In an intensely competitive market, OEMs are no more just technology providers; rather, they are keen on providing total solutions specific to a project. This includes meeting clients? business needs around project costs, managing topline and bottomline impact, and overall cost of ownership. No wonder fuel and energy efficiency have become two major parameters while selecting equipment, as the end-user community is more focused on the operating cost in a market where bidding of projects is ultimately influenced by the lowest bid. The bonus is, environmental and energy issues have made the construction equipment industry develop more efficient and energy-saving machines in the automotive industry in the past two decades.

One of the challenges faced by the manufacturers of diesel engines today is to develop products that will deliver higher performance, longer life, lower operating costs and at the same time, have less of an environmental impact. To comply with these standards, engine manufacturers have invested in the research and development of new, cutting edge technologies aimed at taking diesel emissions levels down to near zero.

JCB has already launched the ecoMAX, customised for Indian conditions and emission norms.

?EcoMAX is optimised for JCB construction equipment, to offer maximised fuel efficiency,? says Vipin Sondhi, Managing Director and Chief Executive Officer, JCB India. The JCB engine ecoMAX is optimised for JCB construction equipment, to offer a package that produces maximised fuel efficiency while enhancing productivity and operating efficiency solutions. JCB respects the environment and designs all its products in a way that helps maximise the green quotient. Four valves per cylinder ensure better mixing of fuel hence better combustion and lower emissions. Speaking about the design aspects Sondhi says, ?The JCB engine ecoMAX is based on the same platform as the JCB Dieselmax, the record-breaking engine that powered the car which holds the world?s land speed record. It is also the first engine designed specifically for off-highway applications. A JCB machine working in sub-zero temperatures building roads in Leh might also be called on to work in the searing heat in the deserts in Rajasthan. Then, there are difficult off-highway fuel conditions to deal with. The usage pattern in India is different from the American or European markets and the engine has been adapted specifically considering these factors.?

Fuel efficiency often tops the list of demands that customers place on their machines. Thanks to Volvo?s OptiShift, an innovative system to make equipment more fuel efficient while reducing emissions and environmental impact. Sven-?ke Carlsson and Bj?rn Brattberg, the two engineers who developed the OptiShift system, were awarded the Volvo Technology Award 2012 for their outstanding technological achievement and engineering expertise. OptiShift was first launched as an option on Volvo wheel loaders in 2009 and since 2011, it has been a standard feature on the larger machines ? the L150G, L180G, L220G and L250G.

Volvo?s unique OptiShift technology consists of two new features: a torque converter with lock-up and free wheel stator, and Volvo?s patented Reverse By Braking (RBB) function. The combination of this technology has reduced fuel consumption by up to 15 per cent as well as increased machine performance. ?When a wheel loader carries a load over longer transport distances, a lock-up function can reduce the engine revs,? explains Sven-?ke, a retired Volvo CE employee who invented the concept behind OptiShift. ?When lock-up is activated, it creates a direct connection between the engine and the transmission without the aid of the torque converter. With OptiShift, the lock-up function is used during a larger part of the work cycle and that saves fuel. When the operator wishes to change direction, OptiShift senses the loader?s speed, direction and accelerator position and slows the machine by applying the service brakes automatically. This results in faster loading cycles, reduced load on the powertrain, smoother changes in direction and lower fuel consumption. All of this adds up to lower operating costs for Volvo customers and a more comfortable working environment for operators.?

Construction equipment, say for example excavators, loaders, have unique power train mechanisms, thus raising unique technical issues with respect to efficiency improvement or energy savings. Due to heavy work load and long daily operation hours compared to automobiles, the economic impact of energy efficient equipment on customers? maintenance budget will be greater than that of automotives.

The project team at Dynapac Construction Equipment, Atlas Copco, recently bagged the Environmental Award for its new series energy-efficient soil rollers with a completely new engine management system called ECO. The new ECO system reduces fuel consumption and noise emissions by keeping the engine running at the lowest level possible while meeting required needed output. The average saving of fuel consumption is 10-15 per cent compared to the previous solution. The lower engine speed and the lower running speed of the cooling fans reduce the noise emissions from the machines, which is a positive effect for the machine operators and the people working around the machine.

Volvo Construction Equipment has invested over Rs 90 crore for a production facility in Bengaluru and has launched two of its best-selling products, the EC210B Prime and EC290BLC Prime in the 21T and 30T crawler excavators. The EC210B Prime is a 21.5 tonne machine, with a six-cylinder turbo charged after-cooled Volvo diesel engine. The larger EC290BLC Prime, meanwhile, weighs about 30 T and is also fitted with a six-cylinder turbo charged after-cooled Volvo diesel engine. At the core of both the EC210B Prime and EC290BLC Prime are Volvo engines that work in harmony with tailored hydraulics to provide industry-leading fuel efficiency, especially during hard trenching or mass excavation. Other features that keep engines running smoothly include a charged air cooler that works with the turbocharger for more efficient combustion and lower emissions; a three-stage air cleaning system which prolongs engine life, and an oil bath pre-cleaner that provides additional particle filtration, easier maintenance and lower cost.

Says AM Muralidharan, President, Volvo CE S&M India, ?Volvo CE believes in delivering fuel efficiency across all elements of our machines including engines, systems, operator behaviour and future technologies while increasing the productivity of our customers. Hybrid technology is one part of this wider range of fuel saving solutions.? He adds, ?Volvo also launched the mid-sized paver P6820 during Excon 2011; this has a smart power mode, which reduces engine RPM to match a job?s demands and can result in fuel savings of up to 30 per cent. The reserve power of the machine allows the machine to work effectively even at maximum paving width, with extremely large loads. On the other hand, engine power is effectively transferred to the road through a combination of wide crawler tracks and excellent weight distribution.?

In the wheel loader segment, Volvo has come out with L220G one of the latest generation of wheel loaders from Volvo. With a Volvo-designed engine, powertrain and hydraulics that work in harmony, the L220G wheel loader sets a new standard in terms of fuel efficiency. The L220G engine is joined with a drive train, hydraulics and lifting systems that are all designed and produced by Volvo to work in productive harmony. This unity of purpose means that fuel efficiency is significantly increased compared to the previous F-Series loaders ? by up to 15 per cent. The L220G is fitted with Volvo?s 13-litre, six-cylinder turbocharged after-cooled diesel engine. Producing 274 kW (373 hp), these purpose-built off-highway engines lead the industry in terms of fuel efficiency and reliability. The production of torque and power at low engine speeds, combined with load-sensing hydraulics, removes the need to overrun the engine, which in turn extends engine life and lowers fuel consumption and noise.

The L220G?s transmission features the exceptional Volvo Automatic Power Shift (APS) concept, which ensures the loader always operates in the ideal gear by sensing engine and travel speed, kick-down, engine braking and other factors. Offering operators a choice of four gear shifting programs, APS results in more efficient work cycles with lower fuel consumption and wear. Consisting of a new torque converter with lock up and free wheel stator, Optishift is a new system that integrates the Volvo patented Reverse-by-Braking (RBB) function , significantly reducing fuel consumption, by up to 15 per cent, as well as increasing operator comfort and driveline durability. When changing from forward to reverse or vice versa, RBB applies the standard service brake instead of the torque converter, bringing the machine to a halt and putting less stress on the converter and transmission. OptiShift can significantly reduce fuel consumption in operations such as load and carry, as well as in short cycle loading. The driveline lock up, meanwhile, improves drive response, rim pull and incline performance and fuel efficiency.
As per Off-Highway Research forecasts, crawler excavators will be the fastest growing segment in the coming years and the sales are projected to reach 40,000 units or 3,223 million in 2016. Energy saving technology in the excavator market is expected to play a significant role in the future. Speaking about technology trends, Samir Bansal, Country Manager, India, Off Highway Research, has this to say. ?A very significant point to note is the varying levels of technological sophistication in excavators that are currently being promoted in India. This varies from the basic technology to be found in the L&T90 and EX200 models, to the latest generation machines from Caterpillar, Hitachi, Kobelco, Komatsu and Volvo, with varying levels of technology in between. Contemporary machines have electronically controlled engines, electronic monitoring and control systems with automatic mode selection. They are fitted with efficient hydraulic systems, which results in higher breakout forces, faster cycle times and greater fuel efficiency.? He further explained, ?Initially, local producers used dated technology but the pressures of time bound contracts, with heavy penalties for delays, have pushed many buyers towards more contemporary machines. The demand for lower technology machines is clearly on the decline and now stems mainly from smaller, price sensitive contractors. A large number of Indian contractors are also now executing projects abroad and therefore require machines that are compliant with global emissions and safety standards which will encourage the further enhancement of quality in the future.?

Says Sondhi, ?The focus is on whole-life costs which include increasing fuel efficiency, lower maintenance costs and higher performance as there is pressure on margins due to higher fuel costs. Also, the operator comfort and operator- friendly features are gaining attention. JCB offers wide range of excavators with 6 models starting from 8T operating weight (JS80) to 21T operating weight (JS 210) to serve plant hire, earthmoving and quarrying customer base. Our latest entrant is the rugged and reliable JS120, the 12-tonne excavator. All JCB excavators are fitted with unique filtration system which increases hydraulic oil and filter life resulting in huge cost savings and better emissions. The auto idler system and high efficiency hydraulics also result in increased fuel efficiency. JCB gives utmost importance to safety on construction sites and JCB tracked excavators the safest choice for the customers today in India with servo lock override system and swing lock system to prevent unintended machine operation when the machine is idling. Sondhi adds, ?Hydraulics is the one of the key systems contributing to overall system efficiency. Our products have optimised design of hydraulic components with regenerative circuits which provide higher speeds of operation with minimal power consumption, thus providing higher performance and fuel
efficiency.?

Says Sunil Sapru, President, LiuGong India, ?Our efforts have always been to make the most fuel- efficient machines for our customers, which also mean our machines are environment friendly. A very efficient hydraulic system has been incorporated in the LiuGong machines, a result of a long R&D process, followed by the rigorous reliability and performance tests before it is offered to the customers. The variable displacement axle piston type hydraulic pumps support the hydraulic system and made to synergise with the engine through the intelligent electronic system, the CAPC (Computer Aided Power Control System), which comprises unmatched features like the total horsepower and control system which leads to better performance and fuel efficiency.?

?There is a positive trend in mid-sized excavators segment with clear user preferences for higher technology. This has come in owing to squeeze in project time and stiff competition in rates. The demand is for higher productive machines with lesser fuel consumption and higher component life. The consumption of spares and other running items and the cost thereof is of paramount importance while choosing the make and series of equipment in a project,? quips Dheeraj Panda, Head - Marketing & Key Accounts, Hyundai India. Hyundai excavators operate on CAPO (Computer Aided Power Optimisation) technology which offers better matching of hydraulic circuitry and engine torque curve. The boom, arm regeneration coupled with swing priority ensures lesser cycle time and more productivity. The main USP for Hyundai machines is low fuel consumption, high productivity and lesser maintenance cosy.? he adds.

Adds Sunil Sapru, ?Product improvements enhance the productivity and performance of engine and hence, it is an ongoing process for Liugong as well as for other equipment manufacturers. With shifts in trends in machine utilisation, type of applications and hours of usage of a machine several technological improvements are making excavator better. The latest technology machines have electronically controlled engines, electronic monitoring and control systems with automatic mode selection. They operate at higher pressures and hydraulic flow which results in better breakout forces and faster cycle time with leads to better fuel efficiency.? He adds, ?We have a unique innovation process to develop insights and understand better the needs and the preferences of the Indian customers and the end users of our products. Fuel efficiency often tops the list of demands that customers place on their machines. That?s why LiuGong engineers are constantly developing clever innovations to make equipment more fuel efficient while reducing emissions and environmental impacts. The BSIII machines are the prime examples of this.?

Sapru further adds, ?The environmental impacts from road building are quite common and such projects usually call for comprehensive environmental assessment studies, carried out by environmental professionals who support the main engineering team. There is a growing awareness in the road- building industry which has major environmental impacts including damage to sensitive ecosystems, loss of productive agricultural lands, resettlement of large numbers of people, permanent disruption of local economic activities, demographic change and accelerated urbanisation. To avoid substantial time loss, efforts are often required for identifying potential impacts and options for minimising them and to consult with various groups who have an interest in the project and to develop and implement mitigation plans. In addition, contract clauses covering work procedures and staff training needs to be prepared, and work processes in relation to roadside communities, flora, and fauna given considerable attention.?

?We as an environment friendly company have understood the need for cleaner biosphere. All our products here are customised to meet the local application, emission norms and are ARAI certified. LiuGong India has come up with its BSIII compliant diesel engines in their wheel loaders models CLG835, CLG856 and motor grader CLG 414. LiuGong is the only company which manufactures the 5- tonne pay load capacity wheel loader (CLG856) & 150 HP motor grader (CLG 414 motor grader) in India with a BSIII compliant engine. Further, in terms of safety, our products are in-built with ROPS/FOPS and fully air-conditioned cabin. Moreover, the products are manufactured using internationally reliable components, advanced electronic VDO sensors and ergonomically designed which follow the environmental regulations and policies applied across the globe since motor vehicle emissions contribute air pollution and concentrations of air pollutants and adverse respiratory health effects are greater near the road than at some distance away from it,? Sapru further adds.

?More customers are paying attention to factors such as fuel efficiency when purchasing new cranes. Running costs are a key part of lifecycle costing, and as fuel costs continue to rise, customers are looking to minimise their exposure to these increased costs by selecting fuel-efficient equipment,? says Raman Joshi, Managing Director, Manitowoc Cranes India. ?The big challenge in fuel economy for mobile and crawler cranes is getting the balance right between the size of the engine and the power required by the crane. Fitting a crane with an incorrectly-specified engine (whether too big or too small) can lead to fuel inefficiencies, as well as performance inefficiencies. In addition, as a manufacturer we are faced with continually changing legislation, as governments impose restrictions on engine design and use,? Joshi points out.

Speaking about the major focus on its product lines, Joshi adds, ?For our mobile and crawler cranes, we are using the very latest engine technology which is focused on fuel efficiency and economy. We have long-standing and close relationships with most of the world?s leading engine manufacturers, and our design teams always work closely with suppliers, including engine companies, when designing new cranes. This way, we can ensure the engine choice is optimal not only for the crane?s performance but also for its cost of ownership.?

According to him, the design of mobile and crawler cranes is also becoming more refined. He says ?We use the Finite Element Analysis in designing the structure of our cranes and this ensures a lighter, more streamlined design. This, in turn, ensures that the engine needs less power to move the crane when it is moving without full counterweight, and this saves fuel. For our tower cranes, we have frequency controlled technology available in the drive systems for hoisting, slewing and trolleying. This stepless movement automatically provides the correct level of power for any operation, optimising its speed and ensuring no power is wasted.?

?All our cranes are highly energy efficient. We achieve this by optimising the motor frame size and by using regenerative drives particularly for higher capacity cranes like ladle cranes. Our mechanisms are all transmission-efficient which again adds to the energy efficiency,? says Mehul Patel, Managing Director, Anupam Industries.

According to Saeesh Nevrekar, Deputy Country Manager, Konecranes, energy efficiency is the crucial parameter while selecting any crane as it increases the operating cost. ?Crane operation requires frequent starting and stopping and during each braking period and load lowering the generated energy is either wasted or fed back to the supply line. In regenerative network braking, which is a standard feature in the Smarton crane, the crane?s braking energy is fed back to the power grid instead of just going to waste and raising the temperature of the facility.

The regenerative multi-drive technology involved several parallel DynAReg network braking units eliminates the braking resistors used in traditional single drive technology. The greatest benefit provided by this technology is significantly reduced energy consumption. Depending on the customer process, up to as much as 30 per cent of cranes total power consumption can be saved via feeding the braking energy back to power grid for other uses.

Nevrekar adds, ?We have recently launched a new RTG crane for container handling application equipped with the Hybrid Power Pack Technology. The Konecranes Hybrid Power Pack turns a diesel RTG into a diesel-electric hybrid RTG. Whenever possible, the crane is operated with electrical power drawn from the energy store. Like a hybrid car, it takes the energy generated during braking and converts it into electricity to recharge the energy store. This solution can reduce diesel fuel consumption dramatically. The RTG can operate much longer on every tank of diesel fuel improving the productivity.?