuous was part of
and rapidly growing economy, with an
can bridge the power gap as needed.
the project specifications,” explains
energy demand growing by four to
Wolfgang Frank in retrospect. As Proj-
eight percent every year. Hydropower
Purely high-tech
ect Manager at MAN Diesel & Turbo in
currently supplies around 80 percent
Back in 2011, following a construction
Augsburg, Frank played a significant
of the country’s electricity. While the
period of about 18 months, Wolfgang
strict environmental rules
“The control system is operated
via remote from headquarters.”
overgrown nature. It is hard to believe
3
man
projects
Frank’s project team of 12 handed over
a complete power generation facility
with 11 four-stroke generator sets and
a total output of 200 megawatts to
the Grupo Instituto Costarricense de
Electricidad (ICE) and its partners. “At a
scale of €190 million, this project relies on nothing but high tech, ” says
Frank. “Due to the optimized combustion of heavy oil and diesel, we have
succeeded in lowering fuel consumption, which in turn results in fewer nitric oxide emissions and less CO2 .” Today, Costa Rica’s largest power station
alone could cover around 10 percent of
the entire country’s power needs.
hidden in the jungle
It should therefore come as no surprise that not a hint of billowing
clouds of smoke and steam would lead
the way at the Panamericana turnoff.
The modern and highly complex powMAN Power
Eleven heavy diesel
generator sets type
18V48/60 produce
electricity at the
world’s most modern
and efficient diesel
power station.
building on the left, then the large and
plant floor. “When it came to the
drawn-out turbine building, which
choice of location, the infrastructure
gleams in silver and features two gi-
in the Puntarenas region was the deci-
gantic metal filter towers. Behind it,
sive factor,” explains Rojas as we walk.
there is an assortment of other build-
“It’s an intersection point for several
ings, pump stations and four huge,
overhead and high-voltage power
liters of rain per square meter every
round heavy-oil storage drums, paint-
lines. And as we are close to the har-
month. In September, this will rise to
ed black for additional visual empha-
bor, we also have a reliable fuel sup-
almost 300 liters per square meter. In
sis, and another diesel tank.
ply.” A security code opens the door to
er plant blends in harmoniously with
the luscious natural landscape. It is
April, and the sultry air offers a taste
of the rainy season soon to arrive at
the Pacific side of Costa Rica. Precipitation is still modest, with merely 30
line with demand, Termoeléctrica Ga-
At the entrance, we are welcomed
the large control room of the facility.
rabito will not run at full capacity dur-
by pla nt ma nager Ver ny Rojas
Switches and levers, monitors and dis-
ing that time. Now, in April, the plant
Vásquez, who leads us to his office at
plays dominate the scene. The staff su-
is still at full throttle. Considering the
the end of the hallway. It is sparsely
pervising the system seem fairly re-
massive scale of this power plant com-
furnished. Clearly, the main emphasis
laxed. “This is where we continuously
plex, the prevailing quiet at this site is
here is on functionality, rather than
check the smooth functionality of this
on presentation. Like all employees at
system,” says Rojas. “Yet the actual
the facility, he wears jeans and the yel-
control system is operated mostly
low ICE corporate shirt.
via remote from ICE headquarters in
46
MANFORUM 04/2013
Photos: Hauke Dressler
utterly astonishing. At best, only a
Respect for nature
Adhering to the country’s
stringent environmental
requirements and emission
standards, the power
station blends inconspicuously into the surrounding
hilly landscape.
subdued hum would suggest that 11
heavy diesel generator sets are on
duty here.
Heading for the administrative
buildings allows for an expansive view
of the entire complex: the transformer
Plant manager
Verny Rojas Vásquez
is delighted to welcome visitors from
Germany and has
also visited MAN
Diesel & Turbo in
Augsburg.
perfect infrastructure
Costa Rica’s capital, San José, some
100 kilometers away. Either directly
Together, we make our way together to
via interface, or through telephone
the control station on the adjoining
contact with our control room.”
04/2013 MANFORUM
47
3
man
projects
Emergency
exercises
As Costa Rica is a
seismological hot
spot and earthquakes are relatively
frequent, the workforce carries out
disaster response
drills on a regular
basis.
An expansive glass door offers a
look at the diesel engines: 11 massive
generator sets, each with an output of
18,900 Kw. “When going full throttle,
the plant needs around 900 tons of
heavy oil and diesel every day—the
equivalent of roughly 60 truck loads,”
explains the plant manager Vásquez.
Around 45,000 cubic
meters of fuel
is the capacity of the
heavy oil and diesel
tanks. The fuel is trucked
from a ship to the plant.
Photos: Hauke Dressler
MANFORUM 04/2013
keep the entire plant up and running
for one and a half months. Several
trucks are lined up at the unloading
station, waiting their turn to pump
out their fuel. A driver takes advantage of the idle time, catching a little
siesta in the shade underneath his ve-
while it is still cold. Only when we
hicle. “When a tanker docks in Puntar-
reach an operating temperature of 70
enas, it takes around 800 truckloads
to 80 degrees will the heavy oil reach
to carry 20,000 cubic meters of heavy
sufficiently elastic properties to flow
oil and diesel to Garabito,” explains
through the pipes.”
Freddy González Cruz. The entire op-
Freddy González Cruz takes over as
eration takes two days. “During that
tour guide for exploring more of the
time, we have trucks arriving at and
leaving from the pumping stations
ployed in the workshop and is visibly
Right next to the power unit build-
proud to present his facility. With a
ing is the ESP filter installation, with
promising smile, he opens the door
its two mighty towers reaching for the
leading to the engine room. As quiet as
skies akin to silver fingers. ESP is the
the entire system may seem from the
abbreviation for Electrostatic Precipi-
outside, getting close to the generators
tator. Utilizing electrostatic charging,
is an incredibly noisy experience.
the filter installation separates parti-
engines of 320 tons
48
fuel—a quantity that is enough to
“We need diesel to start up the system
site. The 36-year-old mechanic is em-
Teamwork and control
The functionality of the
diesel engines and filter system is monitored at all times.
hold about 45,000 cubic meters of
Short transport
routes from the
port, as well as the
presence of an electricity infrastructure,
were decisive factors
when choosing a site
for the Costa Rican
power station.
cles out of the engine exhausts, thus
without a break.”
earthquake proof
Back at the administrative offices,
there is a sudden burst of activity.
Shouting is heard across the grounds.
“It’s a disaster drill,” relates Freddy
González Cruz. “These are scheduled at
playing a key role in the reduction of
Caribbean
Sea
regular intervals. Safety is a top prior-
The machines are built on an impres-
emissions. Similar to the heavy-duty
sive scale. The generator sets were
transports, assembly of the filter sys-
first assembled at the premises of
tems was something of an adventure,
MAN Diesel & Turbo Costa Rica in San
remembers Business Project Manager
common here. During the construc-
José, and transpor ting the heav y
Maria Grande del Valle at MAN Diesel
tion phase, Wolfgang Frank himself
equipment was one of the biggest
& Turbo in Augsburg: “The ESP filter
experienced three earthquakes, one of
challenges for Wolfgang Frank and his
was delivered to us in the form of a
them very severe. “It was quite a shake-
team at their construction site. After
component kit weighing 1,500 tons.
up,” he remembers. “The filter towers
all, just one of the engines weighs
The logistical challenge for project
swayed mightily, but didn’t suffer any
about 320 tons, and had to be carried
management was to get the parts to
damage in the end.” This, he says, was
for a distance of 35 kilometers on a
the construction site in the right se-
due to stringent regulations, as well as
semitrailer truck. The dimensions of
quence. ‘Plug and play’ wasn’t in the
farsighted planning and the use of
these shipments reached a height of 8,
cards—so it took us months to get the
highly advanced technology such as
a length of 45 and a width of 6.5 me-
25-meter-high filter in place.”
earthquake-proof foundations, smart-
Pacific
Ocean
ity for us.” And for good reason, as Costa Rica sits on a seismological hot spot
of the planet. Earthquakes are not un-
ters. “These transport operations took
Our guide Freddy González Cruz
steel structural solutions and shock-
three or four days each,” recalls Frank.
leads us from the filter plant to the
resistant pipeline fasteners. “Thus, the
“And all this while moving at a walk-
fuel unloading terminal. This termi-
plant is well prepared,” concludes
ing pace, and having to contend with
nal is directly linked to the heavy-oil
Frank. And not just for doing duty dur-
river crossings as well.”
and diesel storage depot, which can
ing the dry season.
04/2013 MANFORUM
49
3
man
projects
Rail engines
fast track
to growth
The future is
on rails
In order to serve
the Metro area
of Bydgoszcz in
Poland, the railcar manufacturer
PESA relies on
the drive of
MAN’s new serial
six-cylinder diesel
engine.
Air conditioning
Seeking a high level of
comfort in modern railcars—including air
conditioning—requires
powerful engines.
Roof cooling system
In order to save space, the air
and water heat exchanger
that provides cooling for the
engine and gears is mounted
on the roof of the train.
Digital ­direction
of travel display
The illuminated display
modules are among the
new energy consumers
placing greater demands
on engine performance.
while The market for diesel traction vehicles is growing
worldwide, MAN enjoys an excellent reputation due to its
compact and powerful engines for trains.
700,000 people
ore than
is the new serial six-cylinder D2876
LUE631 diesel engine from MAN,
which meets the standards of the current EU Stage 3B emission level. Compared with the exhaust standard in
place until January 1, 2012, the designers at MAN Truck & Bus in Nuremberg
had to cut nitric oxide emissions by
live in the metro-
half and limit the share of carbon
politan area of Bydgoszcz, the eighth-
monoxide to just 3.5 grams. In addi-
largest city in Poland. Increasingly,
tion, the efficient engine offers an ex-
they are using rail rather than the road
tended performance range of 530 hp
in order to travel from A to B in a fast,
and 390 kW—as compared with the
safe and environmentally friendly
480 hp and 353 kW of its predecessor.
fashion. As demands on passenger
transport are growing continuously,
140 kilometers per hour
the Polish railcar manufacturer PESA
With top speeds of 140 kilometers per
is building four two-part diesel motor
hour or even more—depending on the
coaches just for the Bydgoszcz catch-
condition of the tracks—diesel trac-
ment area to keep up. The centerpiece
tion units are definitely on par with
of the drive systems supplied by Voith
their electric counterparts. And addi-
50
MANFORUM 04/2013
Fuel tank
On average, the tank holds
1,000 liters of diesel. This
amount of fuel suffices for a
workday of nine hours.
Illustration: Hokolo 3D
M
Turbo based in Heidenheim, Germany,
Coolant circuits
The pipes complete the
circuit between the cooling
system and the engine.
Drive package
Centerpiece of the
system supplied by
Voith Turbo is the
new D2878 LUE631
type rail engine
from MAN, which
also meets current
Stage 3B emission
standards.
Bogies
Traction bogies that transfer the engine output to
the rail are located at the front end of the rail cars.
A so-called “Jakobs bogie” with non-motorized axles connects the car bodies of the two-section unit.
04/2013 MANFORUM
51
3
Generator
The hydrostatically powered generator is responsible for the on-board
power supply of the railcar.
man
projects
tional energy demands caused by rail
pay off—if only to keep up with rising
features are accelerating the trend to-
fuel prices that make for 90 percent of
ward a performance boost. “More pow-
rail operation costs.
erful air conditioning systems as well
as passenger information systems use
Truck drive as a basis
more electrical power, and therefore
The basis of all rail engines is a highly
Powerpack
The complex drive
system comprises
components from
both MAN and Voith.
Diesel engine
The 530 hp serial sixcylinder D2876 LUE631
engine from MAN meets
EU Stage 3B emission
level requirements for rail
operation.
Air-to-air cooler
The air-to-air cooler allows for
increased operating pressure
at constant temperatures in
the cylinder.
Hydrostatic oil tank
The hydrostatic oil container supplies
the hydrostatic components for operation of the cooling system and the
generator integrated in the Powerpack.
supplied the Heidenheim technology
company Voith with 66 engines type
D2876 LUE605, the predecessor of the
Metering line
Exhaust gas and urea are mixed in the
metering line. In this process, absolute
accuracy is a prerequisite for compliance with the 3B emission standard.
present models. They were installed in
traction units of the VLT Mobile 4
class. With a length of roughly 60 me-
demand more of the engines,” ex-
robust and compact truck drive, which
plains Günter Gmelch from the Busi-
is adapted to the special requirements
ness Center Rail Sales Engineering at
of rail operation. For one, these include
MAN Truck & Bus. The third genera-
frequent changes of load and rotation-
tion of the tried and tested six- and
al speeds in different operating modes
two large cities in the east of Brazil,
12-cylinder engine series, with an out-
of a rail vehicle. Secondly, the engine
carrying more than 770 passengers
put of up to 1,000 hp, meets these re-
must be designed in such a way that it
safely to their destination every time.
quirements of the railcar makers. Rail
can work in either diesel mechanical,
customers enjoy enhanced comfort as
diesel electric or diesel hydraulic
growing market
well as extended services.
mode—depending on which style is
Now Voith has ordered an additional
favored by the customer. Special en-
68 serial six-cylinder engines with a
gine control technology prevents the
performance of 460 hp and 338 kW
“At the same time, our customers ben-
wheels from spinning and can there-
each, which will be installed in the
efit from maximum flexibility in
fore react swiftly in hazardous situa-
compact railcars by utilizing Voith’s
adapting their engine systems to any
tions. In case of a serious defect, the
Powerpack. The follow-up order en-
new standards,” emphasizes Martin
engine comes to a stop automatically.
sued not only due to the positive out-
Schwindt, Product Strategy and Man-
“This is a particularly important safety
come that Voith experienced with the
agement Off-Highway at MAN Truck
requirement and an absolute necessi-
engine economically incorporated un-
& Bus. Advantageous opportunities
ty,” explains Gmelch, “after all, trains
der the floor of the vehicle. The reputa-
range from identical interfaces in the
carry people.” In juxtaposition to their
tion of MAN’s high quality standards
drive system to replacement parts
powerful performance, these six- and
that rail operators already have in
12-cylinder engines are both quite
stock and can further use. The same
light and compact. This allows for
flexibility is also offered by the MAN
space-saving installation either under
engines in combination with all gear
the floor or on the roof. Depending on
and generator types utilized in the
functional needs, the multiple-engine
given performance class. Thus, older
concept—which allows for engaging or
traction unit models can also be easily
turning off engines as needed—facili-
upgraded to the current Stage 3B ex-
tates performance variation of the
haust standard. A sensible approach,
traction unit. It may carry a full load to
considering that a very large number
its destination, for example, and re-
of motor coaches, locomotives and
turn with none.
rail service vehicles equipped with
The great flexibility of MAN Truck
MAN rail engines are currently in ser-
& Bus has rendered the company a
vice throughout Europe. “Many of
trusted partner of railroad manufac-
them have been in operation for more
turers—and not just in Europe. In Bra-
than 30 years,” says Günter Gmelch. In
zil, the German diesel-engine maker is
view of such a long service life, a new
market leader in the railcar sector. Just
and more efficient engine alone will
in the last two years, MAN Truck & Bus
52
MANFORUM 04/2013
Bom Sinal, the compact lightweight
railcars serve the local public transport systems of Fortaleza and Recife,
also played an important role. As the
Cardan shaft
The cardan shaft ensures the
power transmission between
drive system and bogie.
Exhaust turbocharger
The exhaust turbocharger
boosts engine performance
and efficiency. The turbo system draws its energy from the
residual pressure of
exhaust gases.
Voith gears
The Voith hydraulic gears
are ideally adapted to the
special requirements of rail
operation, with its frequent
changes of output range.
ScR converter
The ScR catalytic converter is an important
element to meet EU
exhaust standards.
quality of fuel in Brazil varies widely,
and no mandatory exhaust standards
exist as yet, European emission standards do not apply for now.
The market for diesel traction
units has been steadily expanding
around the world, for in light of growing population figures, an ever increasing number of local transport arteries are either under construction,
being privatized or even being reacti-
Illustration: Hokolo 3D
Easy upgrade
ters and built by train manufacturer
Metering unit
The metering units controls the exact
inflow of the AdBlue reaction fluid.
AdBlue tank
Used for the exhaust treatment of diesel
engines to reduce nitric oxide emissions,
the urea-based solution is stored in the
AdBlue tank.
vated once more. On these routes, diesel-powered operation is a much more
economical option than the expensive
installation of overhead wiring. Thus,
MAN rail engines will continue to safely carry passengers to all their destinations in the future.
04/2013 MANFORUM
53
3
Moving 50% of the
world’s trade with a
116-year-old idea?
We are your MAN.
size matters
man
projects
Augsburg, 1897. Rudolf Diesel puts
the first diesel engine into use at MAN.
Since then, MAN engineers have continuously improved the diesel engine.
That’s why, today, MAN is the undisputed number 1 in two-stroke marine
engines worldwide. Every second ship
on the world’s seas is powered by an
MAN diesel engine. Together, MAN
diesel engines drive half of the world’s
trade. It’s amazing how much can be
moved with a 116-year-old idea! See
what else MAN can move around the
world with intelligent technology at
www.man.eu
60 tons is the
weight of this
planetary gear
built by transmission manufacturer
Renk. The gigantic
wheel set is inwind power plants.
Photo: MAN
stalled in offshore
Engineering the Future –
since 1758.
MAN Group
54
MANFORUM 04/2013